Operator’s Maintenance Manual - Beta Marine Koreabetamarinekorea.com/sg/beta_28/b28_07.pdf · 2010-06-23 · CALIFORNIA – Proposition 65 Warning: Diesel engine exhaust and some

CALIFORNIA – Proposition 65 Warning: Diesel engine exhaust and some of its constituents are knownto the state of California to cause cancer, birth defects and other reproductive harm.

Operator’s Maintenance

Manual

Heat Exchanger CooledSmall Diesel Engine Range

Beta 28, Beta 35 & Beta 38

Operator’s Maintenance

Manual

Heat Exchanger CooledSmall Diesel Engine Range


1640.qxd:beta 1660 manual 30/6/09 12:21 Page 1

Engine Details IMPORTANT - Please fill in details at moment of purchase - it really willhelp you! (and it will really help us specify the correct spare parts for you).

Engine Type: Power: bhp Speed: rpm

BETA WOC NO: K

Gearbox Type:

Purchased From:

Invoice No.:

Date Commissioned:

Specification / Special Details:


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My engine details (to be completed now) Inside front cover

Introduction

Engine identification 2

Initial receipt of the engine 2

Engine storage 2

Safety precautions 3

Technical specifications 4

Section 1: Installation guidelines

Engine mounting 5

Engine alignment - drives, flanges, flexible couplings 6

Exhausts and mounting exhausts 7

Fuel supply and "leak off" 8

Cooling - sea water inlet system 9

Calorifier connections (if fitted) 9

Electrical Installation 10

Section 2: Guidelines for operation of the engine

Important checks prior to initial use 11

Initial start-up and bleeding the fuel system 11

Starting and stopping 12 & 13

Section 3: Maintenance & Service guidelines

Maintenance schedule 14 & 15

Lubrication - checking and changing oil 16 & 17

Fuel system - fuel/water separator, fuel lift pump, fuel filter 18

Cooling - fresh water system, heat exchanger 19

Sea water pump, heat exchanger 20 & 21

Belt tensioning adjustment 21

Air filter inspection / replacement 22

Electrical maintenance 22

Laying up - winterising 23

Troubleshooting 24

Torque settings 35

Wiring diagrams and general arrangement drawings index 36

Exhaust Emission - Declaration of Conformity 65

Exhaust Emission - Durability 66

Fast Moving Parts Listing 67 & 68

Maintenance record Inside back cover

Contents


Engine Identification

NOTE: In all communications with thedistributor or Beta Marine, the W.O.C. and engine number must be quoted.

Beta 28, Beta 35 and Beta 38

The engine serial number is stamped above starter motor onthe port side of the engine, and is shown on the rocker coverlabel.

Initial Receipt of the Engine

A full inspection of the engine must be made immediatelyon delivery to confirm that there is no damage. If there isany damage then write this clearly on the delivery note andinform your dealer or Beta Marine within 24 hours. Aphotograph would always help.

Engine Storage

The engine must be stored in a dry, frost free area and this isbest done in its packing case. If storage is to be more thansix months then the engine must be inhibited (contact yourdealer or Beta Marine). Failure to inhibit the engine mayresult in the formation of rust in the injection system and theengine bores, this could invalidate the warranty.

OPERATION AND MAINTENANCE MANUAL FOR THE FOLLOWINGBETA MARINE ENGINES BASED ON KUBOTA SERIES


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This manual has been compiled to provide the user with important information and recommendations to ensure trouble freeand economical operation of the engine.

As manufacturers we have obviously written this “Operators Maintenance Manual’ from our ‘involved technical viewpoint’assuming a certain amount of understanding of marine engineering. We wish to help you, so if you do not fully understandany phrase or terminology or require any explanations please contact Beta Marine Limited or its distributors and we will bepleased to provide further advice or technical assistance.

All information and recommendations given in this publication are based on the latest information available at the time ofpublication, and are subject to alteration at any time.

The information given is subject to the company’s current conditions of Tender and Sale, is for the assistance of users, andis based upon results obtained from tests carried out at the place of manufacture and in vessels used for developmentpurposes. We do not guarantee the same results will be obtained elsewhere under different conditions.


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A Keep the engine, gearbox and surrounding area clean,including the area immediately below the engine

B Drives - Power Take Off Areas

i) Gearbox Output Flange

The purpose of a marine diesel propulsion engine is toprovide motive power to propel a vessel. Accordingly thegearbox output shaft rotates at between 300 and 3600rev/min. This flange is designed to be coupled to apropeller shaft by the installer and steps must be taken toensure adequate guarding.

ii) Forward End Drive

Engines are supplied with unguarded belt drives to powerthe fresh water pump and battery charging alternator. The installer must ensure that it is not possible for injuryto occur by allowing access to this area of the engine.The three pulleys run at high speed and can cause injuryif personnel or clothing come in contact with the belts orpulleys, when the engine is running.

iii) Power Take Off Shaft (Engine Mounted Option)

Shaft extensions are available as an option and rotate atbetween 850 and 3600 rev/min. If contact is made withthis shaft when the engine is running, injury can occur.

C Exhaust Outlet

Diesel marine propulsion engines emit exhaust gases atvery high temperatures - around 400 - 500°C. Enginesare supplied with either wet exhaust outlet (waterinjection bend) or dry outlet (dry exhaust stub) - seeoption list. At the outlet next to the heat exchanger /header tank, the exhaust outlet can become very hot andif touched, can injure. This must be lagged or avoided byensuring adequate guarding. It is the responsibility of theinstaller to lag the exhaust system if a dry system is used.Exhaust gases are harmful if ingested, the installer musttherefore ensure that exhaust lines are led overboard andthat leakage in the vessel does not occur.

D Fuel

i) Fuel Lines

Diesel engines are equipped with high pressure fuelinjection pumps, if leakages occur, or if pipes fracture,fuel at a high pressure can harm personnel. Skin must bethoroughly cleaned in the event of contact with dieselfuel.

ii) Fuel Supply Connections

Engines are supplied with 8mm compression fittings. Theinstaller must ensure that when connections are made,they are clean and free of leaks.

E Oil

The Beta propulsion unit is supplied with 2 dipsticks, onefor the engine and one for the gearbox. Ensure dipsticksare returned and secure after checking, if not oil leaks cancause infection when touched. All oil must be removedfrom the skin to prevent infection.

F Scalding

An engine running under load will have a closed circuitfresh water temperature of 85° to 95°C. The pressurecap on the top of the heat exchanger must not beremoved when the engine is running. It can only beremoved when the engine is stopped and has cooleddown.

G Transportation / Lifting

Engines are supplied on transportable pallets. Lifting eyeson engines are used for lifting engine and gearboxassembly only, not the pallet and associated kit.

GENERAL DECLARATION

This machinery is not intended to be put into service until ithas been incorporated into or with other machinery. It is theresponsibility of the purchaser / installer / owner, to ensurethat the machinery is properly guarded and that all necessaryhealth and safety requirements, in accordance with the lawsof the relevant country, are met before it is put into service.

Signed:

J A Growcoot, C.E.O, Beta Marine Limited

NOTE: Recreational Craft

Where applicable, the purchaser / installer / owner andoperator must be responsible for making sure that theRecreational Craft Directive 94/25/EC is complied with.

Safety Precautions!


Maximum Angle of Installation: Maximum 15° flywheel up or flywheel down when static; or up to 25° when heeling.

Rotation: Anti-clockwise on flywheel, clockwise on output gearbox flange for use with right hand propeller in ahead, onmechanical gearboxes. Hydraulic gearboxes can be left or right handed. Diesel fuel must conform to BS2869-1970 class A1or A2. The fuel must be a distillate and not a residual oil or blend.

Lubricant:Engine - engine oil must meet API Classification CF (CD or CE), See section 2 for detailsGearbox - see gearbox operator’s manual for the gearbox oil type and capacityOil pressure - minimum (tickover) 0.5 bar

Power outputs: These comply with BS EN ISO 8665:1996 crankshaft power

Note: Declared Powers to ISO8665:1996

1. The declared powers are at the same engine speed as the ISO 3046 figures. This speed is the speed related to the outputs / powers shown.

2. Declared powers are at the gearbox coupling (coupling to the propeller shaft) as per clause 3.2.1 with standardspecifications as per our current price lists. Additional accessories or alternative gearboxes may affect the declared powers.

3. Operation at parameters outside the test parameters may affect the outputs / powers which in any case are subject to theISO tolerance bands.

Standard Engines Beta 28 Beta 35 Beta 38

Cylinder 3 4 4

Bore (mm) 76 78 78

Stroke (mm) 73.6 74.8 74.8

Displacement (cc) 1001 1498 1498

Combustion 3 Vortex 3 Vortex 3 Vortex

Cooling Water Water Water

Starter voltage (V) 12 12 12

Starter output (kW) 1.2 1.2 1.2

Starter alternator output (Amps) 65 (standard) 65 (standard) 65 (standard)

Glow plug resistance (each) 1Ω 1Ω 1Ω

Engine speed (RPM) 3,600 3,000 3,600

Power output to ISO3046 (BHP) 25.0 35.0 37.0

Declared power ISO8665 (kW) 17.5 24.5 25.5

Compression Ratio 22.0:1 22.0:1 22.0:1

Fuel timing BTDC 21° 21° 21°

Capacity of standard sump approx. (litres) 6.0 7.5 7.5

Capacity of shallow sump approx. (litres) 5.0 6.5 6.5

Nett dry weight with gearbox (kg) 140 170 170

Fuel ASTM Diesel fuel oil No.2D

Coolant 33%-50% maximum antifreeze:water

Coolant capacity approx.. (H/E litres) 5.5 7.0 7.0

Min. recommended battery capacity 12V, 80Ah (500 CCA Min)

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Technical Specifications


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Installation Recommendations

The installation details are basic guidelines to assist installation, however due to the great diversity of marine craft it isimpossible to give definitive instructions. Therefore Beta Marine can accept no responsibility for any damage or injury incurredduring the installation of a Beta Marine Engine whilst following these guidelines.

Engine Mounting

To ensure vibration free operation, the engine must beinstalled and correctly aligned on substantial beds, extendingas far forward and aft as possible, well braced and securelyfastened to form an integral part of the hull.

The engine must be installed as low as possible on theflexible mount pillar stud. This will limit vibration and extendthe life of the flexible mount. To assist with enginereplacement we offer ‘Special Engine Feet’ manufactured toyour dimensions, as an optional extra to suit your existingengine bearers and shaft alignment/installation.

Warning

(1) Do not set the engine feet high up the flexible mountpillar stud. This will cause excessive engine movementand vibration. Pack under the flexible mount with steelshims securely bolted into the engine bearer.

(2) The pillar stud on the flexible mount is secured intoposition by the lower locknut, do not forget to tightenthis. Also ensure that the stud is not screwed too farthrough the mounting body so that it can touch thebearer. This will cause vibration and knocking noiseswhich are very hard to find!

Section 1

Flexible Output Couplings

A flexible coupling should be mounted on the gearbox outputflange and is strongly recommended in almost every case.

Flexible couplings do not accommodate bad alignment, theyare designed to absorb torsional vibrations from the propeller(transmitted along the propeller shaft).

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• All engines shall be placed within an enclosure separatedfrom living quarters and installed so as to minimise therisk of fires or spread of fires as well as hazards from toxicfumes, heat, noise or vibrations in the living quarters.

• Unless the engine is protected by a cover or its ownenclosure, exposed moving or hot parts of the engine thatcould cause personal injury shall be effectively shielded.

• Engine parts and accessories that require frequentinspection and / or servicing must be readily accessible.

• The insulating materials inside engine spaces shall benon-combustible.

• The engine compartment must be adequately ventilatedas the engine will produce radiated heat - approximatelyequal to 1/3 of the engine output power.

Also the battery charging alternator(s) create lots of heat.

Ventilation is normally best with two holes; an inlet of atleast 200 cm2 allowing colder air to enter near to thealternator and drive belts and a second outlet (a thirdbigger than the inlet) for the hot air to rise and ventilateout from the opposite side of the top of the enginecompartment.

In yachts we strongly recommend forced ventilation -using an extractor fan to draw out the hot air and limitthe engine compartment /room temperature to amaximum of 60 °C. You can check the temperature inthe engine compartment with a thermometer - the coolerthe better - maximum temperature 60 °C; this is bestdone on a hot sunny day. (A symptom of overheatingproblems is black belt dust).


4 Angular Mis-alignment

Angular Mis-alignmentEngine / gearbox

flangePropeller

shaft

Alignment

To obtain accurate alignment the flexible mountings must beadjusted until alignment is attained, and the mountings mustbe locked in position.

The engine/gearbox unit has to be aligned with the propellershaft in two ways. The traditional engine alignment methodinvolves measuring with either feeler gauges or a DTI (DialTest Indicator) mounted on a magnetic foot so that they arealigned within 0.125mm (0.005”).

The engine mountings and the couplings must now be tightened in position and the alignment re-checked.

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Engine Installation at an Angle

Beta Marine propulsion engines can be installed at angles upto a maximum of 15° flywheel up or flywheel down whenstatic, or can be run at up to 25° when heeling. When ourengines are installed at varying angles of inclination thenormal markings on the dipstick should be disregarded.

It is probably better to totally drain the lubricating oil from thesump, replacing the oil filter with a new one; then add therecommended amount of lubricating oil – noting its positionon the dipstick – and then marking the dipstick. If in doubtask Beta Marine.

Angular Alignment

5 Parallel Mis-alignment

Parallel Mis-alignmentEngine / gearbox

flangePropeller

shaft

Parallel Alignment


Normal Seawater Level

Anti syphon valve orT piece fitted here

Propeller Clearance:between tip of propeller blade and undersideof hull should be at least 10 percent of thepropeller blade diameter

If a rope cutter is fitted, allow approximately 1/2”for movement of engine, see manufacturer’s literature

30 cmminimum

Maximum Seawater levelwhen heeled (measured onthe centre line of the boat) 40 cm

minimum

a

X

5 cmminimum Waterlock

Silencer

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Exhausts(a) An engine correctly installed in accordance with this

handbook will meet the emission requirements of theRCD (see back of manual).

(b) Keep dry exhaust systems to a minimum length and haveswept bends (NOT right angle elbows). Exhaust backpressure is increased by longer exhaust length and sharpbends.

Back pressure should be measured; with the completeexhaust system connected and the engine running at fullspeed; and should NOT exceed: 80mm Hg (3.15 inchesHg) at 3,600 rev/min or 70 mm Hg (2.75 inches Hg) at3,000 rev/min. The correct measuring point is before theinjection bend (at the manifold flange). Wet Exhaust hoseshould be matched to the injection bend sizes detailedbelow.

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Engine Connections

Actual Connector: Required Pipe Size:

Fuel supply and fuel leak-off connections are 8 mm OD piping for both, a flexible section 8 mm conex with olives is required

Seawater cooling pump connections are 22 mm OD Sea water pump inlet = 22 mm ID hose

Exhaust water injection bend is 50 mm OD Flexible exhaust rubber pipe to correct quality = 50 mm ID hose

Typical Yacht Exhaust Installation

Warning

(1) One of the most common problems with engineinstallations (and possibly expensive), is water enteringthe engine exhaust manifold from the exhaust system bysyphoning when the engine is switched off. This canoccur when the point of water injection "X" on the engineis close to or below the water line. Water entering thepistons can cause bent con rods, emulsified engine oiland a wrecked fuel pump! It’s best avoided!

(2) This diagram shows a typical exhaust installation. Therubber hose connecting the heat exchanger to theinjection bend must be replaced by a hose (a) ofsufficient length, connecting to a "T" piece or anti-syphonvalve that is above the maximum seawater level whenheeled (at least 30 cms / 12 inches above the water line)on the centre line of the boat. The pipe then returns tothe injection bend and the seawater is pumped down theexhaust pipe.

(3) The exhaust back pressure should NOT exceed: 80mmHg (3.15 inches Hg) at 3,600 rev/min or 70 mm Hg(2.75 inches Hg) at 3,000 rev/min.


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Fuel supply & leak off

Fuel tank

Stop tap/valve Fuel/waterseparator

Fuel filter

Fuel lift pump

Fuel injectionpump

Engine (All Fuel Connections Supplied)

Flexible FuelConnections to be used

Fuel injectors

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Notes:

1) A fuel/water separator must be installed.

2) The mechanical fuel lift pump is fitted to all engines asstandard, but if a suction head of 0.25m or more isrequired, then an electric fuel lift pump must be fitted(ask your dealer or Beta Marine).

3) It is very important that the excess fuel from the injectorsis fed back to the fuel tank and not back to any point inthe supply line. This will help prevent air getting into thesystem.

4) The fuel return (leak off) pipe must loop down to be levelwith the bottom of the tank before it enters the top of thetank – see drawing. This prevents fuel ‘drain down’.

5) Fuel lines and hoses connecting the fuel tank to theengine, must be secured, separated and protected fromany source of significant heat. The filling, storage,venting, fuel supply arrangements and installation mustbe designed and installed so as to minimise the risk offire. When connecting the engine to the fuel supply andreturn lines, flexible fuel hoses must be used (next to theengine) and must meet the requirements set in standardISO7840:1995/A1:2000 and/or as required by yoursurveyor / authority.

6) Any fuel leaks in the system when static are likely tocause poor starting and erratic running and must becorrected immediately. These leaks will allow air to besucked in when the engine is running.

Vent

Seawater Inlet System(Heat exchanger Cooled Engines)

Your engine is fitted with a gear driven sea water pumpwhich sucks in seawater (raw water) to cool the closed circuitsystem via the heat exchanger.

1. It is very important that the seawater inlet should have a strainer system either built into the sea cock or a highlevel system with visual inspection glass (as shown)mounted just above the water line.

2. The inlet sea cock and pipe work to the sea water pumpshould be 25 mm ID or 1” minimum.


Calorifier SystemAll Beta engines can be fitted with the calorifier connections to allowthe hot water from the closed fresh water / antifreeze system tocirculate through a calorifier tank, which in turn heats up domesticwater. Calorifier connections on this range of engine are shown.

1. The big problem with a calorifier is to remove all the air fromthe system. If this is not achieved then they don’t work!

2. Try and keep the supply and return pipes either horizontal orsloping down in a continuous fall towards the calorifier. Thisavoids air pockets being created.

3. Extra care must be taken when first filling the calorifier circuitsystem with 50% antifreeze to water solution as the enginemay appear to be full but it soon disappears into the calorifierpipe work. Run the engine off load for 10 minutes then checkthe level as described in ‘Filling The Fresh Water System’. Alsocheck to see if the pipe going to the calorifier is getting warmafter 15 minutes. Top up the water level as required and run foranother ten minutes then repeat.

4. If the water level is steady but no warm water is getting to theCalorifier (then with engine stopped) very carefully remove thepressure/filter cap using a large rag/cloth to protect you handfrom scalding. Now very carefully open the Calorifier bleed valve(see manufacturers instructions) or if none is provided then verycarefully loosen the jubilee clip securing the supply pipe to theCalorifier. Air should escape. Refasten securely when no furtherbubbles are seen. Caution: Do not do this when the engine ishot as scalding hot water may be forced out of the pipe.

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10

9a

Calorifiersupply

Beta 28

9b

Calorifiersupply

Calorifierreturn

3. Good access to the inlet sea cock is essential so thatplastic bags or seaweed trapped in the intake can bepoked out

4. All pipe work should have approved marine gradestainless steel hose clips. Any loose clamps or badconnections can cause flooding and sinking of the vessel.

5. If water is required for stern tube lubrication then thisshould be taken from a ‘T’ piece in the pipe going fromthe heat exchanger outlet to the water injection bend.

6. Scoop type water pickups should never be used, as waterwill be forced through the pump and into the exhaustsystem whilst the vessel is in motion. This is verydangerous as the exhaust will eventually fill and sea/rawwater will back up into the engine through the exhaustvalve. Catastrophic failure will result as soon as theengine is restarted. Note: The maximum lift of the seawater pump is 2m when primed.

Water Level

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Beta 35 and Beta 38


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Electrical Installations

Beta Marine has 6 control panels: A, AB, ABV, ABVW B or C.

The Beta 28, Beta 35 and Beta 38, use the ABV, ABVW, Band C control panels.

The engine harness is common to all.

1. These control panels must not be installed where seawater spray can get at them. A suitable flap or cover must be fitted.

2. Control Panels must be fitted in a location where thehelmsman can either see or hear the alarm system.

3. For standard wiring diagrams, see back of manual.

4. Our standard wiring harness has a 3 metre loom. As an optional extra, Beta can provide various lengths ofextension looms for runs of over 3m, but this kit includesa start relay to overcome the voltage drop (See drawing300-58520).

5. All electrical equipment must be protected from sea water.Sea water or rust in the starter will invalidate thewarranty. Care must be taken when pushing the twohalves of the plug together to ensure that individual pinsdo not fall out.

To prevent corrosion and assist in assembly werecommend that the plug is packed with petroleum jelly(Vaseline) and then carefully pushed together. The plasticboots should cover both halves and overlap. A cable tie isthen put around to hold the two halves in position andhelp prevent any ingress of water.

6. All cables must be adequately clipped and protected fromabrasion.

7. Electrical systems shall be designed and installed so as toensure proper operation of the craft under normalconditions of use and shall be such as to minimise risk offire and electric shock.

8. Attention shall be paid to the provision of overload andshort circuit protection of all circuits; except enginestarting circuits, supplied from batteries.

9. Ventilation shall be provided to prevent the accumulationof gases, which might be emitted from batteries. Batteriesshall be firmly secured and protected from ingress ofwater.

Typical Starter Motor Ratings

Starters used in Kobuta engines have the followingstandard capacities:

Engine Starter Capacity (kW)

Less than 700cc 0.8 - 1.0

700 to 1,500cc 1.0 - 1.4

1,500 to 3,000cc 1.4 - 2.0

Over 3,000cc 2.0 - 2.5

Suggested Minimum Engine StarterBattery Size

Engine Typical Battery Typical C.C.ACapacity (AH) Cold Crankingat a 20hr Rate Amperage

Beta 10, Beta 14, 35 - 50 AH 350 - 400Beta 16, Beta 20

Beta 25, Beta 28,Beta 35, Beta 38, 65 - 75 AH 450 - 540Beta 43

Beta 50, Beta 60 100 - 120 AH 580 - 670

Beta 75, Beta 90 150 - 180 AH 1050 - 1200

Keyswitch Terminations

The standard panel keyswitch can be used to tap off aswitched positive ignition feed to power additional gauges. Inthis way these gauges will only be live whilst the engine isrunning, the engine is starting or the heaters are being used.For silver keyswitches, the terminal to achieve this ignitionswitched positive is marked ‘AC’. For black keyswitches, theterminal to achieve this ignition switched positive is marked‘15/54’. For panels without any keyswitch, gauges can bedriven from the 1 mm2 brown wire which terminates at 11 way connector terminal 4. This is a lower power switchedpositive, any additional power required from this connectionmust be feed through a relay, as noted below.

Note: these keyswitch terminals are rated at 10 ampsmaximum, since they are already utilised for panel andalternator feeds Beta Marine recommend any additionalrequirements from these terminals must be fed through arelay. This relay should then be connected to it’s own fusedpositive supply directly from the engine battery. Beta drawing202-06421 illustrating the wiring of a typical electric fuel liftpump with ignition switched relay is included in this manual.


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Guidelines for Operation of EngineImportant Checks Prior to Initial Use

1. Generally, a new engine has the oil and anti-freezeremoved after the works test. Fill the engine with thecorrect oil and antifreeze (see sections on Engine oil andCooling). Check gearbox oil level - see gearbox ‘OwnersHand Book’.

2. Ensure the engine is free to turn without obstructions.

3. Ensure battery is fully charged and connected with thebattery isolator in the ‘ON’ position.

4. Ensure "Morse" speed and gearbox cables are fittedcorrectly and that cable travel lengths are correct. Gearselection lever - all mechanical gearboxes: care must betaken to ensure that the remote control cable is adjustedso that the selector lever on the gearbox moves full traveland is brought "hard up" against its end stop in bothdirections. Failure to achieve the correct adjustment willreduce efficiency of the clutch and may cause slippage atlow revs. Warranty will not be accepted on gearboxesreturned in the warranty period for failure due to incorrectadjustment.

5. Open the sea water cock - carefully checking there are nowater leaks.

6. Bleeding the fuel system for initial start up.

a) The fuel system must have all the trapped air carefully‘bled’ out; starting at the fuel tank and progressivelyworking through to: the fuel/water trap, the fuel filter, to the fuel injection pump.

b) Open the fuel tank stop tap / valve and then bleed thefuel/water separator of air as shown in manufacturer’sliterature.

c) Fuel should now arrive at the fuel lift pump.

d) Open the fuel bleed screw on top of the fuel filter by 1 to 2 turns, see photo 12.

e) Move the hand priming lever on fuel lift pump up anddown (photo 11) until fuel with “no bubbles” comes outof the fuel filter bleed screw (photo 12). The handpriming lever normally has about 90° travel; but thecamshaft lobe may block this travel requiring you to rotatethe engine to obtain full travel.

f) Shut / tighten the bleed screw.

g) Open the bleed screw on the fuel injection pump andagain ‘bleed’ through to the injection pump. Continue tohand prime for 30 seconds to push fuel and anyremaining air through the fuel pump. Clean all areasthoroughly of fuel with tissue paper.

7. Ensure engine is out of gear and set to 1/3 throttle - see "single lever control" instructions/manual.

8. Start engine (see normal starting). Note the engine mayhave to be turned over with the starter for a few secondsbefore it fires. Do not run the starter for more than 20seconds. If the engine has not started after 20 secondsthere is probably still air in the fuel system; disengage thestarter and continue to hand prime the engine with thefuel lift pump lever for a further 30 seconds, then repeat.If engine does not start after 3 attempts then allow 5minutes for the starter to cool down before repeating 6 (c)to 8. Note: The starter motor windings can be burnt outwith continuous cranking.

Section 2

11

12 Fuel bleed screw

Caution. To avoid personal injury:

• Do not try to start the engine until you know how to stop the engine.

• Do not bleed a hot engine as this could cause fuel to spill onto a hot exhaust manifold creating a dangerof fire.

• Do not mix petrol/gasoline or alcohol with diesel fuel. This mixture can cause an explosion.

• Do not get diesel fuel or oil on the flexible mounts - they will deteriorate rapidly if soaked in these.

• All fuel must be removed from skin to preventinfection.


To operate the engine: with the engine out of gear, set speedcontrol lever to 1/3 throttle.

1) Turn key anti-clockwise to ‘HEAT’ position and hold forten seconds.

2) Turn key clockwise to ‘RUN’ position. At this stage theinstrument panel should illuminate:

• Green lamp for panel ‘power on’ should illuminate.

• Buzzer should sound.

• Red lamp for ‘low oil pressure’ should illuminate.

• Red lamp for ‘high engine temperature’ should not

illuminate (when engine is cold / cool / warm). This lamp

will only ever illuminate if the engine is over temperature.

• Red lamp for ‘no starter battery charge’ should illuminate.

• Red lamp for ‘no domestic battery charge’. Only fitted with

panels AB and C and will illuminate only if 2nd ‘domestic’

alternator is fitted.

3) Turn to ‘START’ position and engine will motor, hold inposition until engine fires (see initial start-up section formaximum time starter can be used).

4) Release key (when engine has started) to ‘RUN’ position.

• All red warning lamps should extinguish and buzzer should

stop sounding. The oil pressure lamp may take a few

seconds to switch off and the charge fail lamp may remain

on until engine rpm is increased to approximately 1,000rpm

if the engine was started on tickover.

• Green lamp for ‘panel power on’ should still function.

• If the ‘charge fail’ lamp remains on then “blip” the engine

speed up to 2000 rev/min and it will go out (split charge

relay drain).

12

Beta Control Panels - A, AB, ABV, B and C Deluxe - with keyswitch.

Beta Control Panel ABVW - Keyless (without keyswitch)This panel controls the engine with three water resistant pushbuttons instead of a keyswitch, and is less prone to damageand corrosion from sea water spray.

To operate the engine: with the engine out of gear, set speedcontrol lever to 1/3 throttle.

1) Press and hold ‘HEAT’ button for ten seconds maximum.

• Green lamp for panel ‘power on’ should illuminate.

• Buzzer should sound.

• Red lamp for ‘no starter battery charge’ should illuminate.

• Red lamp for ‘high engine temperature’ should not

illuminate (when engine is cold / cool / warm). This lamp

will only ever illuminate if the engine is over temperature.

• Red lamp for ‘low oil pressure’ should illuminate.

2) Press ‘START’ button and hold in position until enginefires (see initial start-up section for maximum timestarter can be operated). Release button (when enginehas started)

• All red warning lamps should extinguish and buzzer should

stop sounding. The oil pressure lamp may take a few

seconds to switch off and the charge fail lamp may remain

on until engine rpm is increased to approximately 1,000rpm

if the engine was started on tickover.

• Green lamp for ‘panel power on’ should still function.

3) To stop the engine press the ‘STOP’ push button, hold inuntil engine stops. This button also switches the power offto the gauges, engine and ‘power on’ lamp.

4) To re-start the engine, simply repeat steps from ‘1’ above,there is no need to switch battery isolators off whilstremaining on board.

5) If leaving the boat, isolate start battery from engine andpanel, to prevent accidental start up of engine and stoppower leakage.

Normal Starting

13

14


13

Stopping

Every propulsion engine is fitted with a stop solenoid. To stop the engine simply press stop push button, hold inuntil engine stops, then turn key from ‘RUN’ to ‘OFF’ position.Do not turn the key to the off position when the engine isrunning, this will not allow the alternator to charge thebattery.

Warning!

Do not leave the key in ‘HEAT’ position for more than 15 seconds - this will damage the heater plugs andeventually lead to poor starting.

When leaving the boat for an extended period:

• Turn off sea-cock (heat exchanger cooled engines).

• Turn off battery isolator.

Notes for all panel types: Do not depress the stop buttonfor more than ten seconds as this will lead to overheatingand failure of the solenoid. These engines are equipped witha mechanical stop lever in the event of electrical systemfailure. This lever is located on the starboard side of theengine behind the speed control lever. See illustration below.Move the stop lever aft to stop the engine then return it to therun position.

15

Speed lever

Stop lever


14

Maintenance Schedule

Daily or every 8 hours running

• Check engine oil level.

• Check gearbox oil level.

• Check coolant level.

• Check battery fluid.

• Check drive belt tension

• Ensure raw water inlet strainer is clear.

• Check stern gland lubrication if used.

• Drain off any water in fuel/water separator.

After the first 25 hours running

• Change gearbox lubricant (See separate gearbox manual).

• Check that all external nuts, bolts and fastenings are tight.See table for torque values. Do NOT over tighten. Specialattention should be paid to the flexible mount lock nuts,these should be checked for tightness, starting with lowernut first in each case. If the lower nuts are found to bevery loose, then the alignment of the shaft to the gearboxhalf coupling should be re-checked. Poor alignment dueto loose flexible mount nuts will cause excessive vibrationand knocking.

• Check the belt tension on any second alternators fittedand adjust, see page 11.

• Check ball joint nyloc nuts for tightness on both gearboxand speed control levers. Grease both fittings all over.

After first 50 hours

• Change engine lubricating oil.

• Change oil filter.

• Check for leaks on header tank tubestack. Tighten end cap bolt if required.

• Drain off any water in fuel/water separator.

Every 150 hours

• If shallow sump (option) is fitted, change enginelubricating oil and filter.

Every year or 250 hours if sooner

• Change engine lubricating oil (standard sump)

• Change lubricating oil filter

• Check air cleaner element

• Check sea water pump impeller and change if worn.

• Check wasting anode condition, replace when necessary.In some environments this may be six monthly or less.

• Remove heat exchanger tube stack, by undoing the bolteach end of the tube stack. Remove end cover, pull outtube stack and clean. Replace rubber ‘O’ rings and re-assemble. Top up with antifreeze. Immediately engine isstarted check for leaks.

• Spray the key switch with WD40 or equivalent tolubricate the barrel.

• Check that all external nuts, bolts and fastenings are tight.See table for torque values.

• Check ball joint nyloc nuts for tightness on both gearboxand speed control levers.

Every 750 hours (In addition to 250 hours maintenance)

• Change air cleaner element.

• Change fuel filter.

• Change antifreeze.

• Change gearbox oil.

• Check electrical equipment, condition of hoses and belts,replace as necessary.

Section 3


15

Maintenance ScheduleDaily or After After Every Every Year Every

every 8hrs first first 150hrs with or 250hrs 750hrs

running 25hrs 50hrs shallow sump if sooner

Check engine oil level

Check gearbox oil level

Check engine coolant level

Check battery fluid

Check drive belt tension

Ensure raw water inlet

strainer is clear

Check stern gland lubrication

Drain off any water in fuel /

water separator

Change gearbox oil See separate gearbox manual

Check all external nuts, bolts and

fastenings are tight. Check belt

tension. Check for leaks

Change engine oil

Change oil filter

Lubricate keyswitch on control

panel with “vaseline” or WD40

Check coolant ”sacrificial” zinc

anode and replace if necessary

- sometimes frequently

Check general condition

Remove heat exchanger tube stack

and replace rubber O-rings

Check sea water pump impeller

and change if worn

Check air cleaner element

and change if required

Change air cleaner element

Change diesel fuel filter

Change gearbox oil

Drain and replace engine

coolant / anti-freeze


16

Lubrication

Engine oil: Engine oil quality should have the minimumproperties of the American Petroleum Institute “API”classification CF (CD, or CE). The following table gives gradesof oil viscosity required for various ambient temperatureranges.

Note: A good quality SAE 15W/40 mineral based multigradeoil as used in most car diesel engines will meet requirements.Do not use ‘Turbo Diesel Oil’ or additives, and the use ofsynthetic oil is not recommended.

Checking engine oil level

For quantities of oil required see section marked ‘TechnicalSpecification’, page 4.

When checking the engine oil level, do so before starting, ormore than five minutes after stopping.

1. To check the oil level, draw out the dipstick, wipe it clean,re-insert it, and draw it out again. Check to see that theoil level lies between the two notches.

2. If the level is too low, add new oil to the specified level -Do not over fill.

Important: When using an oil of different make or viscosityfrom the previous one, drain old oil. Never mix two differenttypes of oil. Engine oil should be changed after first 50 hoursrunning time and then every year or every 250 hours ifsooner. Oil filter is a cartridge type mounted on the starboardside of the engine.

Ambient Temp. Single Grade Multi-Grade

-30°C to 0°C SAE 10W S AE 10W/30

-15°C to +15°C SAE 20W SAE 15W/40

0°C to +30°C SAE 30 SAE 15W/40

25°C and above SAE 30 SAE 15W/40

Changing engine oil

(1) Run the engine for 10 minutes to warm up the oil.

(2) Drain the engine sump of the used engine oil. Yourengine is provided with a sump drain pump. Unscrewthe end cap on the end of the pump spout, turn the tapto ‘on’. Use the hand pump as shown, to pump out theoil into a bucket. When empty turn the tap to ‘off’position and replace end cap. See photo 18.

(3) Unscrew the oil filter and replace with a new one. Seephoto 19. Note: It is best to have a plastic bag wrappedround the filter to catch any oil left in the system.(Always keep your bilges clean!) Before screwing in thenew filter spread a thin film of oil round the rubbergasket to ensure a good seal and screw in - hand tight.

(4) Fill the engine with new oil as described above.

(5) Run the engine and check for oil leaks.

16 17

Dipstick

Oil goes in here


17

Checking Gearbox oil level

1) The gearbox is fitted with a dipstick and oil filler plug, see photo 20.

2) Each engine is supplied with a gearbox ‘operatorsmanual’ which specifies the type of lubricating oil to beused, the capacity and frequency of changing of the oil.

3) New engines are normally supplied with the gearboxtopped up with lubricant but check the level beforestarting the engine for the first time.

4) The oil can be changed via the drain plug at the bottomof the box or sucked out with a hand pump via the fillerplug.

5) A guide to the type of oil to be used is as follows:

Gearbox Lubricant Capacity (approx.)

TMC40 Use ATF Oil 0.20 litres

TMC60 Use ATF Oil 0.65 litres

PRM80 Use Engine Oil 15W40 0.60 litres




TTMC 35A-2 Use Engine Oil 15W40 0.65 litres

ZF15MIV Use ATF Oil 1.00 litres

Note: ATF is Automatic Transmission Fluid. For additional information see: www.prm-marine.com

18 19

20

End cap

Sump pump

Dipstick


18

Fuel Filter Replacement

1. The fuel filter is a spin on type. Remove by turning anti-clockwise when viewed from below.

2. Replace the fuel filter cartridge every 750 hours or every2 years. See photo 21.

3. Apply fuel oil thinly over the gasket and tighten intoposition - hand tight.

4. Bleed as detailed - see ‘initial start up’.

5. Check for leaks.

6. Do not get fuel on the flexible mounts, this will degradethe rubber.

21

22 Heat Exchanger Cooled

Fresh water ‘coolant’ circulates through the engine and thenthe heat exchanger body where the engine heat is transferredto the sea water that is pumped through the heat exchangercooling tubes (tube stack). The heated sea water is theninjected into the exhaust system (see diagram).

Fuel System

Important

• Always fit a fuel/water separator in the fuel supplysystem. Water in the fuel can seriously damage theinjection system.

• If a fuel supply shutoff valve is fitted do not use a tapertap, only use a ball valve tap. The ball valve type aremore reliable and less likely to let air into the fuel system.

• Be sure to use a strainer when filling the fuel tank. Dirt orsand in the fuel may cause trouble in the fuel injectionpump.

• Always use diesel fuel. Do not use paraffin / kerosene,which is very low in cetane rating, and adversely affectsthe engine.

• Bio-diesel fuel can be added to the normal diesel fuel upto a maximum limit of 5% without affecting the warranty.

• We know that some customers are using 100% Bio-diesel fuel, Important; Beta Marine warranty will notcover fuel equipment when more than 5% Bio-diesel isused. If you use Bio-diesel fuel you must fit an electric liftpump into the fuel supply line and the fuel filter and oilfilter must both be changed together when the oil filter isnormally replaced.

• Be careful not to let the fuel tank become empty, or aircan enter the fuel system, necessitating bleeding beforenext engine start.

• The fuel lift pump will only lift fuel through 0.25m. If this is insufficient then an electric fuel lift pump mustbe fitted. Drawing 202-06421, illustrating recommendedwiring for this pump is included in the back of themanual.


19

Filling the Freshwater System

New engines are supplied with the fresh water ‘coolant’drained off. The following instructions must be followed to fillthe system.

a) Pour into a clean bucket a mixture of both fresh waterand anti-freeze; with an anti-freeze ratio of 33% to 50%(see next page). For the required volume see technicalspecification page 4.

b) Check that the coolant drain tap or plug is turned off. Seephoto 23.

c) Fill engine with freshwater / anti-freeze solution throughthe top of the heat exchanger or header tank with thefiller cap removed. See photo 24.

d) Fill header tank to the top of the filler neck and replacecap. Press down firmly on filler cap and hand tighten ina clockwise direction.

e) Run the engine for 5 minutes on no load (out of gear)and check coolant level, this will help remove air fromthe system. Top up as necessary.

f) Check system for leaks.

g) If a calorifier is fitted care must be taken to see that thisis also full of coolant and all the air is removed. (Seecalorifier fitting notes under Section 1).

h) Run the engine on one third load for 15 minutes,preferably with the boat tied up. As the system warmsup coolant may be expelled from the overflow pipe intothe bilge. Stop the engine and allow the engine to cooldown before removing the pressure cap and top up thecoolant to 25 mm / 1 inch below the filler neck.

Important: Removal of the pressure cap when the engine ishot can cause severe injury from scalding hot water underpressure. Always allow the engine to cool and then use alarge cloth when turning the cap anti-clockwise to the stop.This allows the pressure to be released. Press firmly down onthe cap and continue to turn anticlockwise to release thepressure cap.

i) Repeat (h) if coolant level is more than 1 inch below thebase of the filler neck when the engine has cooled down.

j) Run engine on 2/3 full load for 20 minutes, check forleaks and repeat (i) if necessary.

k) Anti-freeze solutions should be drained off every 2 yearsand replaced with a new solution.

Note: When draining your fresh water system, ensure theengine has cooled sufficiently to prevent scalding from hotpressurised water. Prior to draining a cold engine, remove thefiller cap from the header tank and then open the water draintap. This allows the water to drain freely from the system.

23

24

water / antifreezegoes in here


20

Yachts and launches with heat exchanger cooling

It is essential that a solution of fresh water and anti-freeze isused as engine coolant. The amount of anti-freeze must bebetween 33% to 50%. This not only stops ‘freezing up’ inwinter, but it prevents overheating and corrosion.

The warranty is invalid unless the correct ratio is used. The concentration of ethylene must NOT exceed 50%.

The anti-freeze in the fresh water system enables the boilingpoint of water to rise to 124°C with a 13 psi pressure capfitted.

The water temperature alarm switch will however beactivated at 95°C to 100°C. If no anti-freeze or a very weaksolution is used, then the water temperature switch may notbe activated before coolant is lost.

Cleaning the heat exchanger tube stack and replacing ‘wasting zinc anode’

(1) The wasting zinc anode should be checked regularly atleast every six months and replaced every year or sooner,as necessary. The anode is attached to the bolt insertedin the end cap of the heat exchanger. See photo 25. Onmost engines this is on the aft end.

(2) Unscrew the bolt and replace the complete unit with anew one.

(3) It is possible for fine sea weed and other debris to getpast the inlet filter and into the tube stack. This shouldbe removed and cleaned. See photo 26.

(4) Drain off coolant into a bucket.

(5) Unscrew the 2 end cap retaining bolts (one each end ofthe tube stack). Remove the ‘O’ rings and pull out tubestack. Clean tube stack and end caps.

Sea water pump and cooling system(Heat exchanger-cooled engines)

Caution: Before working on the sea water system ensure that the sea cock is in the off position.

1) It is very important that the correct sea water flow ismaintained to cool the closed circuit system of theengine. The key component in this system is the seawater pump impeller. This should be checked every yearby removing the circular plate. See photo 27.

2) Withdraw the rubber impeller from its drive shaft asshown. See photo 28.

3) Check impeller for cracks in the rubber, excessive wearor lost vanes. Replace with a new impeller as necessary.

25 26

Zinc anode


21

Note: If any pieces of rubber impeller are missing then theymust be found as they are most likely to be trapped in theentrance to the heat exchanger cooling stack. See ‘CleaningTube Stack’.

4) Re-assemble using new ‘O’ rings. Do not over tightenend cap bolts and make sure the tube stack is theright way round for end cap location.

5) Re-fill engine with coolant (water/anti-freeze solution)and run engine up to temperature to check for leaks.

2827

Belt Tension

Warning: Belt tension must only be checked with the engineswitched off.

These engines are fitted as standard with a single belt thatdrives both the 65 Amp battery charging alternator and thefresh water / engine coolant circulating pump.

65 Amp alternator (heat exchanger cooled)

(1) The belt tension is adjusted by swinging the alternatoroutboard as it pivots on its support bolts. See photo 29.

(2) With the engine stopped, loosen the support bolts andthe link adjusting bolt.

3) Push alternator outboard by hand to tension the belt,then tighten link bolt.

(4) Check that the depression of the belt (at position shown)is approximately 1/2” or 12 mm when pushed downfirmly by thumb. Tighten support bolts. See photo 30.

(5) Belt tension should be regularly checked especiallyduring the first 20 hours of running in a new belt, asstretching occurs.

100 Amp alternator (option)

The same method applies as outlined above with the‘polyvee’ flat belt, but final tensioning must be by hand only.Over tensioning will cause premature failure of components.

29 30

Adjuster bolt


22

Air Filter Intake

These engines are fitted with an air intake filter which should be checked every season and changed every 2 years or sooner ifbadly clogged. If badly clogged check more often.

Panels and Wiring

See installation notes, page 30.

General maintenance

(1) The panel must be protected from rain and sea water,see installation. Sea water entering the key switch willeventually cause corrosion and could result in the startermotor being permanently energised and burning out.Spray key switch every month with WD40 or equivalent;or apply ‘vaseline’.

(2) Check batteries for acid level and top up if required. For low maintenance and ‘gel’ batteries seemanufacturers instructions.

(3) Loose spade terminal connections are the most commoncause for electrical faults - check on a regular bases (seemaintenance instructions).

Maintenance - Electrical

Warning:

Under no circumstances should the battery be disconnected or switched off whenthe engine is running. This will seriously damage the alternator.

31 32


Winterising and Laying up

Heat Exchanger Cooled Engines Left Afloat and Ashore

a) The engine lubricating oil and lubricating oil filter shouldbe changed at the end of the season rather than in thespring. See section 2.

b) The closed circuit cooling system must contain an anti-freeze coolant solution. The coolant solution is a mixtureof fresh water and anti-freeze (Ethylene Glycol basedconforming to BS6580:1992) with the anti-freeze beinga minimum of 33% up to a maximum of 50% solution(this also applies to warm and tropical climates). Thewarranty is invalid if the correct percentage/ratio is notused.

c) For cold climates where the air or water temperaturescan fall below 3°C, the sea water circuit must beprotected in addition to the fresh water system. This isbest achieved as follows:

• Close the inlet seacock to the engine (engine stopped).

• Disconnect the sea water inlet pipe and dip it into asmall bucket containing 50/50 anti-freeze solution.

• Start the engine (out of gear) and run for 5 to 10seconds until the anti-freeze is used up and can be seencoming out of the exhaust outlet.

• Shut engine off and reconnect the inlet pipe to theseacock. The sea water or raw water circuit is nowprotected by anti-freeze.

d) Ensure instrument panel is well protected and give thekey switch a spray of WD40 / Petroleum Jelly orequivalent.

e) With the engine stopped, disconnect the battery (alwaysdisconnect the negative cable first and re-connect thenegative cable last) and take it ashore for trickle chargingand top up as necessary. If AC power is available thenthis can be done on the boat.

Fuel tanks should be kept full during the lay up period toeliminate water condensation in the tank. Water enteringthe fuel injection system can cause considerabledamage.

Laying up Ashore

a) Change the engine oil before the boat is taken out of thewater. Remember that warm engine oil is much easier topump than cold!

b) Cooling system - As above in ‘Winterising and Laying up’paragraphs (b) to (f) should be followed.

c) If the engine is to be laid up for more than 6 monthsthen remove the sea water pump impeller.

d) If the engine will not be used or run for periods longerthan 6 months we recommend that the engine is‘inhibited’ - this means involves running the engine forabout 5 minutes to:

• Replace all the diesel fuel in the fuel system andinjection pump by running the engine with ‘calibrationfluid’ (fuel pump test oil ISO 4113).

• Allow ‘Ensis’ to circulate around the lubricating oil systemby draining out the standard lubricating oil and replacingit with a rust preventative oil such as ‘Ensis’ or similar.

23


33

24

Trouble ShootingBeta diesels are very reliable if installed and serviced correctly, but problems can occur and the following list gives the mostcommon ones and their solution.

Fuse.

Note: For convenience, some engines are supplied witha spare fuse and holder attached to the main enginefuse holder.

Problem: Engine does not start but starter motor turns over OKPossible Cause Solution

No fuel: Turn fuel cock on and fill tank.

Air in fuel system: Vent air (see initial start-up)

Water in fuel: Change fuel filter and bleed system.

Blocked fuel pipe: Clean out and bleed system.

Fuel filter clogged: Change filter and bleed system.

Fuel lift pump blocked: Remove and replace.

Blocked injector: Remove and clean.

Fuel return not fed back to the tank: Re-route fuel return pipe.

Heater plugs not working: Check wiring to the plugs, and replace plugs if theyare burnt out.

Stop solenoid stuck in off position: Check solenoid is free to return to run position.

Problem: Starter motor will not turn or turns over very slowlyPossible Cause Solution

Battery discharged: Charge battery or replace. Check alternator belt tension.

Starter motor flooded with sea water: Remove and clean or replace.

Wiring disconnected or loose: Check circuit for loose connections.

Water in cylinders: Incorrect installation. This is serious - check engine oilfor signs of water (creamy-coloured oil). Ring your dealer.

Engine harness fuse blown: Replace fuse located by starter motor (or aboveflywheel housing) and check for wiring faults.


25

Problem: Erratic running / huntingPossible Cause Solution

Air in fuel supply: Check supply system for leaks and fix.

Fuel lift pump faulty: Replace.

Clogged fuel filter: Replace.

Fuel return not fed back to the fuel tank, or blocked pipe: Re-route pipe or clean.

Air filter blocked: Replace.

Worn or blocked injector: Service injectors.

Engine rpm in gear is too low, this must be 850 min: Increase engine tick over speed.

Faulty stop solenoid: Disconnect wiring to solenoid. If running improvescheck for a wiring fault.

Broken fuel injection pump spring: Replace, this is usually caused by water in theengine oil/fuel

Fuel suction head is too much: Fit electric fuel lift pump.

Problem: Hunting at idlePossible Cause Solution

Knurled leak-off valve may be closed, or Open knurled leak-off valve fully, with idle adjustment -idle adjustment screw may need adjusting: speak to Beta Marine for advice - discuss problem.

Problem: Hunting at higher speedsPossible Cause Solution

Fuel supply problem: Change fuel filters and check fuel supply.

Problem: Low power outputPossible Cause Solution

Propeller is too big: Change or depitch.

Check gearbox reduction ratio relative to propeller size: Change.

Blocked fuel filter: Replace.

Blocked air filter: Replace.

Air in fuel system: Check system and bleed

Governor spring incorrectly mounted: Dealer to adjust.

Single lever control not operating correctly: Disconnect speed control cable and move the leverby hand. Adjust cable.

The electrical load is too large on start up: Disconnect or reduce the load.

Problem: White or blue exhaust gasPossible Cause Solution

Engine oil level too high: Reduce the level.

Blocked injector: Service injectors.

Piston ring and bore worn or con rod bent due to water Get compression checked by your dealer or ingression, giving a low compression: Kubota service agent. He will advise action to be taken.

Check that the breather pipe is clear and not obstructed: Remove and clean out


26

Problem: Low oil pressure warning light on when engine speed is reduced to tick overPossible Cause Solution

Faulty switch sender: Replace.

Engine running too hot: Check cooling water flow (see section 2 Cooling).

Oil relief valve stuck partially open with dirt: Remove and clean.

Blocked oil filter: Change.

Wiring fault: Check circuit.

Insufficient oil: Top up and check for leaks.

Problem: Panel rev counter not working (when fitted).

Problem: Low oil pressure warning light on when underwayPossible Cause Solution

Oil frothing due to high installation angle or too high oil level: Refer to Beta Marine for advice

Problem: High oil consumptionPossible Cause Solution

Oil leaks: Check for leaks.

Piston rings worn: Overhaul required.

Valve stem and guide worn: Overhaul required.

Piston rings gap facing the same direction: Shift ring gap position. Service Agent to check.

Problem: Water in lubricating oil - generalPossible Cause Solution

Core plug pushed out due to frozen block: Service Agent to check and replace.

Water pump seal damaged: Service Agent to check and replace.

Problem: Water in lubricating oil - heat exchanger cooledPossible Cause Solution

Oil goes "milky" due to seawater entering exhaust manifold: Check installation - has anti-siphon valve been fitted?Change engine oil and run engine for 10 minutes eachtime to eliminate any water. Get fuel injection pump andcompression checked by Service Agent.

Problem: Black exhaust gasPossible Cause Solution

Blocked air filter element: Inspect and replace.

Over pitched propeller - engine will not reach its full rpm: Get the propeller re-pitched if necessary.

Accumulated debris on hull: Inspect and clean if required.


27

Problem: Engine overheatsPossible Cause Solution

Check coolant level: Top up.

Pressure cap loose: Tighten correctly or replace.

Switch sender faulty: Replace.

Insufficient restrictions in pipe to calorifier: Clamp off pipe to confirm.

High exhaust back pressure: Must not exceed: 80 mm of Hg (3.2" of Hg) @ 3,600rpm,70 mm of Hg (2.8” of Hg) @ 3,000rpm.

Keel cooler insufficient size: Contact boat builder

Problem: Engine overheats - Heat exchanger only

The most common cause of overheating is insufficient seawater flow due to a blocked intake (weed or a plastic bag!). Ifthis happens then clear the blockage. If the problem is not cured then check the system for sea water flow which shouldbe 15 litres / minute minimum at 1,500 rpm as follows:

(a) With the boat tied up and out of gear run the engine up to 1500 rpm. Hold a plastic bucket over the exhaust outlet for10 seconds and measure the amount of water collected*. Multiply this value by 6 to give the flow in litres/min. Repeattwice and take an average. If the flow rate is noticeably less than the 15 litre per minute minimum at 1,500 rpm, then:

(b) Check impeller in sea water pump - if worn replace.

(c) If impeller has a vane missing then this will be lodged either in the pipe to the heat exchanger or in the end of theexchanger. This must be removed.

(d) Check flow again as in (a).

*Note: This operation must only be done in safe conditions, in port and with two assistants. Working from a rubber dinghyis best. The person holding the bucket should take precautions against breathing in the exhaust gasses.

Problem: Engine overheats - Keel cooling only

Sometimes overheating is caused by:

(a) Not fully venting the engine cooling system of air. It is necessary to remove all air from the cooling system - includingthe “skin” tanks and (if fitted) the Calorifier and associated piping.

(b) Incorrectly sized “skin” tanks that have been sized for ‘usual’ canal use (rather than maximum engine output that cansometimes be required) on fast flowing rivers. An additional “skin” tank may need to be fitted; please refer to ourwebsite: Inland waterways - Guidelines: keel cooling tank sizes.

Problem: Water in lubricating oil - keel cooledPossible Cause Solution

Oil goes "milky" due to water entering exhaust Check installation - has dry exhaust system been fitted manifold and then into the sump: correctly, and ensuring rain water cannot enter the

exhaust port and run back? (See Dry Exhaust System).Change engine oil and run engine for 10 minutes eachtime to eliminate any water. Get injection pump checkedby Service Agent.


28

Problem: Transmission noisePossible Cause Solution

Check gearbox oil level: Top up.

"Singing" propeller: Check with propeller supplier about ‘harmonics’.

Drive plate rattle at tickover: Check engine rpm (must be 850rpm min. in gear).

Worn drive plate: Change.

Propeller shaft hitting the Gearbox half coupling: Move shaft back to give 5mm - 10mm clearance(Type 12/16 couplings only).

Propeller torsionals causing gears to rattle at low rpm: Fit a torsional flexible coupling such as Centatype 16 or equivalent.

Problem: Panel rev counter not working (when fitted)Possible Cause Solution

No W connection to alternator: Check output from ‘W’ connection. Should be about 9V AC

Wiring fault: Check circuit

Problem: Morse control cable will not fitPossible Cause Solution

Incorrect fitting: Cables are being fitted the wrong way around,switch over and fit the opposite way.

Problem: Battery quickly dischargesPossible Cause Solution

High load and insufficient running: Reduce load or increase charging time. Large domesticbattery banks subject to high electrical loads will takea considerable time to recharge from a single alternator.

Low electrolyte level: Top up.

Fan belt slipping - black dust in engine compartment, Adjust tension / replace belt with a high temperatureengine compartment temperature too high: type and / or improve engine compartment ventilation.

Alternator defective: Check with Agent.

Battery defective: Replace.

Poor wiring connection: Check wiring system.


29

Problem: VibrationsPossible Cause Solution

Poor alignment to shaft: The alignment must be accurate even if a flexiblecoupling is used (see section 1, Alignment).

Flexible mounts not adjusted correctly to take even weight: Check relative compression of each mount.

Flexible mount rubber perished: Replace. (Diesel or oil will eventually perishmost rubbers.)

Loose securing nut on flexible mount: Check alignment and then tighten the nuts.

Insufficient clearance between the propeller There must be at least 10% of the propeller diametertip and the bottom of the boat: as tip clearance between the propeller and the bottom

of the boat. Reduce propeller diameter / increase pitch.

Loose zinc anode on the shaft: Tighten or replace.

Worn cutless bearing or shaft: Replace.

Weak engine support/bearers: Check for cracked or broken feet.

Problem: Knocking noisePossible Cause Solution

Propshaft touching gearbox output coupling Adjust, giving correct clearance give 5mm - 10mmthrough split boss or Type 16 coupling: between gearbox and propeller shaft

Flexible mount stud touching engine bed: Adjust stud to clear

Drive plate broken: Replace / repair

Engine touching engine bed: Re-align engine / modify bed

Injectors blocked through excess carbon Remove and check injector nozzles, replace if required.caused by water in the fuel:


30

The following chart is compiled to aid diagnosis of electricalfaults, based on the Beta 10 - 90hp range of engines. If yourengine was built before July 2005, contact Beta Marine forthe relevant electrical trouble shooting guide.

Note: our standard control panels are for earth returninstallations only (where battery negative cable is connecteddirectly to engine ground). For insulated earth (where batterynegative cable is isolated from engine ground) differentharnesses, alternators, switches for oil pressure and enginetemperature are fitted.

Standard sea specification engines (heat exchanger cooled)are supplied with a single alternator, mounted port side,supplying power to starter battery and control panel.

Standard canal specification engines (keel cooled) aresupplied with twin alternators:

• 1st alternator, mounted port side, supplying power tostarter battery and control panel

• 2nd alternator, the standard mounting position for this isabove the engine on the starboard side (or below 1stalternator on 75 and 90hp), supplying power to thedomestic battery system.

Both of these alternators work independently, if the domesticbattery system is disconnected, the engine will still runcorrectly but:

• Domestic charge warning lamp will not function

• Warning buzzer will remain on at all times

Note: The two way plug on panel loom will only have acorresponding socket to connect into from the engine if a 2ndalternator is fitted which requires this connection. Engineswith only one alternator do not utilise this connection.

Standard Keyswitch Control Panels aresupplied with four or five lamps.

Four lamp panels: A, ABV, B these panels utilise bulbsinside sealed lamp holders.

Five lamp panels: AB and C; these panels also utilisebulbs inside sealed lamp holders, having an additionallamp for ‘domestic battery charge’.

Electrical Fault Finding & Trouble Shooting - Engines built after July 2005 only

RUN

START

OFFHEAT

With keyswitch* in run position and engine off:

Red lamp for ‘low oil pressure’ should function

Red lamp for ‘high engine temperature’ shouldnot function (when engine is cold/cool/warm). This lamp will only ever function if theengine is over temperature.

Red lamp for ‘no starter battery charge’ should function

Red lamp for ‘no domestic battery charge’should function (Note: this will only functionif a second alternator is fitted to the engine and connected to a charged battery)

Green lamp for ‘panel power on’ should function

Buzzer should sound

34 Battery positive

Battery negative

35


31

ABVW - Keyless four lamp panel(without keyswitch)

This panel controls the engine with three water resistantpush buttons instead of a keyswitch, and is less prone todamage and corrosion from sea water spray. This panelutilises bulbs inside sealed lamp holders

1) Press and hold ‘HEAT’ button for ten secondsmaximum.

Red lamp for ‘low oil pressure’ should function

Red lamp for ‘high engine temperature’ should not function (when engine is cold/cool/warm). This lamp will only ever function if the engine is over temperature.

Red lamp for ‘no starter battery charge’ should function

Green lamp for ‘panel power on’ should function

Buzzer should sound.

2) Press ‘START’ button and hold in position until enginefires (see initial start-up section for maximum timestarter can be operated). Release button (whenengine has started).

All red warning lamps should extinguishand buzzer should stop sounding. The oilpressure lamp may take a few seconds toswitch off and the charge fail lamp mayremain on until engine rpm is increased toapproximately 1,000rpm if the engine wasstarted at tickover.

Green lamp for ‘panel power on’ should still function.

3) To stop the engine press the ‘STOP’ push button, holdin until engine stops. This button also switches thepower off to the gauges, engine and power on lamp.Before investigating any specific electrical problem,always check:

• Connection between panel harness and panelloom. It must be clean, dry and secured with acable tie.

• Check the start battery is connected to the correctterminal on the starter motor.

• Check the domestic battery is switched on andconnected to the correct terminals for the 2ndalternator.

• Battery connections, inspecting condition of cablesfrom battery to engine. If in doubt measure thevoltage at the engine.

• If alternator charge problem, measure batteryvoltage with engine off and again with enginerunning, if there is an increase alternator isfunctioning correctly, if not refer to check list.

STOPHEAT START

Electrical Fault Finding & Trouble Shooting - Engines built after July 2005 only

36


32

Electrical Fault Finding - All Lamp Panels

Problem Possible Cause and Solution

No warning lamps or • Battery isolation switch in off position - switch onbuzzer functioning, engine • Starter battery discharged - chargewill not start or stop • Engine fuse blown - check fuse (above starter motor or flywheel housing) and

replace if necessary.• Check for wiring faults.

Non function of warning lamp. • Disconnect switch wire to non-functioning lamp: green/blue –water temperature, The water temperature lamp white/brown –oil pressure, brown/yellow –alternator charge. Reconnect wire will not function unless engine temporarily to another warning lamp that is functioning; if wire switches lamp onis overheating or there is a replace faulty lamp.wiring fault • Disconnect positive feed to non-functioning lamp. Reconnect temporarily with wire

from another warning lamp that is functioning, if wire switches lamp on rewire withnew connection.

• If none of the above, check continuity of connections from panel to engine.

Water temperature warning lamp If engine is cold:on when engine is not over • Faulty wiring, check connection and continuity (small green/blue) from switch to temperature (Not 2B or 2C deluxe panel lamp. Ensure this connection is not shorting to earth (ground).panel see table on following page) • Faulty temperature switch –if lamp switches off on removal of connection to switch

unit, replace.If engine is warm:• Switch wire connected to large sender terminal of switch/sender unit. Remove and

refit to smaller (switch) terminal.

Buzzer not functioning. • If lamp is functioning but buzzer not sounding, check connection and continuityThe buzzer will not sound for from illuminated warning lamp (red not green) to buzzer board.green ’power on’ lamp • Faulty warning panel buzzer board - replace.

Starter battery charge lamp If tacho not functioning:not functioning • Alternator not connected properly, check continuity of small brown wire from rear

of alternator to ‘AC’ position on keyswitch.• Alternator connected properly, faulty alternator - replaceIf tacho functioning correctly:• Check continuity of small brown/yellow wire from rear of alternator to no charge

warning lamp on rear of panel.• If alternator connected properly, faulty panel warning lamp - replace

If tacho not functioning • Check connections on rear of tacho, especially black/blue wire, terminal ‘4’• Check connection of black/blue wire on rear of 1st alternator (W connection, usually

a bullet on flying lead, or lowest connection on alternators with 3 pin coupler)• Check continuity of black/blue wire from alternator to tacho• Measure voltage from alternator W connection to earth (ground), should be

approx. 7.5 - 9.0 volts AC

Domestic charge lamp not • Domestic battery not connected functioning, buzzer remains • Domestic battery not connected correctly:on with engine running B+ to domestic isolation block on starboard rail (port on 75 - 95hp)

B- to engine earth (ground)• Domestic battery flat• Panel relay faulty / incorrectly wired: Check voltage at relay terminal 86, white wire

is positive feed for warning lamp from AC position of keyswitch.

Domestic charge lamp not • No second alternator fitted to engine, domestic lamp not usedfunctioning, buzzer switching • D+ (charge indication) lamp connection at rear of alternator not connectedoff with engine running. • Two way plug and socket disconnected between engine harness and panel loomThis lamp will only functionif a second alternator is fittedto the engine


33

Electrical Fault Finding - C Deluxe and Water Temperature Function on B Panels

Problem Possible Cause and Solution

Oil pressure warning lamp not functioning, • Faulty wiring - check wire connection and continuity oil pressure gauge showing maximum deflection. (small white/brown) from sender to panel lamp.Engine off and keyswitch in run position Ensure this connection is not shorting to earth

(ground).

Oil pressure gauge showing no movement - even • Faulty wiring - check oil pressure sender wire when engine is started. Warning lamp functioning correctly (small white/brown) is connected.

Oil pressure showing no movement, • Check connection to oil pressure gauge, if plug is not Warning lamp not functioning correctly connected to socket on rear of gauge, reconnect.

• If all connections are correctly made, possible faultysender unit - check resistance to earth (ground) approx. 50 Ω . Replace if no reading or short-circuited.

• If adjusted correctly & buzzer still sounding, possible faulty switch gauge unit - replace.

Oil pressure showing normal operating pressure Engine warm:(0.75 - 5 bar). Buzzer sounding and lamp illuminated. • Incorrectly calibrated switching point for warning lamp,

adjust on rear of gauge to 0.5 bar (minimumadjustment on gauge).

• If adjusted correctly & buzzer still sounding, faultyswitch gauge unit - replace.

Water temperature gauge showing 120°C / 250°F. Engine cold / cool:This also applies to the B Panel with Murphy gauge • Faulty wiring, check water temperature sender wire is

not shorting to earth (ground).• Faulty sender unit, - check resistance to earth (ground),

approx. 3.5k Ω (cold) – 0.5k Ω (warm).Replace if notably less.

Water temperature gauge showing normal operating Engine warm:temperature (85°C). Buzzer sounding and lamp illuminated. • Incorrectly calibrated switching point for warning lampThis also applies to the B Panel with Murphy gauge adjust on rear of gauge to 100°C / 210°F.

• If adjusted correctly & buzzer still sounding, faultyswitch gauge unit – replace.

Water temperature gauge showing no movement, • Check connection to sender, if disconnected gauge lamp not illuminated, engine warm. will not function.This also applies to the B Panel with Murphy gauge • Check connection to temperature gauge, if plug is not

connected to socket on rear of gauge reconnect.

Water temperature gauge showing no movement, • Check connection to sender, if disconnected gauge lamp not illuminated, engine warm. will not function.This also applies to the B Panel with Murphy gauge • Check connection to temperature gauge, if plug is not

connected to socket on rear of gauge reconnect. If allconnections are correctly made, faulty sender unit -check resistance to earth (ground), approx. 3.5k Ω (cold) – 0.5k Ω (warm). Replace if no reading.

In addition to the fault finding detailed on the previous table, the following is specific for the deluxe panel (Also applicable forthe B panel with Murphy water temperature gauge)


34

Some installations require one of the panel extensions 11way connectors to be removed to allow the cable to bepassed through bulkheads etc.

If any panel problems are experienced, after this may havebeen carried out, visually check all 11 way connections onengine harness to panel extension (and panel extension topanel on C ‘Deluxe’) to ensure wire colours to each terminalmatch up to the correct colour in its corresponding terminal.

Extra attention must be given to black (ground) andblack/blue (tacho), also brown (switched positive toalternator) and brown/yellow (charge fail) as theseconnections are harder to distinguish between in poorly litareas. Whilst doing this check integrity of each connection toensure terminals have not become damaged. Once checked,re-fit cable tie around each connection to keep them secure.

Engines can be supplied wired up to suit VDO switchsenders, usually fitted to a non-Beta control panel. If so referto our wiring diagram 200-60971/01 (also part number forreplacement harness)

• Loom is configured differently in the 11-way plug toaccommodate the extra wiring.

• Small brown wire (battery sensed alternator feed) fittedwith bullet connection beside harness plug.

• Oil pressure and water temperature switch / senders fittedto engine, requiring individual connections for drivinggauges and warning lamps.

Note: Water temperature switch/sender(Part number 200-01133)

Large spade is sender connection (green/blue)

Small spade is switch connection (blue/yellow)

Oil pressure switch/sender(Part number 200-62680)

G Gauge wire (white/brown)

M Earth (ground) (black)

WK Warning lamp (green/yellow)

Electrical Fault Finding – Non-Beta Panels

Electrical Fault Finding – Extension Harnesses

If your application is wired as insulated earth return and theengine will not operate correctly, always check starter batterynegative is connected to the correct terminal on the isolatingsolenoid.

It should be connected to the terminal which is also used forall the small black wires, NOT the terminal with the singleblack wire connected directly to engine ground.

Electrical Fault Finding – Insulated earth


35

Tightening Torques for general use bolts and nuts

ITEM Size x Pitch kgf m lbf ft (ft lbs) N m

M6 (7T) : 6mm (0.24in) - 1.0~1.15 7.2~8.3 9.8~11.3

M8 (7T) : 8mm (0.31) - 2.4~2.8 17.4~20.3 23.5~27.5

M10 (7T) : 10mm (0.39in) - 5.0~5.7 36.2~41.2 49.0~55.9

M12 (7T) : 12mm (0.47in) - 7.9~9.2 57.1~66.5 77.5~90.5

Tightening Torques for special use bolts and nuts

Head Bolts M10 x 1.25 6.5~7.0 47.0~72.3 63.7~68.6

Bolts, Connecting Bolts M8 x 1.0 4.2~4.7 30.4~34.0 41.2~46.1

Bolts, Flywheel M10 x 1.25 5.5~6.0 39.8~43.4 53.9~58.8

Bolts 1, Bearing Case M8 x 1.25 3.0~3.5 21.7~25.3 29.4~34.3

Bolts 2, Bearing Case M9 x 1.25 5.0~5.5 36.2~39.8 49.0~53.9

Nozzle Holder Assembly M20 x 1.5 5.0~7.0 36.2~50.6 49.0~68.6

Caps Nuts, Head Cover M7 x 1.0 0.7~0.9 5.1~6.5 6.9~8.8

Glow Plugs M10~1.25 2.0~2.5 14.5~18.1 19.6~24.5

Oil Switch PT 1/8 1.5~2.0 10.8~14.5 14.7~19.6

Nuts, Rocker Arm Bracket M7 x 1.0 2.2~2.7 15.9~19.5 21.6~26.5

Bolts, Idle Gear Shaft M6 x 1.0 1.0~1.15 7.2~8.3 9.8~11.3

Spanner Torque Settings


36

1. Typical starter motor ratings Page 10

2. Suggested engine starter battery size Page 10

3. Keyswitch terminations Page 10

4. Standard engine harness (65 Amp) 200-05452 Page 37

6. Standard engine harness (100 Amp) 100-06077 Page 38

6. Diagram of extension harness 200-04588 Page 39

7. Diagram of panel ‘A’ & cut-out 200-06516 & 200-06305 Page 40 & 41

8. Diagram of panel ‘AB’ & cut-out 200-06517 & 200-06304 Page 42 & 43

9. Diagram of panel ‘ABV’ & cut-out 200-06519 & 200-06320 Page 44 & 45

10. Diagram of panel ‘ABVW’ & cut-out 200-06333 & 200-06331 Page 46 & 47

11. Diagram of panel ‘B’ & cut-out 200-06520 & 200-06303 Page 48 & 49

12. Diagram of Deluxe panel ‘C’ & cut-out 200-06518 & 200-06306 Page 50 & 51

13. GA of Beta 28 H/E TMC 40 100-01939 Page 52

14. GA of Beta 28 H/E PRM 80 100-99550 Page 53

15. GA of Beta 35/38 H/E TMC 60 100-01725 Page 54

16. GA of Beta 35/38 H/E PRM 120 100-98915 Page 55

17. GA of Beta 28 7° Down angle 100-06358 Page 56

18. GA of Beta 35/38 ‘V’ Drive 100-06545 Page 57

19. Split charge relay wiring (65 Amp) 300-62210/05 Page 58

20. Starter relay wiring - over 4 metres 300-58520 Page 59

22. Beta Controller information. Page 60 & 61

23. Wiring 100 Amp alternator and Beta Controller 100-05475 Page 62

24. Electric Fuel Lift Pump 202-06421 Page 63

25. Declaration of Conformity for Recreational Craft Page 65

26. Emission durability Page 66

27. Quick reference parts list Page 67 & 68

28. Maintenance record and service items Inside back cover

Index - Wiring Diagrams and General Arrangements


37


38


39


40


41

01

DO

NO

T S

CA

LED

IME

NS

ION

S IN

MM

(IN

CH

)

BE

TA M

AR

INE

TEL:

(014

53) 8

3528

2

FA

X: (

0145

3) 8

3528

4

RE

VD

ES

CR

IPTI

ON

NO

TES

AP

P'D

DA

TED

RA

WN

DR

AW

N B

Y:-

CH

EC

KED

BY

:-S

CA

LEP

AG

E

SIZ

E

TITL

E

DW

G N

O.

DA

TE

RE

V

NTS

A4

2 of

2

200-

0630

505

/09/

2008

A P

AN

EL

TW LT

MA

TL:

01 B

ETA

MAR

INE

LTD

,D

AV

Y W

AY

,W

ATE

RW

ELL

S,

QU

ED

GE

LEY

, GLO

UC

ES

TER

,G

L2 2

AD

, U.K

.

1010

150

10 1090

514

0

5

80

62AD

D 30

mm

FOR

WIR

ES

2041

CHAN

GED

KEY

SWIT

CH05

/09/

08LT

TW


42


43

01

DO

NO

T S

CA

LED

IME

NS

ION

S IN

MM

(IN

CH

)

BE

TA M

AR

INE

TEL:

(014

53) 8

3528

2

FA

X: (

0145

3) 8

3528

4

RE

VD

ES

CR

IPTI

ON

NO

TES

AP

P'D

DA

TED

RA

WN

DR

AW

N B

Y:-

CH

EC

KED

BY

:-S

CA

LEP

AG

E

SIZ

E

TITL

E

DW

G N

O.

DA

TE

RE

V

NTS

A4

2 of

2

200-

0630

405

/10/

2007

AB

PA

NE

L

TW LT

MA

TL:

01 B

ETA

MAR

INE

LTD

,D

AV

Y W

AY

,W

ATE

RW

ELL

S,

QU

ED

GE

LEY

, GLO

UC

ES

TER

,G

L2 2

AD

, U.K

.

1010

195

1010

180

63AD

D 30

mm

FO

R W

IRES

23

41

518

5

5

170

O 5

THR

U

CHAN

GED

KEY

SWIT

CH05

/09/

08LT

TW


44


45

01

DO

NO

T S

CA

LED

IME

NS

ION

S IN

MM

(IN

CH

)

BE

TA M

AR

INE

TEL:

(014

53) 8

3528

2

FA

X: (

0145

3) 8

3528

4

RE

VD

ES

CR

IPTI

ON

NO

TES

AP

P'D

DA

TED

RA

WN

DR

AW

N B

Y:-

CH

EC

KED

BY

:-S

CA

LEP

AG

E

SIZ

E

TITL

E

DW

G N

O.

DA

TE

RE

V

NTS

A4

2 of

2

200-

0632

0/01

05/1

0/20

07

AB

V P

AN

EL

timw

LT

MA

TL:

00 B

ETA

MAR

INE

LTD

,D

AV

Y W

AY

,W

ATE

RW

ELL

S,

QU

ED

GE

LEY

, GLO

UC

ES

TER

,G

L2 2

AD

, U.K

.

140

10

180

10

10

O 5

THR

U

5

517

0

130

20

20

23

63AL

LOW

30m

m F

OR W

IRES

41

CHAN

GED

KEY

SWIT

CH05

/09/

08LT

TW


46


47

01

BE

TA M

ARIN

E L

TD,

ME

RR

ETT

S M

ILLS

,B

ATH

RO

AD

,S

OU

TH W

OO

DC

HE

STE

R,

STR

OU

D, G

LOS

. GL5

5E

U

DO

NO

T S

CA

LED

IME

NS

ION

S IN

MM

(IN

CH

)

BE

TA M

AR

INE

TEL:

(014

53) 8

3528

2

FA

X: (

0145

3) 8

3528

4

RE

VD

ES

CR

IPTI

ON

NO

TES

AP

P'D

DA

TED

RA

WN

DR

AW

N B

Y:-

CH

EC

KED

BY

:-S

CA

LEP

AG

E

SIZ

E

TITL

E

DW

G N

O.

DA

TE

RE

V

NTS

A4

2 of

2

200-

0633

105

/10/

2007

AB

VW

SP

LAS

H P

RO

OF

PA

NE

L

TW LT

MA

TL:

AS U

SED

ON K

1474

4

00

180.

00

10.0

016

0.00

5.00

20.0

0

5.00

10.0

0

120.

0014

0.00

5.00

20.0

0

5.00

50.5

0AL

LOW

30m

m F

OR W

IRES

22.6

2

O 5

.00

THRU


48


49

01

DO

NO

T S

CA

LED

IME

NS

ION

S IN

MM

(IN

CH

)

BE

TA M

AR

INE

TEL:

(014

53) 8

3528

2

FA

X: (

0145

3) 8

3528

4

RE

VD

ES

CR

IPTI

ON

NO

TES

AP

P'D

DA

TED

RA

WN

DR

AW

N B

Y:-

CH

EC

KED

BY

:-S

CA

LEP

AG

E

SIZ

E

TITL

E

DW

G N

O.

DA

TE

RE

V

NTS

A4

2 of

2

200-

0630

305

/10/

2007

B P

AN

EL

TW LT

MA

TL:

01 B

ETA

MAR

INE

LTD

,D

AV

Y W

AY

,W

ATE

RW

ELL

S,

QU

ED

GE

LEY

, GLO

UC

ES

TER

,G

L2 2

AD

, U.K

.

210

1010

10

165

520

0

5

155

63AL

LOW

30m

m F

OR W

IRES

2341

CHAN

GED

KEY

SWIT

CH05

/09/

08LT

TW


50


51

01

DO

NO

T S

CA

LED

IME

NS

ION

S IN

MM

(IN

CH

)

BE

TA M

AR

INE

TEL:

(014

53) 8

3528

2

FA

X: (

0145

3) 8

3528

4

RE

VD

ES

CR

IPTI

ON

NO

TES

AP

P'D

DA

TED

RA

WN

DR

AW

N B

Y:-

CH

EC

KED

BY

:-S

CA

LEP

AG

E

SIZ

E

TITL

E

DW

G N

O.

DA

TE

RE

V

NTS

A4

2 of

2

200-

0630

605

/10/

2007

C P

AN

EL

TW LT

MA

TL:

01B

ETA

MAR

INE

LTD

,D

AV

Y W

AY

,W

ATE

RW

ELL

S,

QU

ED

GE

LEY

, GLO

UC

ES

TER

,G

L2 2

AD

, U.K

.

1010

298

10

166

10

528

8

5

156

63AD

D 30

mm

FOR

WIR

ES

23

41

CHAN

GED

KEY

SWIT

CH05

/09/

08LT

TW


52

01

DO

NO

T S

CA

LED

IME

NS

ION

S IN

MM

(IN

CH

)

TEL:

(014

52) 7

2349

2

FA

X: (

0145

2) 7

2991

6

RE

VD

ES

CR

IPTI

ON

NO

TES

AP

P'D

DA

TED

RA

WN

DR

AW

N B

Y:

CH

EC

KED

BY

:S

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LEP

AG

E

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TITL

E:

DW

G N

O:

DA

TE

RE

V

NTS

A4

1 of

1

100-

0193

909

/09/

2008

B

ETA

28 H

EA

T E

XCH

AN

GE

TMC

40

GE

AR

BO

X

TW LT03

BE

TA M

ARIN

E L

TD,

DA

VY

WA

Y,

WA

TER

WE

LLS

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DG

ELE

Y,

GLO

UC

ES

TER

. GL2

2A

D, U

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100-

0193

9 B

ETA

28 (B

D10

05) H

E T

MC

40.a

smP

AR

T FI

LE N

AM

E:

8 M

10 X

50

BOLT

SEQ

UI-

SPAC

ED O

NAN

82.

5 PC

D

FLEX

IBLE

COU

LPIN

G DE

TAILS

FLEX

IBLE

MOU

NT D

ETAI

LS

100

120

63

65M

IN90

.0 M

AX

155

216

271

369 262±03

185

WIT

H SH

ALLO

W S

UM

P

67.5

82

172

354

320

50O

205 205

172

354

737

FUEL

FIL

TER

FUEL

FIL

TER

F.W

FIL

LER

CAP

F.W

FIL

LER

CAP

65 A

MP

12V

ALTE

RNAT

OR

OIL

FILT

ER

SUM

P PU

MP

TAPE

SUM

P PU

MP

SUM

P PU

MP

FUEL

RET

URN

8mm

HOS

E TA

IL

FUEL

FEE

D8m

m H

OSE

TAIL

MAN

UAL

ENGI

NE S

TOP

SPEE

D LE

VER

FUEL

PU

MP

(WIT

H PR

IMM

ER)

AIR

FILT

ERAI

R FI

LTER

ENGI

NE O

IL C

AP

GEAR

BOX

OIL

CAP

GEAR

BOX

DIP

STIC

K

SACR

IFIC

IAL

ANO

DE

BATT

ERY

POSI

TIVE

BATT

ERY

NEGA

TIVE

SUM

P PI

CK U

P ON

SHAL

LOW

SU

MP

ONLY

FUEL

BLE

ED S

CREW

GEAR

BOX

OU

TPU

TO

82.5

O10

.5

O82

.532

SEA

WAT

ER P

UM

P(IN

LET O

22m

m M

ALE

STU

B

6


53

01

DO

NO

T S

CA

LED

IME

NS

ION

S IN

MM

(IN

CH

)

TEL:

(014

52) 7

2349

2

FA

X: (

0145

2) 7

2991

6

RE

VD

ES

CR

IPTI

ON

NO

TES

AP

P'D

DA

TED

RA

WN

DR

AW

N B

Y:

CH

EC

KED

BY

:S

CA

LEP

AG

E

SIZ

E

TITL

E:

DW

G N

O:

DA

TE

RE

V

NTS

A4

1 of

1

100-

9955

009

/09/

2008

B

ETA

28 H

EA

T E

XCH

AN

GE

PR

M 8

0 G

EAR

BO

X

TW LT03

BE

TA M

ARIN

E L

TD,

DA

VY

WA

Y,

WA

TER

WE

LLS

,Q

UE

DG

ELE

Y,

GLO

UC

ES

TER

. GL2

2A

D, U

K

100-

9955

0 B

ETA

28 (B

D10

05) H

E P

RM

80.a

smP

AR

T FI

LE N

AM

E:

8 M

10 X

50

BOLT

SEQ

UI-

SPAC

ED O

NAN

82.

5 PC

D

FLEX

IBLE

COU

LPIN

G DE

TAILS

FLEX

IBLE

MOU

NT D

ETAI

LS

100

120

63

65M

IN90

.0 M

AX

FUEL

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60

Installation

The Beta Controller has been designed for mounting off theengine, in a location away from vibration, water andcondensation. Ideally, as there is a charge mode LED, theunit should be positioned so it can be seen.

All goods are offered and supplied in accordance with our‘General Terms of Tender Sale’.

TIME

VOLTS

A.MODERED L.E.D

AMPS

B.MODEORANGE L.E.D

C.MODEGREEN L.E.D

Beta Controller - Sea Spec Engines

The BETA CONTROLLER is only offered as an option withour 70 Amp or 100 Amp Iskra alternators. These upratedalternators also include a polyvee drive (with a 6 groove flatbelt and pulleys designed for the increased power loading).These alternators develop the following outputs:

a) 70 Amp Iskra alternator develops: 35 Amps at ‘tick over’increasing to 70 Amps at 2,700 rev/min.

b) 100 Amp Iskra alternator develops: 60 Amps at ‘tickover’ increasing to 100 Amps at 1,800 rev/min.

The BETA CONTROLLER is an integrated battery chargingregulator. The controller provides a three stage chargingsystem enabling a rapid charge rate for batteries:

A mode the first stage is a boost charge, when operating theLED shows red.

B mode the second stage is where the voltage is at a highlevel and the current is between 10% and 95% of thenominal alternator current, the LED shows orange.

C mode the third and last stage is intended for maintenanceof battery voltage only. When the alternator current drops to alow level for longer than 2 minutes, the regulating mode ischanged from B to C.

The controller automatically adjusts the charge mode to suitthe load and is set for conventional lead-acid batteries asstandard during production. It can easily be re-set for deepcycle or gel batteries.


61

Maintenance-free Batteries and deep-cycle Batteries

60

Gell Batteries

60

Conventional Batteries

-20

12

200 40

Volt

14

13

16

15

15

13

-20

12

14

200 40

Volt

16

1 - OFF2 - ON

C

DIP-switchpositions

U2

U1

1 - ON2 - OFF

CU2

U1

DIP-switchpositions

60-20

13

12

200 40

15

14

Volt

16

U1

1 - OFF2 - OFF

U2

C

DIP-switchpositions

DIP-switch

LED

Cover removal for resetting of DIP switches

U1 = Mode B (Orange lamp)

U2 = Mode C (Green lamp)

Note: ensure all batteries are switched off, controller isdisconnected from wiring before removing any covers.

Voltage setting for battery charge is done through thetwo DIP switches inside the controller. Remove thecover by removing the top four screws and looseningthe bottom four. This cover is sealed on to preventwater ingress, this seal must be broken for coverremoval.Set the dip switches to the required settings asillustrated on the charts opposite.Re-seal controller with silicon sealant or equivalentafter setting switches.

As standard the controllers are supplied to Beta Marineto suit lead acid batteries.

If in doubt on battery type check with battery supplierbefore fitting controller. Beta Marine are notresponsible for incorrect switch setting for eachinstallation.

THIS CONTROLLER SHOULD NOT BE MOUNTED ON THE ENGINE!

The graphs below illustrate charging voltage for different battery types

Remove cover for setting of DIP switches:

U1 = Mode B (Orange lamp)

U2 = Mode C (Green lamp)

Note: Before removing any covers ensure that allbatteries and the controller are disconnected.

The two DIP switches inside the controller must be setaccording to battery type. As standard the BetaController is supplied to suit lead acid batteries. If youare in doubt of your battery type, check with batterysupplier before fitting the controller.

The cover is removed by undoing the top four screwsand loosening the bottom four. This cover is sealed onto prevent water ingress, this seal will be broken whenthe cover is removed.

Set the dip switches to suit your battery – the settingsare detailed on the charts opposite.

Re-seal controller with silicon sealant or equivalent aftersetting switches.

Beta Marine is not responsible for the incorrect settingof dip-switches as we do not know which batteries youhave.

All goods are offered and supplied in accordance withour ‘General Terms of Tender Sale’.


62


63


64


65


66

The engine must be installed, maintained and operated within the parameters detailed in theOperator’s Maintenance Manual. Maintenance must use approved materials, parts and consumables.Should the engine lie unused for a period in excess of 6 months it must be inhibited otherwise it willdeteriorate with resulting decrease in performance. See also the Winterising and Laying Upprocedures in the Operator’s Maintenance Manual.

The fuel settings of the diesel injection system must not be tampered with otherwise the guaranteewill be invalid and the performance may fall outside prescribed limit. Such adjustment cannot beallowed under the terms of the emission certification.

Performance of the engine depends upon the use of correct fuels, lubricants and inhibitors. Theseare fully detailed in the Operator’s Maintenance Manual.

Particular attention must be paid to the installation with respect to the exhaust system. The systemmust be designed so that water cannot back feed into the engine. The run must be such that theback pressure at the engine manifold does not exceed the level detailed in the Operator’sMaintenance Manual. Wet, water injected, exhaust systems must be at least the bore mentioned inthe Operator’s Maintenance Manual and should the run be excessive this bore must be increasedaccordingly. Back pressure is measured at the outlet of the engine manifold before the waterinjection bend or dry bellows.

Our experience over 19 years has shown that properly installed and maintained engines hold theirperformance without major mishap even when running hours exceed those mentioned in theRecreational Craft Directive. It is the owners / users responsibility to ensure that the engine continuesto function properly and any malfunction must be immediately investigated. The Trouble Shootingsection as detailed in the Operator’s Maintenance Manual is particularly helpful in this respect.Engine performance, especially with respect to erratic running, exhaust condition, low power outputand high oil consumption are indications of engine conditions that may result in emissions outsidethe prescribed limits and must therefore be investigated and rectified immediately.

In respect to the Recreational Craft Directive 94/25/EC and amendment 2003/44/EC Annex 1, B3.

Emission durability


67

Description Part Number Qty per Engine

Alarm board – all panels from June 2005 200-04655 1

Relay 12 Volt 40A (28Ra) fitted to rear of panels 200-87020 1

Stop Solenoid - energised to stop 600-79660

Fuse (Blade) 40 Amp 200-00959 1

Standard Engine Harness 200-60973/05 1

65 Amp Alternator Sub Loom Iskra 200-01196 1

1 Metre Control Panel Extension Loom 200-04588/01




Water Temperature Switch (Panels A, AB, ABV & ABVW) 200-62820 1

Water Temperature Sender (Panel B & C) 200-94360 1

Oil Pressure Switch (Panels A, AB, ABV & ABVW) 600-62670 1

Oil Pressure Sender (Panels B & C) 200-94350 1

Exhaust Flange Gasket 600-62620 1

Drive Plate 22-B-60 TMC 40/60 & PRM 80 /120 - Mechanical 206-91950 1

Drive Plate PRM150 - Hydraulic 206-02094 1

Flexible Mountings (Standard - RAB60) 213-93440 4

Flexible Mountings (Type 55 - USA only) 213-80170/01 4

Rocker Cover Gasket Beta 28 600-66490 1

Rocker Cover Gasket Beta 35 & Beta 38 600-68810 1

Manuals

Operators Maintenance Manual 221-02888 1

Workshop Manual – base engine only 600-00757 1

Spare Parts Manual – base engine only, Beta 28 (BD1005) 600-02439 1 Available as a “PDF”

Spare Parts Manual – base engine only, Beta 35 (BV1305) 600-02440 1 Available as a “PDF”



Fast Moving Parts ListingsKeel Cooled: Beta 28, Beta 35 & Beta 38. In all cases please quote Beta Marine WOC “K” number and Engine type.

Note: the above part numbers are suitable for earth returninstallations only (where battery negative cable is connecteddirectly to engine ground).

For insulated earth (where battery negative cable is isolatedfrom engine ground) different harnesses, alternators, switchesfor oil pressure and engine temperature will be required.


68

Description Part Number Qty per Engine

Wasting Zinc Anode 209-61840 1

Header Tank ‘O’ Ring 209-80110 2

Pressure Cap 95kPa 209-80130 1

Thermostat 600-72450 1

Thermostat Gasket 600-80490 1

Fuel Filter 211-60210 1

Air Filter Element Beta 28 211-62950 1

Air Filter Element Beta 35 & Beta 38 211-61831 1

Lubricating Oil Filter 211-60390 1

Sump Pump 210-80061 1

Sump Pump Clamp 212-00793 2

Dip Stick Extended - Guide and stick kit 600-96300 1

Sea Water Pump 207-61500/01 1

Sea Water Pump Impeller Kit 207-05355 1

Fuel Lift Pump 600-67830 1

Fuel Lift Pump Gasket 600-00065 1

Belt – Standard “Vee” – 55 Amp 214-63090/Q Correctly Select a Belt

Belt – PolyVee 100 Amp 214-04618 Correctly Select a Belt

Alternator 65 Amp External Fan 200-01155 1

Alternator 100 Amp Internal Fan 200-03008 1

Control Panel standard Key (To June 2008) 600-00058 a pair

Control Panel standard Key (From June 2008) 600-00058/01 a pair

Control Panel Key Switch (To June 2008) 600-00057 a pair

Control Panel Key Switch (From June 2008) 600-00057/01 a pair

Control Panel Stop Button (and Heat & Start on ABVW) 200-00072 1

Tachometer 0 - 4000rpm with digital hour counter 200-02373 1

Water temperature switch Gauge (B & C panels) 200-96200 1

Oil pressure switch Gauge (C panels only) 200-96190 1

Voltmeter (C panels only) 200-96210 1

Green power on indicator lamp & retaining clip 200-04656 1

Red warning indicator lamp & retaining clip 200-04657 3 or 4

Fast Moving Parts ListingsKeel Cooled: Beta 28, Beta 35 & Beta 38. In all cases please quote Beta Marine WOC “K” number and Engine type.


69

Service RecordService Date Responsible

1 Commissioned

2 First 25 hours

3 First 50 hours

4 Every 150 hours with shallow sump

5 Every Year / Every 250 hours if sooner

6

7

8

9 Every 750 hours

10

11

12

13

14

15

16


Beta Marine LimitedDavy Way, Waterwells Quedgeley, Gloucester GL2 2AD, UK.

Tel: 01452 723492 Fax: 01452 883742Email: [email protected]

Ref: 1640, October 2008.

Des

igne

d an

d pr

oduc

ed b

y M

ono

Stud

io, T

el: 0

1453

756

366

Keel Cooled10 to 90bhp

Marine Generating Sets3.7 to 40kVA

Heat Exchanger Cooled10 to 90bhp

Sail Drives13.5 to 50bhp

Marine Generating Sets30 to 900kVA


Documents

Operator’s Maintenance Manual - Beta Marine Koreabetamarinekorea.com/sg/beta_28/b28_07.pdf · 2010-06-23 · CALIFORNIA – Proposition 65 Warning: Diesel engine exhaust and some