Egg Harbor Manual



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OPERATIONAL MANUAL

37’ Egg Harbor

Sportfisherman Flybridge

Wood Hull # 1474 (1966)

US Coast Guard Documentation No. 1087001

VHF - WAE 6497 Exp. 00/00/05

Owners:

Sherman, Charline and Bobby MacCready

Jackson, Michigan

Last Revision 6/1/1999

10:50 AM

EGG HARBOR BOAT CO., INC.

412 Boston Ave.

Egg Harbor City, N.J.

In preparing this manual the Egg Harbor Boat Company feels that the owner and/or operator of our boat uses, above all, common sense and sound judgment. In this brochure are included various items of interest and information. Due to varying circumstances of use and location of the boat an owner might wish to add to this booklet. To follow maintenance schedule blindly is foolhardy and any extra moments of spare time devoted to your boat will pay off handsomely both in enjoyment and operation of your craft.

It is imperative that the owner and/or the boatyard periodically check all joints and seams in the boat. This is especially important during the first two seasons use. It is natural characteristic of wood to experience some expansion and contraction until such time as this movement of wood ceases. Any opening, no matter how minute appearing, should be sealed with compound and covered with paint.

Detection of discoloration in the wood can be traced to a leak or open seams. If neglected this can lead to wood rot and major damage. A few minutes periodically devoted to preventive maintenance will obviate costly repairs and assure the personal satisfaction of a carefully maintained boat. Where the boat is lettered in Gold Leaf it is imperative this lettering be protected with several coats of varnish each season.

Engine maintenance should be carried out according to the manufacturer instructions which booklet is furnished with each boat upon delivery. Also various other booklets will be supplied in regard to mechanical components installed aboard your boat.

EGG HARBOR 37'

OPERATIONS MANUAL

TABLE OF CONTENTS

FUEL SYSTEM 6

Gas Tanks 6

Gas Tanks Vents 6

Gas Tank Valves and Lines 6

Gas Strainers 6

Gas Measuring Stick 7

Fueling 7

Schematic Drawing 7

DRINKING WATER SYSTEM 9

LAKE WATER SYSTEM (FRESH WATER) 9

Water Tank 9

Hot Water Heater 9

Draining the Water Systems 9

Schematic Drawing 10

BILGE PUMPS AND SHOWER SUMP PUMP 10

General 10

Automatic-Manual Electric Bilge Pump 10

Manual Electric Bilge Pump 10

Electric Shower Sump Pump 11

Electric Circuit of the Bilge Pump 11

ELECTRICAL SYSTEM 11

110 Volt System 11

Schematic Drawing 12

12 VOLT BATTERY SYSTEM 13

Master Switch 13

Alternators 14

Converter 14

Schematic Drawings 15

-12VDC Circuit Breakers Diagram 15

-12VDC ELECTRICAL SYSTEM (Lower) 15

-12VDC ELECTRICAL SYSTEM (Fly bridge) 15

-12VDC ELECTRICAL SYSTEM (Batteries) 15

NAVAGATION ELECTRONICS 15

Overview 15

REFRIGERATOR / DEEPFREEZE SYSTEM 15

Overview 15

REVERSE CYCLE HEATER / AIR CONDITIONING SYSTEM 15

Overview 15

STEREO SYSTEM 16

Overview 16

ENGINE COOLING SYSTEM 17

Launching 17

Intake 17

Recirculating 17

Flushing the Engine 17

FIBERGLASS MAINTENANCE 18

Patching 18

Applying the patch 18

Finishing 18

Replacing Hardware 18

ENGINE MAINTENANCE AND ELECTRICAL MAINTENANCE 19

100 Hour Inspection Procedure 19

AVON JET R.I.B. TENDER 21

Overview 21

LIGHT BULB LIST 21

FUEL SYSTEM

Gas Tanks

Two, welded monel gas tanks of one hundred eight gallon capacity each are located outboard of each engine.

Gas Tanks Vents

Each gas tank is independently vented overboard.

Gas Tank Valves and Lines

All fuel lines have been replaced with new, Coast Guard approved, Aeroquip high-pressure type hoses and brass, reusable fittings.

Shut-off valves are installed at the top of each tank and at filters. Cross-feed valves are located at the rear of center hatch as a three-valve manifold.

With the center cross-feed valve closed, the port engine draws gas form the port tank and the starboard engine draws gas from the starboard tank.

With the port gas tank shut-off valves closed and with the cross-feed valve and starboard shut-off valve open, both the port and the starboard engines draw gas from the starboard tank.

With the starboard gas tank shut-off valves closed and with the cross-feed valve and the port shut-off valve open, both the port and the starboard engines draw gas from the port tank.

The gas powered Kohler Generator system normally draws fuel from the port tank.

CAUTION: Do not operate with all valves open. The gas will not draw evenly for both the port and starboard gas tanks. Gas will be unevenly consumed from either tank arbitrarily.

Gas Strainers

Each gas tank has a gas strainer located in the line between the gas tank and the engine. The strainer is mounted on the main bulkhead forward of each engine.

Caution: After emptying the gas strainers, replace the bottom plug securely and check for leaks. A loose gas strainer cap, valve, packing nut or fitting will permit air to enter the line, which will block the flow of fuel to the engine.

Gas Measuring Stick

A gas measuring stick is supplied with the boat. The stick is calibrated, representing a total of twenty inches equaling the total depth of the gas tank. Thus, when measuring the tank twenty inches equals full, ten inches equals one-half full, etc.

Caution: When inserting the measuring stick into the tank, do so without dropping the stick. Repeated dropping of the stick into the tank could result in damage to the bottom of the gas tank.

Fueling

Important: Run bilge blower immediately after taking on fuel and prior to starting engines.

Schematic Drawing

See drawing diagram for FUEL SYSTEM on the next page.

See drawing diagram for FUEL TANK STICK on the next page.

Egg Harbor 37’ - Fuel Stick Table

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DRINKING WATER SYSTEM

A fresh water supply will be installed in the main refrigeration compartment with a water tap on the face of the refer door. This system will hold approx. 2.5gal of chilled water at all times.

LAKE WATER SYSTEM (FRESH WATER)

A thru hull fitting located under the galley steps provides Lake Water Supply for both a fantail washdown faucet and a filter refill of the main water supply.

Water Tank

One Monel water tank of sixty-gallon capacity is located under the cockpit floor aft of the engines. The fill pipe for the water tank is in the cockpit floor. A key for the water fill pipe cap is supplied and is stored in the knife and fork drawer at the galley.

Hot Water Heater

A ten (10) gallon Galley Maid Hot Water Heater is located forward of the water tank between the shafts. Hot water is obtained by passing hot water from the engine cooling system through the coils in the Galley Maid Hot Water unit. The heater contains a galvanic protector plug.

The Galley Maid Hot Water unit is also equipped with an automatic electric heating element for use at dockside.

The circuit breakers for the Galley Maid Hot Water Heater unit are installed below the refrigerator door in galley.

Cockpit faucet

This cockpit faucet is an additional faucet supplied by the fresh water from your water tank. It is meant to wash your hands while fishing or sparingly wash some accumulation in the cockpit.

Draining the Water Systems

To drain the water system, lift the floorboards below the steps in the cabin. Unscrew the petcock at the bottom of line and permit the system to drain. All faucets should be opened to permit the complete system to drain freely. The Galley Maid Hot Water Heater should be drained separately.

CAUTION: Do not drain the water tank by running the pressure pump. The electric motor on the pump is designed for intermittent use only.

Schematic Drawing

See drawing diagram of FRESH WATER SYSTEM on the next page.

BILGE PUMPS AND SHOWER SUMP PUMP

General

The boat is equipped with three Lovett electric pumps. They are an Automatic-Manual Electric Bilge Pump, a Manual Electric Bilge Pump, and an Electric Shower Sump Pump.

Automatic-Manual Electric Bilge Pump

The Automatic-Manual Electric Bilge Pump is located in the bilge under the floorboards in the main cabin between the dinette and bunk area.

Some water will remain in the bilge after the pump stops running. This is because the water level must be high enough to actuate the automatic switch installed near the pump housing.

A "push-pull" switch is installed in the wheelbox to manually actuate this pump and permit removal of water not removed by the automatic operation.

Manual Electric Bilge Pump

A Manual electric bilge pump is located in the bilge at the stern below the large storage compartment in the cockpit. A "push-pull" switch is installed in the wheelbox, which is used to actuate this pump.

The pump can be used effectively for removing excess water, which will drain to the stern when the boat is underway.

Electric Shower Sump Pump

The Electric Shower Sump Pump is an automatic pump located in the bilge under the floorboards in the cabin aft of the automatic-manual electric bilge pump and forward of the main bulkhead.

This pump also has a manual feature that can be actuated by the "push-pull" switch installed on the aft bulkhead in the shower.

Electric Circuit of the Bilge Pump

The automatic circuit of the Automatic-Manual Electric Bilge Pump is fused thru circuit breakers and directly connected to the battery. This feature permits the pump to remain operative when the Master Switch is in the "OFF" position.

The manual circuit of all pumps is fused in the circuit breaker panel located in the wheelbox. The Master Switch regulates this circuit.

ELECTRICAL SYSTEM

110 Volt System

When dock cord is installed, check polarity light in port side of chart table to see if polarity is correct. If buzzer and light reset, reverse plug at dock end of shore line to correct polarity. When a two prong plug is installed be sure to ground clip to a ground pipe. This is a safety feature designed to assure the correct grounding and prevent electrolysis. Only then is the boat ready for 110 V.A.C. operations.

The standard sedan is equipped with nine 110 V. outlets for service at dockside. The Sport fisherman is equipped with eight.

Outlets are located:

Port side aft in cockpit

Below chart table

Inside cabinet for converter

At Galley

At Dinette

At Port side hanging locker

At Starboard side hanging locker

In head

Fifty feet of shore line is furnished with the boat. The shore line receptacle is installed in the cabin side.

The 110-Volt system is fused by circuit breakers in the cabinet on the port side, below the refrigerator door, in the galley. Two switches are installed in this compartment for each 110-Volt circuit.

CAUTION: Do not use electrical tools on the boat without using a three-wire shore line which is grounded to a properly grounded shore receptacle.

Schematic Drawing

See drawing diagram for 110VAC ELECTRICAL SYSTEM on next page.

12 VOLT BATTERY SYSTEM

The boat is equipped with four (4) batteries (2 banks of 2) servicing both engines. The batteries are six volt each and are wired in series to the 12-Volt system.

The batteries are wired to the engine through a "Master Switch". In addition to opening and closing, the switch offers the advantage of starting either engine from either bank of batteries. The switch further protects the owner from having to depend on the independent operation of the engine alternators. Should either alternator fail, the switch can be positioned to allow the remaining operative generator or alternator to charge all batteries.

Master Switch

A Master Switch is installed in the battery compartment aft of the main bulkhead. The switch is a four position vapor-proof unit. The important feature of the switch is it enables starting either engine from either set of batteries. It also offers the flexibility of having two independent battery charging systems available to each set of batteries.

Positioning the switch will select the effective operating circuit. Four positions are used as follows;

#1 Position:

With the switch on the #1 position the port bank of batteries are in circuit. Both engine starters, the 12-volt lighting system and other accessories are operating off the port batteries.

#2 Position:

With the switch on the #2 position the starboard bank of batteries are in circuit. Both engine starters, the 12-volt lighting system and other accessories are operating from the starboard batteries. It is recommended to wire electronic equipment to #2 batteries so as to split up use of current.

BOTH Position:

With the switch on the BOTH position the port bank of batteries and the starboard bank of batteries are in the circuit.

Both engine starters, the 12-volt lighting system and other accessories are operating from the port and the starboard batteries.

CAUTION: This position should be used only in the event of failure of some component of the electrical system such as an alternator or battery. Normal operation should be conducted by periodically alternating from the #1 position to the #2 position. With the batteries fully charged and the switch in the BOTH position, should the regulator fail, the alternator could be damaged.

OFF Position:

With the switch in the OFF position the entire 12-volt electrical system is OFF with the exception of the automatic circuit of the automatic-manual electric sump pump.

Alternators

All Models Equipped with Alternators

Attached is a wiring diagram covering all models equipped with alternators. It is to be noted that a cut out relay assembly is inserted in the system between the output stud on the alternator and the hot lead from the battery. This cut out relay opens the circuit from battery to alternator when the ignition circuit is opened, thus avoiding the possibility of damage in the event the alternator becomes shorted due to foreign matter.

With models equipped with alternators, it must be stressed that this is a negative ground circuit only and extreme caution must be exercised to prevent expensive damage to the electrical circuits which can result from reverse polarity or excessive voltage caused by incorrectly installing a battery or using a booster to start the engines.

IMPORTANT: In all cases where a "Fast Charger" type battery charger is be used, the two battery cables must be disconnected from the battery. Never use a "Fast Charger" as a booster to provide starting voltage.

When using a booster battery the negative lead of the booster battery must be connected to negative (ground) terminal of the battery and the positive lead to the positive terminal of the battery.

Caution: Reversing the polarity on an alternator system will immediately burn out the wiring harness and may possibly damage the alternator.

Converter

Your converter is located in a cabinet on the port side of the cockpit locker.

It is operating and charging port and starboard batteries when the 110-Volt outlet breakers are turned on.

Be sure to turn on both outlet breakers at once because the positive breaker will cause a loud buzz until neutral breaker is turned on.

Schematic Drawings

-12VDC Circuit Breakers Diagram

-12VDC ELECTRICAL SYSTEM (Lower)

-12VDC ELECTRICAL SYSTEM (Fly bridge)

-12VDC ELECTRICAL SYSTEM (Batteries)

See drawings on next pages

NAVAGATION ELECTRONICS

Overview

The vessel is loaded with electronic devices to aid in navigation as well as extending safety issues to a new level. Among the equipment are two(2) compasses, two(2) GPS units with two(2) dedicated GPS antenna, two(2) VHF radios with two(2) dedicated high-rise VHF antenna, Cellular telephone with high-rise antenna, two(2) depth gauge displays with two(2) dedicated depth transducers, flybridge to main helm intercom with fog horn and hailer, speed log, temperature transducer, engine synchronizers, dual station fume detector and 42” hydraulic trim plans. In addition to the above electronics, a bilge pump cycle counter and quad tachometers are installed. An autopilot system is planned for installation following completion of the hydraulic steering system upgrade. All of the above devices that support NMEA 0183 are planned to buss connect in the near future to the ships main computer which is running Nobeltec Visual Navigation Suite Ver 5.0.

REFRIGERATOR / DEEPFREEZE SYSTEM

Overview

The vessel has a built-in Refrigerator/Deepfreeze located in the galley with a rear access door to the refrigerator located below the map table drawer in the main cabin. The refrigeration unit is 110VAC and is located under the rear access hatch on the fantail deck.

REVERSE CYCLE HEATER / AIR CONDITIONING SYSTEM

Overview

The vessel has a built-in Reverse Cycle Heater / Air Conditioning unit. The control head and fan unit is mounted on the port side galley bulkhead and draws air from the Vee Birth. The compressor unit is located below decks just aft of the port engine.

STEREO SYSTEM

Overview

Two stereo systems are installed on the vessel. One, a BMW AM/FM/Cassette unit is installed just forward of the upper bunk. Two, a JVC unit with AM/FM/Cassette with an attached 6 pack CD player is installed over the main helm station. Four (4) speaker systems are installed in the following locations: Vee Birth, main cabin, outside in the fantail area and on the flybridge.

ENGINE COOLING SYSTEM

Launching

When the boat is launched be certain to open the sea cock, close all engine drain valves, and close the recirculating valve.

Intake

The engine water enters through a hull fitting ahead of the engines. The line has a shut-off valve and a tee. One outlet of the tee supplies water directly to the water pump. The other outlet of the tee by passes heated water for the thermostat housing.

Recirculating

A thermostat is installed in the line form the water outlet connection at the cylinder head. It regulates the return of warm water to the intake side of the pump to regulate and maintain a predetermined engine outlet temperature. When the engine is cold the thermostat valve remains in the open position so that all water discharged from the cylinder blocks returns to the pump inlet. After the water is sufficiently heated to actuate the thermostat, the thermostat valve closes and allows a portion of the water from the cylinder block to discharge through the spring-loaded valve to the exhaust pipe.

After the engine is started, check for a flow of water from the exhaust pipe. Run the engine for five minutes and then open the recirculating valve. You will now notice a very small amount of water flowing from the exhaust pipe. The recirculating system is then in normal operation. Some of the heated water is being fed to the intake side of the water pump and the excess water is bypassed to the exhaust system.

Turning the recirculating valve can regulate the water temperature. Should the thermostat become inoperative the valve will regulate the amount of water bypassed to the exhaust system.

Flushing the Engine

Closing the recirculating valve can flush the engine. If the water temperature becomes excessive and you have reason to believe you have sucked mud or any other foreign matter into the engine, close the recirculating valve to flush the engine.

EGG HARBOR BOAT CO., INC.

412 Boston Ave.

Egg Harbor City, N.J.

FIBERGLASS MAINTENANCE

Patching

Sand thoroughly;

Sand the area 4" to 5" form the point to be patched. It is not necessary to sand through the cloth as long as it appears to have maintained adhesion to the wood. Crazing, running cracks, etc. are generally caused by an excessive build-up of resin over the fiberglass cloth. It is desirable to remove most of the excess resin before applying the patch.

Applying the patch

Cut a piece of fiberglass cloth large enough to completely cover the area to be patched. Allow the patch to extend 2" to 3" beyond the damaged area. Saturate the cloth evenly with resin. Do not allow the resin to float the cloth. (To "float" the cloth indicates excessive resin below the cloth.) The excessive resin can be moved by lightly going over the area with a squeegee.

Finishing

When the patch has hardened and it can be sanded without shredding the cloth, feather the edges and sand lightly. Apply one or two coats of resin to hide the cloth pattern sanding lightly between coats. Do not build up excessive resin. Allow the sanding to create a smooth finish as opposed to obtaining the smooth finish from resin saturation. Note: Resin build-up above the cloth should not be as thick as the original layer of saturated cloth. After the area has been sanded smooth it should show no glossy spots or un-sanded areas. It is now ready to be primed and painted.

General

If the repair is to be made using epoxy resin follow the same procedure. However, in small areas of light crazing it may not be necessary to use the cloth but instead simply sand the area and apply one or two coats of epoxy resin. This is not a recommended practice if a crack appears through the cloth.

Replacing Hardware

When replacing hardware, drill oversized holes for the shoulder of the screw or bolt. Wedging the shoulder of a screw or bolt in the fiberglass could start a new crack.

ENGINE MAINTENANCE AND ELECTRICAL MAINTENANCE

100 Hour Inspection Procedure

Feeler-gauge check of valve settings.

Check the dwell of the breaker points in the distributor with a dwell meter.

Check engine timing.

Check compression at all cylinders.

Drain engine oil.

Replace oil filter.

Replace fuel filter.

Clean flame arrestors.

Check belt tensions.

Remove and clean thermostats.

Check manifold (intake) vacuum; check fuel pressure; check oil pressure; adjust carburetors.

Check engine to propeller alignment

Check shaft log stuffing nut.

Check rudder port stuffing nut.

CAUTION: Make sure 110V. Dockside current is off before proceeding.

Clean and tighten all battery terminals.

Check all nuts on Master Switch.

Check all nuts on converter solenoids or control box

Check all screws on circuit breakers and terminal strips in wheel box.

Check all 110V circuit breakers for tightness.

AVON JET R.I.B. TENDER

Overview

The vessel is complimented by a high performance, Jet powered, Rigid Inflatable Boat. The inflatable boat is 11’4” overall and is rated for four (4) persons or 800lbs persons and gear. It is powered by a 60hp inboard, Yamaha 2 stroke/2 cylinder gas engine. The tender utilizes a Yamaha single stage axial flow, jet pump propulsion system.

LIGHT BULB LIST

Anchor Light #90

Bow Light #90

Side Lights #90

Stern Lights #90

Dome Lights #94

Panel Lights #67

Compass Light (fly bridge) #1474

Forward Bunk Lights 15 Watt

Engine Room Lights 15 Watt

Tachometer Light #53

Tachometer Light (lower) #194 plug in

Electrolysis Light OMNI-GLOW #1050F67

Converter Tell-Tale Light #1891

Cigarette Lighter at Bridge #57

All Bulbs are 12 VDC except OMNI-GLOW

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