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Beta 26 75 And 90 Bhp Engine Manual



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                                                     Operator's
                                                   Maintenance
                                                        Manual




Heat Exchanger Cooled
Mid Diesel Engine Range
62, 75 & 90 bhp
CALIFORNIA ­ Proposition 65 Warning: Diesel engine exhaust and some of its constituents are known to
the state of California to cause cancer, birth defects and other reproductive harm.
                                  CONTENTS

Introduction
       Engine Identification                                                2

       Initial Receipt of the engine                                        2

       Engine Storage                                                       2

Safety Precautions                                                          3


Technical Specifications                                                    4


Section 1:          Guidelines for operation of engine
       Important checks prior to initial use                                5

       Initial Start-up and bleeding The Fuel System                        5

       Starting/Stopping                                                    5


Section 2: Maintenance and service guidelines
       Maintenance Schedule                                                 7

       Lubrication ­ Checking and changing oil                              8

       Fuel System, Pumps, Filter, fuel/water separator                     9

       Cooling ­ Fresh water system, Keel Cooling, Heat Exchanger Cooling   10

       Sea Water Pump, Heat Exchanger                                       11

       Belt Tensioning                                                      12

       Air Filter                                                           13

       Electrical                                                           13

       Laying up - Winterising                                              13

       Troubleshooting                                                      14

       Torque Settings                                                      23


Section 3:          Installation Guidelines
       Engine Mounting                                                      24

       Alignment - Drives, Flanges, Flexible Drives                         24

       Exhausts & Bends                                                     24

       Mounting Exhausts                                                    25

       Fuel Supply                                                          26

       Cooling (seawater inlet & keel cooler systems)                       26

       Calorifier System                                                    27

       Electrical installations                                             28

       Appendices ­wiring diagrams and general arrangements                 28

       Maintenance Record                                                   60

       Component identification at rear of manual                           60




                                                          1
  Operation and Maintenance Manual for the following
           BETA MARINE engines based on

                  Kubota BF2803, BV3300 & BV3800
This manual has been compiled to provide the user with important information and
recommendations to ensure a trouble free and economical operation of the engine.

For further advice or technical assistance, application should be made to BETA MARINE
LIMITED or its distributors.

All information and recommendations given in this publication are based on the latest
information available at the time of publication, 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, and is based upon results obtained from tests carried out at the place of
manufacture and in vessels used for development purposes. We do not guarantee the same
results will be obtained elsewhere under different conditions.


ENGINE IDENTIFICATION

NOTE: In all communications with the distributor or Beta Marine, the engine number and
works order number (WOC) must be quoted.




                         Fig. 1a


For the BF2803, the engine serial number is stamped below the fuel injection pump on the
starboard side of the engine. For the BV3300 & BV3800, the engine serial number is
stamped behind the fuel filter (Fig. 1a) on the starboard side of the engine. For all engine
types this is also shown on the rocker cover label with the WOC number.


INITIAL RECEIPT OF THE ENGINE
A full inspection of the engine must be made immediately on delivery to confirm that there is
no damage. If there is any damage then write this clearly on the delivery note and inform
your dealer or Beta Marine within 24 hours.


ENGINE STORAGE
The engine must be stored in a dry, frost free area and this is best done within its packing
case. If storage is to be for more than six months then the engine must be inhibited (contact
your dealer or Beta Marine). Failure to inhibit the engine may result in the formation of rust in
the injection system and the engine bores, this could invalidate the warranty.




                                                2
                                  SAFETY PRECAUTIONS!

A.   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 made,
B.   Drives - Power Take Off Areas                             they are clean and free of leaks.

i). 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
    rev/min. 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 Scalding
ii). 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 95°C. 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 Transportation/Lifting
     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 only,
iii). 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
     rev/min. 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 or
C Exhaust Outlet                                           with other machinery. It is the responsibility of
  Diesel marine propulsion engines emit                    the purchaser /installer/owner, to ensure that
  exhaust gases at very high temperatures -                the machinery is properly guarded and that all
  around 400-500°C. 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 exchanger/header 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, C.E.O, Beta Marine Limited

D Fuel

i). 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 94/25/EC is complied with.



                                                      3
   TECHNICAL SPECIFICATIONS (Standard Engines)
   Standard Engines BD1703 BV1903 BV2203
Standard Engines                                   BF2803                 BV3300                     BV3800
Cylinder                                              5                        4                          4
Bore (mm)                                            87                       98                        100
Stroke (mm)                                         92.4                      110                       120
Displacement (cc)                                  2,746                     3318                      3769
Combustion                                     Spherical type          Indirect Injection         Direct Injection
                                                  (TVCS)                  (E-TVCS)                   (E-CDIS)
Cooling                                                                      Water
Starter voltage (V)                                                           12
Starter output (kW)                                  1.4                                    2.5
Alternator output -heat exchange (Amps)                                 65 (standard)

Alternator output ­keel cooled (Amps)        45 (starter ) & 2nd                   65 (starter )
                                              150 (domestic)                   & 2nd 150 (domestic)
Glow plug resistance (each)                                        1                              N/A
Engine speed (RPM)                                  2,800                             2,600
Power output ISO3046 (BHP)                            62                      75                   90
Declared power ISO8665 (kW)                           42                     50.7                 60.8
                                                                                o                         o
Compression Ratio                                   23.0:1                   16               12.5 ­ 13.5
Fuel timing BTDC                                     18°
Capacity of standard sump (litres)                    12              13.2                 13.2
Nett dry weight with std gearbox (kg)                350               390                 392
Fuel                                                          Diesel fuel oil No.2D
Coolant                                                  33%-50% (max) antifreeze / water
Approx Coolant capacity H/E (litres)               11.25                          10.2
Min. recommended battery capacity               12V, 120Ah                    12V, 180Ah
                                               (600CCA Min)                 (1,200CCA Min)

   Maximum Angle of Installation: Trim 15°, Roll 25° (intermittent), 20° continuous


   Rotation:   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 handed.

   Diesel fuel must conform to BS2869-1970 class A1 or A2. The fuel must be a distillate
   and not a residual oil or blend.


   Lubricant: Engine - Engine oil must meet MIL-L-2104C (see section 2 for details)
              Gearbox - see operator's manual for the gearbox oil type and capacity

               Oil pressure - minimum (tickover) 0.5 bar

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

   Note: Declared Powers to ISO8665:1995
   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 standard specifications 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 the ISO tolerance bands.


                                               4
         SECTION 1 GUIDELINES FOR OPERATION OF THE ENGINE
IMPORTANT CHECKS PRIOR TO INITIAL USE
1.    Generally, a new engine has the oil and anti-freeze removed after the works test. Fill the
      engine with the correct oil and anti-freeze (see sections on ENGINE OIL and COOLING).
      Check gearbox oil level - see separate operator's hand book.
2.    Ensure the engine is free to turn without obstructions.
3.    Check that the sea-cock is open (heat exchanger cooled engines only).
4.    Ensure battery is fully charged and connected (the isolator is in the 'ON' position).
5.    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 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 adjustment.
6.       Ensure engine is out of gear with 1/3 throttle - see single lever control
         instruction manual.
7.       Open the fuel stop cock and bleed the fuel water separator of air as
         shown in manufacturers literature.
8.       Fuel should now be at the fuel lift pump, see diagram 1b.
9.       Open the sea cock.
INITIAL STARTUP AND BLEEDING THE FUEL SYSTEM
(a)       Open fuel bleed screw on top of fuel filter by 1 ˝ turns, see diagram 1b.
(b)       Move hand priming plunger (on the fuel filter head for keel cooled
          engines, on the separate fuel lift pump for some heat exchange) up and
          down until fuel with no bubbles comes out of the bleed screw.
(c)       Shut/tighten the bleed screw. Clean area thoroughly with tissue paper.
(d)       Continue to hand prime for 30 seconds to push fuel through the fuel
          pump.
(e)       Start engine (see normal starting).                              Fig. 1b
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 repeat.
 (f)      If engine does not start after 3 attempts then allow 5 minutes for the starter to cool down before
          repeating (b) to (e).
Note: The starter windings will be burnt out with continuous cranking.

CAUTION          To 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 infection.
NORMAL STARTING (ALL BETA PANELS WITH SILVER KEYSWITCH)
With the engine out of gear, set speed control lever to 1/3 throttle. Turn key anti-clockwise to HEAT* (A)
position and hold for ten seconds, turn key clockwise to RUN (C) position at which point the instrument
panel should illuminate, an alarm buzzer will sound and two (*or three) red warning lights will illuminate:
STARTER BATTERY CHARGE,
DOMESTIC BATTERY CHARGE (D in battery symbol ­2AB'D' & 2C'D' PANELS ONLY)
(Note: this will only illuminate if 2nd alternator is fitted)
OIL PRESSURE
and green POWER ON / RUN LIGHT (this will stay on)                                   Fig. 1c
Turn to START (D) position and engine will motor, hold in position until engine fires (see initial start-up
section for maximum time starter can be used). Release key (when engine has started) to RUN
position. Ensure alarm buzzer is not sounding and that red warning lights are extinguished. If one or
both of the alternator warning lights are still on, then increase engine speed to excite the alternator -
then return to idle. The battery charge lights should then go out. The run light will remain on (green
LED). Check for sea water flow. If no flow then SWITCH OFF IMMEDIATELY AND CHECK SEA
WATER SYSTEM
Note: For panels without keyswitch, see separate instruction sheet, page 21.
Note: BV3800 does not have glow plugs, i.e. preheat operation is not required



                                                      5
STOPPING
Most propulsion engines are fitted with a stop solenoid, which is energised to stop. To stop
engine simply press the stop push button, hold in until engine stops, then turn key from 'RUN'
to 'OFF' position.

When leaving the boat for an extended period:
· Turn off sea-cock (heat exchanger cooled engines).
· Turn off battery isolator.

*WARNING
·   Do not turn the key to the off position when the engine is running. This will not
    allow the alternator to charge and will damage the alternator.
·   Do not leave the key in 'HEAT' position for more than 15 seconds ­ this will
    damage the heater plugs and eventually lead to poor starting.
·   Do not depress stop button for more than ten seconds, as this will lead to
    overheating and failure of the solenoid.


This range of engine is equipped with a mechanical stop lever in the event of electrical
system failure. This lever is located on the starboard side of the engine in front of the speed
control lever. See illustration below:




                                                Speed lever (BF2803)


                                                   Stop lever (BF2803)




                                              Fig. 1d




                                                   Speed lever (BV3300 & BV3800)




                                                   Stop lever (BV3300 & BV3800)

                                              Fig. 1e




                                               6
                                            SECTION 2
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 and replace if necessary.
·   Ensure raw water inlet strainer is clear (heat exchanger cooled engines only).
·   Check stern gland lubrication.
·   Drain off any water in fuel / water separator.

After the first 25 hours running
·   Change gearbox oil or ATF (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 re-checked. 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 Section 2 Belt tensioning.
·   Check ball joint nyloc nuts for tightness on both gearbox and 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 tube stack. Tighten end cap bolt if required.
· Drain off any water in fuel / water separator.

Every year ­or every 250 hours if sooner
·   Change engine lubricating oil.
·   Change lubricating oil filter.
·   Check air cleaner element and replace if necessary.
·   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 (on sea water cooled engines only):
    BF2803 ­ by undoing the single bolt at each end of the tubestack
    BV3300 / 3800 - by undoing the four cap screws at each end of the tubestack.
    Remove end cover, pull out tube stack and clean. Replace rubber `O' rings and re-assemble.
    Immediately engine is started check for leaks.
·   Spray the keyswitch with WD40 or equivalent to lubricate the barrel.
·   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 re-checked. Poor alignment due to
    loose flexible mount nuts will cause excessive vibration and knocking.
·   Check ball joint nyloc nuts for tightness on both gearbox and speed control levers. Grease both
    fittings all over.

Every 750 hours
As every 250 hours, plus the following:
·   Change air cleaner element.
·   Change fuel filter.
·   Change antifreeze.
·   Change gearbox oil or ATF (See separate gearbox manual).
·   Check electrical equipment, condition of hoses and belts, replace as necessary.




                                                   7
LUBRICATION
Engine oil
Engine oil should be MIL-L-2104C or have properties of API classification CC/CD/CE grades.
The following table gives grades of oil required for various ambient temperatures.
         TEMPERATURE                 SINGLE GRADE                 MULTI GRADE
         Below 0°C                        SAE 10W                 SAE 15W/40
         0°C TO +25°C                     SAE 20                  SAE 15W/40
         Above +25°C                      SAE 30                  SAE 15W/40
Note: A good quality 15W/40 multigrade oil as used in most diesel car engines will meet
these requirements. Do not use 'Turbo Diesel Oil' or additives.
Checking engine oil level                                 Fig. 2a
For quantities of oil required see section marked 'Technical
Specification',
When checking the engine oil level, do so before starting, or
more 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 the
    oil level lies between the two notches.
2. If the level is too low, add new oil to the specified level -
    Do not overfill.

IMPORTANT                                                 Fig. 2b
When using an oil of different make or viscosity from the
previous one, drain old oil. Never mix two different types of
oil. Engine oil should be changed after first 50 hours running
time and then every 250 hours or every year. Oil filter is a
cartridge type mounted on the starboard side of the engine.
CHANGING ENGINE OIL
1. Run the engine for 10 minutes to warm up the oil.
2. Your engine is provided with a sump drain pump.
   Unscrew the end cap on the end of the pump (optional),
   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 Fig. 2d).
3. Unscrew the oil filter and replace with a new one
   (see Fig. 2c).                                        Fig. 2c
   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 filter
   spread a thin film of oil round the rubber gasket to
   ensure a good seal and screw in - hand tight.
4. Fill the engine with new oil as described above.




                                               Sump Pump




                                               End Cap (Optional)

                                               Tap
                                     Fig. 2d



                                                 8
CHECKING GEARBOX OIL LEVEL

1. The gearbox is fitted with a dipstick and oil filler
   plug, see fig 2e.
2. Each engine is supplied with a gearbox operator's
   manual, which specifies the type of lubricating oil
   to be used, the capacity and frequency of
   changing of the oil.
3. New engines are normally supplied with the
   gearbox topped up with lubricant but check the
   level before starting the engine for the first
   time.
4. 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.
5. A guide* to the type of oil to be used is as follows:
                                                       Gearbox filler & dipstick Fig. 2e
      Gearbox type                Lubricant                Capacity (approx.)
        PRM260             Use Engine Oil 15W40                  1.5 litres
         ZF25M         Use Automatic transmission fluid         0.75 litres
         ZF25H         Use Automatic transmission fluid          2.0 litres
*See separate gearbox manual for further details

FUEL SYSTEM
IMPORTANT
· 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 0.25 metres. If this is insufficient then an
   electric fuel lift pump must be fitted.
· The fuel return must be led back to the top of the fuel tank with a loop to prevent "drain
   down" (see fig. 3e).


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.
   See fig. 2f.
3. Apply fuel oil thinly over the gasket and tighten
   into position - hand tight.
4. Bleed as detailed - see initial start up.
5. Check for leaks.
6. Do not get fuel on the flexible mounts.




                                                           Fig. 2f




                                                9
COOLING
This range of engines are normally fresh water cooled. This water circulates through the engine and on
to a heat exchanger where it is cooled by sea water which is pumped through the cooling tubes. The
sea water is then injected into the exhaust system (see fig. 2g).
KEEL COOLING is an option. In this system the freshwater is pumped through the engine and then
through a cooler built into the side of the boat where it is cooled by heat transfer before returning to the
engine. (see fig. 2h, 2i & 2j). The ideal keel cooling tank should have:
a. Baffle continuously welded to outer skin and close fitting on inner skin
b. Be thin in section to allow good mixing of the water over the cool outer surface.
c. Air bleed valves should be fitted on both ends.

Fig. 2g                                                      Fig. 2h




Heat Exchanger Cooling
                                                                       Keel cooled ­Note, efficient cooling tanks
                                                                       are side mounted, see page 27
Keel cooled skin tank connections from engine:
                                                                   Fig. 2j ­BV3300 & BV3800
Fig. 2i -BF2803




                                                              To cooler

                                                              From cooler



FILLING THE FRESHWATER SYSTEM                              Fig. 2k (BF2803)
New engines are supplied with the freshwater drained off. The following
instructions must be followed to fill the system.
(a) Mix up in a clean bucket the correct strength and volume required of
     solution (see notes page 4).
(b) Check that the drain tap is turned off. (see Figs. 2k & 2l)
(c) Fill engine with freshwater / anti freeze solution through the top of the
     heat exchanger or header tank with the filler cap removed. (see Fig.
     2m).
(d) 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 direction.               Fig. 2l (BV3300 & BV3800)
Note: For keel cooled engines a much larger quantity of
freshwater/anti-freeze solution is required depending on the size
of the keel cooling tank - refer to the builder.
(e) Run the engine for 5 minutes on no load (out of gear) and
     check coolant level. Top up as necessary.
(f)   Check system for leaks.
      Note: For keel cooled engines it is very important to bleed all the air out of
      the system before the engine is run on load (check with builder's
      instructions).
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 notes under Section 3).

                                                                                Fig. 2m




                                                        10
(g) 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 notes under Section 3).
(h) 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 neck.
IMPORTANT
Removal of the pressure cap when the engine is hot can cause severe injury from scalding hot water
under pressure. Always allow the engine to cool and then use a large cloth when turning the cap anti-
clockwise to the stop. This allows the pressure to be released. Press firmly down on the cap and
continue to turn anticlockwise to release the cap.
(i) Repeat (h) if coolant level is more than 1 inch below the base of the filler neck when the engine has
    cooled down.
(j) Run engine on 2/3 full load for 20 minutes, check for leaks and repeat (i).
(k) Anti-freeze solutions should be drained off every 2 years and replaced with a new solution.
Note: When draining the fresh water system, ensure the engine has cooled sufficiently to prevent
scalding from hot pressurised water. Prior to draining a cold engine, remove the filler cap from the
header tank and then open the water drain tap. This allows the water to drain freely from the system.
Yachts and Launches with Heat Exchanger Cooling
It is essential that a mix of 33% to 50% anti-freeze/water mixture is used. This not only stops freezing
up in winter, but it prevents overheating and corrosion. The warranty is invalid unless the correct
ratio is used.
Canal Boats with Keel Cooler
A 33% anti-freeze to water mixture is recommended to give protection against very cold winter
temperature of -15°C and to allow the water temperature switch to be activated. This anti-freeze will
also give the engine internal protection against corrosion. For keel cooled engines the total system
capacity must be taken into consideration, i.e. engine volume plus skin tank/keel cooler volume.
Concentration of ethylene should not exceed 50%.
All engine types:
The anti-freeze in the fresh water system enables the boiling point of water to rise to 124°C with a
95kPa pressure cap fitted. The water temperature alarm switch will however be activated at 95° to
100°C. If no anti-freeze or a very weak solution is used, then the water temperature switch may not be
activated before coolant is lost.

SEA WATER PUMP AND COOLING SYSTEM
(Heat exchanger-cooled engines)                            Fig. 2n

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 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. 2n ­BF2803, fig.2o ­BV3300 &
      BV3800).
2.    Withdraw the rubber impeller from its drive shaft.
3.    Check impeller for cracks in the rubber, excessive wear or
      lost vanes. Replace 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 Stack'.
                                                            Fig. 2o




                                                     11
CLEANING THE HEAT EXCHANGER TUBE STACK AND REPLACING WASTING ZINC ANODE
                                                                               Fig. 2p
1.   The wasting zinc anode should be replaced every year. The anode is
     attached to the bolt inserted in the forward end cap of the heat exchanger.
     See fig. 2p ­BV3300 / BV3800 shown.
2.   Unscrew the bolt and replace the complete unit with a new one.
3.   Check for leaks.
4.   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. 2q.
5.   Drain off coolant into a bucket.
6.   Unscrew the 8 end cap retaining bolts (four each end of the tube stack).
     Remove the 'O' rings and pull out tube stack. Clean tube stack and end
     caps. Note: the BF2803 has one bolt on each endcap.
7.   Re-assemble using new 'O' rings. Do not overtighten end cap bolts and
     make sure the tube stack is the right way round.
8.   Re-fill engine with water/anti-freeze solution and run engine up to
     temperature to check for leaks.                                    Fig. 2q
ALTERNATOR DRIVEBELT TENSIONING (Heat exchanger cooled)

WARNING                                                              Fig. 2r
1. Belt tension must only be checked with the engine switched off.
   These engines are usually fitted with a single belt to drive the 65 amp
   battery charging alternator (heat exchange) and the fresh water
   circulating pump.
2. The belt tension is adjusted by swinging the alternator outboard as it
   pivots on its support bolt.
3. With the engine stopped, loosen the lower support bolt and the link
   adjusting arm held by the top bolt.
4. Push alternator outboard to tension and tighten link bolt. Check that
   the depression of the belt is approximately 1/2" or 12 mm when
   pushed down firmly by thumb (See fig. 2r). Tighten link bolt then lower support bolt.
5. Belt tension should be regularly checked especially during the first 20 hours of running in a new
   belt, as stretching occurs.
                                    BELT TENSION - 45 and 150 AMP ALTERNATOR (Keel Cooled)

                                       WARNING
                                       Belt tension must only be checked with the engine switched off.
                                       (1) This standard range of engines are fitted with a single belt to
                                       drive the 65 Amp starter battery charging alternator (45 Amp on
                                       BF2803) and the fresh water circulating pump. A second 150 Amp
                                       alternator is fitted for charging domestic batteries.
                                       (2) The belt tension is adjusted by swinging the alternator outboard
                                       as it pivots on its support bolts.
                                       (3) With the engine stopped, loosen the support bolts and the link
                                       adjusting bolt.
                                       (4) Push alternator outboard to tension and tighten link bolt. Check
                                       that the depression of the belt at position shown is approximately
                                      1/2" or 12 mm when pushed down firmly by thumb. Tighten support
                                      bolts.
                                      (5) Belt tension should be regularly checked especially during the
                                      first 20 hours of running in a new belt, as stretching occurs.
                                      Note: Over tensioning will cause premature failure of
                                      components.
                                      (Note: BF2803 alternators illustrated)




                                                      12
AIR INTAKE FILTER
These engines are fitted with an air intake filter, which should be checked every season and changed
every two years. Check and change more often if badly clogged.


                                                     Air filter (BV3300 / BV3800 shown)




                                                     Fig. 2s


MAINTENANCE - ELECTRICAL

WARNING
Under no circumstances should the battery be disconnected or switched off when the engine is running.
This will seriously damage the alternator.
PANELS AND WIRING
See installation notes, page 28
GENERAL MAINTENANCE
1. 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 keyswitch every month with WD 40 or equivalent.
2. Check batteries for acid level and top up if required. For low maintenance and 'gel' batteries see
   manufacturers instructions.
3. Loose spade terminal connections are the most common cause for electrical faults - check on a
   regular bases (see maintenance instructions).
4. Engine loom plug and socket connections should be packed with Vaseline to prevent corrosion,
   plastic shrouds should be checked to be overlapping and connection should be made secure with a
   cable tie. This will help prevent the ingress of water and keep the connection secure.
WINTERISING AND LAYING UP
Heat Exchanger Cooled Engines Left Afloat and Ashore
(a) The engine oil and oil filter should be changed at the end of the season rather than the spring. See
    section 2.
(b) The closed circuit system should contain a 50/50 solution of anti-freeze (this also applies to warm
    and tropical climates).
(c) For cold climates where the air or water temperatures can fall below 3°C, 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 50/50 anti-freeze
          solution.
    (iii) Start the engine (out of gear) and run for 5 to 10 seconds until the anti-freeze 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 seawater or raw water circuit is now protected by anti-freeze. Remove sea water pump
    impeller & store
(d) Ensure instrument panel is well protected and give the key switch a spay of WD 40 or equivalent.
(e) With the engine stopped, disconnect the battery (always disconnect negative cable first / reconnect
    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 boat.
(f) 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 damage.
LAYING UP ASHORE
(a) Change the engine oil before the boat is taken out of the water. Warm engine oil is much easier to
    pump than cold!
(b) to (f) should be followed as above.
LAYING UP CANAL BOATS WITH KEEL COOLING
Follow items a, b, d, e and f. Item (c) does not apply. Special care must be taken to ensure that the
whole cooling system has a 30% anti-freeze solution and this includes the calorifier circuit.
If the system has been topped up or refilled then run the engine for 10 to 15 minutes on load (if possible)
to get the solution circulated throughout the cooler and calorifier.



                                                    13
                                      TROUBLE SHOOTING
Beta diesels are very reliable if installed and serviced correctly, but problems can occur and the
following list gives the most common ones and their solution.

Problem: Engine does not start but starter motor turns over OK

Possible 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 they are 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 slowly

Possible 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 oil for signs
                                 of water (creamy-coloured oil). Ring your dealer.
Engine 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.




                                                 14
Problem: Erratic running
Possible 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 improves check for a
                                   wiring fault.
Broken fuel injection pump
spring:                            Replace.
Problem: White or blue exhaust gas
Possible Cause               Solution
Engine oil level too high:   Reduce the level.
Blocked injector:                  Service injectors.
Piston ring and bore worn,
giving a low compression:          Get compression checked by your dealer or Kubota service
                                   agent. He will advise action to be taken.
Check that the breather pipe is
clear and not obstructed:       Remove and clean out
Problem: Black exhaust gas
Possible 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
Problem: Low power output
Possible 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.
Governor spring incorrectly
mounted:                           Dealer to adjust.
Single lever control not
operating correctly:               Disconnect speed control cable and move the lever by hand.
                                   Adjust cable.
The electrical load is too large
on start up:                       Disconnect or reduce the load.



                                                   15
Problem: High oil consumption
Possible 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.

Problem: Water in lubricating oil (heat exchanger cooled)
Possible 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 each time to eliminate
                                 any water. Get fuel injection pump and compression checked by
                                 Service Agent.

Problem: Water in lubricating oil (general)
Possible 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 (keel cooled)
Possible Cause                     Solution
Oil goes "milky" due to water Check installation - has dry exhaust system been fitted correctly,
entering exhaust manifold and ensuring rain water cannot enter the exhaust port and run back?
then 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 Agent.

Problem: Low oil pressure warning light comes on when engine speed reduced to tick over:
Possible 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)
Possible Cause                     Solution
No W connection to alternator: Check output from `W' connection. Should be about 9V AC
Wiring fault:                      Check circuit




                                                    16
Problem: Engine overheats

Possible Cause                   Solution
Check coolant level:             Top up.
Insufficient sea water flow:     Clear blocked intake or filter.
Damaged or worn pump
impeller:                        Replace.
Blocked tube stack in heat
exchanger:                       Remove tube stack and clean ­ replace `O' rings.
Zinc anode flakes blocking tube
stack:                          Remove and clean tube stack as above.
Pressure cap loose:              Replace.
Switch sender faulty:            Replace.
Inlet sea cock is too small:     Replace (see heat exchanger cooled seawater inlet system in
                                 section 3).
High exhaust back pressure:      Must not exceed 3.1" of Hg.
Air locks in cooling pipe work
to keel cooler:                  Vent the system and top up coolant.
Keel cooler insufficient size:   Contact boat builder

GENERAL -HEAT EXCHANGE ONLY: The most common cause of overheating is insufficient
seawater flow due to a blocked intake (weed or a plastic bag!). If this happens then clear the
blockage. If the problem is not cured then check the system for sea water flow which should be
·       For BF2803: 15 litres / minute minimum at 1,500 rpm
·       For BV3300 & BV3800: 57 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 for 10 seconds and measure the amount of water collected. Multiply this
value by 6 to give the flow in litres/min. Repeat twice and take an average. If the flow rate is
noticably less than noted above, 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 the exchanger. 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 dinghy is best. The person holding the bucket should take precautions
against breathing in the exhaust gasses.

Problem: Knocking noise

Possible Cause                   Solution
Propshaft touching gearbox
output coupling through split
boss or Type 16 coupling:        Adjust, giving correct clearance (10mm) 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



                                                 17
Problem: Battery quickly discharges
Possible Cause                    Solution
High load and insufficient        Reduce load or increase charging time. Large domestic battery
running:                          banks subject to high electrical loads will take a considerable
                                  time to recharge from a single alternator.
Low electrolyte level:            Top up.
Fan belt slipping - black dust in
engine compartment, engine
compartment temperature too Adjust tension / replace belt with a high temperature type and /
high:                             or improve engine compartment ventilation.
Alternator defective:             Check with Agent.
Battery defective:                Replace.
Poor wiring connection:           Check wiring system.

Problem: Transmission noise

Possible Cause                    Solution
Check gearbox oil level:          Top up.
"Singing" propeller:              Check with supplier.
Drive plate rattle at tickover:   Check engine rpm (must be 850 rpm minimum in gear).
Worn drive plate:                 Change.
Propeller shaft hitting the       Move shaft back to give at least 5mm clearance (Type 12/16
Gearbox half coupling:            couplings only)
Problem: Vibration

Possible Cause                    Solution
Poor alignment to shaft:          The alignment must be accurate even if a flexible coupling is
                                  used (see section 3 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 perish most rubbers.)
Loose securing nut on flexible
mount:                            Check alignment and then tighten the nuts.
Insufficient clearance between There must be at least 10% tip clearance between propeller and
the propeller tip and the bottom bottom of the boat (ie 10% of the propeller diameter as
of the boat:                     clearance). Refer to boatbuilder.
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: Morse control cable will not fit

Possible Cause                    Solution
Fitting incorrectly               Cables are being fitted the wrong way around, switch over and fit
                                  the opposite way.



                                                 18
           Electrical fault finding & trouble shooting ­engines built after July 2005 only
The following chart is compiled to aid diagnosis of electrical faults, based on the Beta 10-90hp range of
engines. If your engine was built before July 2005, contact Beta Marine for the relevant electrical
trouble shooting guide.
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) 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 system.
Both of these alternators work independently, if the domestic battery system is disconnected, the engine
will still run correctly but:
·     Domestic charge warning lamp will not function
·     Warning buzzer will remain on at all times
Standard control panels are supplied with four or five lamps:
Four lamp panels:         2a, 2ab'V', 2ab'V'W and 2b, these panels utilise bulbs inside sealed lamp
                          holders
Five lamp panels:         2ab'd' and 2c'd', these panels also utilise bulbs inside sealed lamp holders,
                          having an additional lamp for domestic battery charge
All Beta panels have the following warning lamps:                     (2a, 2ab'd', 2ab'V', 2ab'V'W, 2b, 2c'd')
Starter battery charge warning lamp                                              Red
·   High engine temperature warning lamp                                         Red
·   Low engine oil pressure warning lamp                                         Red
All panels also have:
·    Panel power on (this is not a warning lamp)                                 Green
In addition to above the domestic panels also have:                   (2ab'd', 2c'd' only)
·    Domestic battery charge warning lamp                                      Red
With 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 keyless
panels' later in this section
When the engine is started, all the red warning lamps should switch off leaving just the green power on
indication lamp illuminated. 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 at tickover).
Before 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 negative

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



                                                        19
Electrical fault finding ­all lamp panels

Problem                                     Possible cause & solution
No warning lamps or buzzer functioning,     -     Battery isolation switch in off position ­switch on
engine 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 faults.
Non function of warning lamp                -     Disconnect switch wire to non-functioning lamp:
                                                  green/blue ­water temperature, white/brown ­oil
 THE WATER TEMPERATURE LAMP                       pressure, brown/yellow ­alternator charge. Reconnect
   WILL NOT FUNCTION UNLESS                       wire temporarily to another warning lamp that is
ENGINE IS OVERHEATING OR THERE                    functioning; if wire switches lamp on replace faulty lamp.
        IS A 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
                                                  with new connection.
                                            -     If none of the above, check continuity of connections
                                                  from panel to engine.
Water temperature warning lamp on           If engine is cold:
when engine is not over temperature         -     Faulty wiring, check connection & continuity (small green
                                                  / blue) from switch to panel lamp. Ensure this
(Not 2B or 2C deluxe panel see table on           connection is not shorting to earth (ground).
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 & 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 ­replace.
Starter battery charge lamp not             If tacho not functioning:
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 ­replace
                                            If 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
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 functioning,       -     Domestic battery not connected
buzzer 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 keyswitch.
Domestic charge lamp not functioning,       -    No second alternator fitted to engine, domestic lamp not
buzzer switching off with engine running         used
                                            -    D+ (charge indication) lamp connection at rear of
THIS LAMP WILL NOT FUNCTION IF A
                                                 alternator not connected
SINGLE ALTERNATOR IS FITTED TO
                                            -    Two way plug & socket disconnected between engine
          THE ENGINE
                                                 harness & panel loom




                                                   20
Electrical fault finding ­2c'd' & water temperature function on 2b panels
In addition to the fault finding detailed on the previous table, the following is specific for the 2c'd' type
deluxe panel (Also applicable for the 2b panel with Murphy water temperature gauge)
Problem                                        Possible cause & solution
Oil pressure warning lamp not                  -  Faulty wiring ­check wire connection & continuity (small
functioning, oil pressure gauge showing           white/brown) from sender to panel lamp. Ensure this
maximum deflection. Engine off and                connection is not shorting to earth (ground).
keyswitch in run position
Oil pressure gauge showing no                  -    Faulty wiring ­check oil pressure sender wire (small
movement -even when engine is started.              white / brown) is connected.
Warning lamp functioning correctly
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 faulty
                                                      sender unit ­check resistance to earth (ground) approx.
                                                      50. Replace if no reading or short-circuited.
                                               -      If adjusted correctly & buzzer still sounding, possible
                                                      faulty switch gauge unit ­ replace.
Oil pressure showing normal operating          Engine warm:
pressure (0.75­5 bar). Buzzer sounding         -      Incorrectly calibrated switching point for warning lamp,
& lamp illuminated.                                   adjust on rear of gauge to 0.5 bar (minimum adjustment
                                                      on gauge).
                                               -      If adjusted correctly & buzzer still sounding, faulty switch
                                                      gauge unit ­ replace.
Water temperature gauge showing                Engine cold / cool:
   o       o
120 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. 3.5k (cold) ­ 0.5k (warm). Replace if
                                                      notably less.
Water temperature gauge showing                Engine warm:
normal operating temperature (85oC).           -      Incorrectly calibrated switching point for warning lamp,
                                                                                      o        o
Buzzer 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 ­ replace.
Water temperature gauge showing no             -      Check connection to sender, if disconnected gauge will
movement, lamp not illuminated, engine                not function.
warm.                                          -      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. 3.5k (cold) ­
                                               0.5k (warm). Replace if no reading.
Electrical ­Correct operation of keyless panels
These panels control the engine with three water resistant push buttons instead of a keyswitch, which
are less prone to damage and corrosion from sea water spray than a keyswitch.
To operate the engine:
1. 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 sound
2. Press `START' button and hold in position until engine fires (see initial start-up 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 1,000rpm if the engine was started at tickover.
·     Green lamp for panel power on should still function
3. 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 lamp.
4. To re-start the engine, simply repeat steps from `1' above, there is not need to switch battery
     isolators off whilst remaining on board.
5. If leaving the boat, isolate start battery from engine and panel, to prevent accidental start up of
     engine.



                                                       21
Electrical fault finding ­Non Beta Panels

Engines can be supplied wired up to suit VDO switch senders, usually fitted to a non-Beta control panel.
If so refer to our wiring diagram 200-60971/01 (also part number for replacement harness)
·   Loom is configured differently in the 11-way 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 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 ­Extension harnesses
Some installations require one of the panel extensions 11 way connectors to be removed to allow the
cable to be passed through bulkheads etc. If any panel problems are experienced after this may have
been carried out, visually check all 11 way connections on engine harness to panel extension (and
panel extension to panel on 2c deluxe) to ensure wire colours to each terminal match up to the
correct colour in its corresponding terminal. Extra attention must be given to black (ground) and
black/blue (tacho), also brown (switched positive to alternator) and brown/yellow (charge fail) as these
connections are harder to distinguish between in poorly lit areas. Whilst doing this check integrity of
each connection to ensure terminals have not become damaged. Once checked, re-fit cable tie around
each connection to keep them secure
Beta P/N's for replacement items:

Description                                                                Part number
40 amp blade fuse (all panels)                                             200-00959
Alarm board ­all panels from June 05                                       200-04655
Oil pressure switch 1/8"BSP (not 2c panels)                                600-62670
Oil pressure sender (2c panels only)                                       200-94350
Oil pressure switch gauge (2c panels only)                                 200-96190
Temperature switch with single terminal (on some BZ602 & BD902)            600-62820
Temperature switch / sender 1/8"BSP (not 2b or 2c panels)                  200-01133
Temperature sender (2b & 2c panels only)                                   200-94360
Water temperature switch gauge (2b & 2c panels only)                       200-96200
Voltmeter (2c panels only)                                                 200-96210
28Ra relay 12V 40A (fitted to rear of domestic panels)                     200-87020
Keyswitch, silver bezel                                                    600-00057
Panel stop button (all panels) ­Also heat and start on 2ab'V'W             200-00072
Tacho, 0-4000rpm with digital hour counter (all panels but 2a)             200-02373
Standard engine harness Mini Series                                        200-98380/01
Standard engine harness S5 Series                                          200-60973/05
Standard engine harness S3 series                                          200-05267
Iskra 65 amp sub loom                                                      200-01196
1m panel extension loom                                                    200-04588/01
2m panel extension loom                                                    200-04588/02
3m panel extension loom                                                    200-04588/03
4m panel extension loom                                                    200-04588/04
Domestic charge engine sub loom (top mounted alternators)                  200-01197
Green power on indicator lamp & retaining clip                             200-04656
Red warning indicator lamp & retaining clip                                200-04657
Note: the above part numbers are suitable for earth return installations only (where battery negative
cable is connected directly to engine ground). For insulated earth (where battery negative cable is
isolated from engine ground) different harnesses, alternators, switches for oil pressure and engine
temperature will be required. If your application is wired as insulated earth return and the engine will not
operate correctly, always check starter battery negative is connected to the correct terminal on the
isolating solenoid. It should be connected to the terminal which is also used for all the small black wires,
NOT the terminal with the single black wire connected directly to engine ground.



                                                    22
                              SPANNER TORQUE SETTINGS


Tightening Torques for general use bolts and nuts
ITEM                       Size x Pitch       N.m         kgf.m        ft.lbs
M6 (7T) : 6mm (0.24in)          -          9.8~11.3     1.0~1.15      7.2~8.3
M8 (7T) : 8mm (0.31)            -          23.5~27.5     2.4~2.8     17.4~20.3
M10 (7T) : 10mm (0.39in)        -          49.0~55.9     5.0~5.7     36.2~41.2
M12 (7T) : 12mm (0.47in)        -          77.5~90.5     7.9~9.2     57.1~66.5


Tightening Torques for special use bolts and nuts ­BF2803:
ITEM                       Size x Pitch        N.m        kgf.m         ft.lbs
Head bolts                 M12 x 1.25       93.1~98.0   9.5 ~10.0    68.7~72.36
Bolts, connecting bolts    M18 x 1.0        44.1~49.0    4.5~5.0      32.5~36.2
Bolts, flywheel            M12 x 1.25      98.0~107.8     10~11       72.3~79.5
Bolts 1, bearing case      M9 x 1.25        46.1~50.9    4.7~5.2      34.0~37.6
Bolts 2, bearing case      M10 x 1.25       68.6~73.5    7.0~7.5      50.6~54.2
Nozzle, holder assy.       M20 x 1.5        49.0~68.6    5.0~7.0      36.2~50.6
Head cover, nuts           M8 x 1.25         6.9~8.8     0.7~0.9       5.1~6.5
Glow plugs                 M10 x 1.25       19.6~24.5    2.0~2.5      14.5~18.1
Oil switch, taper screw     1/8"BSP         14.7~19.6    1.5~2.0      10.8~14.5
Bolts, rocker arm          M8 x 1.25        23.5~27.5    2.4~2.8      17.4~20.3
Bolts, idle gear shaft     M8 x 1.25        23.5~27.5    2.4~2.8      17.4~20.3
Nuts, crankshaft           M30 x 1.5      137.3~156.9   14.0~16.0   101.2~115.7
Nuts, injection pipe       M12 x 1.5        24.5~34.3    2.5~3.5      18.1~25.3



Tightening Torques for special use bolts and nuts ­BV3300 & BV3800:
ITEM                       Size x Pitch        N.m        kgf.m        ft.lbs
Head bolts                 M12 x 1.25      98.1~107.9     10~11      72.3~79.6
Bolts, connecting bolts    M10 x 1.25       78.5~83.4    8.0~8.5     57.8~61.5
Bolts, flywheel            M12 x 1.25      98.1~107.9     10~11      72.3~79.6
Bolt, crankshaft           M16 x 1.5      343.4~372.8     35~38     253.1~274.7
Bolts, bearing case        M14 x 1.5      137.7~147.2     14~15     101.2~108.5
Bolts, rocker arm          M10 x 1.25       49.0~61.8    5.0~5.7     36.2~41.2
Nozzle, holder assy.       M20 x 1.5        49.0~68.6    5.0~7.0     36.2~50.6
Nuts, injection pipe       M12 x 1.5        22.6~36.3    2.3~3.7     16.6~26.8
Nuts, overflow pipe        M12 x 1.5        19.6~24.5    2.0~2.5     14.5~18.1
Glow plugs (BV3300)        M10 x 1.25       19.6~24.5    2.0~2.5     14.5~18.1
Oil switch, taper screw      R 1/8          14.7~19.6    1.5~2.0     10.8~14.5
Nut, inj pump drive        M14 x 1.5        73.5~83.4    7.5~8.5     54.2~61.5




                                              23
                                               SECTION 3
INSTALLATION RECOMMENDATIONS
The installation details contained herewith are basic guidelines to assist installation, due to the great
diversity of marine craft it is impossible to give definitive instructions. Therefore Beta Marine can accept
no responsibility for any damage or 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
        combustible.

ENGINE MOUNTING                                                            Fig. 3a
To ensure vibration free operation, the engine must be installed on
substantial beds, extending as far forward and aft as possible and well
braced to form an integral part of the hull.
The engine must be installed as low as possible on the flexible mount
pillar stud. This will limit vibration and extend the life of the flexible mount.
If necessary, fit spacer blocks below the mounts.
A flexible coupling must be fitted for all engines which are flexibly
mounted. Flexible couplings do not accommodate bad alignment. The
mating faces of the gearbox and tailshaft must be checked for alignment,
they must be parallel and concentric to within 0.005" (0.127mm).
ALIGNMENT                                                          Fig. 3b
Alignment must be checked for parallel (A) and concentric (B)
misalignment using a set of feeler gauges.
To obtain accurate alignment the flexible mountings must be adjusted
until alignment is attained, and the mountings must be locked in position.
Once mounts are tightened, alignment must be re-checked. Coupling can
now be fitted in accordance with instructions supplied with coupling.

WARNING
(1) Do not set the engine feet high up the flexible mount pillar stud. This will cause excessive engine
movement and vibration. Pack under the flexible mount with steel shims securely bolted into the engine
bearer.
(2) The pillar stud on the flexible mount is secured into position by the lower locknut, do not forget to
tighten this. Also ensure that the stud is not screwed too far through the mounting body so that it
can touch the mounting bearer. This will cause vibration and knocking noises which are very
hard to find!


Exhausts
(a)       A correctly installed engine as described in this handbook will meet the exhaust emission
          requirements of Directive 2003/44/EC amending the Recreational Craft Directive 94/25/EC.
(b)       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 (3.1 inches Hg / 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 bellows.


Wet Exhaust hose should be matched to the following injection bend sizes.

                                        BF2803               BV3300             BV3800

Standard                                60mm                 60mm               60mm



                                                        24
Typical Yacht Installation


                             Maximum sea water level when healed
                               (on the centre line of the boat)



                                                           300mm minimum
                                          Normal sea water level




Allow at least 10% of
propeller diameter for tip
clearance to hull



                                                                   If a rope cutter is fitted, allow approximately ˝" for
                                                                   movement of engine, see manufacturer's literature




WARNING:                                                                                                       Fig. 3c
(1) 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
    avoided!
(2) 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 pipe.
(3) The exhaust back pressure should not exceed 3.1 inches of Hg.


DRY EXHAUST SYSTEM
The exhaust system installed in a canal boat or work boat with a dry exhaust should be 2"
minimum ID. The engine is fitted with a 2" BSP male connector when a dry exhaust system is
specified. A flexible exhaust bellows and dry exhaust silencer should be used. It is up to the
installer to work out his own pipe run but care should be taken as follows:
1. Ensure that rain water cannot enter the
    exhaust port and run back down the system,
    flooding the silencer and eventually the
    engine (Fig.3d)
2. The system should be lagged if there is any
    danger of the crew getting near it.
3. A dry exhaust system will give off
    considerable heat and suitable ventilation
    must be provided.
4. The exhaust back pressure should not
    exceed 3.1 inches of Hg.




                                                                                                                Fig. 3d




                                                      25
                                                                                                     Fig. 3e
1. The mechanical fuel lift pump is fitted to all engines as standard, but if a suction head of 0.25m is
required then an electric fuel lift pump must be fitted (ask your dealer or Beta Marine).
2. It is very important that the excess fuel from the injectors is fed back to the fuel tank and not back to
any point on the supply line. This will help prevent air getting into the system.
3. Fuel pipe sizes are:               Supply (mm)                  Leak off (mm)
                                                8                           8
4. Any fuel leaks in the system are likely to cause poor starting and erratic running and must be
corrected immediately.
5. A fuel/water separator must be installed.
6. The fuel return (leak off) pipe must loop down to be level with the bottom of the tank before it enters
the top of the tank - see 12. This prevents fuel `drain down'.
7. Fuel lines and hoses must be secured and separated or protected from any source of significant heat.
The filling, storage, venting and fuel supply arrangements and installations must be designed and
installed so as to minimise the risk of fire and explosion. Flexible fuel hoses connecting the engine to
fuel tank supply and return lines must meet the requirements set in standard ISO 7840:1995/A1:2000
and as required by your surveyor / authority.
SEAWATER INLET SYSTEM (Heat exchanger cooled engines)
Your engine is fitted with a gear driven sea water pump which sucks in seawater or raw water to cool the
closed circuit system via the heat exchanger.                                                    Fig. 3f
1. It is very important that the seawater inlet should
have a strainer system either built into the sea cock
or a high level 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
pump should be 25mm ID or 1" minimum.
3. Good access to the inlet sea cock is essential so
that plastic bags or seaweed trapped in the intake
can be poked out!
4. All pipe work should have approved marine grade
stainless steel hose clips. Any loose clamps or bad
connections can cause flooding and sinking the
vessel.
5. If water is required for stern tube lubrication then this should be taken from a `T' piece in the pipe
going from the heat exchanger outlet to the water injection bend.
6. Scoop type water pickups should never be used, as water will be forced through the pump and into
the exhaust system whilst the vessel is in motion. This is very dangerous as the exhaust will eventually
fill and raw water will back up into the engine through the exhaust valve. Catastrophic failure will result
as soon as the engine is restarted.
Note: The maximum lift of the sea water pump is 2m




                                                      26
Keel cooled
1. The supply pipe to the keel cooler should be 32mm bore and the return 32mm bore (28mm supply &
34mm return on BF2803).
2. The tank size should have a surface area (x) exposed to the sea water or canal water of (0.25 x the
bhp of the engine) = sq ft of cooling area required. For canal boats this should be adequately baffled and
a vent provided to expel any air. The supply (hot water) goes in at the top of the tank and the return
comes out of the bottom. Also refer to cooling tank notes on page 10.




(1) Baffle continuously welded to outer
skin and close fitting on inner skin.
(2) The tank should be thin in section to
allow good mixing of the water over the
cool outer surface.
(3) Air bleed valves should be fitted both ends.

CALORIFIER SYSTEM                                                                     Fig. 3g (All BF2803)
All Beta engines can be fitted with the engine tappings to allow the
hot water from the closed fresh water/antifreeze system to circulate
through a calorifier tank which in turn heats up domestic water.
Calorifier tappings on this range of engine are shown below.
1. The big problem with a calorifier is to remove all the air from the
system. If this is not achieved then they don't work!
2. Try and keep the supply (b) and return pipes (a) either horizontal
or sloping down in a continuous fall. This avoids air pockets being
created.
3. Extra care must be taken when first filling the calorifier circuit
system with 50% antifreeze to water solution as the engine may
appear to be full but it soon disappears into the calorifier pipe work.
Run the engine off load for 10 minutes then check the level as
described in `Filling The Fresh Water System'.
Also check to see if the pipe going to the calorifier is getting warm
after 15 minutes. Top up the water level as required and run for
another 10 minutes then repeat.
4. If the water level is steady but no warm water is getting to the
calorifier then very carefully open the calorifier bleed valve (see
manufacturers instructions) or if none is provided then very carefully               Fig. 3h (BF2803 H/E)
loosen the jubilee clip securing the supply pipe to the calorifier. Air
should escape. Refasten securely when no further bubbles are seen.
CAUTION
Do not do this when the engine is hot as scalding hot water may be forced out of the pipe under
pressure.                                                                            Fig. 3i (BF2803 K/C)




                              b

                              a
                                                                          b




Fig. 3j (BV3300 & BV3800 H/E)               Fig. 3k (BV3300 & BV3800 K/C)



                                                     27
ELECTRICAL INSTALLATIONS
Beta has 4 panel options: 2a
                          2ab'D' or 2ab'V' or 2ab'V'W
                          2b
                          & 2c'D'
The engine harness is common to all.
1. These panels must not be installed where sea water spray can get at them. A suitable flap or cover
must be fitted.
2. Panels must be fitted in a location where the helmsman can either see or hear the alarm system.
3. For standard wiring diagrams see following pages.
4. Extension looms longer than 3m (10 feet): As an option, Beta can provide various lengths of
extension looms for runs of over 3m, but this kit includes a start relay to overcome the voltage drop.
(See drawing 300-58520)
5. All electrical equipment must be protected from sea water. Sea water or rust in the starter will
invalidate warranty. Care must be taken when pushing the two halves of the plug together to ensure
that individual pins do not push out. To prevent corrosion and assist in assembly we recommend that
the plug is packed with petroleum jelly (Vaseline) and then carefully pushed together. The plastic boots
should cover both halves and overlap. A cable tie is then put round to hold the two halves in position
and help prevent any ingression of water.
6. All cables must be adequately clipped and protected from abrasion.
7. Electrical systems shall be designed and installed so as to ensure proper operation of the craft under
normal conditions of use and shall be such as to minimise risk of fire and electric shock.
8. Attention shall be paid to the provision of overload and short-circuit protection of all circuits, except
engine starting circuits, supplied from batteries.
9. Ventilation shall be provided to prevent the accumulation of gases, which might be emitted from
batteries. Batteries shall be firmly secured and protected from ingress of water

APPENDICES
Wiring diagrams & General Arrangements
1. Typical starter motor ratings                                                       Page 29
2. Suggested engine starter battery size                                               Page 29
3. Keyswitch terminations                                                              Page 29
4. Standard engine harness H/E (65 Amp)                            200-05451           Page 30
5. Standard engine harness H/E (100 Amp)                           200-06015           Page 31
6. Standard engine harness K/C                                     200-05442           Page 32
7. Diagram of 2a panel & cut-out                                   200-06516           Page 33 & 34
8. Diagram of 2ab'd' panel & cut-out                               200-06517           Page 35 & 36
9. Diagram of 2ab'V' panel & cut-out                               200-06519           Page 37 & 38
10. Diagram of 2ab'V'W panel & cut-out                             200-06333           Page 39 & 40
11. Diagram of 2b panel & cut-out                                  200-06520           Page 41 & 42
12. Diagram of 2c'd' deluxe panel & cut-out                        200-06518           Page 43 & 44
13. Diagram of domestic extension harness                          200-04588           Page 45
14. Diagram of domestic charge sub loom (K/C)                      200-01197           Page 46
15. GA of BF2803 K/C ­PRM260                                       100-05714           Page 47
16. GA of BF2803 H/E ­ZF25H                                        100-01423           Page 48
17. GA of BV33/3800 K/C ­PRM260                                    100-06201           Page 49
18. GA of BV33/3800 H/E ­PRM260                                    100-06202           Page 50
19. Split charge relay wiring (machine sensed alt.)                300-62210           Page 51
20. Split charge relay wiring (battery sensed alt.)                300-62220           Page 52
21. Starter booster relay diagram                                  300-58520           Page 53
22. 100 Amp alternator information (H/E only)                      200-05466           Page 54
23. Beta Controller information (H/E only)                                             Page 55
24. Wiring 100 Amp & Controller (H/E only)                         100-05470           Page 57
25. Declaration of Conformity for Recreational Craft                                   Page 58 & 59
26. Maintenance record and service items                                               Page 60



                                                      28
TYPICAL STARTER MOTOR RATINGS:-
Starters used in Kubota engines have the following standard capacities
 Engine                            Starter capacity (kW)
          BF2803                            1.4
          BV3300                            2.5
          BV3800                            2.5

SUGGESTED ENGINE STARTER BATTERY SIZE:
 Engine                         Typical Battery Capacity (Ah)               Typical C.C.A. (A)
                                        at a 20hr Rate                   Cold Cranking Amperage
          BF2803                           100 ~120                              580 ~ 670
          BV3300                           150 ~ 180                           1,050 ~ 1,200
          BV3800                           150 ~ 180                           1,050 ~ 1,200


1. Keyswitch terminations
The standard panel keyswitch can be used to tap off a switched positive ignition feed to
power additional gauges. In this way these gauges will only be live whilst the engine is
running, the engine is starting or the heaters are being used.

For silver keyswitches, the terminal to achieve this ignition switched positive is marked `AC'.

For black keyswitches, the terminal to achieve this ignition switched positive is marked `15/54'.

For panels without any keyswitch, gauges can be driven from the 1mm2 brown wire, which
terminates at the 11 way connector terminal 4. This is a low power switched positive, any
additional power required from this connection must be fed through a relay, as noted below.

Note: these keyswitch terminals are rated at 10 amps maximum, since they are already
utilised for panel and alternator feeds Beta Marine recommends any additional
requirements from these terminals must be fed through a relay. This relay should then be
connected to it's own fused positive supply directly from the engine battery. Beta
drawing 202-06421 illustrating the wiring of a typical electric fuel lift pump with ignition
switched relay can be supplied upon request.




                                                  29
                                                                      150.00
                    5.00       10.00                                                          10.00
                                                                                                                      10.00




                           80.00                                                                                    90.00




                                                                                                                      10.00
                                                                      140.00                                        5.00
                                                                                                                                                             20.12
                                                                                                                                                                    36.68
                                                                                                                     50.32 ADD 30mm FOR WIRES




REV   DESCRIPTION                      DATE   APP'D   DRAWN   NOTES
                                                                                                                                                            TITLE
01                                                                                                                                                                                          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                200-06305                       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          15/11/2004
                                                  195.00
              10.00                                                                  10.00



                                                                                                            10.00




                170.00                                                                                          180.00




           5.00                                                                                             10.00
                  5.00                            185.00
                                                                                                      O 5.00 THRU
                                                                                                                                                                        22.62
                                                                                                                                                                           36.68
                                                                                                                              50.32 ADD 30mm FOR WIRES



REV   DESCRIPTION        DATE   APP'D   DRAWN   NOTES
                                                                                                                                            TITLE
01                                                                                                                                                                      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                200-06304                       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          15/11/2004
                                                            180.0
          5.0                    10.0                                                           10.0




                130.0                                                                                            140.0




                         20.0


                                       20.0                                                                        10.0
                        5.0                                 170.0                                               O 5.0 THRU
                                                                                                                                                                                 22.6

                                                                                                                                   50.3 ALLOW 30mm FOR WIRES                       36.7




REV   DESCRIPTION               DATE      APP'D   DRAWN   NOTES
                                                                                                                                                       TITLE
01                                                                                                                                                                                 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                200-06320/01                     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          23/11/2004
                                                                                      O 5.00 THRU
                              5.00




     140.00                                                                                  120.00



         5.00
                                                                                    5.00


                                                                                        20.00


                                         5.00       20.00                                             10.00
                                                                                                                                           22.62
                               160.00                                                 10.00
                                180.00
                                                                                                50.50 ALLOW 30mm FOR WIRES




REV             DESCRIPTION      DATE      APP'D   DRAWN    NOTES
                                                                                                                                                         TITLE
01
                                                                    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                200-06331                       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          01/12/2004
                                                              210.00

                    10.00                                                                                10.00
          5.00




               155.00                                                                                                              165.00




                                                                                                                                10.00




                    5.00                                      200.00                                                                                                                       22.62
                                                                                                                                                                                              36.68
                                                                                                                                            50.32 ALLOW 30mm FOR WIRES




REV   DESCRIPTION           DATE   APP'D   DRAWN   NOTES
                                                                                                                                                         TITLE
01                                                                                                                                                                                    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                200-06303                         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          15/11/2004
                                                                   298.00
             10.00                                                                                                                         10.00
      5.00



                                                                                                                                              10.00




         156.00                                                                                                                                      166.00




                                                                                                                                               10.00
                                                                   288.00                                                                       5.00                                         22.62
                                                                                                                                                                                                  36.68
                                                                                                                                                             50.32 ADD 30mm FOR WIRES




REV                  DESCRIPTION   DATE   APP'D   DRAWN   NOTES
                                                                                                                                                     TITLE
01                                                                                                                                                                                  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               200-06306                               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                  15/11/2004
                           BETA CONTROLLER
                                SEA SPEC ENGINES
The BETA CONTROLLER is an integrated battery charging external regulator. It
is designed to be used with Beta's 70 and 100amp Iskra alternators.
The system utilises a three stage charging characteristic which optimises the rapid
charge of battery systems.
The first stage (A mode) is a boost charge, which is indicated by the indicator LED
showing red.
The second stage (B mode) is where the voltage is kept at a high level and where
the current is between 10% and 95% of the nominal alternator current, the LED
shows orange.
The third and last stage (C mode) is intended for maintenance of battery voltage
only. When the alternator current is under a predetermined value for a time greater
than 2 minutes, the regulating mode is changed from B to C mode.
The system automatically adjusts the charge mode to suit the load and is set in our
works for conventional lead-acid batteries. It can easily be re-set for deep cycle or
gel batteries. A more detailed specification can be obtained from BETA MARINE.



                     A.MODE           B.MODE                       C.MODE
                    RED L.E.D       ORANGE L.E.D                 GREEN L.E.D




            AMPS




           VOLTS




                                                   TIME




INSTALLATION

The Beta Controller has been designed
for mounting off the engine in a location
away from vibration, water and
condensation. Ideally as there is a
charge mode status LED, the unit should
be positioned to allow for inspection of
charge operating condition.

All goods are offered and supplied in accordance with our 'General Terms of Tender Sale'.   1
  The graphs below illustrate charging voltages for different battery types.



Volt
16
                                           DIP-switch
                                            positions
15


14                                                       DIP-switch
                                U1

13
                                U2

12                                °C        1 - OFF
       -20   0   20   40   60               2 - OFF



                                                                               LED
Maintenance-free Batteries and deep-cycle Batteries




Volt
                                                        Cover removal for resetting of DIP switches
16
                                           DIP-switch
                                            positions
15

                                                        U1 = Mode B (Orange lamp)
14


13                              U1
                                                        U2 = Mode C (Green lamp)
                                U2
12                                °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 prevent
Volt                                                    water ingress, this seal must be broken for cover
16
                                           DIP-switch
                                                        removal.
15
                                            positions   Set the dip switches to the required settings as
                                                        illustrated on the charts opposite.
14                                                      Re-seal controller with silicon sealant or equivalent
                                U1
                                                        after setting switches.
13
                                U2


12                                °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
APPENDICES                                SERVICE ITEMS
26. MAINTENANCE RECORD                    Please complete the following from new when commissioning the engine,
                                          if there are any additional items fitted please note these here too. Write
Date                Service carried out   full numbers for additional drivebelts.

                                           Item ­BF2803 only                                     Beta P/No
                                           Standard 65 Amp drivebelt: BF2803 K/C                  600-02963
                                                                          BF2803 H/E              214-96830
                                           Optional 100 Amp drivebelt (H/E only)                  214-01471
                                           2nd alternator drivebelt (K/C)                         214-00003
                                           Oil filter                                             211-80830
                                           Fuel filter: BF2803 H/E                                211-60210
                                                         BF2803 K/C                               211-02817
                                           Air filter element                                     211-61831
                                           40 Amp blade fuse                                      200-00959
                                           Zinc wasting anode (H/E only)                          209-61840
                                           Jabsco sea water pump impeller (H/E only)              207-80800
                                           Jabsco sea water pump gasket (H/E only)                207-62600
                                           Jabsco sea water pump service kit (H/E only)           207-80810
                                           Tubestack nitrile O ring (H/E only)                    209-80110
                                           Flexible mount 55 shore                               213-96970/01

                                           Item ­BV3300 & BV3800 only                            Beta P/No
                                           Standard 65 Amp drivebelt                              214-94260
Engine identification                      Optional 100 Amp drivebelt (H/E only)                  214-03853

Engine serial number                       2nd alternator drivebelt (K/C)                         214-03226
WOC number                                 Oil filter                                            211-70510/02
                                           Fuel filter                                            211-02817
Date of purchase                           Air filter element                                     211-04109
                                           40 Amp blade fuse                                      200-00959
First operated                             Zinc wasting anode (H/E only)                          209-61840
Where purchased/Distributor                Jabsco sea water pump impeller (H/E only)              207-98880
                                           Jabsco sea water pump gasket (H/E only)                207-01101
                                           Jabsco sea water pump service kit (H/E only)           207-01104
                                           Tubestack nitrile O ring (H/E only)                    209-00814
                                           Flexible mount 55 shore                               213-96970/01
                                                        Sail Drives 13.5 to 50bhp




Heat Exchanger Cooled 10 to 90bhp




Keel Cooled 10 to 90bhp                                 Beta Marine Generating Sets
                                                        3.7 to 40kVA



                                                                                                  www.mono-studio.co.uk




    Beta Marine Limited
    Davy Way, Waterwells,
    Quedgeley, Gloucester
    GL2 2AD, U.K.

    Tel: 01452 723492
                                                        Beta Marine Generating Sets
    Fax: 01452 883742
                                                        30 to 900kVA

    www.betamarine.co.uk
    Technical Spares email: spares@betamarine.co.uk
    Technical Warranty email: adrian@betamarine.co.uk                                 Ref: 1680


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