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Aspen C120 Owner's Manual

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C120 OWNERS MANUAL
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  • Page 1 C120 OWNERS MANUAL...
  • Page 2 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.
  • Page 3 TOPIC PAGE SECTION 1 Specifications 1 – 10 Engine Maintenance Schedules 11 – 13 SECTION 2 Aspen Warranty Boat US Membership SECTION 3 Batteries & Chargers 16 – 21 AC / DC Panels 22 – 31 Shore Power 32 – 34 Generator 35 –...

  • Page 4: Vessel Specifications

    VESSEL SPECIFICATIONS VESSEL NAME: Keep Calm REGISTRATION NUMBER: HULL IDENTIFICATION NUMBER: US –APE10158F818 Aspen C120 MANUFACTURER: MODEL: 43’-10” LENGTH OVERALL: 38’ LENGTH AT WATER LINE: 14’ 39” BEAM: DRAFT: 22,500lbs Fiberglass DISPLACEMENT: HULL MATERIAL: Bronze Fixed RUDDER TYPE: KEEL TYPE:...

  • Page 5: Serial Numbers

    SERIAL NUMBERS 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 4Z4002073 GMR Fantom 24 GHS 20 VHF Wireless Remote VHF 210 with Hailer &...

  • Page 6: Capacity Specifications

    CAPACITY SPECIFICATIONS Unit Capacity Material Waste Port Gallons Polypropylene Waste Starboard Gallons Fiberglass Water Port Gallons Polypropylene Water Starboard Gallons Polypropylene Fuel Port Gallons Aluminum Fuel Starboard Gallons Aluminum Engine Oil 5.28 Gallons Transmission Fluid 1.84 Gallons Generator Oil Quarts Hot Water Gallons Batteries House Bank...
  • Page 7 SERVICE POINTS & PARTS OIL CHANGE 1 ea Crank Case Breather Filter(D6-435) 3584145 Volvo Oil Filter (D6) 22030848 1 ea 1 ea Volvo Oil Filter By-Pass (D6) 22030852 5.28 gallons Delo 15W-40 Motor Oil GALLON TRANSMISSION FLUID CHANGE Transmission Filter 1 ea 3312199031 Trans Oil (D6 435)

  • Page 8: Engine Specifications

    ENGINE SPECIFICATIONS Volvo Penta ENGINE MANUFACTURER: D6-435 MODEL NUMBER: SERIAL NUMBER: A977251 Diesel FUEL TYPE: ZINC SIZE: 210 / 180 ALTERNATOR AMPERAGE: Part #21407028 ALTNERATOR BELT SIZE: 2” PROPELLOR SHAFT DIAMETER: Right PROPELLOR SHAFT ROTATION: 23” 20” PROPELLOR DIAMETER: PROPELLOR PITCH: NUMBER OF BLADES: PROPELLOR MATERIAL: Bronze Racor 30 Micron...
  • Page 9 VOLVO D6 435 PARTS...
  • Page 10 ENGINE SPECTROGRAPHIC CHART...

  • Page 11: Engine Maintenance Schedule

    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.
  • Page 12 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 Crankcase ventilation filter Coolant level and antifreeze mixture Air filter Fuel pre-filter and fuel fine filter Seawater filter...

  • Page 16: Battery Switches

    BATTERY SWITCHES The C120 has six main battery switches: 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 –...

  • Page 17: Battery Locations

    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.
  • Page 18 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 STARBOARD COMPANION WAY disconnected they typically come back on when they see 120V power again.
  • Page 19 MAGNUM CHARGER INVERTER 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.

  • Page 20: Charging Sources

    CHARGING SOURCES 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.
  • Page 21 FULL-TIME POWER BREAKER 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.
  • Page 22 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.
  • Page 23 DC PANEL LAYOUT 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.

  • Page 24: Electrical Drawing

    ELECTRICAL DRAWING 1 of 4 Starboard Bow Under Steps Wire #12 House Wire #23 House Pwr Fuse 500 Amp ANL Wire #13 House Wire #24 Wire #7 See Page #2 House Electronics Wire #14 Wire #6 Wire #8 Wire #19 Wire #20 Wire #26 Electronics Battery...
  • Page 25 ELECTRICAL DRAWING 2 of 4 See Page #1 Outboard Starboard Companionway House Wire #23 See Page #3 House Wire #24 House Mid Wire #29 House Mid Wire #30 Inverter / Charger Wire #35 Wire #32 Inverter Switch Wire #31 Wire #34 Inverter Fuse 300 Amp Class T Wire #20...
  • Page 26 ELECTRICAL DRAWING 3 of 4 Queen Stateroom Under Berth Balmar / House Wire #40 Balmar / House Wire #41 See Page #4 House Power Fuse Furnace Breaker 500 Amp ANL See Page #2 Wire #38 House Mid Wire #29 House Mid Wire #30 Balmar Temperature Sensor Balmar Voltage Sensing Wire House Battery...
  • Page 27 ELECTRICAL DRAWING 4 of 4 Engine Room Balmar / House Wire #40 Volvo D6 Balmar / House Wire #41 435 Engine See Page 3 House Power Fuse 300 Amp ANL Wire #40 Balmar Wire #41 200 Amp Alternator Wire #45 Wire #46 See Page 3 Davit Breaker...
  • Page 28 BALMAR CHARGER DIAGRAM...
  • Page 30 AC ELECTRICAL SCHEMATICS...
  • Page 31 AC ELECTRICAL SCHEMATICS...
  • Page 32 SHORE POWER DISCONNECT 1) SWITCH OFF BREAKER 2) UNPLUG CORD PORT DECK TRAIL * NOTE: NEVER LEAVE A HOT OR LOOSE CORD ON DOCK, IT COULD SHOCK SWIMMERS IF IT FELL IN THE WATER. IF A CORD DOES FALL IN THE SALT WATER, REPLACE THE ENTIRE CORD; A FIRE COULD OCCUR AS IT CORRODES INSIDE.
  • Page 33 AC SHORE POWER SYSTEM Overview: The C120 AC (Alternating Current) system is robust with all US made components, with three sources of power. The first is shore power through a 30 amp 120 volt shore power plug (Note: on boats with Air Conditioning there is a second 30 Amp Plug for the two Air units).
  • Page 34 AC SHORE POWER SYSTEM The AC panel is fed through the whole boat ELCI, mounted just behind the deck side shore panel connection. The whole boat ELCI does have a reset button on it. If the Green light is on, everything is good. If the Red light is on, check your dock-side shore power, then reset.
  • Page 35 GENERATOR GENERATOR FUEL FILTER GENERATOR STRAINER Generator: The boats standard generator is a 6 Kw diesel by Kohler, we also offer a Northern lights 5Kw. Both are reliable and quiet but depending on or area of use the service can favor one unit vs the other. In normal use you will go to the generator control panel engage the glow plug toggle for 10 seconds and then the crank toggle, the generator will start.
  • Page 36 GENERATOR PROCEDURES GENERATOR START/STOP PROCEDURES START 1. Momentarily press the green light side of the switch 2. Press in and let off quickly STOP 1. Press and hold the green side of the switch until the generator stops PANEL RE-SET ERROR CODES 1.

  • Page 37: Tank Gauges

    TANK GAUGES FUEL WATER FUEL WASTE WATER WASTE PORT STARBOARD BILGE PUMP COUNTERS PORT BILGE PUMPS: Port side contains 4 bilge pumps. Compartment 1 indicates the most forward bilge pump in the bow, then goes in order with Compartment 4 indicating the most aft bilge pump in the stern.
  • Page 38 PUMP LOCATIONS CRASH PUMP: Located Aft of the Engine in the STBD Lazarette, this is a high volume pump that is activated automatically by a float switch only and pumps water overboard. It also has an alarm at the dash to notify you when it activates.
  • Page 39 LENCO TRIM TABS The C120 is equipped with large trim tabs. The tabs are primarily used to trim the boat for maximum efficiency and comfort while cruising. Due to their size and positioning, they can lift a great deal while creating very limited drag.
  • Page 40 GETTING READY TO GO Before getting under-way, there are key things to do and check: 1. Check all safety equipment, bilges, machinery spaces and service points. 2. Turn on remote battery switches at the helm. Check voltage on House, Engine and Electronics batteries and make sure you have adequate voltage on all systems.
  • Page 41 GETTING STARTED: THRUSTERS, RADIO & WIPERS Thrusters: These side power units are very handy while docking. Caution: Be certain no one is in the water near the boat when the thrusters are on. The thrusters work like a vacuum, sucking from a large area. To use, ensure battery switches are on, then press both ON buttons simultaneously.
  • Page 42 GETTING STARTED: ENGINE Starting Engine: Once Engine Computer: The engine batteries are on, you can computer is very useful as it allows start. Hold Key Fob flat with you to view engine data. Toggling square edge toward key box the propeller button allows you to and pass down over box.
  • Page 43 GARMIN CHART PLOTTER To start the chart plotter, locate the power button at the top right of the unit. Press and hold the power button for three seconds. The unit will start in approximately ten seconds. The screen will display chart and data fields. To zoom in, press the + key;...

  • Page 44: Windlass / Anchor

    Too much tension while the anchor is lifted can cause damage. When the anchor rode has been purchased from Aspen, it includes depth markers every 30’ to aid in anchoring.
  • Page 45 WINDLASS / ANCHOR (OPTION) WINDLASS WRENCH WINDLASS LEWMAR Use wrench to tighten/loosen clutch, capstan. Note: The wrench is key to adjusting how much force the windlass pulls in with. Too tight and you will damage the roller assembly. ANCHOR DEPTH MARKERS LINE AFTER STACKING - DETANGLE...
  • Page 46 ENGINE & TRANSMISSION OIL The Volvo D6 435 engine uses premium 15W-40 oil. It’s best to check oil levels prior to use. Be careful not to spill or overfill. Change your oil & filter at 100 hrs, then every 200 hours or every 12 months after.
  • Page 47 FUEL SYSTEM: FILTERS & PRIMING The C120 fuel system includes two filters. In normal operation, you will only need to inspect the Racor Filters clear glass bowl for water (clear liquid). If water is present, you will need to remove the brass plug under the petcock (typically in finger tight) then drain it into a cup through the petcock at the bottom.
  • Page 48 ENGINE PRIME PROCEDURES FUEL SYSTEM - BLEEDING The fuel system must be bled after a filter change, if the fuel tank has been run dry and after a long-term stoppage. (1) BLEED NIPPLE (2) HAND PUMP IMPORTANT : never disconnect the pressure pipe. 1.
  • Page 49 RUDDER BEARING, PACKING GLAND & SHAFT SEAL RUDDER PACKING GLAND The gland should be tightened just so it stops leaking and the nuts locked with blue lock-tight. Over tightening will make steering stiff. TIDES MARINE SHAFT SEAL It is maintenance free and water cooled from the raw water off the engine.
  • Page 50 RAW WATER BALL VALVES Valves should be left on while running the boat, as closing the valves while running the boat will damage the engine and impellers. GENERATOR STBD AFT EXHAUST SEACOCK PORT AFT SEACOCK ENGINE SEACOCK GENERATOR SHOWN OFF – INTAKE –...

  • Page 51: Fresh Water System

    180 degrees after a long cruise. This is VERY HOT! Pressure Water Pump and Strainer: The C120 has three water tanks (47 gallons port side and 21/32 gallons Starboard side – 100 gallons total) each side has a dedicated pump.

  • Page 52: Holding Tanks

    HOLDING TANKS The port holding tank is a 38-gallon tank. The port The starboard holding tank is built tank is located under the genset in the aft cockpit into the floor of the liner. The lines and is equipped with a Wema sensor gauge system run behind the floor step in the Queen located on the dash.
  • Page 53 OK to turn off, as this shuts the solenoid off anyway. Gas is ON when the green Light is ON. There are 2 LPG sensors on the C120: 1 is located in the Galley under the toe kick, and 1 is located on the aft bulkhead, low in the quarter berth.
  • Page 54 LPG TANK STORAGE & OPERATION Propane tank is in the Bustle on the To use, make sure hose connection is swim platform. Note: Locker is plumbed tight, open valve, gauge will show approx. with a hose to a through hull overboard 90 Psi.

  • Page 55: Lpg System

    LPG SYSTEM Apply twice a year to prevent corrosion.
  • Page 56 STOVE IGNITER BATTERY LOCATION STOVE IGNITER BATTERY LOCATION: UNDER GALLEY SINK...
  • Page 57 TOILET FRESH WATER SEA WATER OPERATION Picture shown in Fresh Water Position Toilet sea Toilet fresh Toilet fresh water pump water sea water valve ON/OFF switch water valve OPERATION TO SWTICH TO SEA WATER: 1. Turn toilet sea water pump switch OFF 2.
  • Page 58 DINGHY LAUNCH 2) LOWER DAVIT UNTIL UPPER ARMS 1) UN-CLIP SS SUPPORT RODS ARE JUST BELOW LEVEL 4) SWING STERN OUT, EXTEND PAST 3) DISENGAGE TRACK CAR LOCK SWIM PLATFORM PINS, SWING BOW OUT 5) LOWER TO WATER, TIE TO CLEAT *DAVIT MOTOR IS LOCATED IN THE AND UN-CLIP FROM DAVIT.
  • Page 59 UNDERWATER GEAR PORT STARBOARD STARBOARD BOW THRUSTER STARBOARD STERN THRUSTER...

  • Page 60: Lifting Strap Location

    LIFTING STRAP LOCATION SLINGING THE BOAT SEE “SLING” LABELS LOCATED ON HULL SIDES UNDER THE GUNNEL It is very important that you DO NOT LIFT ON SAND BAR. Strap needed to be on Keel.
  • Page 61 OUTFITTING YOUR BOAT...
  • Page 62 OUTFITTING YOUR BOAT...
  • Page 63 OUTFITTING YOUR BOAT...
  • Page 64 OUTFITTING YOUR BOAT...
  • Page 65 OUTFITTING YOUR BOAT...
  • Page 66 BOAT CLEANING PRODUCTS MAGUIRE’S MARINE BOAT SOAP WITH WAX KEEPS THE BOAT WAX INTACT. GREAT FOR GEL-COAT.
  • Page 67 BOAT CLEANING PRODUCTS T-9 BOESHIELD: 303 AEROSPACE This is wonderful for your engine rooms PROTECTANT: metal parts, all of them, bronze, SS This material is for plastic clamps, motor metal parts, battery that’s out in the sun, I.E. Vinyl connections, bonding system seats, Zodiac boats, recoat connections and kicker motor.
  • Page 68 STARBOARD OPEN HULL 1. BOW THRUSTER 2. BOW THRUSTER SHUT OFF 3. FUEL TANK 4. WASTE PUMP 5. BATTERIES: HOUSE, START & GENERATOR 6. MAIN ENGINE MUFFLER 7. FUEL FILTER 8. MAIN ENGINE 9. THRUSTER SHUT-OFF / EMERGENCY PARALLEL SWITCH...
  • Page 69 PORT OPEN HULL 1. TRANSDUCER 2. SHOWER SUMP PUMP 3. WATER TANK W/ FUEL TANK BELOW 4. WATER HEATER 5. TOILET SEA-WATER PUMP 6. WASTE PUMP 7. GENERATOR BATTERY SWITCH 8. GENERATOR 9. WASTE TANK 10.GENERATOR STRAINER 11.FRESH WATER PUMPS 12.GENERATOR EXHAUST...

  • Page 70: Troubleshooting

    TROUBLE SHOOTING This list is developed from common customer questions. ELECTRICAL • I hear beeping but can’t figure out from where? There are about 5 devices on the boat that can beep a warning. Here is a list of them and what to do. •...
  • Page 71 TROUBLE SHOOTING – High water Alarm/Pump. This alarm is behind the dash, it’s tied to a second high capacity bilge pump (2200Gph most models). This pump is mounted 2” above the first pump in the engine room. If you hear a very loud alarm from behind the dash this is probably it.
  • Page 72 MECHANICAL SYSTEMS • Ships Hydraulic Steering. Aspen uses a Teleflex Sea Star steering system made in Richmond, BC. The unit’s hydraulic reservoir is filled by removing the rubber cover on top, then the black screw cap on top of helm. The boat ships with a clear hose with the fitting to attach to the bottle and the helm (in owner’s manual bag).
  • Page 73 TROUBLE SHOOTING • Hatches. Easy to use but many owners miss the “open just a crack” option. If you look at the area where the handle latches, there are two tabs that protrude. If you open the hatch ¼ Inch and twist the latch, it locks in that position.

  • Page 82: Winterizing Your Boat

    WINTERIZING YOUR BOAT Drain water tanks, Port & Starboard: Flip on DC breakers. Then push toggle switch for water pump switch (Left = port tank, Right = starboard tank) and open faucets. Hot Water Heater Drain: Flip open the hot water tank drain and drain to bilge, then turn on bilge pump to empty over.
  • Page 83 ATF fluid from a trucker friend and recently asked the owner of a brand new Peterbuilt who was hauling a C120 to Florida what he used, “ATF-type F every 50 gallons”. A third option is Shell Rotela DFT (Diesel Fuel Treatment) available at many truck stops.
  • Page 84 The fix may involve replacing the engines harness and computers which means the engine is pulled for easy access (seems like a big deal but actually only about 2 hrs. or less each way on an Aspen 32).
  • Page 85 VOLVO D3 & D6 DETAILS Continued notes from Larry Graf Muffler Crack On 2 boats, we’ve seen the Cyntec Muffler develop a hair line crack after use, just under where the exhaust hose connects. The symptom is a little puddle of water under the hose connection caused by a fine mist from the crack area when at cruise speed.
  • Page 86 VOLVO 435 D6 SERVICE HISTORY Notes from Larry Graf Information is based upon experience with 4 boats over 2 years (updated as of November 18, 2016) NUMBER ESTIMATED ITEM DESCRIPTION DETAILS OF BOATS COST These are very large bolts – nuts top ENGINE MOUNT and bottom, they can rattle loose, Re-align, lock nuts with full...
  • Page 87 NUMBER ESTIMATED ITEM DESCRIPTION DETAILS OF BOATS COST ENGINE AIR Low power $90 + $40 Typically replace bi-annually CLEANER DIRTY Electronic Throttle units left ELECTRONICS Replaced part, made canvas uncovered out in salty environment THROTTLES $2,400 + $180 cover to protect when not in failed after 2 years;...
  • Page 88 PETTIT HYDROCOAT PROCEDURES Notes from Larry Graf Notes as of November 18, 2016: Washington State law will eliminate copper bottom paint next year (2017). We began testing copper free paint last year (2015). These are notes from a discussion with Rachael Cartwright of Pettit paints after our one-year test of Rich Pettit’s C100 (no relation) using the new Hydrocoat ECO water based copper free bottom paint.
  • Page 89 PETTIT HYDROCOAT PROCEDURES Continued notes from Larry Graf ECO Application Procedure: Hull over Interlux Paint • Clean/wash all growth off • Light Sand/scuff w 60 grit – remove any loose paint and feather in chipped edges. • Wash with WATER – Do Not use solvent to clean •...
  • Page 90 20-30 minutes until it cools down. To give you a comparative feel for battery loads, the refrigerator on a 32 Aspen on average uses 4 amps, the house lights use 5 amps if all are on, so 530 amps is a lot of power.
  • Page 91 TOILET LOGIC: DETAILS & MAGIC Notes from Larry Graf Notes as of November 18, 2016: Marine toilets are mission critical components in cruising but also one of the most problem prone areas for new owners. The goal is reliability and little or no smell while in use or storage.
  • Page 92 The Coast guard inspectors are required to see your Y valve is locked in the (waste in Tank Position). Aspen’s don’t have a Y valve as most boat owners don’t position it correctly and things get plugged in the valve. In our design all the waste always goes into the holding tank, you have no way to pump directly from the head to the ocean.

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