Operators Maintenance ManualHeat Exchanger CooledMid Diesel Engine Range43 and 50 bhpCALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known tothe state of California to cause cancer birth defects and other reproductive harm Engine identification 2 Initial receipt of the engine 2 Engine storage 2Safety precautions 3Technical specifications 4Section 1 Guidelines for operation of the engine Important checks prior to initial use 5 Initial startup and bleeding the fuel system 5 Starting stopping 5Section 2 Maintenance and service guidelines Maintenance schedule 6 Lubrication checking and changing oil 7 Fuel system pumps filter fuelwater separator 8 Cooling fresh water system 9 Sea water pump heat exchanger 10 Belt tensioning 11 Air filter 11 Electrical 12 Laying up winterising 12 13 Torque settings 22Section 3 Installation guidelines Engine mounting 23 Alignment drives flanges flexible drives 23 Exhausts mounting exhausts 23 Fuel supply 25 Cooling sea water inlet system 25 Calorifier system 26 Electrical and installations 26 Appendices wiring diagrams and general arrangements 27 Component identification at rear of manual 54 Maintenance record 54 1 OPERATION AND MAINTENANCE MANUAL FOR THE FOLLOWING BETA MARINE ENGINES BASED ON KUBOTA SUPER 3 SERIES BV1903 BV2203This manual has been compiled to provide the user with important information to ensure a trouble free and economical operation of the engineFor further advice or technical assistance application should be made to BETA MARINE LIMITEDor its information and given in this publication are based on the available at the time of publication and are subject to alteration at any time Theinformation given is subject to the companys current conditions of Tender and Sale is for theassistance of users and is based upon results obtained from tests carried out at the place ofmanufacture and in vessels used for development purposes We donot guarantee the same results will be obtained elsewhere underdifferent In all communications with the distributor or Beta Marinethe engine number type and WOC number must be quotedBV1903 BV2203 XE5567 BV1903The engine serial number is stamped above starter motor on the K12345port side of the engine and is shown on the rocker cover label 43bhp 2800rpmINITIAL RECEIPT OF THE ENGINEA full inspection of the engine must be made immediately ondelivery to confirm that there is no damage If there is any damage then write this clearly on thedelivery note and inform your dealer or Beta Marine within 24 hoursENGINE STORAGEThe engine must be stored in a dry frost free area and this is best done in its packing case Ifstorage is to be more than six months then the engine must be inhibited contact your dealer orBeta Marine Failure to inhibit the engine may result in the formation of rust in the and the engine bores this could invalidate the warranty 2 SAFETY PRECAUTIONSA Keep the engine gearbox and ii Fuel Supply Connections surrounding area clean including the Engines are supplied with 8mm area immediately below the engine compression fittings The installer must ensure that when connections are madeB Drives Power Take Off Areas they are clean and free of leaksi Gearbox Output Flange E Oil The purpose of a marine diesel propulsion The Beta propulsion is supplied with 2 engine is to provide motive power to propel dipsticks one for the engine and one for the a vessel Accordingly the gearbox output gearbox Ensure dipsticks are returned and shaft rotates at between 280 and 2400 secure after checking if not oil leaks can revmin This flange is designed to be cause infection when touched All oil must coupled to a propeller shaft by the installer be removed from the skin to prevent and steps must be taken to ensure infection adequate guarding F Scaldingii Forward End Drive An engine running under load will have a Engines are supplied with unguarded vee closed circuit fresh water temperature of belt drives to power the fresh water pump 85 to 95C The pressure cap on the top and battery charging alternator The of the heat exchanger must not be installer must ensure that it is not possible removed when the engine is running It for injury to occur by allowing accessibility can only be removed when the engine is to this area of the engine The three pulleys stopped and has cooled down run at high speed and can cause injury if personnel or clothing come in contact with G the belts or pulleys when the engine is Engines are supplied on transportable running pallets Lifting eyes on engines are used for lifting engine and gearbox assembly onlyiii Power Take Off Shaft Engine Mounted not the pallet and associated kit Option Shaft extensions are available as an option and rotate at between 850 and 3600 revmin If contact is made with this shaft when the engine is running injury can GENERAL DECLARATION occur This machinery is not intended to be put into service until it has been incorporated into orC Exhaust Outlet with other machinery It is the responsibility of Diesel marine propulsion engines emit the purchaser installerowner to ensure that exhaust gases at very high temperatures the machinery is properly guarded and that all around 400500C Engines are supplied necessary health and safety requirements in with either wet exhaust outlet water accordance with the laws of the relevant injection bend or dry outlet dry exhaust country are met before it is put into service stub see option list At the outlet next to the heat tank the exhaust outlet can become very hot and if touched can injure This must be lagged or Signed avoided by ensuring adequate guarding It is the responsibility of the installer to lag the exhaust system if a dry system is used Exhaust gases are harmful if ingested the installer must therefore ensure that exhaust lines are led overboard and that leakage in the vessel does not occur J A Growcoot CEO Beta Marine LimitedD Fueli Fuel Lines Diesel engines are equipped with high pressure fuel injection pumps if leakages NOTE Recreational Craft occur or if pipes fracture fuel at a high Where applicable the purchaser installer pressure can harm personnel Skin must be owner and operator must be responsible for thoroughly cleaned in the event of contact making sure that the Recreational Craft with diesel fuel Directive 9425EC is complied with 3TECHNICAL SPECIFICATIONS Standard Engines BD1703 BV1903 BV2203Standard Engines BV1903 BV2203Cylinder 4 4Bore mm 80 87Stroke mm cc 1857 2197Combustion 3 VortexCooling WaterStarter voltage V 12Starter output kW 14Alternator output Amps 65 standardGlow plug resistance each 1Engine speed RPM 2800Power output ISO3046 BHP 43 50Declared power ISO8665 kW 310 361Compression Ratio 2301Fuel timing BTDC 18Capacity of standard sump litres 95Capacity of shallow sump litres 7Nett dry weight with std gearbox kg 270 300Fuel Diesel fuel oil No2DCoolant 3350 max antifreeze waterApprox Coolant capacity HE litres 74Min recommended battery capacity 12V 120Ah 600CCA MinMaximum Angle of Installation Trim 15 Roll 25 intermittent 20 ANTI CLOCK ON FLYWHEEL CLOCKWISE ON OUTPUT GEARBOX FLANGE FOR USE WITH RIGHT HAND PROP IN AHEAD on mechanical gearboxes Hydraulic gearboxes can be left or right handedDiesel fuel must conform to BS28691970 class A1 or A2 The fuel must be a distillateand not a residual oil or blendLubricant Engine Engine oil must meet MILL2104C see section 2 for details Gearbox see operators manual for the gearbox oil type and capacity Oil pressure minimum tickover 05 barPower outputs These comply with BS EN ISO 86651996 crankshaft powerNote Declared Powers to ISO866519951 The declared powers are at the same engine speed as the ISO 3046 figures This speed is the speed related to the outputs powers shown2 Declared powers are at the gearbox coupling coupling to the propeller shaft as per clause 321 with standard specifications as per our current price lists Additional accessories or alternative gearboxes may affect the declared powers3 Operation at parameters outside the test parameters may affect the outputs powers which in any case are subject to the ISO tolerance bands 4 SECTION 1IMPORTANT CHECKS PRIOR TO INITIAL USE1 Generally a new engine has the oil and antifreeze removed after the works test Fill the engine with the correct oil and antifreeze see sections on ENGINE OIL and COOLING Check gearbox oil level see separate operators hand book2 Ensure the engine is free to turn without obstructions3 Ensure battery is fully charged and connected the isolator is in the ON position4 Ensure Morse speed and gearbox cables are fitted correctly and that cable travel lengths are correct Gear selection lever all mechanical gearboxes care must be taken to ensure that the remote control cable is adjusted so that the selector lever on the gearbox moves FULL travel and brought hard up against its end stop in both directions Failure to achieve the correct adjustment will reduce efficiency of the clutch and may cause slippage at low revs Warranty will not be accepted on gearboxes returned in the warranty period for failure due to incorrect adjustment5 Ensure engine is out of gear with 13 throttle see single lever control instruction manual6 Open the fuel stopcock and bleed the fuel water separator of air as shown in manufacturers literature7 Fuel should now be at the fuel lift pump see diagram 1a open the sea cockINITIAL STARTUP AND BLEEDING THE SYSTEM Diagram 1aa Open fuel bleed screw on fuel filter assembly by 112 turns See diagrams 1a 1bb Move hand priming lever on fuel lift pump up and down until fuel with no bubbles comes out of the bleed screwc Shuttighten the bleed screw Clean area thoroughly with tissue paperd Continue to hand prime for 30 seconds to push fuel through the fuel pumpe Start engine see normal starting Note the engine may have to be turned over with the starter for a few seconds before it fires Do not run the starter for more than 20 seconds If the engine has not started after 20 seconds then disengage the starter and continue to hand prime for a further 30 seconds then repeatf If engine does not start after 3 attempts then allow 5 minutes for the starter to Diagram 1b cool down before repeating a to e Note The starter windings can be burnt out with continuous avoid personal injury Do not bleed a hot engine as this could cause fuel to spill onto a hot exhaust manifold creating a danger of fire Do not mix gasoline or alcohol with diesel fuel This mixture can cause an explosion Do not get diesel on the flexible mounts they will deteriorate rapidly if soaked in diesel All fuel must be removed from skin to prevent STARTING BETA PANELS WITH SILVER KEYSWITCH FOR KEYLESS SEE PAGE20 B A CWith the engine out of gear set speed control lever to 13 throttle Turn key anticlockwise to OFF ON GLHEAT A position and hold for ten seconds turn key clockwise to RUN C position At this stage D STthe instrument panel should illuminate an alarm buzzer will sound and two or three redwarning lights will BATTERY CHARGEDOMESTIC BATTERY CHARGE D in battery symbol 2ABD 2CD PANELS ONLYNote this will only illuminate if 2nd alternator is fittedOIL PRESSUREand green POWER ON RUN LIGHT this will stay onTurn to START D position and engine will motor hold in position until engine fires see initial startupsection for maximum time starter can be used Release key when engine has started to RUN positionEnsure alarm buzzer is not sounding and that warning lights are extinguished If one or both of thealternator warning lights are still on then increase engine speed to excite the alternator then return toidle The battery charge lights should then go out The run light will remain on green lampCheck for sea water flow If no flow then SWITCH OFF IMMEDIATELY AND CHECK SEA WATER SYSTEM 5STOPPINGEvery propulsion engine is fitted with a stop solenoid which is energised to stop To stop engine simply press stop pushbutton hold in until engine stops then turn key from RUN to OFF positionWhen leaving the boat for an extended period Turn off seacock heat exchanger cooled engines Turn off battery isolatorDo not turn the key to the off position when the engine is running This will damage the not leave the key in HEAT position for more than 15 seconds this will damage the heater plugs and eventuallylead to poor startingDo not depress stop button for more than 10 seconds as this will lead to overheating and failure of the solenoid SpeedNotes for all panel types LeverDo not depress the stop button for more than ten seconds as this will lead tooverheating and failure of the solenoidThis range of engines are equipped with a mechanical stop lever in the event ofelectrical system failure This lever is located on the starboard side of the engineabove the speed control lever See illustration right Stop Lever SECTION 2MAINTENANCE SCHEDULEDaily 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 Drain off any water in fuel water separatorAfter 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 Special attention should be paid to the flexible mount lock nuts these should be checked for tightness starting with lower nut first in each case If the lower nuts are found to be very loose then the alignment of the shaft to the gearbox half coupling should be rechecked Poor alignment due to loose flexible mount nuts will cause excessive vibration and knocking Check the belt tension on any second alternators fitted and adjust see page 11 Check ball joint nyloc nuts for tightness on both gearbox and speed control levers Grease both fittings all overAfter 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 fuelwater separatorEvery 150 Hours If shallow sump option is fitted change engine lubricating oil and filterEvery Year or every 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 bolt each end of the tube stack Remove end cover pull out tube stack and clean Replace rubber O rings and reassemble Immediately engine is started check for leaks 6 Spray the key switch with WD40 or equivalent to lubricate 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 gearbox and speed control levers Grease both fittings all overEvery 750 Hours Change air cleaner element Change fuel filter Change antifreeze Change gearbox oil Check electrical equipment condition of hoses and belts replace as oilEngine oil should be MILL2104C or have properties of API classification CCCDCE grades The following tablegives grades of oil required for various ambient temperatures AMBIENT TEMP SINGLE GRADE MULTI GRADE 30C TO 0C SAE 10W S AE 10W30 15C TO 15C SAE 20W SAE 15W40 0C TO 30C SAE 30 SAE 15W40 25C AND ABOVE SAE 30 SAE 15W40Note A good quality 15W40 multigrade oil as used in most diesel car engines will meet these requirementsDo not use Turbo Diesel Oil or additives Oil goesCHECKING ENGINE OIL LEVEL in hereFor quantities of oil required see section marked Technical Specification Page 4When checking the engine oil level do so before starting or more than fiveminutes after stopping1 To check the oil level draw out the dipstick wipe it clean reinsert it and draw it out again Check to see that the oil level lies between the two notches2 If the level is too low add new oil to the specified level Do not overfill Fig using an oil of different make or viscosity from the previous one drain old Dipstickoil Never mix two different types of oil Engine oil should be changed after first50 hours running time and then every year or every 250 hours if sooner Oilfilter is a cartridge type mounted on the starboard side of the engineCHANGING ENGINE OIL1 Run the engine for 10 minutes to warm up the oil2 Your engine is provided with a sump drain pump Unscrew the end cap on the Fig 2b end of the pump turn the tap to on Use the hand pump as shown to pump out the oil into a bucket Turn the tap to off position and replace end cap See diagram 2c Sump Pump3 Unscrew the oil filter and replace with a new one See diagram 2d Note It is best to have a plastic bag wrapped round the filter to catch any oil left in the system Always keep your bilges clean Before screwing in the new End filter spread a thin film of oil round the rubber gasket to ensure a good seal Cap and screw in hand tight4 Fill the engine with new oil as described on the previous page5 Run the engine and check for oil leaks Fig 2c 7CHECKING GEARBOX OIL LEVEL1 The gearbox is fitted with a dipstick and oil filler plug see fig 2e2 Each engine is supplied with a gearbox operators manual which specifies the type of lubricating oil to be used the capacity and frequency of changing of the oil3 New engines are normally supplied with the gearbox topped up with lubricant but Check the level before starting the engine for the first time4 The oil can be changed via the drain plug at the bottom of the box or sucked out with a hand pump via the filler plug Fig 2d oil filter removal5 A guide to the type of oil to be used is as follows Oil filler Gearbox Lubricant Capacity approx plug ZF12M Use ATF 055 litres ZF15M Use ATF 055 litres ZF25M Use ATF 075 litres ZF25H Use ATF 200 litres ZF25HA Use ATF 180 litres TMC60M Use ATF 080 litres TMC260M Use ATF 120 litres PRM150 Use Engine Oil 15W40 14 litres PRM260 Use Engine Oil 15W40 15 litres Fig 2eNote ATF is Automatic Transmission FluidFUEL SYSTEM see page 24 for a typical Always fit a fuelwater separator in the fuel supply system Water in the fuel can seriously damage the injection system If a fuel supply shutoff valve is fitted do not use a taper tap only use a ball valve tap The ball valve type are more reliable and less likely to let air into the fuel system Be sure to use a strainer when filling the fuel tank Dirt or sand in the fuel may cause trouble in the fuel injection pump Always use diesel fuel Do not use kerosene which is very low in cetane rating and adversely affects the engine Be careful not to let the fuel tank become empty or air can enter the fuel system necessitating bleeding before next engine start The fuel lift pump will only lift fuel through 025 metres If this is insufficient then an electric fuel lift pump must be fitted Drawing 20206421 illustrating recommended wiring for this pump can be supplied upon requestFUEL FILTER REPLACEMENT1 The fuel filter is a spin on type Remove by turning anticlockwise when viewed from below2 Replace the fuel filter cartridge every 750 hours or every 2 years See fig 2g3 Apply fuel oil thinly over the gasket and tighten into position hand tight4 Bleed as detailed see initial start up5 Check for leaks6 Do not get fuel on the flexible mounts Fig 2g 8HEATING EXCHANGER COOLED Heat Exchanger CooledFresh water circulates through the engine and on to a heatexchanger where it is cooled by sea water which is pumpedthrough the cooling tubes The sea water is then injected intothe exhaust system see diagramFILLING THE FRESHWATER SYSTEMNew engines are supplied with the freshwater drained off Thefollowing instructions must be followed to fill the system Draina Mix up in a clean bucket a 33 to 50 antifreeze to Tap freshwater solution see page 10 For the volume required see technical specification page 4b Check that the drain tap or plug is turned off see fig 2lc Fill engine with freshwateranti freeze solution through the top of the heat exchanger or header tank with the filler cap removed see fig 2md Fill header tank to the top of the filler neck and replace cap Press down firmly on filler cap and hand tighten in a clockwise directione Run the engine for 5 minutes on no load out of gear and check coolant level Top up as necessaryf Check system for leaksg If a calorifier is fitted care must be taken to see that this is also full of coolant and all the air is expelled See calorifier fitting Fig 2l notes under Section 3h Run the engine on one third load for 15 minutes preferably with the boat tied up As the system warms up coolant may be expelled from the overflow pipe into the bilge Stop the engine and allow the engine to cool down before removing the pressure cap and top up the coolant to 1 below the filler of the pressure cap when the engine is hot can cause severe injuryfrom scalding hot water under pressure Always allow the engine to cool andthen use a large cloth when turning the cap anticlockwise to the stop Thisallows the pressure to be released Press firmly down on the cap and continueto turn anticlockwise to release the capi Repeat h if coolant level is more than 1 inch below the base of the filler neck when the engine has cooled downj Run engine on 23 full load for 20 minutes check for leaks and repeat i Fig 2mk Antifreeze solutions should be drained off every 2 years and replaced with a new solutionNote When draining fresh water system ensure the engine has cooled sufficiently to prevent scalding from hotpressurised water Prior to draining a cold engine remove the filler cap from the header tank and then open thewater drain tap This allows the water to drain freely from the system 9Yachts and Launches with Heat Exchanger CoolingIt is essential that a 33 to 50 mixture is used This not only stops freezing up in winter but itprevents overheating and corrosionThe warranty is invalid unless the correct ratio is of ethylene should not exceed 50The antifreeze in the fresh water system enables the boiling point of water to rise to 124C with a 13 psi pressurecap fitted The water temperature alarm switch will however be activated at 95 to 100C If no antifreeze or a veryweak solution is used then the water temperature switch may not be activated before coolant is lostSEA WATER PUMP AND COOLING SYSTEMHeat working on the sea water system ensure that the sea cock is in the offposition1 It is very important that the correct sea water flow is maintained to cool the closed circuit system of the engine The key component in this system is the sea water pump impeller This should be checked every year by removing the circular plate see fig 2h2 Withdraw the rubber impeller from its drive shaft as shown See diagram 2i3 Check impeller for cracks in the rubber excessive wear or lost vanes Replace Fig 2h with a new impeller as necessary Note If any pieces of rubber impeller are missing then they must be found as they are most likely to be trapped in the entrance to the heat exchanger cooling stack See Cleaning Tube StackCLEANING THE HEAT EXCHANGER TUBE STACK AND ZINC ANODE1 The wasting zinc anode should be checked every six months and replaced every year or as necessary The anode is attached to the bolt inserted in the end cap of the heat Fig 2I exchanger See Fig 2j On most engines this is on the aft end2 Unscrew the bolt and replace the complete unit with a new one3 Check for leaks4 It is possible for fine sea weed and other debris to get past the inlet filter and into the tube stack This should be removed and cleaned See fig 2k5 Drain off coolant into a bucket6 Unscrew the 2 end cap retaining bolts one each end of the tube stack Remove Zinc Fig 2j the O rings and pull out tube stack Clean tube stack and end caps Anode7 Reassemble using new O rings Do not overtighten end cap bolts and make sure the tube stack is the right way round8 Refill engine with solution and run engine up to temperature to check for leaks Fig 2k 10BELT TENSION ADJUSTING BOLTS65 AMP ALTERNATOR Heat Exchanger tension must only be checked with the engine switched off1 On heat exchanger cooled engines a single 65 amp is fitted as standard This alternator is adjusted as follows2 The belt tension is adjusted by swinging the alternator outboard as it pivots on its support bolts3 With the engine stopped loosen the support bolts and the link adjusting bolt4 Push alternator outboard to tension and tighten link bolt Check that the depression of the belt at position shown is approximately 12 or 12 mm when pushed down firmly by thumb Tighten support bolts5 Belt tension should be regularly checked especially during the first 20 hours of running in a new belt as stretching occurs100 Amp alternator optionThe same method applies as outlined above but final tensioning must be byhand only Over tensioning will cause premature failure of componentsAIR INTAKE FILTERThese engines are fitted with an air intake filter which should be checked every season and changed every 2 yearsor sooner if badly clogged If badly clogged check more often 1 2 3 11MAINTENANCE no circumstances should the battery be disconnected or switched off when the engine is running This willseriously damage the AND WIRINGSee installation notes page 27General maintenance1 The panel must be protected from rain and sea water see installation Sea water entering the key switch will eventually cause corrosion and could result in the starter motor being permanently energised and burning out Spray key switch every month with WD 40 or equivalent2 Check batteries for acid level and top up if required For low maintenance and gel batteries see manufacturers instructions3 Loose spade terminal connections are the most common cause for electrical faults check on a regular bases see maintenance AND LAYING UPHeat Exchanger Cooled Engines Left Afloat And Ashorea The engine oil and oil filter should be changed at the end of the season rather than in the spring See section 2b The closed circuit system should contain a 30 to 50 solution of antifreeze to water this also applies to warm and tropical climatesc For cold climates where the air or water temperatures can fall below 3C the sea water circuit must be protected in addition to the fresh water system This is best achieved as follows i Close the inlet seacock to the engine engine stopped ii Disconnect the sea water inlet pipe and dip it into a small bucket containing 5050 antifreeze solution iii Start the engine out of gear and run for 5 to 10 seconds until the antifreeze is used up and can be seen coming out of the exhaust outlet iv Shut engine off and reconnect the inlet pipe to the seacock The sea water or raw water circuit is now protected by antifreezed Ensure instrument panel is well protected and give the key switch a spray of WD 40 or equivalente With the engine stopped disconnect the battery always disconnect the negative cable first and reconnect the negative cable last and take it ashore for trickle charging and top up as necessary If AC power is available then this can be done on the boatf Fuel tanks should be kept full during the lay up period to eliminate water condensation in the tank Water entering the fuel injection system can cause considerable damageLAYING UP ASHOREa Change the engine oil before the boat is taken out of the water Warm engine oil is much easier to pump than coldb to f should be followed as above 12 TROUBLE SHOOTINGBeta diesels are very reliable if installed and serviced correctly but problems can occur and thefollowing list gives the most common ones and their Engine does not start but starter motor turns over OKPossible Cause SolutionNo fuel Turn fuel cock on and fill tankAir in fuel system Vent air see initial startupWater in fuel Change fuel filter and bleed systemBlocked fuel pipe Clean out and bleed systemFuel filter clogged Change filter and bleed systemFuel lift pump blocked Remove and replaceBlocked injector Remove and cleanFuel return not fed backto the tank Reroute fuel return pipeHeater plugs not working Check wiring to the plugs and replace plugs if they are burnt outStop solenoid stuck in offposition Check solenoid is free to return to run Starter motor will not turn or turns over very slowlyPossible Cause discharged Charge battery or replace Check alternator belt tensionStarter motor flooded withsea water Remove and clean or replaceWiring disconnected or loose Check circuit for loose in cylinders Incorrect installation This is serious check engine oil for signs of water creamycoloured oil Ring your dealerEngine harness fuse blown Replace fuse located by starter motor or above flywheel housing and check for wiring faults FUSE If located by starter motor usually it is positioned above flywheel housing at rear of engine Note For convenience some engines are supplied with a spare fuse and holder attached to the main engine fuse holder 13Problem Erratic Cause SolutionAir in fuel supply Check supply system for leaks and fixFuel lift pump faulty ReplaceClogged fuel filter ReplaceFuel return not fed back to thefuel tank or blocked pipe Reroute pipe or cleanAir filter blocked ReplaceWorn or blocked injector Service rpm in gear is too lowthis must be 850 min Increase engine tick over speedFaulty stop solenoid Disconnect wiring to solenoid If running improves check for a wiring faultBroken fuel injection pumpspring ReplaceProblem White or blue exhaust gasPossible Cause SolutionEngine oil level too high Reduce the levelBlocked injector Service ring and bore worngiving a low compression Get compression checked by your dealer or Kubota service agent He will advise action to be takenCheck that the breather pipe isclear and not obstructed Remove and clean outProblem Black exhaust gasPossible Cause air filter element Inspect and replaceOver pitched propeller enginewill not reach its full rpm Get the propeller repitched if debris on hull Inspect and clean if Low power outputPossible Cause is too big Change or depitchCheck gearbox reduction ratiorelative to propeller size ChangeBlocked fuel filter ReplaceBlocked air filter ReplaceAir in fuel system Check systemGovernor spring Dealer to adjustSingle lever control notoperating correctly Disconnect speed control cable and move the lever by hand Adjust cableThe electrical load is too largeon start up Disconnect or reduce the load 14Problem High oil Cause SolutionOil leaks Check for leaksPiston rings worn Overhaul requiredValve stem and guide worn Overhaul requiredPiston rings gap facing thesame direction Shift ring gap Water in lubricating oil heat exchanger cooledPossible Cause SolutionOil goes milky due to exhaust manifold Check installation has antisiphon valve been fitted Change engine oil and run engine for 10 minutes each time to eliminate any water Get fuel injection pump and compression checked by Service AgentProblem Water in lubricating oil Cause SolutionCore plug pushed out due tofrozen block Service Agent to check and replaceWater pump seal damaged Service Agent to check and replaceProblem Water in lubricating oil keel cooledPossible Cause SolutionOil goes milky due to water Check installation has dry exhaust system been fitted exhaust manifold and ensuring rain water cannot enter the exhaust port and run backthen into the sump See DRY EXHAUST SYSTEM Change engine oil and run engine for 10 minutes each time to eliminate any water Get injection pump checked by Service AgentProblem Low oil pressure warning light comes on when engine speed reduced to tick overPossible Cause SolutionFaulty switch sender ReplaceEngine running too hot Check cooling water flow see section 2 CoolingOil relief valve stuck partiallyopen with dirt Remove and cleanBlocked oil filter ChangeWiring fault Check oil Top up and check for leaksProblem Panel rev counter not working when fittedPossible Cause SolutionNo W connection to alternator Check output from W connection Should be about 9V ACWiring fault Check circuit 15Problem Engine Cause SolutionCheck coolant level Top upInsufficient sea water flow Clear blocked intake or filterDamaged or worn pumpimpeller ReplaceBlocked tube stack in heatexchanger Remove tube stack and clean replace O ringsZinc anode flakes blocking tubestack Remove and clean tube stack as abovePressure cap loose ReplaceSwitch sender faulty ReplaceInlet sea cock is too small Replace see heat exchanger cooled seawater inlet system in section 3High exhaust back pressure Must not exceed 31 of HgAir locks in cooling pipe workto keel cooler Vent the system and top up coolantKeel cooler insufficient size Contact boat builderGENERAL HEAT EXCHANGE ONLY The most common cause of overheating is flow due to a blocked intake weed or a plastic bag If this happens then clear theblockage If the problem is not cured then check the system for sea water flow which should be15 litres minute minimum at 1500 rpm as followsa With the boat tied up and out of gear run the engine up to 1500 rpm Hold a plastic bucketover the exhaust outlet for 10 seconds and measure the amount of water collected Multiply thisvalue by 6 to give the flow in litresmin Repeat twice and take an average If the flow rate isnoticably less than the 15 litre per minute minimum at 1500 rpm thenb Check impeller in sea water pump if worn replacec If impeller has a vane missing then this will be lodged either in the pipe to the heat exchangeror in the end of the exchanger This must be removedd Check flow again as in aNote This operation must only be done in safe conditions in port and with two from a rubber dinghy is best The person holding the bucket should take breathing in the exhaust gassesProblem Knocking noisePossible Cause touching gearboxoutput coupling through splitboss or Type 16 coupling Adjust giving correct clearance 10mm between gearbox and propeller shaftFlexible mount stud touchingengine bed Adjust stud to clearDrive plate broken Replace repairEngine touching engine bed Realign engine modify bed 16Problem Battery quickly Cause SolutionHigh load and insufficient Reduce load or increase charging time Large domestic batteryrunning banks subject to high electrical loads will take a considerable time to recharge from a single alternatorLow electrolyte level Top upFan belt slipping black dust inengine compartment temperature too Adjust tension replace belt with a high temperature type and high or improve engine compartment defective Check with AgentBattery defective ReplacePoor wiring connection Check wiring systemProblem Transmission noisePossible Cause SolutionCheck gearbox oil level Top upSinging propeller Check with supplierDrive plate rattle at tickover Check engine rpm must be 850 rpm minimum in gearWorn drive plate shaft hitting the Move shaft back to give at least 5mm clearance Type 1216Gearbox half coupling couplings onlyProblem Cause SolutionPoor alignment to shaft The alignment must be accurate even if a flexible coupling is used see section 3 mounts not to take even weight Check relative compression of each mountFlexible mount rubber perished Replace Diesel or oil will eventually perish most rubbersLoose securing nut on flexiblemount Check alignment and then tighten the clearance between There must be at least 10 tip clearance between propeller andthe propeller tip and the bottom bottom of the boat ie 10 of the propeller diameter asof the boat clearance Refer to zinc anode on the shaft Tighten or replaceWorn cutless bearing or shaft ReplaceWeak engine supportbearers Check for cracked or broken feetProblem Morse control cable will not fitPossible Cause incorrectly Cables are being fitted the wrong way around switch over and fit the opposite way 17 Electrical fault finding trouble shooting engines built after July 2005 onlyThe following chart is compiled to aid diagnosis of electrical faults based on the Beta 1090hp range ofengines If your engine was built before July 2005 contact Beta Marine for the relevant shooting guideStandard sea specification engines heat exchanger cooled are supplied with a single port side supplying power to starter battery and control panelStandard canal specification engines keel cooled are supplied with twin alternators 1st alternator mounted port side supplying power to starter battery and control panel 2nd alternator the standard mounting position for this is above the engine on the starboard side or st below 1 alternator on 75 90hp supplying power to the domestic battery systemBoth of these alternators work independently if the domestic battery system is disconnected the enginewill still run correctly but Domestic charge warning lamp will not function Warning buzzer will remain on at all timesStandard control panels are supplied with four or five lampsFour lamp panels 2a 2abV 2abVW and 2b these panels utilise bulbs inside sealed lamp holdersFive lamp panels 2abd and 2cd these panels also utilise bulbs inside sealed lamp holders having an additional lamp for domestic battery chargeAll Beta panels have the following warning lamps 2a 2abd 2abV 2abVW 2b 2cdStarter battery charge warning lamp Red High engine temperature warning lamp Red Low engine oil pressure warning lamp RedAll panels also have Panel power on this is not a warning lamp GreenIn addition to above the domestic panels also have 2abd 2cd only Domestic battery charge warning lamp RedWith keyswitch in run position engine off Red lamp for no starter battery charge should function Red lamp for no domestic battery charge should function Note this will only function if a second alternator is fitted to the engine and connected to a charged battery 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 low oil pressure should function Green lamp for panel power on should function Buzzer should sound For operation of engines controlled with keyless panels refer to Correct operation of keylesspanels later in this sectionWhen the engine is started all the red warning lamps should switch off leaving just the green power onindication lamp illuminated The oil pressure lamp may take a few seconds to switch off and the chargefail lamp may remain on until engine rpm is increased to approximately 1000rpm if the engine wasstarted at tickoverBefore investigating any specific electrical problem always check Connection between panel harness and panel loom It must be clean dry and secured with a cable tie Check the start battery is connected to the correct terminal on the starter motor nd Check the domestic battery is switched on and connected to the correct terminals for the 2 alternator Battery connections inspecting condition of cables from battery to engine If in doubt measure the voltage at the engine If alternator charge problem measure battery voltage with engine off and again with engine running if there is an increase alternator is functioning correctly if not refer to check list Typical start battery positive Typical start battery negativeNote 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 Engines withonly one alternator do not utilise this connection 18Electrical fault finding all lamp panelsProblem Possible cause solutionNo warning lamps or buzzer functioning Battery isolation switch in off position switch onengine will not start or stop Starter battery discharged charge Engine fuse blown check fuse above starter motor or flywheel housing replace if necessary Check for wiring faultsNon function of warning lamp Disconnect switch wire to nonfunctioning lamp greenblue water temperature whitebrown oil THE WATER TEMPERATURE LAMP pressure brownyellow alternator charge Reconnect WILL NOT FUNCTION UNLESS wire temporarily to another warning lamp that isENGINE IS OVERHEATING OR THERE functioning if wire switches lamp on replace faulty lamp IS A WIRING FAULT Disconnect positive feed to nonfunctioning lamp Reconnect temporarily with wire from another warning lamp that is functioning if wire switches lamp on rewire with new connection If none of the above check continuity of connections from panel to engineWater temperature warning lamp on If engine is coldwhen engine is not over temperature Faulty wiring check connection continuity small green blue from switch to panel lamp Ensure thisNot 2B or 2C deluxe panel see table on connection is not shorting to earth 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 terminalBuzzer not functioning If lamp is functioning but buzzer not sounding check connection continuity from illuminated warning lamp THE BUZZER WILL NOT SOUND FOR red not green to buzzer board GREEN POWER ON LAMP Faulty warning panel buzzer board replaceStarter battery charge lamp not If tacho not Alternator not connected properly check continuity of small brown wire from rear of alternator to AC position on keyswitch alternator connected properly faulty alternator replace If tacho functioning correctly Check continuity of small brownyellow wire from rear of alternator to no charge warning lamp on rear of panel If alternator connected properly faulty panel warning lamp replaceTacho not functioning Check connections on rear of tacho especially blackblue wire terminal 4 Check connection of blackblue 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 blackblue wire from alternator to tacho Measure voltage from alternator W connection to earth ground should be approx 75 90 volts ACDomestic charge lamp not functioning Domestic battery not remains on with engine running Domestic battery not connected correctly 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 charge lamp not functioning No second alternator fitted to engine domestic lamp notbuzzer switching off with engine running used D charge indication lamp connection at rear ofTHIS LAMP WILL NOT FUNCTION IF A alternator not ALTERNATOR IS FITTED TO Two way plug socket disconnected between engine THE ENGINE harness panel loom 19Electrical fault finding 2cd water temperature function on 2b panelsIn addition to the fault finding detailed on the previous table the following is specific for the 2cd typedeluxe panel Also applicable for the 2b panel with Murphy water temperature gaugeProblem Possible cause solutionOil pressure warning lamp not Faulty wiring check wire connection continuity oil pressure gauge showing whitebrown from sender to panel lamp Ensure thismaximum deflection Engine off and connection is not shorting to earth in run positionOil pressure gauge showing no Faulty wiring check oil pressure sender wire smallmovement even when engine is started white brown is lamp functioning correctlyOil pressure showing no movement Check connection to oil pressure gauge if plug is notWarning lamp not functioning correctly connected to socket on rear of gauge reconnect If all connections are correctly made possible faulty sender unit check resistance to earth ground approx 50 Replace if no reading or shortcircuited If adjusted correctly buzzer still sounding possible faulty switch gauge unit replaceOil pressure showing normal operating Engine warmpressure 0755 bar Buzzer sounding Incorrectly calibrated switching point for warning lamp lamp illuminated adjust on rear of gauge to 05 bar minimum adjustment on gauge If adjusted correctly buzzer still sounding faulty switch gauge unit replaceWater temperature gauge showing Engine cold cool o o120 C 250 F Faulty wiring check water temperature sender wire is THIS ALSO APPLIES TO THE 2b not shorting to earth ground PANEL WITH MURPHY GAUGE Faulty sender unit check resistance to earth ground approx 35k cold 05k warm Replace if notably lessWater temperature gauge showing Engine warmnormal operating temperature 85oC Incorrectly calibrated switching point for warning lamp o oBuzzer sounding lamp illuminated adjust on rear of gauge to 100 C 210 F THIS ALSO APPLIES TO THE 2b If adjusted correctly buzzer still sounding faulty switch PANEL WITH MURPHY GAUGE gauge unit replaceWater temperature gauge showing no Check connection to sender if disconnected gauge willmovement lamp not illuminated engine not functionwarm Check connection to temperature gauge if plug is not THIS ALSO APPLIES TO THE 2b connected to socket on rear of gauge reconnect PANEL WITH MURPHY GAUGE If all connections are correctly made faulty sender unit check resistance to earth ground approx 35k cold 05k warm Replace if no Correct operation of keyless panelsThese panels control the engine with three water resistant push buttons instead of a keyswitch whichare less prone to damage and corrosion from sea water spray than a keyswitchTo operate the engine1 Press and hold HEAT button for ten seconds maximum Red lamp for no starter battery charge 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 low oil pressure should function Green lamp for panel power on should function Buzzer should sound2 Press START button and hold in position until engine fires see initial startup section for maximum time starter can be operated Release button when engine has 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 1000rpm if the engine was started at tickover Green lamp for panel power on should still function3 To stop the engine press the STOP push button hold in until engine stops This button also switches the power off to the gauges engine and power on lamp4 To restart the engine simply repeat steps from 1 above there is not need to switch battery isolators off whilst remaining on board5 If leaving the boat isolate start battery from engine and panel to prevent accidental start up of engine 20Electrical fault finding Non Beta PanelsEngines can be supplied wired up to suit VDO switch senders usually fitted to a nonBeta control panelIf so refer to our wiring diagram 2006097101 also part number for replacement harness Loom is configured differently in the 11way plug to accommodate the extra wiring Small brown wire battery sensed alternator feed fitted with bullet connection beside harness plug Oil pressure water temperature switch senders fitted to engine requiring individual connections for driving gauges warning lampsNoteWater temperature switch sender Part number 20001133 large spade is sender connection greenblue small spade is switch connection blueyellowOil pressure switch sender Part number 20062680 G Gauge wire whitebrown M Earth ground black WK Warning lamp fault finding Extension harnessesSome installations require one of the panel extensions 11 way connectors to be removed to allow thecable to be passed through bulkheads etc If any panel problems are experienced after this may havebeen carried out visually check all 11 way connections on engine harness to panel extension andpanel extension to panel on 2c deluxe to ensure wire colours to each terminal match up to thecorrect colour in its corresponding terminal Extra attention must be given to black ground andblackblue tacho also brown switched positive to alternator and brownyellow charge fail as are harder to distinguish between in poorly lit areas Whilst doing this check integrity ofeach connection to ensure terminals have not become damaged Once checked refit cable tie aroundeach connection to keep them secureBeta PNs for replacement Part number40 amp blade fuse all panels 20000959Alarm board all panels from June 05 20004655Oil pressure switch 18BSP not 2c panels 60062670Oil pressure sender 2c panels only 20094350Oil pressure switch gauge 2c panels only switch with single terminal on some BZ602 BD902 switch sender 18BSP not 2b or 2c panels sender 2b 2c panels only 20094360Water temperature switch gauge 2b 2c panels only 2c panels only 2009621028Ra relay 12V 40A fitted to rear of domestic panels silver bezel 60000057Panel stop button all panels Also heat and start on 2abVW 20000072Tacho 04000rpm with digital hour counter all panels but 2a engine harness Mini Series engine harness S5 Series engine harness S3 series 20005267Iskra 65 amp sub loom 200011961m panel extension loom 20004588012m panel extension loom 20004588023m panel extension loom 20004588034m panel extension loom charge engine sub loom top mounted alternators 20001197Green power on indicator lamp retaining clip 20004656Red warning indicator lamp retaining clip 20004657Note the above part numbers are suitable for earth return installations only where battery negativecable is connected directly to engine ground For insulated earth where battery negative cable isisolated from engine ground different harnesses alternators switches for oil pressure and will be required If your application is wired as insulated earth return and the engine will notoperate correctly always check starter battery negative is connected to the correct terminal on theisolating solenoid It should be connected to the terminal which is also used for all the small black wiresNOT the terminal with the single black wire connected directly to engine ground 21 SPANNER TORQUE Torques for general use bolts and nutsITEM Size x Pitch kgf m ft lbs N mM6 7T 6mm 024in 10115 7283 98113M8 7T 8mm 031 2428 174203 235275M10 7T 10mm 039in 5057 362412 490559M12 7T 12mm 047in 7992 571665 Torques for special use bolts and nutsITEM Size x Pitch kgfm ftlbs NmHead Bolts M11 x 125 95 100 687723 931980Bolts Connecting Bolts M8 x 10 4550 325362 441490Bolts Flywheel M12 x 125 100110 723795 9801078Bolts 1 Bearing Case M9 x 125 4752 340376 461509Bolts 2 Bearing Case M10 x 125 7075 506542 686735Nozzle Holder Assembly M20 x 15 5070 362506 490686Caps Nuts Head Cover M8 x 125 0709 5165 6988Glow Plugs M10125 2025 145181 196245Oil Switch PT 18 1520 108145 147196Nuts Rocker Arm Bracket M8 x 125 2428 174203 235275Bolts Idle Gear Shaft M8 x 125 2428 174203 235275Nut Crank Shaft M30 x 15 140160 10121157 13731569Nut Injection Pipe M12 x 15 2535 181253 245343 22 SECTION 3INSTALLATION installation details contained herewith are basic guidelines to assist installation due to great diversity of marinecraft it is impossible to give definitive instructions Therefore Beta Marine can accept no responsibility for any damageor injury incurred during the installation of a Beta Marine Engine whilst following these guidelines All engines shall be placed within an enclosure separated from living quarters and installed so as to minimise the risk of fires or spread of fires as well as hazards from toxic fumes heat noise or vibrations in the living quarters Unless the engine is protected by a cover or its own enclosure exposed moving or hot parts of the engine that could cause personal injury shall be effectively shielded Engine parts and accessories that require frequent inspection and or servicing must be readily accessible The insulating materials inside engine spaces shall be not MOUNTINGTo ensure vibration free operation the engine must be installed on extending as far forward and aft as possible and well braced to form anintegral part of the hullThe engine must be installed as low as possible on the flexible mount pillar studThis will limit vibration and extend the life of the flexible mount If necessary fitspacer blocks below the mountsA flexible coupling should be fitted Flexible couplings do not accommodate badalignment The mating faces of the gearbox and tailshaft must be checked foralignment they must be parallel and concentric to within 0005 must be checked for parallel A and concentric B misalignment usinga set of feeler gaugesTo obtain accurate alignment the flexible mountings must be adjusted untilalignment is attained and the mountings must be locked in positionOnce mounts are tightened alignment must be rechecked Coupling can now befitted in accordance with instructions supplied with Do not set the engine feet high up the flexible mount pillar stud This will causeexcessive engine movement and vibration Pack under the flexible mount withsteel shims securely bolted into the engine bearer2 The pillar stud on the flexible mount is secured into position by the lowerlocknut do not forget to tighten this Also ensure that the stud is not screwed too far through the mountingbody so that it can touch the mounting bearer This will cause vibration and knocking noises which are veryhard to findExhaustsa A correctly installed engine as described in this handbook will meet the exhaust emission requirements of Directive 200344EC amending the Recreational Craft Directive 9425ECb For compliance with exhaust emissions requirements engines must have correctly installed exhaust systems To ensure exhaust emissions are kept within permissible limits it is most important to reduce exhaust back pressure to a minimum whilst ensuring exhaust is adequately muffled Back pressure increases as exhaust length increases and from bends in the exhaust system The exhaust back pressure measured with the exhaust system connected and the engine running at full speed must not exceed 80mmHg 31inchesHg 42 inches WG The correct measuring point is at the position where the exhaust connects to the exhaust manifold That is before the water injection elbow or dry exhaust bellowsWet Exhaust hose should be matched to the following injection bend sizes BV1903 BV2203Standard 50mm 50mmHigh rise water injection bend SS 50mm 50mm 23Typical Yacht Installation Maximum sea water level when healed on the centre line of the boat 300mm minimum Normal sea water levelAllow at least 10 ofpropeller diameter for tipclearance to hull If a rope cutter is fitted allow approximately for movement of engine see manufacturers One of the most common problems with engine installation is water entering the exhaust manifold from the exhaust system by syphoning This can occur when the point of water injection X on the engine is close to or below the water line Water entering the pistons can cause bent con rods emulsified engine oil and a wrecked fuel pump Its best avoided2 The diagram shows a typical installation It is essential that the small black rubber hose connecting the heat exchanger with the injection bend is removed and replaced by a hose marked a This must be of sufficient length to supply either a T piece or an anti syphon valve sited at least 300mm 12 inches above the water line and on the centre line of the boat The pipe then returns to the injection bend and the sea water is pumped down the exhaust pipe3 The exhaust back pressure should not exceed 31 inches of Hg 241 The mechanical fuel lift pump is fitted to all engines as standard but if a suction head of 025m isrequired then an electric fuel lift pump must be fitted ask your dealer or Beta Marine2 It is very important that the excess fuel from the injectors is fed back to the fuel tank and not back toany point on the supply line This will help prevent air getting into the system3 Fuel pipe sizes are Supply mm Leak off mm 8 84 Any fuel leaks in the system are likely to cause poor starting and erratic running and must becorrected immediately5 A fuelwater separator must be installed See 76 The fuel return leak off pipe must loop down to be level with the bottom of the tank before it entersthe top of the tank see 12 This prevents fuel drain down This can cause poor starting See 127 Fuel lines and hoses must be secured and separated or protected from any source of significant heatThe filling storage venting and fuel supply arrangements and installations must be designed andinstalled so as to minimise the risk of fire and explosion Flexible fuel hoses connecting the engine tofuel tank supply and return lines must meet the requirements set in standard ISO as required by your surveyor INLET SYSTEM Heat exchanger cooled enginesYour engine is fitted with a gear driven sea water pump which sucks in seawater or raw water to cool theclosed circuit system via the heat exchanger1 It is very important that the seawater inlet shouldhave a strainer system either built into the sea cock or ahigh level system with visual inspection glass asshown mounted just above the water line2 The inlet sea cock and pipe work to the sea waterpump should be 25mm ID or 1 minimum3 Good access to the inlet sea cock is essential so thatplastic bags or seaweed trapped in the intake can bepoked out4 All pipe work should have approved marine gradestainless steel hose clips Any loose clamps or badconnections can cause flooding and sinking the vessel5 If water is required for stern tube lubrication then this should be taken from a T piece in the pipegoing from the heat exchanger outlet to the water injection bend6 Scoop type water pickups should never be used as water will be forced through the pump and intothe exhaust system whilst the vessel is in motion This is very dangerous as the exhaust will eventuallyfill and raw water will back up into the engine through the exhaust valve Catastrophic failure will resultas soon as the engine is restartedNote The maximum lift of the sea water pump is 2m 25CALORIFIER SYSTEMAll Beta engines can be fitted with the engine tappingsto allow the hot water from the closed system to circulate through a calorifiertank which in turn heats up domestic tappings on this range of engine are shown1 The big problem with a calorifier is to remove all theair from the system If this is not achieved then theydont work2 Try and keep the supply and return pipes or sloping down in a continuous fall towardsthe calorifier This avoids air pockets being created3 Extra care must be taken when first filling thecalorifier circuit system with 50 antifreeze to watersolution as the engine may appear to be full but it soondisappears into the calorifier pipe work Run the engineoff load for 10 minutes then check the level asdescribed in Filling The Fresh Water SystemAlso check to see if the pipe going to the calorifier is getting warm Top up the water level as requiredand run for another 10 minutes then repeat4 If the water level is steady but no warm water is getting to the calorifier then very carefully open thecalorifier bleed valve see manufacturers instructions or if none is provided then very carefully loosenthe jubilee clip securing the supply pipe to the calorifier Air should escape Refasten securely when nofurther bubbles are seenCAUTIONDo not do this when the engine is hot as scalding hot water may be forced out of the pipe has 4 panel options 2a 2abD or 2abV or 2abVW 2b 2cDThe engine harness is common to all1 These panels must not be installed where sea water spray can get at them A suitable flap or covermust be fitted2 Panels must be fitted in a location where the helmsman can either see or hear the alarm system3 For standard wiring diagrams see following pages4 Extension looms longer than 3m 10 feet As an option Beta can provide various lengths ofextension looms for runs of over 3m but this kit includes a start relay to overcome the voltage dropSee drawing 300585205 All electrical equipment must be protected from sea water Sea water or rust in the starter willinvalidate warranty Care must be taken when pushing the two halves of the plug together to ensurethat individual pins do not push out To prevent corrosion and assist in assembly we recommend thatthe plug is packed with petroleum jelly Vaseline and then carefully pushed together The plastic bootsshould cover both halves and overlap A cable tie is then put round to hold the two halves in positionand help prevent any ingression of water6 All cables must be adequately clipped and protected from abrasion7 Electrical systems shall be designed and installed so as to ensure proper operation of the craft undernormal conditions of use and shall be such as to minimise risk of fire and electric shock8 Attention shall be paid to the provision of overload and shortcircuit protection of all circuits exceptengine starting circuits supplied from batteries9 Ventilation shall be provided to prevent the accumulation of gases which might be emitted frombatteries Batteries shall be firmly secured and protected from ingress of water diagrams General Arrangements1 Typical starter motor ratings Page 272 Suggested engine starter battery size Page 273 Keyswitch terminations Page 274 Standard engine harness 65 Amp 20005451 Page 285 Standard engine harness 100 Amp 20006015 Page 296 Diagram of 2a panel cutout 20006516 Page 30 317 Diagram of 2abd panel cutout 20006517 Page 32 338 Diagram of 2abV panel cutout 20006519 Page 34 359 Diagram of 2abVW panel cutout 20006333 Page 36 3710 Diagram of 2b panel cutout 20006520 Page 38 3911 Diagram of 2cd deluxe panel cutout 20006518 Page 40 4112 Diagram of domestic extension harness 20004588 Page 4213 GA of BV192203 HE ZF1215M 10002011 Page 4314 GA of BV192203 HE TMC60M 10005154 Page 4415 GA of BV192203 HE ZF25H 10001333 Page 4516 GA of BV192203 HE PRM260 10001351 Page 4617 Split charge relay wiring 65 Amp 30062210 Page 4718 Starter booster relay diagram 30058520 Page 4819 100 Amp alternator information 20005466 Page 4920 Beta Controller information Page 5021 Wiring 100 Amp Controller 10005470 Page 5222 Declaration of Conformity for Recreational Craft Page 53 5423 Maintenance record and service items Page 55TYPICAL STARTER MOTOR used in Kubota engines have the following standard capacities Engine Starter capacity kW BV1903 14 BV2203 14SUGGESTED ENGINE STARTER BATTERY SIZE Engine Typical Battery Capacity AH Typical CCA A at a 20hr Rate Cold Cranking Amperage BV1903 100 123 580 670 BV2203 100 123 580 6701 Keyswitch standard panel keyswitch can be used to tap off a switched positive ignition feed topower additional gauges In this way these gauges will only be live whilst the engine isrunning the engine is starting or the heaters are being usedFor silver keyswitches the terminal to achieve this ignition switched positive is marked ACFor black keyswitches the terminal to achieve this ignition switched positive is marked 1554For panels without any keyswitch gauges can be driven from the 1mm2 brown wire at the 11 way connector terminal 4 This is a low power switched positive anyadditional power required from this connection must be fed through a relay as noted belowNote these keyswitch terminals are rated at 10 amps maximum since they are for panel and alternator feeds Beta Marine recommends any from these terminals must be fed through a relay This relay should then beconnected to its own fused positive supply directly from the engine battery Betadrawing 20206421 illustrating the wiring of a typical electric fuel lift pump with relay can be supplied upon request 27 15000 500 1000 1000 1000 8000 9000 1000 14000 500 2012 3668 5032 ADD 30mm FOR WIRESREV DESCRIPTION DATE APPD DRAWN NOTES TITLE01 2A PANEL DIMENSIONS IN MM INCH MATL DO NOT SCALE BETA MARINE LTD DRAWN BY SIZE DWG NO REV MERRETTS MILLS BATH ROAD TW A4 20006305 00 BETA MARINE SOUTH WOODCHESTER STROUD GLOS GL5 5EU CHECKED BY SCALE PAGE DATE TEL 01453 835282 FAX 01453 835284 LT NTS 2 of 2 15112004 19500 1000 1000 1000 17000 18000 500 1000 500 18500 O 500 THRU 2262 3668 5032 ADD 30mm FOR WIRESREV DESCRIPTION DATE APPD DRAWN NOTES TITLE01 2AB PANEL DIMENSIONS IN MM INCH MATL DO NOT SCALE BETA MARINE LTD DRAWN BY SIZE DWG NO REV MERRETTS MILLS BATH ROAD TW A4 20006304 01 BETA MARINE SOUTH WOODCHESTER STROUD GLOS GL5 5EU CHECKED BY SCALE PAGE DATE TEL 01453 835282 FAX 01453 835284 LT NTS 2 of 2 15112004 1800 50 100 100 1300 1400 200 200 100 50 1700 O 50 THRU 226 503 ALLOW 30mm FOR WIRES 367REV DESCRIPTION DATE APPD DRAWN NOTES TITLE01 ABV PANEL DIMENSIONS IN MM INCH MATL DO NOT SCALE BETA MARINE LTD DRAWN BY SIZE DWG NO REV MERRETTS MILLS BATH ROAD TW A4 2000632001 00 BETA MARINE SOUTH WOODCHESTER STROUD GLOS GL5 5EU CHECKED BY SCALE PAGE DATE TEL 01453 835282 FAX 01453 835284 LT NTS 2 of 2 23112004 O 500 THRU 500 14000 12000 500 500 2000 500 2000 1000 2262 16000 1000 18000 5050 ALLOW 30mm FOR WIRESREV DESCRIPTION DATE APPD DRAWN NOTES TITLE01 AS USED ON K14744 ABVW WATER PROOF PANEL DIMENSIONS IN MM INCH MATL DO NOT SCALE BETA MARINE LTD DRAWN BY SIZE DWG NO REV MERRETTS MILLS BATH ROAD TW A4 20006331 00 BETA MARINE SOUTH WOODCHESTER STROUD GLOS GL5 5EU CHECKED BY SCALE PAGE DATE TEL 01453 835282 FAX 01453 835284 LT NTS 2 of 2 01122004 21000 1000 1000 500 15500 16500 1000 500 20000 2262 3668 5032 ALLOW 30mm FOR WIRESREV DESCRIPTION DATE APPD DRAWN NOTES TITLE01 2B PANEL DIMENSIONS IN MM INCH MATL DO NOT SCALE BETA MARINE LTD DRAWN BY SIZE DWG NO REV MERRETTS MILLS BATH ROAD TW A4 20006303 00 BETA MARINE SOUTH WOODCHESTER STROUD GLOS GL5 5EU CHECKED BY SCALE PAGE DATE TEL 01453 835282 FAX 01453 835284 LT NTS 2 of 2 15112004 29800 1000 1000 500 1000 15600 16600 1000 28800 500 2262 3668 5032 ADD 30mm FOR WIRESREV DESCRIPTION DATE APPD DRAWN NOTES TITLE01 2C PANEL DELUXE DIMENSIONS IN MM INCH MATL DO NOT SCALE BETA MARINE LTD DRAWN BY SIZE DWG NO REV MERRETTS MILLS BATH ROAD TW A4 20006306 00 BETA MARINE SOUTH WOODCHESTER STROUD GLOS GL5 5EU CHECKED BY SCALE PAGE DATE TEL 01453 835282 FAX 01453 835284 LT NTS 2 of 2 1511200439 BETA CONTROLLER SEA SPEC ENGINESThe BETA CONTROLLER is an integrated battery charging external regulator Itis designed to be used with Beta s 70 and 100am p Iskra alternatorsThe system utilises a three stage charging characteristic which optimises the rapidcharge of battery systemsThe first stage A mode is a boost charge which is indicated by the indicator LEDshowing redThe second stage B mode is where the voltage is kept at a high level and wherethe current is between 10 and 95 of the nominal alternator current the LEDshows orangeThe third and last stage C mode is intended for maintenance of battery voltageonly When the alternator current is under a predetermined value for a time greaterthan 2 minutes the regulating mode is changed from B to C modeThe system automatically adjusts the charge mode to suit the load and is set in ourworks for conventional leadacid batteries It can easily be reset for deep cycle orgel batteries A more detailed specification can be obtained from BETA MARINE AMODE BMODE CMODE RED LED ORANGE LED GREEN LED AMPS VOLTS Beta Controller has been designedfor mounting off the engine in a locationaway from vibration water Ideally as there is acharge mode status LED the unit shouldbe positioned to allow for inspection ofcharge operating conditionAll goods are offered and supplied in accordance with our General Terms of Tender Sale 1 41 The graphs below illustrate charging voltages for different battery typesVolt16 DIPswitch positions1514 DIPswitch U113 U212 C 1 OFF 20 0 20 40 60 2 OFF Batteries and deepcycle BatteriesVolt Cover removal for resetting of DIP switches16 DIPswitch positions15 U1 Mode B Orange lamp1413 U1 U2 Mode C Green lamp U212 C 1 ON 20 0 20 40 60 2 OFF Note ensure all batteries are switched off controller is disconnected from wiring before removing any covers Conventional Batteries Voltage setting for battery charge is done through the two DIP switches inside the controller Remove the cover by removing the top four screws and loosening the bottom four This cover is sealed on to preventVolt water ingress this seal must be broken for cover16 DIPswitch removal positions Set the dip switches to the required settings as15 illustrated on the charts opposite14 Reseal controller with silicon sealant or equivalent U1 after setting switches13 U212 C As standard the controllers are supplied to Beta Marine 1 OFF 20 0 20 40 60 2 ON to suit lead acid batteries If in doubt on battery type check with battery supplier Gell Batteries before fitting controller Beta Marine are not responsible for incorrect switch setting for each installation THIS CONTROLLER SHOULD NOT BE MOUNTED ONTO THE ENGINE BODY All goods are offered and supplied in accordance with our General Terms of Tender Sale 2 42 SERVICE Please complete the following from new when commissioning the engine23 MAINTENANCE RECORD if there are any additional items fitted please note these here too Write full numbers for additional drivebeltsDate Service carried out Item Beta PNo Standard 65 Amp drivebelt 21496830 Optional 100 Amp drivebelt 21400497 Oil filter 2117051002 Fuel filter 21160210 Air filter element 21161831 40 Amp blade fuse 20000959 Zinc wasting anode 20961840 Jabsco sea water pump impeller 20780800 Jabsco sea water pump gasket 20762600 Jabsco sea water pump service kit 20780810 Tubestack nitrile O ring 20980110 Flexible mount 45 shore BV1903 standard not if fitted with PRM260 2138590002 Flexible mount 55 shore All BV2203 BV1903 PRM260 only 2139697001 Engine identification Engine serial number WOC number Date of purchase First operated Where Sail Drives 135 to 50bhpHeat Exchanger Cooled 10 to 90bhpKeel Cooled 10 to 90bhp Beta Marine Generating Sets 37 to 40kVA Beta Marine Limited Davy Way Waterwells Quedgeley Gloucester GL2 2AD UK Tel 01452 723492 Beta Marine Generating Sets Fax 01452 883742 30 to 900kVA Technical Spares email Technical Warranty email Ref 1660