Aspen C120 Owner's Manual

C120 OWNERS MANUAL

1

SMART ADVENTURE YACHTS

11656 Knudson Road, Burlington, WA | Office: 360.668.4347 | email: [e-mail]

www.aspenpowercatamarans.com

September 6, 2018

Tom & Linda,

Congratulations on the purchase and delivery of your custom C120 cruising cat! As

you get her out on the water and become more familiar with the boat, don’t hesitate

to call with any questions or concerns; we are here and happy to help you! We will be
in touch with you regularly regarding our annual events we hold for our owners which

I’ve listed below. We hope you’re able to make it!

•

Weekend Spring Owners Cruise: 1stweekend of June (dates & locations vary)

•

1-2 Week Summer Owners Cruise: end of July through beginning of August (dates &
locations vary)

•

Christmas Party: 1stSaturday in December

Please be sure to check in with your local boat service company and get your Volvo
engine registered for its warranty.

Continue to check our website for updates: www.aspenpowercatamarans.com

We hope to see you out on the water!

Smooth cruising,

Larry Graf & Aspen Team
Aspen Power Catamarans

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APPENDIX

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SECTION TOPIC PAGE

SECTION 1 Specifications 1 – 10

Engine Maintenance Schedules 11 – 13

SECTION 2 Aspen Warranty 14

Boat US Membership 15

SECTION 3 Batteries & Chargers 16 – 21

AC / DC Panels 22 – 31

Shore Power 32 – 34

Generator 35 – 36

Tank Gauges 37

Pump Locations 38

Lenco Trim Tabs 39

SECTION 4 Getting Ready to Go 40 – 43

Anchor Operation 44 – 45
Engine & Transmission 46 – 49
Raw Water Ball Valves 50

Fresh Water System 51 – 52

LPG System 53 – 56

Toilet Water Operation 57

Dinghy Launch 58

Underwater Gear 59

Lifting Strap 60

Outfitting Your Boat 61 – 67

Open Hull 68 – 69

SECTION 5 Troubleshooting 70 – 81

Winterizing 82

SECTION 6 Larry’s Notes: Volvo Details 83 - 87

Larry’s Notes: Pettit Hydrocoat Details 88 - 89

Larry’s Notes: Thruster Logic & Strategy

90

Larry’s Notes: Toilet Logic, Details, Magic

91 – 95

VESSEL SPECIFICATIONS

VESSEL NAME: Keep Calm

REGISTRATION NUMBER:

HULL IDENTIFICATION NUMBER: US

–APE10158F818

MANUFACTURER:

Aspen

MODEL:

C120

LENGTH OVERALL:

43’-10”

LENGTH AT WATER LINE:

38’

BEAM:

14’

DRAFT:

39”

DISPLACEMENT:

22,500lbs

HULL MATERIAL:

Fiberglass

RUDDER TYPE:

Bronze

KEEL TYPE:

Fixed

BOTTOM PAINT: Pettit Hydrocoat Eco

GENERATOR 1:

Kohler

MODEL NUMBER:

EGEKOD

SERIAL NUMBER: SGM32K6TW

FUEL TYPE:

Diesel

ZINC SIZE:

0.25” x 0.78”

ALTERNATOR AMPERAGE:

50 @ 120V AC

ALTERNATOR BELT SIZE:

ED0024403380-S

PRIMARY FUEL FILTER:

Racor 30 Micron

SECONDARY FUEL FILTER:

ED0037302020-S

AIR FILTER:

OIL FILTER:

ED0021752850-S

ENGINE OIL TYPE:

SAE 15W-40

ENGINE OIL QUANTITY:

2.6 quarts

IMPELLER PUMP MAKE:

Kohler

IMPELLER PUMP MODEL:

229826

4

SERIAL NUMBERS

5

ENGINE

Volvo D6 435 A977251

GENERATOR

SGM32M9NK

DINGHY

ELECTRONICS

7612xsv Color Chart Plotter

401025278

7612 Display Screen (flybridge)

7616 Display Screen

46L004680

7612xsv Display Screen

3N1008474

GHC 20 (Flybridge)

5ET006154

GMR Fantom 24

4Z4002073

GHS 20 VHF Wireless Remote

VHF 210 with Hailer & Remote Mic

GHP 20 Autopilot with Smart Pump Kit

2Q4010932

GHC 20 Marine Autopilot Control Unit

5ET004303

Autopilot Reactor 40 CCU

5EE002801

AIS 600

1SS018912

Battery House 6V (quantity 4)

Batteries: Start, Generator, Electronics,

House (1 ea, 4 total)

CAPACITY SPECIFICATIONS

6

Unit Capacity Material

Waste Port

38 Gallons Polypropylene

Waste Starboard

45 Gallons Fiberglass

Water Port

52 Gallons Polypropylene

Water Starboard

53 Gallons Polypropylene

Fuel Port

92 Gallons Aluminum

Fuel Starboard

137 Gallons Aluminum

Engine Oil

5.28 Gallons

Transmission Fluid

1.84 Gallons

Generator Oil

2.4 Quarts

Hot Water

11 Gallons

Batteries House Bank

514 Amp Hours

SERVICE POINTS & PARTS

1

OIL CHANGE

Crank Case Breather Filter(D6-

435)

3584145

1 ea

Volvo Oil Filter (D6) 22030848

1 ea

Volvo Oil Filter By-Pass (D6) 22030852

1 ea

Delo 15W-40 Motor Oil GALLON

5.28 gallons

2

TRANSMISSION FLUID CHANGE

Transmission Filter

3312199031

1 ea

Trans Oil (D6 435) ATF Dexron iii 1.84 gallons

3

GENERATOR SERVICE KOHLER 6EKOD

Oil Filter

ED2175-285-S

1 ea

Oil

Secondary Fuel Filter

ED2175-288-S

1 ea

Zinc

90802150

1 ea

Belt Sea Water Pump

229125

1 ea

Impeller repair kit

229826

1 ea

4

ZINCS

Transom Zinc

MFG# CMDIVERMINI

2

Trim Tab Zinc (2-13/16”) MFG# CMR02

1

Sand Bar Zinc MFG# CMM24

1

Swim Step Zinc MFG# CMX07

4

Bow Thruster Zinc

MFG # SM71190A 2

Stern Thruster Zinc

MFG # SM71190A 1

7

ENGINE SPECIFICATIONS

ENGINE MANUFACTURER:

Volvo Penta

MODEL NUMBER:

D6-435

SERIAL NUMBER:

A977251

FUEL TYPE:

Diesel

ZINC SIZE:

N/A

ALTERNATOR AMPERAGE:

210 / 180

ALTNERATOR BELT SIZE:

Part #21407028

PROPELLOR SHAFT DIAMETER:

2”

PROPELLOR SHAFT ROTATION:

Right

PROPELLOR DIAMETER:

23”

PROPELLOR PITCH:

20”

NUMBER OF BLADES:

4

PROPELLOR MATERIAL:

Bronze

PRIMARY FUEL FILTER:

Racor 30 Micron

SECONDARY FUEL FILTER:

Part #21718912

AIR FILTER:

Part #21702999

OIL FILTER:

#22030848

BYPASS

#22030852

ENGINE OIL TYPE:

15W-40

ENGINE OIL QUANTITY:

5.3 gal

IMPELLER PUMP MAKE & MODEL:

Volvo

TRANSMISSION MANUFACTURER:

ZF

TRANSMISSION REDUCTION RATIO:

2:1

TRANSMISSION FLUID TYPE:

ATF

TRANSMISSION FLUID QUANTITY:

1.8 US Gallons

8

VOLVO D6 435 PARTS

9

ENGINE SPECTROGRAPHIC CHART

10

ENGINE MAINTENANCE SCHEDULE

Your Volvo Penta engine and its equipment are designed for high reliability

and long life. The engines are built to withstand the marine environment,

but also to have the smallest possible environmental impact. If the engine

and transmission are serviced regularly according to the schedule, these

qualities will be retained and unnecessary malfunctions will be avoided.

C = Clean
R = Replace
A = Adjust
L = Lubricate

I = Inspect

(clean, adjust, lubricate or replace if necessary)

FSI = First Service Inspection

A – F = Type of service

(regular service)

FSI: FIRST SERVICE INSPECTION, after 50

-100 running hours

Or within 180 days of the date of delivery, or the end of the first season, whichever comes first

Coolant level and antifreeze mixture

I

Drive belt and belt tensioner

I

Fuel pre

-filter, draining water / contamination

I C

Outboard drive, corrosion protection

I

Outboard drive, oil level in Power Trim

I

Outboard drive, oil level in Power steering

I

Start and warm up engine

Engine and transmission, oil / fuel / water leakage

I

Engine and transmission, abnormal noises

I

Power steering and Power Trim, function and leakage

I

Stop engine

Reverse gear, oil level

I

11

EVERY 100

-200 HOURS / AT LEAST EVERY 12 MONTHS

Oil change intervals vary, depending on engine type, oil grade, and sulfur content of the fuel

Engine oil and oil filters / by

-pass filter

R

Crankcase ventilation filter

R

Coolant level and antifreeze mixture

I

Air filter

R

Fuel pre

-filter and fuel fine filter

R

Seawater filter

I

Drive belt (tension)

I

Impeller, raw water pump

I

Reverse gear, oil and filter

R

Reverse gear, propeller shaft seal

I

Outboard drive, oil

R

Outboard drive, corrosion protection

R

Outboard drive, propeller shaft. Visual inspection of propeller seal

I L

Outboard drive, U

-joint and primary bearing

L

Outboard drive, bellows, rubber hoses, and clamps

I

Checking exhaust line

I

Outboard drive, universal joint bellow

I

Hydraulic hoses and fittings. Thoroughly inspect for signs of leaks, wear, cracks, aging

I

Engine and transmission, oil / fuel / water leakage

I

Engine and transmission, touch up paint as required

L

Batteries, electrolyte level

I

EVERY SECOND YEAR

Impeller, seawater pump

R

Outboard drive, universal joint bellow

R

EVERY FOUR YEARS

Coolant

R

EVERY 400 HOURS / AT LEAST EVERY 4 YEARS

Outboard drive, hydraulic valve oil and oil filter (steering control unit)

R

1213141516

BATTERY SWITCHES

The C120 has six main battery switches:

Normal operation position is to leave both House,
Electronics, and Engine switches in the ON position.
Emergency Parallel should be in the OFF position and is
rarely used and then only for 3 to 5 minutes max.

Thruster battery switches.

These must be switched OFF

when swimmers are in the water, or for service.

The
thrusters are very powerful and will suck objects in the
water toward them.

Do not operate the thruster for more than 30 seconds at

a time or the motor’s thermal breaker may shut the

motor off until it cools down.

Thruster Fuses: Bow is 400 AMP ANL Slow Blow. Stern
Is a 275 AMP ANL Slow Blow. (Note:

Stern thruster will

NOT operate if bow thruster fuse is blown

.)

1

HOUSE ON/OFF

Top of DC Panel Dash

2

ENGINE ON/OFF

Top of DC Panel Dash

3

ELECTRONICS ON/OFF

Top of DC Panel Dash

4

BOW THRUSTER

Under Master Bed-Stbd

5

STERN THRUSTER

Stbd Lazarette –

left lip

6

EMERGENCY PARALLEL

Starboard Lazarette

BOW THRUSTER

FUSE

BOW THRUSTER

SWITCH

STARBOARD LAZARETTE

EMERGENCY PARALLEL SWITCH

STERN THRUSTER FUSE

STERN THRUSTER SWITCH

BATTERY LOCATIONS

The C120 house battery bank is located in the starboard forward bow under the

bed steps and floor compartments. It’s comprised of 4 AGM 6 Volt golf cart style

batteries (in series for 12 volts) and one G-27 style batteries. The G-27 house

battery is near the engine and generator batteries under the starboard queen beds

aft cushion, this makes the run for the aft thruster shorter and more powerful.

17

HOUSE BATTERIES

ELECTRONICS

BATTERY

HOUSE

BATTERIES

HOUSE

BATTERY

ENGINE

BATTERY

GENERATOR

BATTERY

MAGNUM CHARGER INVERTER

The Magnum 1,000 or Opt 2,000 inverter
charger are combo units that supply 120V
AC power and also supply 12 volt 3 stage
charging either 60 or 100 amps. If the units
were in the on position when power was
disconnected they typically come back on
when they see 120V power again. To work
you need to see 120 volt power at the 120
V panel display and have the breakers on.
The Magnum inverter charger display will
light up and show its activity initially

typical “Bulk Charging 100 amps” this will

ramp down as the batteries fill up. The
charger is a three stage-smart unit that
charges aggressively when the battery is
low and then ramps down as it charges.
They stop completely when the battery is
fully charged and do a small topping charge
as needed. The design greatly extends
battery life and prevents overcharging and

subsequent battery damage. Note: the

chargers must be set to the AGM setting
to properly charge AGM batteries. Also
with AGM batteries there is no water level
to check they have a gel inside. This is
good but AGM batteries do not like being
run dead flat and will only do this 2-3
times before they must be replaced. We
chose AGM as they out gas hydrogen

(flammable) far less than lead acid

batteries and with their location in the
boat this is important to safety. If you
replace the batteries you must replace
with AGM

NOTE:

Chargers will only charge if they see

voltage. If batteries are dead you will need to

use the Emergency Parallel Switch and charge

for maximum 4-6 minutes for the charger to
see the battery and begin charging.

18

STARBOARD COMPANION WAY

This unit has two jobs, first is to charge the house batteries when in

port or when the generator is switched on and the slide switched

moved to Generator position. If the unit see’s inbound 120 Volt AC

power it passes it right through to those outlets connected to the

inverter. It can make 120 volt power as well by drawing 12Volt power

from the house batteries. But understand this works well for a micro

waving a cup of coffee or two or reheating dinner or charging phones

and computers. But if you’re going to use a LOT of inverted power,

say to run a hair dryer for 10 minutes, you will deplete the house

batteries very fast. The house bank is 420 amp hrs. so if you flatten

them it will take 4 hrs. with your 100 amp inverter charger to refill or

2 hrs. of running at cruise with the optional 210 amp dedicated house

alternator option to bring them back to full charge. For big AV 120

volt loads its best to start the generator let it warm up for 5 minutes

and then do any AC load you want. Note: Heavy loads on a cold

engine will damage the engine.

There are many settings and options on the inverter charger I

typically keep the charge capacity at 100 % with the size of our

house bank 100 Amps is just fine (no damage will occur) the only

time you may want to idle down the charger is when connected to a

limited capacity dock outlet if its popping you can reduce the draw by

lowering the charge amps. In normal use after docking and using the

thrusters the Magnum display will initially show bulk charging 60-90

amps, next it will show float charging 4-12amps (often stays in this

position when you using lights, chargers and other small loads). Just

note that if there are no green lights and nothing on the magnum

display showing you are not charging. The inverter is located under

the port side of the master bed though all its controls are just under

the DC panel at the dash.

19

MAGNUM CHARGER INVERTER

CHARGING SOURCES

20

The House batteries have two charging sources:

1)110 V Electric Battery Chargers:

❖House Inverter Charger (60 Amps for House battery bank) Note: On

boats with optional 2,000 watt inverter, the house bank has 100 Amp
charging. Shore power is connected and AC breakers above ¼ berth
are switched on. Inverter is switched on charging is switched on,
displays amps output on screen. Inverter charger can receive power
from Shore Power or Generator.

❖Engine Generator Charger: 25 AMP

2) Engine driven alternator: Engine battery is an excellent charge source
while cruising. (Optional 210 AMP house bank charger.)

ENGINE
GENERATOR
CHARGER

HOUSE

CHARGER

FULL-TIME POWER BREAKER

21

The Full-Time Power Breaker (Hot Float) is always on. The 12V power fuse is

mounted in a cabinet, inboard, starboard forward stateroom. It is important to

leave this on as it supplies power to the boat’s six automatic bilge pumps and

other devices that need power to save memory settings. It is not affected by

the battery switch position.

NOTE:

When the yellow lever is out/seen, the breaker is off. If the breaker has

popped or fuse is burned out, there is no bilge pump protection from leaks.

22

The main engine

batteries G27s are

located in the starboard

hull mid ships under the

aft end of the queen

berth as is the G27

Stern Thruster boost

battery. This

compartment is

accessed by the

removable bed cushion

and the hatch under. The

engine exhaust and

engine battery charger

are also in this

compartment. The aft

bulkhead here is

removable for easy

access to shaft coupler

and forward engine

mounts.

DC PANELS

DC SYSTEM OVERVIEW:
The C120 Has two main battery banks and two accessory batteries; one for the
generator and one for the electronics. In all there are 8 batteries in the system. These
are all AGM batteries and the chargers are set for AGM charge. The house bank is
comprised of 4ea 6 volt GC golf cart style batteries and one G27 to support the stern
thruster, the house bank supports the lights, pumps, heads, thrusters and Inverter. The
primary house bank is located under the floor boards forward in the master stateroom
Port hull. The dedicated electronics battery is also located in this area. The battery
switches and fuses for the house bank are located in the teak cupboard just above the
batteries as is the switch and Voltage Sensitive relay for the electronics battery. This
switch compartment also includes the Hot Float switch breaker that powers the 7 bilge
pumps even when the batteries are switched off (keeps the pumps active at all times)
Note: If you see the yellow tang hanging down this breaker is off = bad.

DC PANEL LAYOUT

23

Pumps Panel: The pumps panel controls the bilge
pumps and shower sump pump. Most of these are
automatic, but these switches allow you to manually
turn on each of the six pumps for each water-tight
compartment. With the exception of the fresh water
switch, these switches are normally in the off
position. This panel is fed from the pumps breaker
on the main DC panel. The automatic portion of the
bilge pumps is not affected by this panel.

NOTE:

The engine room has a seventh pump
(1100GPH) which serves as an emergency pump. It
is wired to a very loud horn behind the dash. Should
you lose an engine hose and the engine room begins
to fill, this pump will automatically start and the
horn will sound. Stop and fix the problem.

Ship Systems Panel: This panel includes controls
for navigation lights, blower, and many other ship
systems. Like the Pumps Panel, it is fed from the
main DC panel breaker.

These panels have separate resettable circuit
breakers, ranging from 5- to -20 amps. If a breaker
has tripped, determine and fix the cause and reset
the breaker by pushing the clear button in. (Possible

causes could be debris in pump, shorted wire, etc.)

24

ELECTRICAL DRAWING

1 of 4

Starboard Bow Under Steps

Wire #12

Wire #7

Wire #14

Wire #8

Wire #6

Wire #13

House Wire #23

House Wire #24

See Page #2

House Pwr Fuse 500 Amp ANL

ElectronicsACR

House

Wire #19

Wire #20

Wire #16

House Batteries

Electronics Battery

House Batteries

Wire #26

Wire #2

Wire #5

Wire #11

Wire #1

Bow Thruster
Fuse

Wire #9

Thruster Switch

Wire #10

Bow Thruster

Hot Float

50 Amp

Electronics

80 Amp

Windlass

90 Amp

House

150 Amp

Wire #20

See Page #2

25

ELECTRICAL DRAWING

2 of 4

Hot Float Fuse Panel

Fuse Block #1

Fuse Block #2

Electronics Fuse Panel

To Hot Float

50 Amp Breaker

See Page #1

To Electronics

80 Amp Breaker

Main DC Panel

Dash

Wire #20

To House 150 Amp Breaker

Helm Negative Bus

Outboard Starboard

Companionway

See Page #3

See Page #1

House Wire #23

House Wire #24

House Mid Wire #30

House Mid Wire #29

Inverter / Charger

Wire #35

Inverter Switch

Wire #34

Wire #31

Wire #32

Inverter Fuse

300 Amp Class T

To Queen Stateroom

negative bus

Wire

26

ELECTRICAL DRAWING

3 of 4

Wire #50

Wire #45

Wire #46

See Page #4

See Page #4

Negative Bus (Shunt)

Wire #42

Stern Negative Bus

Bonding Bus

Engine / Generator

Generator Battery

Volvo ECM Wire

Magnum Temperature Sensor

Battery Charger Temperature

Balmar Temperature Sensor

Balmar Voltage Sensing Wire

1 Amp Fuse

Wire #38

House Battery

Wire #39

Wire #37

Wire #36

House Battery

Switch

House Mid Wire #30

House Mid Wire #29

Furnace Breaker

See Page #2

House Power Fuse

500 Amp ANL

Start Battery

Balmar / House Wire #41

Balmar / House Wire #40

See Page #4

Queen Stateroom Under Berth

27

ELECTRICAL DRAWING

4 of 4

See Page 3

See Page 3

Volvo D6

435 Engine

Emergency Parallel

Engine Battery Switch

Stern Thruster

Shut Off

Generator Battery Switch

See Page 3

See Page 3

Generator Port Lazarette

Stern Thruster

Wire #45

Davit Breaker

60 Amp

Wire #46

Aft Deck Panel

30 Amp

Engine Room

Balmar
200 Amp Alternator

Wire #40

Wire #41

House Power Fuse

300 Amp ANL

Balmar / House Wire #40

Balmar / House Wire #41

Wire #62

Wire #54

Wire #57

Wire #53

Wire #56

Wire #58

Wire #51

Wire #59

Stern Thruster Fuse

250 Amp

Wire #44

Wire #49

Wire #50

Kohler 6EKOD

Generator

28

BALMAR CHARGER DIAGRAM

29