Beta Marinebd1005, Bv1303, Bv1505 Operators Maintanance Manual
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Operators Maintenance ManualHeat Exchanger CooledSmall Diesel Engine RangeBD1005 BV1305 and Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the state ofCalifornia to cause cancer birth defects and other reproductive harmEngine Details IMPORTANT Please fill in details at moment of purchase it really will help you and it will really help us specify the correct spare parts for youEngine Type Power bhp Speed rpmBETA WOC NO K Engine Serial NoGearbox Type Serial No Ratio 1Purchased fromInvoice No DateDate Special INTRODUCTION 2 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 startup and bleeding the fuel system 5 6 SECTION 2 MAINTENANCE AND SERVICE GUIDELINES Maintenance schedule 7 Lubrication checking and changing oil 8 Fuel system pumps filter fuelwater separator 9 Cooling fresh water system keel cooling heat exchanger 11 Sea water pump heat exchanger 11 Belt tensioning 12 Air filter 13 Electrical 13 Laying up winterising 13 15 Torque settings 25 SECTION 3 INSTALLATION GUIDELINES Engine mounting 26 Alignment drives flanges flexible drives 26 Exhausts mounting exhausts 27 Fuel supply 28 Cooling sea water inlet system 29 Calorifier system 30 Electrical and installations 31 Appendices wiring diagrams and general arrangements 32 Component identification at rear of manual 62 Maintenance record 65 1OPERATION AND MAINTENANCE MANUAL FOR THE FOLLOWINGBETA MARINE ENGINES BASED ON KUBOTA SUPER 5 SERIESBD1005 BV1305 BV1505 This manual has been compiled to All information and carried out at the place of provide the user with important given in this manufacture and in vessels used information and publication are based on the latest for development purposes We do to ensure a trouble free and information available at the time of not guarantee the same results will economical operation of the publication and are subject to be obtained elsewhere under engine alteration at any time The different conditions information given is subject to the For further advice or technical companys current conditions of assistance application should be Tender and Sale is for the made to BETA MARINE LIMITED assistance of users and is based or its distributors upon results obtained from testsENGINE IDENTIFICATION BD1005 BV1305 ENGINE STORAGE BV1505 The engine must be stored in a dryNOTE In all communications with frost free area and this is best done inthe distributor or Beta Marine the The engine serial number is stamped its packing case If storage is to beengine number type and WOC above starter motor on the port side more than six months then thenumber must be quoted of the engine and is shown on the engine must be inhibited contact rocker cover label your dealer or Beta Marine Failure to inhibit the engine may result in the formation of rust in the injection INITIAL RECEIPT system and the engine bores this could invalidate the warranty 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 L E M P S A 2SAFETY PRECAUTIONSA Keep the engine gearbox the outlet next to the heat G surrounding area clean tank the the area immediately exhaust outlet can become very hot and if touched can injure Engines are supplied onbelow the engine transportable pallets Lifting eyes This must be lagged or avoided by ensuring adequate guarding It is on engines are used for lifting the responsibility of the installer to engine and gearbox assemblyB DRIVES Power Take Off lag the exhaust system if a dry only not the pallet andAreas system is used Exhaust gases associated kit are harmful if ingested thei Gearbox Output Flange installer must therefore ensure that The purpose of a marine diesel exhaust lines are lead overboard GENERAL DECLARATION propulsion engine is to provide and that leakage in the vessel This machinery is not intended to motive power to propel a vessel does not occur be put into service until it has been Accordingly the gearbox output incorporated into or with other shaft rotates at between 280 and D FUEL machinery It is the responsibility of 2400 revmin This flange is the to i Fuel Lines ensure that the machinery is designed to be coupled to a propeller shaft by the installer Diesel engines are equipped with properly guarded and that all and steps must be taken to high pressure fuel injection necessary health and safety ensure adequate guarding pumps if leakages occur or if requirements in accordance with pipes fracture fuel at a high the laws of the relevant country areii Forward End Drive pressure can harm personnel met before it is put into service Engines are supplied with Skin must be thoroughly cleaned unguarded vee belt drives to in the event of contact with diesel power the fresh water pump and fuel Signed battery charging alternator The installer must ensure that it is not ii Fuel Supply Connections possible for injury to occur by Engines are supplied with 8 mm allowing accessibility to this area compression fittings The of the engine The three pulleys installer must ensure that when run at high speed and can cause connections are made they are injury if personnel or clothing clean and free of leaks J A Growcoot CEO come in contact with the belts or Beta Marine Limited pulleys when the engine is E OIL running The Beta propulsion is suppliediii Power Take Off Shaft with 2 dipsticks one for the Engine Mounted Option engine and one for the gearbox NOTE Recreational Craft Ensure dipsticks are returned and Shaft extensions are available as secure after checking if not oil Where applicable the an option and rotate at between leaks can cause infection when and operator 850 and 3600 revmin If touched All oil must be must be responsible for making sure contact is made with this shaft removed from the skin to prevent that the Recreational Craft Directive when the engine is running infection 9425EC is complied with injury can occur F SCALDINGC EXHAUST OUTLET An engine running under load will have a closed circuit fresh water Diesel marine propulsion engines temperature of 85 to 95C The emit exhaust gases at very high pressure cap on the top of the temperatures around 400 heat exchanger must not be 500C Engines are supplied with removed when the engine is either wet exhaust outlet water running It can only be removed injection bend or dry outlet dry when the engine is stopped and exhaust stub see option list At has cooled down 3 TECHNICAL SPECIFICATIONS Standard Engines BD1005 BV1305 BV 1505 Cylinder 3 4 4 Bore mm 76 76 78 Stroke mm 736 736 748 Displacement cc 1001 1335 1498 Combustion 3 Vortex Cooling Water Starter voltage V 12 Starter output kW 12 Starter alternator output Amps 65 standard Glow plug resistance each 1 Engine speed RPM 3600 3600 3000 Power output to ISO3046 BHP 280 350 375 Declared power ISO8665 kW 192 257 271 Compression Ratio 221 Fuel timing BTDC 214 Capacity of standard sump approx litres 6 75 75 Capacity of shallow sump approx litres 5 65 65 Nett dry weight with gearbox kg 150 170 170 Fuel Diesel fuel oil No2D Coolant 3350 maximum antifreeze water Coolant capacity approx HE litres 55 7 7 Min recommended battery capacity 12V 80Ah 400CCA Min Maximum Angle of Installation Trim 15 Roll 30 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 BS28691970 class A1 or A2 The fuel must be a distillate and not a residual oil or blend Lubricant Engine Engine oil must meet MILL2104C see section 2 for details Gearbox see operators manual for the gearbox oil type and capacity Oil pressure minimum tickover 05 bar Power outputs These comply with BS EN ISO 86651996 crankshaft power Note Declared Powers to ISO86651995 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 321 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 bandsSECTION 1GUIDELINES FOR OPERATION OF CHECKS PRIOR 4 Ensure Morse speed and gearbox on gearboxes returned in theTO INITIAL USE cables are fitted correctly and that warranty period for failure due cable travel lengths are correct to incorrect adjustment1 Generally a new engine has the oil and antifreeze removed after Gear selection lever all 5 Ensure engine is out of gear with the works test Fill the engine mechanical gearboxes care 13 throttle see single lever with the correct oil and anti must be taken to ensure that control instruction manual freeze see sections on ENGINE the remote control cable is 6 Open the fuel stopcock and bleed OIL and COOLING Check adjusted so that the selector lever the fuel water separator of air as gearbox oil level see separate on the gearbox moves FULL shown in manufacturers operators hand book travel and brought hard up literature against its end stop in both2 Ensure the engine is free to turn directions Failure to achieve the 7 Fuel should now be at the fuel lift without obstructions correct adjustment will reduce pump see diagram 1a Open the3 Ensure battery is fully charged efficiency of the clutch and may sea cock and connected the isolator is in cause slippage at low revs the ON position Warranty will not be STARTUP AND e Start engine see normal Note The starter windings can beBLEEDING THE SYSTEM starting burnt out with continuous crankinga Open fuel bleed screw on fuel Note the engine may have to be filter assembly by 112 turns See turned over with the starter for a diagrams 1a 1b few seconds before it fires Do not run the starter for more thanb Move hand priming lever on fuel 20 seconds If the engine has not lift pump up and down until fuel started after 20 seconds then with no bubbles comes out of the disengage the starter and bleed screw continue to hand prime for ac Shuttighten the bleed screw further 30 seconds then repeat Clean area thoroughly with tissue f If engine does not start after 3 paper attempts then allow 5 minutesd Continue to hand prime for 30 for the starter to cool down before seconds to push fuel through the repeating a to e Diagram 1a fuel pumpCAUTIONTo 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 Diagram 1b 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 5NORMAL STARTING BETA OIL PRESSURE are still on then increase enginePANELS WITH SILVER KEYSWITCH and green POWER ON RUN LIGHT speed to excite the alternator thenFOR KEYLESS SEE PAGE 23 this will stay on return to idle The battery charge lights should then go out The runWith the engine out of gear set speed Turn to START D position and engine light will remain on green lampcontrol lever to 13 throttle Turn key anti will motor hold in position untilclockwise to HEAT A position and hold engine fires see initial startup section Check for sea water flow If no flowfor ten seconds turn key clockwise to for maximum then SWITCH OFF IMMEDIATELY time starter can B AND CHECK SEA WATER SYSTEMRUN C position At this stage the OFF C Ainstrument panel should illuminate an be used HEAT RUN D Note for some deluxe panel with thealarm buzzer will sound and two or Release key START black keyswitch they operatethree red warning lights will illuminate when engine clockwise as legend on panel OFF has started toSTARTER BATTERY CHARGE RUN HEAT START Operation for RUN BATTERY CHARGE D in engine start procedure is the same as Ensure alarmbattery symbol AB C Deluxe standard apart from this buzzer is not sounding and thatpanels only warning lights are extinguished If oneNote this will only illuminate if or both of the alternator warning lights2nd alternator is propulsion engine is fitted with The Super 5 range of engines area stop solenoid which is energised to equipped with a mechanical stopstop To stop engine simply press lever in the event of electrical systemstop push button hold in until engine failure This lever is located on thestops then turn key from RUN to starboard side of the engine aboveOFF position the speed control lever See Fig 2eWhen leaving the boat for anextended period Turn off seacock heat exchanger cooled engines Turn off battery isolatorDo not turn the key to the off Stop leverposition when the engine isrunning This will damage thealternator Speed leverWARNINGDo not leave the key in HEATposition for more than 15 seconds this will damage the heater plugsand eventually lead to poor startingDo not depress stop button for morethan 10 seconds as this will lead tooverheating and failure of thesolenoid Fig 2e 6SECTION 2MAINTENANCE SCHEDULEDAILY OR EVERY 8 HOURS AFTER FIRST 50 HOURS EVERY 750 HOURS As everyRUNNING Change engine lubricating oil 250 hours plus the following Check engine oil level Change oil filter Change air cleaner element Check gearbox oil level Change fuel filter Check for leaks on header tank Check coolant level Change antifreeze tubestack Tighten end cap bolt Check battery fluid Change gearbox oil if required Check drive belt tension Drain off any water in fuelwater Check electrical equipment Ensure raw water inlet strainer is condition of hoses and belts clear separator replace as necessary Check stern gland lubrication EVERY 150 HOURS Drain off any water in fuel water separator If shallow sump option is fitted change engine THE FIRST 25 HOURS oil and filterRUNNING EVERY YEAR OR EVERY 250 Change gearbox lubricant See HOURS IF SOONER separate gearbox manual Change engine lubricating oil Check that all external nuts standard sump bolts and fastenings are tight See table for torque values Change lubricating oil filter Special attention should be paid Check air cleaner element to the flexible mount lock nuts Check sea water pump impeller these should be checked for and change if worn tightness starting with lower nut Check wasting anode condition first in each case If the lower replace when necessary In nuts are found to be very loose some environments this may be then the alignment of the shaft 6 montly or less to the gearbox half coupling Remove heat exchanger tube should be rechecked Poor stack by undoing the bolt each alignment due to loose flexible end of the tube stack Remove mount nuts will cause excessive end cover pull out tube stack vibration and knocking and clean Replace rubber O Check the belt tension on any rings and reassemble second alternators fitted and Immediately engine is started adjust see page 12 check for leaks Check ball joint nyloc nuts for Spray the key switch with tightness on both gearbox and WD40 or equivalent to lubricate speed control levers Grease the barrel both fittings all over Check that all external nuts bolts and fastenings are tight See table for torque values Check ball joint nyloc nuts for tightness on both gearbox and speed control levers Grease both fittings all over oil Engine oil should be MIL 1 To check the oil level draw outL2104C or have properties of API the dipstick wipe it clean re CCCDCE grades The insert it and draw it out again When using an oil of different makefollowing table gives grades of oil Check to see that the oil level lies or viscosity from the previous onerequired for various ambient between the two notches drain old oil Never mix two 2 If the level is too low add new oil types of oil Engine oil should beNote A good quality 15W40 to the specified level Do not changed after first 50 hours runningmineral or multigrade oil as used in overfill time and then every year or everymost diesel car engines will meet 250 hours if sooner Oil filter is athese requirements Do not use cartridge type mounted on the portTurbo Diesel Oil or additives side of the engineCHECKING ENGINE OIL AMBIENT TEMP SINGLE GRADE MULTI GRADELEVELFor quantities of oil required see 30C TO 0C SAE 10W SAE 10W30section marked Technical 15C TO 15C SAE 20W SAE Page 4When checking the engine oil level 0C TO 30C SAE 30 SAE 15W40do so before starting or more thanfive minutes after stopping 25C AND ABOVE SAE 30 SAE 15W40CHANGING ENGINE OIL Oil goes1 Run the engine for 10 minutes to in here warm up the oil2 Your engine is provided with a sump drain pump Unscrew the end cap on the end of the pump turn the tap to on Use the hand pump as shown to pump out the oil into a bucket Turn the tap to off position and replace end cap See diagram 2c Fig 2a Fig 2b Dip stick3 Unscrew the oil filter and replace with a new one See diagram 2d Note It is best to have a plastic bag wrapped round the filter to Sump pump 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 Oil filter4 Fill the engine with new oil as End Cap Fig 2d described above Fig 2c5 Run the engine and check for oil leaks 8CHECKING GEARBOX OIL LEVEL1 The gearbox is fitted with a dip 3 New engines are normally box or sucked out with a hand stick and oil filler plug see fig 2e supplied with the gearbox topped pump via the filler plug up with lubricant but Check the2 Each engine is supplied with a 5 A guide to the type of oil to be level before starting the engine gearbox operators manual which used is as follows for the first time specifies the type of lubricating oil to be used the capacity and 4 The oil can be changed via the frequency of changing of the oil drain plug at the bottom of the Gearbox Lubricant Capacity approx TMC40M Use ATF Oil 02 litres TMC60M Use ATF Oil 08 litres Dip stick PRM 80 Use Engine Oil 15W40 06 litres Oil PRM 120 Use Engine Oil 15W40 08 litres filler plug PRM 150 Use Engine Oil 15W40 14 litres PRM 260 Use Engine Oil 15W40 15 litres Oil drain plug ZF10M Use ATF Oil 035 litres Fig 2e ZF15M Use ATF Oil 055 litres TTMC 35A2 Use Engine Oil 15W40 065 litresNote ATF is Automatic Transmission FluidFUEL SYSTEM see page 28 for a typical installation The fuel lift pump will only liftIMPORTANT 5 Check for leaks fuel through 025 metres If this Always fit a fuelwater separator is insufficient then an electric fuel 6 Do not get fuel on the flexible in the fuel supply system Water lift pump must be fitted Drawing mounts in the fuel can seriously damage 20206421 illustrating the the injection system wiring of a typical electric fuel lift If a fuel supply shutoff valve is pump with ignition switched fitted do not use a taper tap only relay can be supplied upon use a ball valve tap The ball request valve type are more reliable and less likely to let air into the fuel FUEL FILTER REPLACEMENT system Be sure to use a strainer when 1 The fuel filter is a spin on type filling the fuel tank Dirt or sand Remove by turning anticlockwise in the fuel may cause trouble in when viewed from below the fuel injection pump 2 Replace the fuel filter cartridge Always use diesel fuel every 750 hours See fig 2g Do not use kerosene which is 3 Apply fuel oil thinly over the very low in cetane rating and gasket and tighten into position Fig 2g adversely affects the engine hand tight Be careful not to let the fuel tank 4 Bleed as detailed see initial become empty or air can enter start up the fuel system necessitating bleeding before next engine start 9COOLINGBD1005 BV1305 and BV1505engines are normally fresh watercooled This water circulates throughthe engine and on to a heatexchanger where it is cooled by seawater which is pumped through thecooling tubes The sea water is theninjected into the exhaust system THE FRESHWATER SYSTEMNew engines are supplied with the d Fill header tank to the top of the h Run the engine on one third loadfreshwater drained off The following filler neck and replace cap Press for 15 minutes preferably must be followed to fill down firmly on filler cap and the boat tied up As the systemthe system hand tighten in a clockwise warms up coolant may be direction expelled from the overflow pipea Mix up in a clean bucket a 33 to into the bilge Stop the engine 50 antifreeze to fresh water e Run the engine for 5 minutes on and allow the engine to cool solution For the volume required no load out of gear and check down before removing the see technical specification coolant level Top up as pressure cap and top up the page 4 necessary coolant to one inch below theb Check that the drain tap or plug f Check system for leaks filler neck is turned off see fig 2l g If a calorifier is fitted care mustc Fill engine with freshwateranti be taken to see that this is also freeze solution through the top of full of coolant and all the air is the heat exchanger or header expelled See calorifier fitting tank with the filler cap removed notes under Section 3 see fig 2m Drain Tap or plug Fig 2l Fig 2m 10IMPORTANT i Repeat h if coolant level is more than one inch below the base of Note When draining fresh waterRemoval of the pressure cap when the filler neck when the enginethe engine is hot can cause severe system ensure the engine has cooled has cooled down sufficiently to prevent scalding frominjury from scalding hot water underpressure Always allow the engine to hot pressurised water Prior to j Run engine on 23 full load for 20cool and then use a large cloth when draining a cold engine remove the minutes check for leaks andturning the cap anticlockwise to the filler cap from the header tank and repeat istop This allows the pressure to be then open the water drain tap Thisreleased Press firmly down on the k Antifreeze solutions should be allows the water to drain freely fromcap and continue to turn drained off every 2 years and the to release the cap replaced with a new solutionYACHTS AND LAUNCHES WITH HEAT EXCHANGER COOLINGIt is essential that a 33 to 50 Concentration of ethylene should not temperature alarm switch mixture is used exceed 50 however be activated at 95 toThis not only stops freezing up in 100C If no antifreeze or a verywinter but it prevents overheating The antifreeze in the fresh water weak solution is used then the waterand corrosion system enables the boiling point of temperature switch may not be water to rise to 124C with a 13 psi activated before coolant is lostThe warranty is invalid unless thecorrect ratio is used pressure cap fitted The waterSEA WATER PUMP AND COOLING SYSTEMHEAT 3 Check impeller for cracks in theENGINES rubber excessive wear or lost vanes Replace with a newCAUTION impeller as working on the sea water Note If any pieces of rubbersystem ensure that the sea cock is in impeller are missing then theythe off position must be found as they are most likely to be trapped in the1 It is very important that the entrance to the heat exchanger correct sea water flow is cooling stack See Cleaning Tube maintained to cool the closed Fig 2h Stack circuit system of the engine The key component in this system is the sea water pump impeller This should be checked every year by removing the circular plate see fig 2h2 Withdraw the rubber impeller from its drive shaft as shown See diagram 2i Fig 2I 11CLEANING THE HEAT EXCHANGER TUBE STACK AND REPLACING WASTING ZINC ANODE1 The wasting zinc anode should 3 Check for leaks pull out tube stack Clean tube be checked every six months and stack and end caps 4 It is possible for fine sea weed replaced every year or as 7 Reassemble using new O rings and other debris to get past the necessary The anode is attached Do not overtighten end cap bolts inlet filter and into the tube stack to the bolt inserted in the aft end and make sure the tube stack is This should be removed and cap of the heat exchanger See the right way round cleaned See fig 2k fig 2j 5 Drain off coolant into a bucket 8 Refill engine with wateranti2 Unscrew the bolt and replace the freeze solution and run engine up 6 Unscrew the 2 end cap retaining complete unit with a new one to temperature to check for leaks bolts one each end of the tube stack Remove the O rings and Zinc Anode Fig 2j Fig 2kBELT TENSION65 AMP ALTERNATOR HEAT EXCHANGER COOLED Link adjust bolt 4 Push alternator outboard toWARNING tension and tighten link boltBelt tension must only be checked Check that the depression of thewith the engine switched off belt at position shown is approximately 12 or 12 mm1 On heat exchanger cooled engines when pushed down firmly by a single 65 amp is fitted as thumb Tighten support bolts standard These alternators are 5 Belt tension should be regularly adjusted as follows checked especially during the2 The belt tension is adjusted by first 20 hours of running in a swinging the alternator outboard new belt as stretching as it pivots on its power support occursBelt tension must only be bolt checked with the engine3 With the engine stopped loosen switched off the support bolts and the link Support bolts adjusting bolt100 AMP ALTERNATOR OPTIONThe same method as outlined above cause premature failure ofapplies but final tensioning must be componentsby hand only Over tensioning will 12AIR INTAKE FILTERThese engines are fitted with an air intake filter which should be checked every season and changed every 2 years orsooner if badly clogged If badly clogged check more often 1 2 3MAINTENANCE ELECTRICAL GENERAL MAINTENANCE 2 Check batteries for acid level andWARNING top up if required For low 1 The panel must be protected from maintenance and gel batteriesUnder no circumstances should the rain and sea water see instal see manufacturers be disconnected or switched lation Sea water entering the keyoff when the engine is running This 3 Loose spade terminal switch will eventually causewill seriously damage the alternator connections are the most corrosion and could result in the common cause for AND WIRING starter motor being permanently faults check on a regular bases energised and burning out SpraySee installation notes page 31 see maintenance instructions key switch every month with WD 40 or AND LAYING UPHEAT EXCHANGER COOLED i Close the inlet seacock to the d Ensure instrument panel is wellENGINES LEFT AFLOAT AND engine engine stopped protected and give the key switchASHORE a spray of WD 40 or equivalent ii Disconnect the sea watera The engine oil and oil filter inlet pipe and dip it into a small e With the engine stopped should be changed at the end of bucket containing 5050 anti disconnect the battery always the season rather than in the freeze solution disconnect the negative cable first spring See section 2 and reconnect the negative iii Start the engine out of gear cable last and take it ashore forb The closed circuit system should and run for 5 to 10 seconds until trickle charging and top up as contain a 5050 solution of anti the antifreeze is used up and necessary If AC power is freeze this also applies to warm can be seen coming out of the available then this can be done and tropical climates exhaust outlet on the boatc For cold climates where the air or iv Shut engine off and f Fuel tanks should be kept full water temperatures can fall reconnect the inlet pipe to the during the lay up period to below 3C the sea water circuit seacock eliminate water condensation in must be protected in addition to The sea water or raw water the tank Water entering the fuel the fresh water system This is circuit is now protected by anti injection system can cause best achieved as follows freeze considerable damageLAYING UP ASHOREa Change the engine oil before the Warm engine oil is much easier b to f should be followed as boat is taken out of the water to pump than cold above 13TROUBLE SHOOTINGBeta diesels are very reliable if installed and serviced correctly but problems can occur and the following list gives themost common ones and their ENGINE DOES NOT START BUT STARTER MOTOR TURNS OVER OKPossible Cause SolutionNo fuel Turn fuel cock on and fill tankAir in fuel system Vent air see initial startupWater in fuel Change fuel filter and bleed systemBlocked fuel pipe Clean out and bleed systemFuel filter clogged Change filter and bleed systemFuel lift pump blocked Remove and replaceBlocked injector Remove and cleanFuel return not fed back to the tank Reroute fuel return pipeHeater plugs not working Check wiring to the plugs and replace plugs if they are burnt outStop solenoid stuck in off position Check solenoid is free to return to run STARTER MOTOR WILL NOT TURN OR TURNS OVER VERY SLOWLYPossible Cause discharged Charge battery or replace Check alternator belt tensionStarter motor flooded with sea water Remove and clean or replaceWiring disconnected or loose Check circuit for loose in cylinders Incorrect installation This is serious check engine oil for signs of water creamycoloured oil Ring your dealerEngine harness fuse blown Replace fuse located by starter motor or above flywheel housing and check for wiring faults FUSE If located by starter motor usually it is positioned above flywheel housing at rear of engine Note For convenience some engines are supplied with a spare fuse and holder attached onto the main engine fuse holder 14PROBLEM ERRATIC Cause SolutionAir in fuel supply Check supply system for leaks and fixFuel lift pump faulty ReplaceClogged fuel filter ReplaceFuel return not fed back to the fuel Reroute pipe or cleantank or blocked pipeAir filter blocked ReplaceWorn or blocked injector Service rpm in gear is too low this Increase engine tick over speedmust be 850 minFaulty stop solenoid Disconnect wiring to solenoid If running improves check for a wiring faultBroken fuel injection pump spring ReplacePROBLEM WHITE OR BLUE EXHAUST GASPossible Cause SolutionEngine oil level too high Reduce the levelBlocked injector Service ring and bore worn giving a Get compression checked by your dealer or Kubota service agent He willlow compression advise action to be takenCheck that the breather pipe is clear Remove and clean outand not BLACK EXHAUST GASPossible Cause air filter element Inspect and replaceOver pitched propeller engine will Get the propellernot reach its full rpm repitched if debris on hull Inspect and clean if LOW POWER OUTPUTPossible Cause is too big Change or depitchCheck gearbox reduction ratio Changerelative to propeller size 15PROBLEM LOW POWER OUTPUTPossible Cause fuel filter ReplaceBlocked air filter ReplaceAir in fuel system Check systemGovernor spring incorrectly mounted Dealer to adjustSingle lever control not operating Disconnect speed control cable and move the lever by hand Adjust electrical load is too large on start Disconnect or reduce the loadupPROBLEM HIGH OIL Cause SolutionOil leaks Check for leaksPiston rings worn Overhaul requiredValve stem and guide worn Overhaul requiredPiston rings gap facing the same Shift ring gap WATER IN LUBRICATING OIL Heat exchanger cooledPossible Cause SolutionOil goes milky due to sea water Check installation has antisiphon valve been fitted Change engine oil andentering exhaust manifold run engine for 10 minutes each time to eliminate any water Get fuel injection pump and compression checked by Service AgentPROBLEM WATER IN LUBRICATING OIL Cause SolutionCore plug pushed out due to frozen Service Agent to check and pump seal damaged Service Agent to check and replacePROBLEM WATER IN LUBRICATING OIL Keel cooledPossible Cause SolutionOil goes milky due to water entering Check installation has dry exhaust system been fitted correctly ensuring rainexhaust manifold and then into the water cannot enter the exhaust port and run back See DRY EXHAUSTsump SYSTEM Change engine oil and run engine for 10 minutes each time to eliminate any water Get fuel injection pump checked by Service Agent 16PROBLEM LOW OIL PRESSURE WARNING LIGHT COMES ON WHEN ENGINE SPEED REDUCED TO TICK OVERPossible Cause SolutionFaulty switch sender ReplaceEngine running too hot Check cooling water flow see section 2 CoolingOil relief valve stuck partially open Remove and cleanwith dirtBlocked oil filter ChangeWiring fault Check oil Top up and check for leaksPROBLEM PANEL REV COUNTER NOT WORKING WHEN FITTEDPossible Cause SolutionNo W connection to alternator Check power output from W connection Should be about 9V ACWiring fault Check circuitPROBLEM ENGINE Cause SolutionCheck coolant level Top upInsufficient sea water flow Clear blocked intake or filterDamaged or worn pump impeller ReplaceBlocked tube stack in heat Remove tube stack and clean replace O anode flakes blocking tube stack Remove and clean tube stack as abovePressure cap loose ReplaceSwitch sender faulty ReplaceInlet sea cock is too small Replace see heat exchanger cooled seawater inlet system in section 3High exhaust back pressure Must not exceed 31 of HgAir locks in cooling pipe work to keel Vent the system and top up cooler of insufficient size Contact boat builder 17GENERAL HEAT EXCHANGE ONLYThe most common cause of exhaust outlet for 10 seconds and pipe to the heat exchanger or in theoverheating is insufficient seawater measure the amount of water end of the exchanger This must beflow due to a blocked intake weed collected Multiply this value by 6 to removedor a plastic bag If this happens give the flow in litresmin Repeat d Check flow again as in athen clear the blockage If the twice and take an average If the flowproblem is not cured then check the rate is noticably less than the 65 Note This operation must only besystem for sea water flow which litre per minute minimum then done in safe conditions in port andshould be 65 litres minute with two assistants b Check impeller in sea waterminimum at 1000 rpm as follows Working from a rubber dinghy is pump if worn replacea With the boat tied up and out of best The person holding the bucket c If impeller has a vane missinggear run the engine up to 1000 rpm should take precautions against then this will be lodged either in theHold a plastic bucket over the breathing in the exhaust gassesPROBLEM KNOCKING NOISEPossible Cause touching gearbox output Adjust giving correct clearance 10mm between gearbox and propeller shaftcoupling through split boss or Type mount stud touching engine Adjust stud to clearbedDrive plate broken Replace repairEngine touching engine bed Realign engine modify bedPROBLEM BATTERY QUICKLY Cause SolutionHigh load and insufficient running Reduce load or increase charging time Large domestic battery banks subject to high electrical loads will take a considerable time to recharge from a single alternatorLow electrolyte level Top upFan belt slipping black dust in Adjust tension replace belt with a high temperature andor improve engineengine compartment Engine compartment temperature too highAlternator defective Check with AgentBattery defective ReplacePoor wiring connection Check wiring system 18PROBLEM TRANSMISSION NOISEPossible Cause SolutionCheck gearbox oil level Top upSinging propeller Check with supplierDrive plate rattle at tickover Check engine rpm must be 850 rpm minimum in gearWorn drive plate shaft hitting the gearbox Move shaft back to give at least 5mm clearance type 1216 couplings onlyhalf Cause SolutionPoor alignment to shaft The alignment must be accurate even if a flexible coupling is used see section 3 mounts not adjusted correctly Check relative compression of each mountto take even weightFlexible mount rubber perished Replace Diesel or oil will eventually perish most rubbersLoose securing nut on flexible mount Check alignment and then tighten the clearance between the There must be at least 10 tip clearance between propeller and bottom of thepropeller tip and the bottom of the boat ie 10 of the propeller diameter as clearance Refer to zinc anode on the shaft Tighten or replaceWorn cutless bearing or shaft ReplaceWeak engine supportbearers Check for cracked or broken feetPROBLEM MORSE CONTROL CABLE WILL NOT FITPossible Cause incorrectly Cables are being fitted the wrong way around switch over and fit the opposite way 19ELECTRICAL FAULT FINDING TROUBLE SHOOTING ENGINES BUILT AFTER JULY 2005 ONLYThe following chart is compiled to aid All Beta panels have the following warning lamps A AB ABV ABVWdiagnosis of electrical faults based on B and C Deluxethe Beta 1090hp range of engines Ifyour engine was built before July Starter battery charge warning lamp Red2005 contact Beta Marine for therelevant electrical trouble shooting High engine temperature warning lamp sea specification engines Low engine oil pressure warning lamp Redheat exchanger cooled are suppliedwith a single alternator mounted port All panels also haveside supplying power to starter batteryand control panel Panel power on this is not a warning lamp GreenStandard canal specification engines In addition to above the domestic AB C Deluxe panels also have akeel cooled are supplied with Domestic battery charge warning lamp Red 1st alternator mounted port side supplying power to starter battery and control panel Red lamp for high engine switched on and connected to the temperature should not function correct terminals for the 2nd 2nd alternator the standard when engine is cold cool alternator mounting position for this is above warm This lamp will only ever the engine on the starboard side Battery connections inspecting function if the engine is over or below 1st alternator on 75 condition of cables from battery to temperature 90hp supplying power to the engine If in doubt measure the domestic battery system Red lamp for low oil pressure voltage at the engine should functionBoth of these alternators work If alternator charge if the domestic battery Green lamp for panel power on measure battery voltage withsystem is disconnected the engine should function engine off and again with enginewill still run correctly but running if there is an increase Buzzer should sound alternator is functioning correctly if Domestic charge warning lamp For operation of engines controlled not refer to check list will not function with keyless panels refer to correct Note The two way plug on panel Warning buzzer will remain on at operation of keyless panels later in loom will only have a corresponding all times this section socket to connect into from the engineStandard control panels are supplied When the engine is started all the red if a 2nd alternator is fitted whichwith four or five lamps warning lamps should switch off requires this connection Engines with leaving just the green power on only one alternator do not utilise thisFour lamp panels indication lamp illuminated The oil connectionA ABV ABVW B these panels utilise pressure lamp may take a fewbulbs inside sealed lamp holders seconds to switch off and the chargeFive lamp panels fail lamp may remain on until engineAB or Deluxe C these panels also rpm is increased to approximately Typical start battery bulbs inside sealed lamp 1000rpm if the engine was startedholders having an additional lamp for at battery charge Before investigating any specificWith keyswitch in run position electrical problem always checkengine off Connection between panel Red lamp for no starter battery harness and panel loom It must charge should function be clean dry and secured with a Red lamp for no domestic battery cable tie charge should function Note this Check the start battery is will only function if a second connected to the correct terminal alternator is fitted to the engine on the starter motor and connected to a charged battery Check the domestic battery is Typical start battery negative 20ELECTRICAL FAULT FINDING ALL LAMP PANELSPROBLEM POSSIBLE CAUSE SOLUTION Battery isolation switch in off position switch on Starter battery discharged chargeNo warning lamps or buzzer functioning Engine fuse blown check fuse above starter motor or flywheel housing engine will not start or stop replace if necessary Check for wiring faults Disconnect switch wire to nonfunctioning lamp greenblue waterNon function of warning lamp temperature whitebrown oil pressure brownyellow alternator charge Reconnect wire temporarily to another warning lamp that is functioning ifTHE WATER TEMPERATURE LAMP wire switches lamp on replace faulty lampWILL NOT FUNCTION UNLESS Disconnect positive feed to nonfunctioning lamp Reconnect IS OVERHEATING OR THERE with wire from another warning lamp that is functioning if wire switchesIS A WIRING FAULT lamp on rewire with new connection If none of the above check continuity of connections from panel to engine If engine is coldWater temperature warning lamp on when Faulty wiring check connection continuity small green blue from switchengine is not over temperature to panel lamp Ensure this connection is not shorting to earth ground Faulty temperature switch if lamp switches off on removal of connection to switch unit replaceNot B or Deluxe C panel see table on If engine is warmfollowing page Switch wire connected to large sender terminal of switch sender unit Remove and refit to smaller switch terminalBuzzer not functioning If lamp is functioning but buzzer not sounding check connection continuityTHE BUZZER WILL NOT SOUND FOR from illuminated warning lamp red not green to buzzer boardGREEN POWER ON LAMP Faulty warning panel buzzer board replace If tacho not functioning Alternator not connected properly check continuity of small brown wire from rear of alternator to AC position on keyswitch alternator connected properly faulty alternator replaceStarter battery charge lamp not functioning If tacho functioning correctly Check continuity of small brownyellow wire from rear of alternator to no charge warning lamp on rear of panel If alternator connected properly faulty panel warning lamp replace Check connections on rear of tacho especially blackblue wire terminal 4 Check connection of blackblue wire on rear of 1st alternator W connection usually a bullet on flying lead or lowest connection on alternators with 3 pinTacho not functioning coupler Check continuity of blackblue wire from alternator to tacho Measure voltage from alternator W connection to earth ground should be approx 75 90 volts AC Domestic battery not connected Domestic battery not connected correctly B to domestic isolation block on starboard rail port on 75 95hpDomestic charge lamp not functioning B to engine earth groundbuzzer remains on with engine running Domestic battery flat Panel relay faulty incorrectly wired Check voltage at relay terminal 86 white wire is positive feed for warning lamp from AC position of charge lamp not functioning No second alternator fitted to engine domestic lamp not usedbuzzer switching off with engine running D charge indication lamp connection at rear of alternator not connectedTHIS LAMP WILL NOT FUNCTION IF A Two way plug socket disconnected between engine harness panel loomSINGLE ALTERNATOR IS FITTED 21ELECTRICAL FAULT FINDING DELUXE C WATER TEMPERATURE FUNCTIONON B PANELSIn addition to the fault finding detailed on the previous table the following is specific for the C deluxe panel Alsoapplicable for the B panel with Murphy water temperature gaugePROBLEM POSSIBLE CAUSE SOLUTIONOil pressure warning lamp not functioningoil pressure gauge showing maximum Faulty wiring check wire connection continuity small whitebrown fromdeflection Engine off and keyswitch in run sender to panel lamp Ensure this connection is not shorting to earth pressure gauge showing no movement even when engine is started Warning lamp Faulty wiring check oil pressure sender wire small white brown is correctly Check connection to oil pressure gauge if plug is not connected to socket on rear of gauge reconnectOil pressure showing no movement If all connections are correctly made possible faulty sender unit check resistance toWarning lamp not functioning correctly earth ground approx 50 Replace if no reading or shortcircuited If adjusted correctly buzzer still sounding possible faulty switch gauge unit replace Engine warmOil pressure showing normal 0755 bar Buzzer sounding Incorrectly calibrated switching point for warning lamp adjust on rear of gauge tolamp illuminated 05 bar minimum adjustment on gauge If adjusted correctly buzzer still sounding faulty switch gauge unit replace Engine cold coolWater temperature gauge showing120C 250F Faulty wiring check water temperature sender wire is not shorting to earth groundTHIS ALSO APPLIES TO THE B PANEL Faulty sender unit check resistance to earth approx 35k cold 05kWITH MURPHY GAUGE warm Replace if notably lessWater temperature gauge showing normal Engine warmoperating temperature 85C Buzzersounding lamp illuminated Incorrectly calibrated switching point for warning lamp adjust on rear of gauge to 100C210FTHIS ALSO APPLIES TO THE B PANEL If adjusted correctly buzzer still sounding faulty switch gauge unit replaceWITH MURPHY GAUGEWater temperature gauge showing no Check connection to sender if disconnected gauge will not lamp not illuminated engine Check connection to temperature gauge if plug is not connected to socket onwarm rear of gauge reconnectTHIS ALSO APPLIES TO THE B PANEL If all connections are correctly made faulty sender unit check resistance toWITH MURPHY GAUGE earth approx 35k cold 05k warm Replace if no reading 22ELECTRICAL CORRECT OPERATION OF KEYLESS PANELSThese panels control the engine with Green lamp for panel power on Green lamp for panel power onthree water resistant push buttons should function should still of a keyswitch which are less Buzzer should sound 3 To stop the engine press theprone to damage and corrosion from STOP push button hold in until 2 Press START button and hold insea water spray than a keyswitch engine stops This button also position until engine fires seeTo operate the engine initial startup section for switches the power off to the1 Press and hold HEAT button for maximum time starter can be gauges engine and power on ten seconds maximum operated Release button when lamp Red lamp for no starter battery engine has started 4 To restart the engine simply charge should function All red warning lamps should repeat steps from 1 above there extinguish and buzzer should stop is not need to switch battery Red lamp for high engine sounding The oil pressure lamp isolators off whilst remaining on temperature should not function may take a few seconds to switch board when engine is cold cool warm This lamp will only ever off and the charge fail lamp may 5 If leaving the boat isolate start function if the engine is over remain on until engine rpm is battery from engine and panel to temperature increased to approximately prevent accidental start up of 1000rpm if the engine was Red lamp for low oil pressure engine started at tickover should FAULT FINDING NON BETA PANELSEngines can be supplied wired up to Note Water temperature switch sender Part number 20001133suit VDO switch senders usuallyfitted to a nonBeta control panel large spade is sender connection green blueIf so refer to our wiring diagram 200 small spade is switch connection blue yellow6097101 also part number forreplacement harness Oil pressure switch sender Part number 20062680 Loom is configured differently in the 11way plug to G Gauge wire white brown accommodate the extra wiring M Earth black Small brown wire battery WK Warning lamp green yellow 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 FAULT FINDING EXTENSION HARNESSESSome installations require one of the and panel extension to panel on these connections are harder topanel extensions 11 way connectors Deluxe C to ensure wire colours to distinguish between in poorly litto be removed to allow the cable to each terminal match up to the correct areas Whilst doing this checkbe passed through bulkheads etc If colour in its corresponding terminal integrity of each connection to ensureany panel problems are experienced Extra attention must be given to black terminals have not becomeafter this may have been carried out ground and blackblue tacho also damaged Once checked refit cablevisually check all 11 way connections brown switched positive to alternator tie around each connection to keepon engine harness to panel extension and brownyellow charge fail as them secure 23BETA PNS FOR REPLACEMENT ITEMS Description Part number 40 amp blade fuse all panels 20000959 Alarm board all panels from June 05 20004655 Oil pressure switch 18 BSP not C panels 60062670 Oil pressure sender C panels only 20094350 Oil pressure switch gauge C panels only 20096190 Temperature switch with single terminal on some BZ602 BD902 60062820 Temperature switch sender 18BSP not B or C panels 20001133 Temperature sender B C panels only 20094360 Water temperature switch gauge B C panels only 20096200 Voltmeter C panels only 20096210 28Ra relay 12V 40A fitted to rear of domestic panels 20087020 Keyswitch silver bezel 60000057 Panel stop button all panels Also heat and start on ABVW 20000072 Tacho 04000rpm with digital hour counter all panels but A 20002373 Standard engine harness Mini Series 2009838001 Standard engine harness S5 Series 2006097305 Standard engine harness S3 series 20005267 Iskra 65 amp sub loom 20001196 1m panel extension loom 2000458801 2m panel extension loom 2000458802 3m panel extension loom 2000458803 4m panel extension loom 2000458804 Domestic charge engine sub loom top mounted alternators 20001197 Green power on indicator lamp retaining clip 20004656 Red warning indicator lamp retaining clip 20004657Note the above part numbers are alternators switches for oil pressure on the isolating solenoid It should besuitable for earth return installations and engine temperature will be connected to the terminal which isonly where battery negative cable is required If your application is wired also used for all the small blackconnected directly to engine ground as insulated earth return and the wires NOT the terminal with theFor insulated earth where battery engine will not operate correctly single black wire cable is isolated from engine always check starter battery negative directly to engine groundground different harnesses is connected to the correct terminal 24Spanner torque Torques for general use bolts and nutsITEM Size x Pitch kgf m ft lbs N mM6 7T 6mm 024in 10115 7283 98113M8 7T 8mm 031 2428 174203 235275M10 7T 10mm 039in 5057 362412 490559M12 7T 12mm 047in 7992 571665 Torques for special use bolts and nutsITEM Size x Pitch kgfm ftlbs NmHead Bolts M10 x 125 65 70 470506 637686Bolts Connecting Bolts M8 x 10 4247 304340 412461Bolts Flywheel M10 x 125 5560 398434 539588Bolts 1 Bearing Case M8 x 10 3035 217253 294343Bolts 2 Bearing Case M9 x 125 5055 362398 490539Nozzle Holder Assembly M20 x 15 5070 362506 490686Caps Nuts Head Cover M7 x 10 0709 5165 6988Glow Plugs M10125 2025 145181 196245Oil Switch PT 18 1520 108145 147196Nuts Rocker Arm Bracket M7 x 10 2227 159195 216265Bolts Idle Gear Shaft M6 x 10 10115 7283 98113 25Section 3INSTALLATION installation details contained herewith are basic guidelines to assist installation due to great diversity of marine craft itis impossible to give definitive instructions Therefore Beta Marine can accept no responsibility for any damage or injuryincurred during the installation of a Beta Marine Engine whilst following these guidelines All engines shall be placed within Unless the engine is protected by Engine parts and accessories that an enclosure separated from a cover or its own enclosure require frequent inspection and living quarters and installed so as exposed moving or hot parts of or servicing must be readily to minimise the risk of fires or the engine that could cause accessible spread of fires as well as hazards personal injury shall be effectively The insulating materials inside from toxic fumes heat noise or shielded engine spaces shall be not vibrations in the living quarters MOUNTING and extend the life of the flexible mount If necessary fit spacer blocks WARNING below the mounts 1 Do not set the engine feet high Flexible Mount A flexible coupling should be fitted up the flexible mount pillar stud Flexible couplings do not accom This will cause excessive engine modate bad alignment The mating movement and vibration Pack faces of the gearbox and tailshaft under the flexible mount with must be checked for alignment they steel shims securely bolted into must be parallel and concentric to the engine bearer within 0005 0127mm 2 The pillar stud on the flexible mount is secured into position by the lower locknut do not forgetTo ensure vibration free operation the to tighten this Also ensure thatengine must be installed on substan the stud is not screwed too fartial beds extending as far forward through the mounting body soand aft as possible and well braced that it can touch the bearerto form an integral part of the hull This will cause vibration andThe engine must be installed as low knocking noises which are veryas possible on the flexible mount hard to findpillar stud This will limit must be checked for To obtain accurate alignment the Once mounts are A and concentric B flexible mountings must be adjusted alignment must be using a set of feeler until alignment is attained and the Coupling can now be fitted ingauges mountings must be locked in accordance with instructions position supplied with couplingA B 26EXHAUSTSa A correctly installed engine as BD1005 BV1305 in this handbook will meetthe exhaust emission requirements of Standard 50mm 50mm 50mmDirective 200344EC amending the Option 1 58 is available in SS 1 58 NA NARecreational Craft High rise water injection bend SS 50mm 50mm 50mmb For compliance with exhaust Option high rise water injection bend SS 1 58 NA NAemissions requirements enginesmust have correctly installed exhaust Cross over injection bend SS 50mm 50mm 50mmsystems To ensure exhaust to suit Volvo replacement are kept within it is most important to reduce measured with the exhaust system before the water injection elbow orexhaust back pressure to a connected and the engine running at dry exhaust bellowsminimum whilst ensuring exhaust is full speed must not exceed 80mmHg Wet Exhaust hose should beadequately muffled Back pressure 31 inches Hg 42 inches WG matched to the injection bend sizesincreases as exhaust length increases The correct measuring point is at the see aboveand from bends in the exhaust position where the exhaust connectssystem The exhaust back pressure to the exhaust manifold That isTYPICAL YACHT INSTALLATION Maximum sea water level when healed on the centre line of the boat Anti syphon valve or T piece fitted here Normal sea 300mm a water level minimum Sea water Level X Waterlock Allow at least Silencer 10 of propeller diameter for tip clearance to hull If a rope cutter is fitted allow approximately 12 for movement of engine see manufacturers engine oil and a wrecked fuel pump supply either a T piece or an anti1 One of the most common Its best avoided syphon valve sited at least 300mmproblems with engine installation is 12 inches above the water line andwater entering the exhaust manifold 2 The diagram shows a typical on the centre line of the boat Thefrom the exhaust system by installation It is essential that the pipe then returns to the This can occur when the small black rubber hose connecting bend and the sea water is pumpedpoint of water injection X on the the heat exchanger with the injection down the exhaust pipeengine is close to or below the water bend is removed and replaced by aline Water entering the pistons can hose marked a This must be of 3 The exhaust back pressure shouldcause bent con rods emulsified sufficient length to not exceed 31 inches of Hg 27FUEL SUPPLY LEAK OFF A typical system is shown below 8 4 10 2 3 6 1 12 9 5 11 71 Fuel tank 4 Injection pipe 7 Fuel water separator 10 Air vent2 Injection pump 5 Mechanical fuel feed 8 Overflowleak off 11 Stop cock pump with priming lever3 Injection nozzle 9 Drain plug 12 Fuel pipe loop 6 Fuel filterNotes 4 Any fuel leaks in the system are 7 Fuel lines and hoses must be likely to cause poor starting and secured and separated or1 The mechanical fuel lift pump is erratic running and must be protected from any source of fitted to all engines as standard corrected immediately significant heat The filling but if a suction head of 025m is storage venting and fuel supply required then an electric fuel lift 5 A fuelwater separator must be arrangements and installations pump must be fitted ask your installed must be designed and installed dealer or Beta Marine 6 The fuel return leak off pipe so as to minimise the risk of fire2 It is very important that the must loop down to be level with and explosion Flexible fuel hoses excess fuel from the injectors is the bottom of the tank before it connecting the engine to fuel fed back to the fuel tank and not enters the top of the tank see tank supply and return lines back to any point on the supply 12 This prevents fuel drain must meet the requirements set line This will help prevent air down in standard ISO getting into the system 78401995A12000 and as required by your surveyor 3 Fuel pipe sizes are Supply mm Leak off mm authority 8 8 28SEAWATER INLET SYSTEM HEAT EXCHANGER COOLED ENGINESYour engine is fitted with a geardriven sea water pump which sucksin seawater or raw water to cool theclosed circuit system via the heat Water 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 line2 The inlet sea cock and pipe work cause flooding and sinking of the the vessel is in motion This is to the sea water pump should be vessel very dangerous as the exhaust 22mm ID or 34 minimum will eventually fill and raw water 5 If water is required for stern tube will back up into the engine3 Good access to the inlet seacock lubrication then this should be through the exhaust valve is essential so that plastic bags or taken from a T piece in the pipe Catastrophic failure will result as sea weed trapped in the intake going from the heat exchanger soon as the engine is restarted can be poked out outlet to the water injection bend Note The maximum lift of the sea4 All pipe work should have 6 Scoop type water pickups should water pump is 2m approved marine grade stainless never be used as water will be steel hose clips Any loose forced through the pump and clamps or bad connections can into the exhaust system whilst 29CALORIFIER SYSTEMAll Beta engines can be fitted withthe engine tappings to allow the hotwater from the closed system to a calorifier tank which inturn heats up domestic water tappings on this range of supplyengine are shown BV1305 BV15051 The big problem with a calorifier is to remove all the air from the system If this is not achieved then they dont work2 Try and keep the supply and return pipes either horizontal or sloping down in a continuous fall towards the calorifier This avoids air pockets being created3 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 Calorifier Water System return heat exchange Also check to see if the pipe only going to the calorifier is getting warm after 15 mins Top up the water level as required and run for another 10 minutes then repeat4 If the water level is steady but no warm water is getting to the calorifier then very carefully open the calorifier bleed valve see manufacturers instructions or if none is provided then very carefully loosen the jubilee clip securing the supply pipe to the calorifier Air should escape Refasten securely when no further bubbles are seenCAUTION CalorifierDo not do this when the engine is supplyhot as scalding hot water may be BD1005forced out of the pipe under pressure 30ELECTRICAL has 6 panels A standard relay to overcome the voltage clipped and protected from AB or ABV drop See drawing 30058520 abrasion or ABVW 5 All electrical equipment must be 7 Electrical systems shall be B protected from sea water Sea designed and installed so as to C water or rust in the starter will ensure paper operation of the craftThe engine harness is common to all invalidate the warranty under normal conditions of use1 These panels must not be Care must be taken when and shall be such as to minimise installed where sea water spray pushing the two halves of the risk of fire and electric shock can get at them A suitable flap or plug together to ensure that 8 Attention shall be paid to the cover must be fitted individual pins do not fall out To provision of overload and short prevent corrosion and assist in2 Panels must be fitted in a location circuit protection of all circuits assembly we recommend that the where the helmsman can either except engine starting circuits plug is packed with petroleum see or hear the alarm system supplied from batteries jelly Vaseline and then carefully3 For standard wiring diagrams see pushed together The plastic boots 9 Ventilation shall be provided to following pages should cover both halves and prevent the accumulation of4 Extension looms longer than 3m overlap A cable tie is then put gases which might be emitted 10 feet As an option Beta can around to hold the two halves in from batteries Batteries shall be provide various lengths of position and help prevent any firmly secured and protected from extension looms for runs of over ingression of water ingress of water 3m but this kit includes a start 6 All cables must be adequately 31APPENDICES WIRING DIAGRAMS GENERAL ARRANGEMENTS1 Typical starter motor ratings2 Suggested engine starter battery size Page 333 Keyswitch terminations Page 334 Standard harness 65 Amp 20005452 Page 345 Standard harness 100 Amp 20006077 Page 356 Diagram of A panel cutout 20006516 Page 36 377 Diagram of AB panel cutout 20006517 Page 38 398 Diagram of ABV panel cutout 20006519 Page 40 419 Diagram of ABVW panel cutout 10006333 Page 42 4310 Diagram of B panel cutout 20006520 Page 44 4511 Diagram of C Deluxe panel cutout 20006518 Page 46 4712 Split charge diagram 65 Amp alternator 30062210 Page 4813 Starter booster relay 30058520 Page 4914 GA of BD1005 HE PRM 80 10099550 Page 5015 GA of BD1005 HE TMC 40 10001939 Page 5116 GA of BD1005 HE PRM 80 Atomic 10005009 Page 5217 GA of BV131505 HE PRM 120 10098915 Page 5318 GA of BV131505 HE TTMC35A 10006375 Page 5419 GA of BV131505 HE PRM 150 10099660 Page 5520 100 Amp alternator information 10005471 Page 5621 Beta Controller information Page 57 5822 Wiring 100 Amp Beta Controller 10005475 Page 5923 Declaration of Conformity for Recreational Craft Page 60 6124 Maintenance record and service items Page 65 32TYPICAL STARTER MOTOR used in Kubota engines have the following standard capacities Engine Starter capacity kW 1000cc to 1500cc 12SUGGESTED MINIMUM ENGINE STARTER BATTERY SIZE Engine cc Typical Battery Capacity AH Typical CCA A at a 20hr Rate Cold Cranking Amperage BD1005 65 75 450 540 BV1305 70 75 450 540 BV1505 70 75 450 540KEYSWITCH TERMINATIONS For black keyswitches the terminal Note these terminals are rated at 10 to achieve this ignition switched amps maximum since they areThe standard panel keyswitch can be positive is marked 1554 already utilised for panel andused to tap off a switched positive alternator feeds Beta Marineignition feed to power additional For panels without any keyswitch recommend any In this way these gauges will gauges can be driven from the 1mm2 requirements from these terminalsonly be live whilst the engine is brown wire which terminates at 11 must be fed through a relay Thisrunning the engine is starting or the way connector terminal 4 This is a relay should then be connected to itsheaters are being used low power switched positive any own fused positive supply directly additional power required from thisFor silver keyswitches the terminal from the engine battery Beta drawing connection must be fed through ato achieve this ignition switched 20206421 illustrating the wiring of relay as noted below a typical electric fuel lift pump withpositive is marked AC ignition switched relay can be supplied upon request 33343536 15000 500 1000 1000 1000 8000 900037 1000 14000 500 2012 3668 5032 ADD 30mm FOR WIRES REV DESCRIPTION DATE APPD 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 20006305 00 SOUTH WOODCHESTER CHECKED BY BETA MARINE STROUD GLOS GL5 5EU SCALE PAGE DATE TEL 01453 835282 FAX 01453 835284 LT NTS 2 of 2 1511200438 19500 1000 1000 1000 17000 1800039 500 1000 500 18500 O 500 THRU 2262 3668 5032 ADD 30mm FOR WIRES REV DESCRIPTION DATE APPD 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 20006304 01 SOUTH WOODCHESTER CHECKED BY BETA MARINE STROUD GLOS GL5 5EU SCALE PAGE DATE TEL 01453 835282 FAX 01453 835284 LT NTS 2 of 2 1511200440 1800 50 100 100 1300 140041 200 200 100 50 1700 O 50 THRU 226 503 ALLOW 30mm FOR WIRES 367 REV DESCRIPTION DATE APPD 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 2000632001 00 SOUTH WOODCHESTER CHECKED BY BETA MARINE STROUD GLOS GL5 5EU SCALE PAGE DATE TEL 01453 835282 FAX 01453 835284 LT NTS 2 of 2 2311200442 O 500 THRU 500 14000 1200043 500 500 2000 500 2000 1000 2262 16000 1000 18000 5050 ALLOW 30mm FOR WIRES REV DESCRIPTION DATE APPD 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 20006331 00 SOUTH WOODCHESTER CHECKED BY BETA MARINE STROUD GLOS GL5 5EU SCALE PAGE DATE TEL 01453 835282 FAX 01453 835284 LT NTS 2 of 2 0112200444 21000 1000 1000 500 15500 1650045 1000 500 20000 2262 3668 5032 ALLOW 30mm FOR WIRES REV DESCRIPTION DATE APPD 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 20006303 00 SOUTH WOODCHESTER CHECKED BY BETA MARINE STROUD GLOS GL5 5EU SCALE PAGE DATE TEL 01453 835282 FAX 01453 835284 LT NTS 2 of 2 1511200446 29800 1000 1000 500 1000 15600 1660047 1000 28800 500 2262 3668 5032 ADD 30mm FOR WIRES REV DESCRIPTION DATE APPD 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 20006306 00 SOUTH WOODCHESTER CHECKED BY BETA MARINE STROUD GLOS GL5 5EU SCALE PAGE DATE TEL 01453 835282 FAX 01453 835284 LT NTS 2 of 2 durabilityIN RESPECT TO THE RECREATIONAL CRAFT DIRECTIVE 9425EC AND ANNEX 1 B3 The engine must be installed maintained and operated within the parameters detailed in the Operators Maintenance Manual Maintenance must use approved materials parts and consumables Should the engine lie unused for a period in excess of 6 months it must be inhibited otherwise it will deteriorate with resulting decrease in performance See also the Winterising and Laying Up procedures in the Operators Maintenance Manual The fuel settings of the diesel injection system must not be tampered with otherwise the guarantee will be invalid and the performance may fall outside prescribed limit Such adjustment cannot be allowed under the terms of the emission certification Performance of the engine depends upon the use of correct fuels lubricants and inhibitors These are fully detailed in the Operators Maintenance Manual Particular attention must be paid to the installation with respect to the exhaust system The system must be designed so that water cannot back feed into the engine The run must be such that the back pressure at the engine manifold does not exceed the level detailed in the Operators Maintenance Manual Wet water injected exhaust systems must be at least the bore mentioned in the Operators Maintenance Manual and should the run be excessive this bore must be increased accordingly Back pressure is measured at the outlet of the engine manifold before the water injection bend or dry bellows Our experience over 14 years has shown that properly installed and maintained engines hold their performance without major mishap even when running hours exceed those mentioned in the Recreational Craft Directive It is the owners users responsibility to ensure that the engine continues to function properly and any malfunction must be immediately investigated The Trouble Shooting section as detailed in the Operators Maintenance Manual is particularly helpful in this respect Engine performance especially with respect to erratic running exhaust condition low power output and high oil consumption are indications of engine conditions that may result in emissions outside the prescribed limits and must therefore be investigated and rectified immediately 61NOTES 62NOTES 63Quick Reference Parts ListingHEAT EXCHANGER COOLED BD1005 BV1305 AND BV1505In all cases please quote the Beta Marine WOC K number and engine number Description Part Number Qty per Engine Heat Exchanger O Ring 20980110 2 Wasting Zinc Anode 20961840 1 Lubricating Oil Filter 21160390 1 Fuel Filter Heat Exchanger cooling 21160210 1 Fuel Lift Pump 60067830 1 Fuel Lift Pump Gasket 60000065 1 Air Filter Element BD1005 only 21162950 1 Air Filter Element BV1305 BV1505 only 21161831 Sea Water Pump Service Kit includes 20761470 1 Sea Water Pump Impellor 20779630 1 Sea Water Pump Cover Plate O Ring 20704206 1 Sea Water Pump Cover Plate 20705305 1 Sea Water Pump Cover Plate Bolt 20704207 3 Sea Water Pump Seal 20702239 1 Thermostat 60072450 1 Thermostat Gasket 60080490 1 40 Amp Blade Fuse engine wiring harness 20000959 1 Control Panel Key Switch 60000057 1 Control Panel standard Key 60000058 1 Water Temperature Switch Panel A ABV ABVW 20001133 1 Water Temperature Sender Panel C B 20094360 1 Oil Pressure Switch Panel A ABV ABVW 60062670 1 Oil Pressure Sender Panel C B 20094350 1 Vee Belt standard 65 Amp alternator 21463090Q 1 Optional Polyvee Belt 100 Amp alternator 21400493 1 64Service Record Service Date Responsible 1 Commissioned 2 First 25 hours 3 First 50 hours 4 Every 150 hours with Shallow sump 5 Every Year Every 250 hours if sooner 6 7 8 9 10 11 12 13 14 15 65 Sail Drives 135 to 50bhpHeat Exchanger Cooled 10 to 90bhpKeel Cooled 10 to 90bhp Beta Marine Generating Sets 37 to 40kVA Beta Marine Limited Davy Way Waterwells Quedgeley Gloucester GL2 2AD United Kingdom Tel 44 01452 723492 Fax 44 01452 883742 Beta Marine Generating Sets email 30 to 900kVA BM Doc Ref 1640 28375bhp HE
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The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerous of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.