Aspen C120 User 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: 1st weekend of June (dates & locations vary)
• 1-2 Week Summer Owners Cruise: end of July through beginning of August (dates &
locations vary)
• Christmas Party: 1st Saturday 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
2

APPENDIX
3
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
12

13

14

15

16
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