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Beta Marinebd1005, Bv1303, Bv1505 Operators Maintanance Manual



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                                                           Operator's
                                                         Maintenance
                                                              Manual




Heat Exchanger Cooled
Small Diesel Engine Range
BD1005, BV1305 and BV1505

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.
Engine 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 you).




Engine Type:                      Power:                           bhp      Speed:                         rpm




BETA WOC NO:             K                          Engine Serial No:




Gearbox Type:                                       Serial No:                               Ratio               :1




Purchased from:




Invoice No:                                            Date:




Date Commissioned:



Specification / Special Details
Contents
           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 start-up and bleeding the fuel system                5
           Starting/stopping                                             6


           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   11
           Sea water pump, heat exchanger                               11
           Belt tensioning                                              12
           Air filter                                                   13
           Electrical                                                   13
           Laying up - winterising                                      13
           Troubleshooting                                              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



                               1
OPERATION AND MAINTENANCE MANUAL FOR THE FOLLOWING
BETA MARINE ENGINES BASED ON KUBOTA SUPER 5 SERIES



BD1005, BV1305, BV1505

 This manual has been compiled to      All information and                     carried out at the place of
 provide the user with important       recommendations given in this           manufacture and in vessels used
 information and recommendations       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
                                       company's 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 tests




ENGINE IDENTIFICATION                 BD1005, BV1305,                         ENGINE STORAGE
                                      BV1505                                  The engine must be stored in a dry,
NOTE: In all communications with
                                                                              frost free area and this is best done in
the distributor or Beta Marine, the   The engine serial number is stamped     its packing case. If storage is to be
engine number, type, and W.O.C.       above starter motor on the port side    more than six months then the
number 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


                                                          2
SAFETY PRECAUTIONS!
A Keep the engine, gearbox                   the outlet next to the heat              G TRANSPORTATION/
and surrounding area clean,                  exchanger/header tank, the                 LIFTING
including the area immediately               exhaust outlet can become very
                                             hot and if touched, can injure.              Engines are supplied on
below 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 assembly
B DRIVES - Power Take Off                    lag the exhaust system if a dry              only, not the pallet and
Areas                                        system is used. Exhaust gases                associated kit.
                                             are harmful if ingested, the
i) 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 rev/min. This flange is                                                       the purchaser/installer/owner, 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, are
ii) 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, C.E.O,
   come in contact with the belts or                                                  Beta Marine Limited
   pulleys, when the engine is            E OIL
   running.                                  The Beta propulsion is supplied
iii) 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           purchaser/installer/owner and operator
   850 and 3600 rev/min. 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.                               94/25/EC is complied with.
   injury can occur.
                                          F SCALDING
C EXHAUST OUTLET                             An engine running under load will
                                             have a closed circuit fresh water
   Diesel marine propulsion engines          temperature of 85° to 95°C. The
   emit exhaust gases at very high           pressure cap on the top of the
   temperatures - around 400-                heat exchanger must not be
   500°C. 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)                                                               73.6                               73.6                              74.8
    Displacement (cc)                                                         1001                              1335                              1498
    Combustion                                                                                                3 Vortex
    Cooling                                                                                                     Water
    Starter voltage (V)                                                                                           12
    Starter output (kW)                                                                                          1.2
    Starter alternator output (Amps)                                                                       65 (standard)
    Glow plug resistance (each)                                                                                   1
    Engine speed (RPM)                                                        3,600                             3,600                             3,000
    Power output to ISO3046 (BHP)                                              28.0                              35.0                              37.5
    Declared power ISO8665 (kW)                                                19.2                              25.7                              27.1
    Compression Ratio                                                                                           22:1
    Fuel timing BTDC                                                                                             21°




4
    Capacity of standard sump approx (litres)                                   6                                 7.5                              7.5
    Capacity of shallow sump approx (litres)                                    5                                 6.5                              6.5
    Nett dry weight with gearbox (kg)                                          150                               170                               170
    Fuel                                                                                                Diesel fuel oil No.2D
    Coolant                                                                                      33%-50% maximum antifreeze / water
    Coolant capacity approx (H/E litres)                                        5.5                                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 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.
SECTION 1
GUIDELINES FOR OPERATION OF ENGINE
IMPORTANT CHECKS PRIOR                     4. Ensure Morse speed and gearbox             on gearboxes returned in the
TO INITIAL USE                                cables are fitted correctly and that       warranty period for failure due
                                              cable travel lengths are correct.          to incorrect adjustment.
1. Generally, a new engine has the
   oil and anti-freeze removed after           Gear selection lever ­all             5. Ensure engine is out of gear with
   the works test. Fill the engine             mechanical gearboxes: care               1/3 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
   operator's hand book.                       travel and brought "hard up"
                                                                                        literature.
                                               against its end stop in both
2. 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 the
3. 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 accepted



INITIAL STARTUP AND                        (e) Start engine (see normal              Note: The starter windings can be
BLEEDING THE SYSTEM                            starting).                            burnt out with continuous cranking
(a) Open fuel bleed screw on fuel              Note the engine may have to be
    filter assembly by 11/2 turns. See         turned over with the starter for a
    diagrams 1a & 1b.                          few seconds before it fires. Do
                                               not run the starter for more than
(b) 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 a
(c) Shut/tighten 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 minutes
(d) 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 pump.


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                                                            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.



                                                            5
NORMAL STARTING (BETA                           OIL PRESSURE                                  are still on, then increase engine
PANELS WITH SILVER KEYSWITCH,                   and green POWER ON / RUN LIGHT                speed to excite the alternator - then
FOR KEYLESS SEE PAGE 23)                        (this will stay on)                           return to idle. The battery charge
                                                                                              lights should then go out. The run
With the engine out of gear, set speed          Turn to START (D) position and engine
                                                                                              light will remain on (green lamp).
control lever to 1/3 throttle. Turn key anti-   will motor, hold in position until
clockwise to HEAT* (A) position and hold        engine fires (see initial start-up section    Check for sea water flow. If no flow
for ten seconds, turn key clockwise to          for maximum                                   then SWITCH OFF IMMEDIATELY
                                                time starter can             B                AND CHECK SEA WATER SYSTEM.
RUN (C) position. At this stage the                                        OFF     C
                                                                    A
instrument panel should illuminate, an          be used).          HEAT
                                                                                  RUN
                                                                                       D      Note: for some deluxe panel with the
alarm buzzer will sound and two (or             Release key                           START   black keyswitch, they operate
three*) red warning lights will illuminate:     (when engine
                                                                                              clockwise as legend on panel (OFF ­
                                                has started) to
STARTER BATTERY CHARGE                                                                        RUN ­ HEAT ­ START). Operation for
                                                RUN position.
DOMESTIC BATTERY CHARGE (D in                                                                 engine start procedure is the same as
                                                Ensure alarm
battery symbol - AB & C Deluxe                                                                standard apart from this.
                                                buzzer is not sounding and that
panels only)
                                                warning lights are extinguished. If one
*(Note: this will only illuminate if
                                                or both of the alternator warning lights
2nd alternator is fitted)




STOPPING
Every propulsion engine is fitted with          The Super 5 range of engines are
a stop solenoid which is energised to           equipped with a mechanical stop
stop. To stop engine simply press               lever in the event of electrical system
stop push button, hold in until engine          failure. This lever is located on the
stops, then turn key from `RUN' to              starboard side of the engine above
`OFF' position.                                 the speed control lever. See Fig 2e:
When leaving the boat for an
extended period,
· Turn off sea-cock (heat exchanger
  cooled engines).
· Turn off battery isolator.
Do not turn the key to the off
                                                                                                         Stop lever
position when the engine is
running. This will damage the
alternator.
                                                                                                          Speed lever

*WARNING
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 10 seconds as this will lead to
overheating and failure of the
solenoid.


                                                                                          Fig. 2e




                                                                      6
SECTION 2
MAINTENANCE SCHEDULE
DAILY OR EVERY 8 HOURS                 AFTER FIRST 50 HOURS                  EVERY 750 HOURS ­ As every
RUNNING                                · 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 fuel/water   ·   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 lubricating
AFTER THE FIRST 25 HOURS                 oil and filter.
RUNNING
                                       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 re-checked. 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 re-assemble.
  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.




                                                       7
LUBRICATION
Engine oil: Engine oil should be MIL-     1. To check the oil level, draw out
L-2104C or have properties of API            the dipstick, wipe it clean, re-          IMPORTANT
classification CC/CD/CE grades. The          insert it, and draw it out again.         When using an oil of different make
following table gives grades of oil          Check to see that the oil level lies      or viscosity from the previous one,
required for various ambient                 between the two notches.                  drain old oil. Never mix two different
temperatures.                             2. If the level is too low, add new oil      types of oil. Engine oil should be
Note: A good quality 15W/40                  to the specified level - Do not           changed after first 50 hours running
mineral or multigrade oil as used in         overfill.                                 time and then every year or every
most diesel car engines will meet                                                      250 hours if sooner. Oil filter is a
these requirements. Do not use                                                         cartridge type mounted on the port
`Turbo Diesel Oil' or additives.                                                       side of the engine.

CHECKING ENGINE OIL
                                               AMBIENT TEMP                 SINGLE GRADE                   MULTI GRADE
LEVEL
For quantities of oil required see               -30°C TO 0°C                   SAE 10W                     SAE 10W/30
section marked `Technical                       -15°C TO +15°C                  SAE 20W                     SAE 15W/40
Specification', Page 4
When checking the engine oil level,              0°C TO +30°C                       SAE 30                  SAE 15W/40
do so before starting, or more than
five minutes after stopping.                   25°C AND ABOVE                       SAE 30                  SAE 15W/40




CHANGING ENGINE OIL
                                                       Oil goes
(1) Run the engine for 10 minutes to                   in here
    warm up the oil.

(2) 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 stick
(3) 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 filter
(4) Fill the engine with new oil as                  End Cap
                                                                                                       Fig. 2d
    described above.
                                                           Fig. 2c

(5) Run the engine and check for oil
    leaks
                                                                  8
CHECKING GEARBOX OIL LEVEL
(1) 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 the
(2) 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                     0.2 litres
          TMC60M                       Use ATF Oil                     0.8 litres                                               Dip
                                                                                                                                stick
           PRM 80                Use Engine Oil 15W40                  0.6 litres
                                                                                                                                Oil
          PRM 120                Use Engine Oil 15W40                  0.8 litres                                               filler
                                                                                                                                plug
          PRM 150                Use Engine Oil 15W40                  1.4 litres
          PRM 260                Use Engine Oil 15W40                  1.5 litres
                                                                                                                        Oil drain
                                                                                                                        plug
           ZF10M                       Use ATF Oil                    0.35 litres
                                                                                                          Fig 2e
           ZF15M                       Use ATF Oil                    0.55 litres
        TTMC 35A-2               Use Engine Oil 15W40                 0.65 litres
Note: ATF is Automatic Transmission Fluid



FUEL SYSTEM                 (see page 28 for a typical installation)


                                              · The fuel lift pump will only lift
IMPORTANT                                                                                5. Check for leaks.
                                                fuel through 0.25 metres. If this
· Always fit a fuel/water 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              202-06421, 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 anti-clockwise
  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.
                                                               9
COOLING
BD1005, BV1305 and BV1505
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
diagram).




FILLING THE FRESHWATER SYSTEM
New engines are supplied with the        (d) Fill header tank to the top of the    (h) Run the engine on one third load
freshwater drained off. The following        filler neck and replace cap. Press        for 15 minutes, preferably with
instructions must be followed to fill        down firmly on filler cap and             the boat tied up. As the system
the system.                                  hand tighten in a clockwise               warms up coolant may be
                                             direction.                                expelled from the overflow pipe
(a) 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 the
(b) 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 must
(c) Fill engine with freshwater/anti         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



                                                              10
IMPORTANT                               (i) Repeat (h) if coolant level is more
                                            than one inch below the base of       Note: When draining fresh water
Removal of the pressure cap when            the filler neck when the engine
the engine is hot can cause severe                                                system, ensure the engine has cooled
                                            has cooled down.                      sufficiently to prevent scalding from
injury from scalding hot water under
pressure. Always allow the engine to                                              hot pressurised water. Prior to
                                        (j) Run engine on 2/3 full load for 20
cool and then use a large cloth when                                              draining a cold engine, remove the
                                            minutes, check for leaks and
turning the cap anti-clockwise to the                                             filler cap from the header tank and
                                            repeat (i).
stop. This allows the pressure to be                                              then open the water drain tap. This
released. Press firmly down on the      (k) Anti-freeze solutions should be       allows the water to drain freely from
cap and continue to turn                    drained off every 2 years and         the system.
anticlockwise to release the cap.           replaced with a new solution.



YACHTS AND LAUNCHES WITH HEAT EXCHANGER COOLING
It is essential that a 33% to 50%       Concentration of ethylene should not      temperature alarm switch will
anti-freeze/water mixture is used.      exceed 50%.                               however be activated at 95° to
This not only stops freezing up in                                                100°C. If no anti-freeze or a very
winter, but it prevents overheating     The anti-freeze in the fresh water        weak solution is used, then the water
and corrosion.                          system enables the boiling point of       temperature switch may not be
                                        water to rise to 124°C with a 13 psi      activated before coolant is lost.
The warranty is invalid unless the
correct ratio is used.                  pressure cap fitted. The water




SEA WATER PUMP AND COOLING SYSTEM
(HEAT EXCHANGER-COOLED                  (3) Check impeller for cracks in the
ENGINES)                                    rubber, excessive wear or lost
                                            vanes. Replace with a new
CAUTION                                     impeller as necessary.
Before working on the sea water             Note: If any pieces of rubber
system ensure that the sea cock is in       impeller are missing then they
the off position.                           must be found as they are most
                                            likely to be trapped in the
(1) 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. 2h).

(2) Withdraw the rubber impeller
    from its drive shaft as shown.
    See diagram 2i.


                                                                                                 Fig. 2I




                                                        11
CLEANING THE HEAT EXCHANGER TUBE STACK AND REPLACING WASTING ZINC ANODE

(1) 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) Re-assemble 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) Re-fill engine with water/anti-
(2) 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. 2k




BELT TENSION
65 AMP ALTERNATOR (HEAT EXCHANGER COOLED)                                                    Link adjust bolt

                                          (4) Push alternator outboard to
WARNING                                       tension and tighten link bolt.
Belt tension must only be checked             Check that the depression of the
with the engine switched off.                 belt at position shown is
                                              approximately 1/2" or 12 mm
(1) 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 the
(2) 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         occurs.Belt tension must only be
    bolt.                                     checked with the engine
(3) With the engine stopped, loosen           switched off.
    the support bolts and the link                                                      Support bolts
    adjusting bolt.

100 AMP ALTERNATOR (OPTION)

The same method, as outlined above        cause premature failure of
applies, but final tensioning must be     components.
by hand only. Over tensioning will

                                                               12
AIR INTAKE FILTER
These engines are fitted with an air intake filter which should be checked every season and changed every 2 years or
sooner if badly clogged. If badly clogged, check more often.




               1                                          2                                           3


MAINTENANCE - ELECTRICAL
                                         GENERAL MAINTENANCE                        (2) Check batteries for acid level and
WARNING                                                                                 top up if required. For low
                                         (1) The panel must be protected from           maintenance and `gel' batteries
Under no circumstances should the
                                             rain and sea water, see instal-            see manufacturers instructions.
battery be disconnected or switched          lation. Sea water entering the key
off when the engine is running. This                                                (3) Loose spade terminal
                                             switch will eventually cause
will seriously damage the alternator                                                    connections are the most
                                             corrosion and could result in the
                                                                                        common cause for electrical
PANELS AND WIRING                            starter motor being permanently
                                                                                        faults - check on a regular bases
                                             energised and burning out. Spray
See installation notes, page 31.                                                        (see maintenance instructions).
                                             key switch every month with WD
                                             40 or equivalent.



WINTERISING AND LAYING UP
HEAT EXCHANGER COOLED                        (i) Close the inlet seacock to the     (d) Ensure instrument panel is well
ENGINES LEFT AFLOAT AND                      engine (engine stopped).                   protected and give the key switch
ASHORE                                                                                  a spray of WD 40 or equivalent.
                                             (ii) Disconnect the sea water
(a) 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 50/50 anti-              disconnect the battery (always
    the season rather than in the            freeze solution.                           disconnect the negative cable first
    spring. See section 2.                                                              and re-connect the negative
                                             (iii) Start the engine (out of gear)       cable last) and take it ashore for
(b) The closed circuit system should         and run for 5 to 10 seconds until          trickle charging and top up as
    contain a 50/50 solution of anti-        the anti-freeze 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 boat.
(c) 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 3°C, 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 damage.

LAYING UP ASHORE
(a) 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.
                                                          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 onto 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    Re-route pipe or clean.
tank, or blocked pipe:

Air filter blocked:                     Replace.

Worn or blocked injector:               Service injectors.

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

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       Get compression checked by your dealer or Kubota service agent. He will
low compression:                          advise action to be taken.

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

PROBLEM: BLACK EXHAUST GAS
Possible Cause                          Solution

Blocked air filter element:             Inspect and replace

Over pitched propeller - engine will    Get the propeller
not reach its full rpm:                 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           Change.
relative to propeller size:



                                                             15
PROBLEM: LOW POWER OUTPUT
Possible Cause                              Solution

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          Disconnect speed control cable and move the lever by hand. Adjust cable.
correctly:

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


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            Shift ring gap position.
direction:


PROBLEM: WATER IN LUBRICATING OIL - (Heat exchanger cooled)
Possible Cause                              Solution
Oil goes "milky" due to sea water           Check installation - has anti-siphon valve been fitted? Change engine oil and
entering exhaust manifold:                  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          Service Agent to check and replace.
block:

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 entering      Check installation ­ has dry exhaust system been fitted correctly, ensuring rain
exhaust manifold and then into the          water cannot enter the exhaust port and run back? (See DRY EXHAUST
sump:                                       SYSTEM) Change engine oil and run engine for 10 minutes each time to
                                            eliminate any water. Get fuel injection pump checked by Service Agent.

                                                                16
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    Remove and clean.
with dirt:

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 power output from `W' connection. Should be about 9V AC.

Wiring fault:                            Check circuit.


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               Remove tube stack and clean - replace `O' rings.
exchanger:

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   Vent the system and top up coolant.
cooler:

Keel cooler of insufficient size:        Contact boat builder.


                                                          17
GENERAL -HEAT EXCHANGE ONLY:
The most common cause of                 exhaust outlet for 10 seconds and          pipe to the heat exchanger or in the
overheating is insufficient seawater     measure the amount of water                end of the exchanger. This must be
flow due to a blocked intake (weed       collected. Multiply this value by 6 to     removed.
or a plastic bag!). If this happens      give the flow in litres/min. Repeat
                                                                                    (d) Check flow again as in (a).
then clear the blockage. If the          twice and take an average. If the flow
problem is not cured then check the      rate is noticably less than the 6.5        *Note: This operation must only be
system for sea water flow which          litre per minute minimum, then:            done in safe conditions, in port and
should be 6.5 litres / minute                                                       with two assistants.
                                         (b) Check impeller in sea water
minimum at 1,000 rpm as follows:                                                    Working from a rubber dinghy is
                                         pump - if worn replace.
(a) With the boat tied up and out of                                                best. The person holding the bucket
                                         (c) If impeller has a vane missing
gear run the engine up to 1000 rpm.                                                 should take precautions against
                                         then this will be lodged either in the
*Hold a plastic bucket over the                                                     breathing in the exhaust gasses.




PROBLEM: KNOCKING NOISE

Possible Cause                           Solution

Propshaft touching gearbox output        Adjust, giving correct clearance (10mm) between gearbox and propeller shaft.
coupling through split boss or Type 16
coupling:

Flexible mount stud touching engine      Adjust stud to clear.
bed:

Drive plate broken:                      Replace / repair.

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




PROBLEM: BATTERY QUICKLY DISCHARGES

Possible Cause                           Solution

High 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
                                         alternator.

Low electrolyte level:                   Top up.


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

Alternator defective:                    Check with Agent.

Battery defective:                       Replace.

Poor wiring connection:                  Check wiring system.




                                                             18
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.
Propellor shaft hitting the gearbox
                                         Move shaft back to give at least 5mm clearance (type 12/16 couplings only)
half coupling:




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   Check relative compression of each mount.
to take even weight:

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 the       There must be at least 10% tip clearance between propeller and bottom of the
propeller tip and the bottom of the      boat (ie 10% of the propeller diameter as clearance). Refer to boatbuilder.
boat:

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.




                                                         19
ELECTRICAL FAULT FINDING & TROUBLE SHOOTING ­
ENGINES BUILT AFTER JULY 2005 ONLY
The following chart is compiled to aid     All Beta panels have the following warning lamps:            (A, AB, ABV, ABVW,
diagnosis of electrical faults, based on                                                                  B and C Deluxe)
the Beta 10-90hp range of engines. If
your engine was built before July          Starter battery charge warning lamp                                   Red
2005, contact Beta Marine for the
relevant electrical trouble shooting       · High engine temperature warning lamp                                Red
guide.
Standard sea specification engines         · Low engine oil pressure warning lamp                                Red
(heat exchanger cooled) are supplied
with a single alternator, mounted port     All panels also have:
side, supplying power to starter battery
and control panel.                         · Panel power on (this is not a warning lamp)                        Green

Standard canal specification engines       In addition to above the domestic AB, C Deluxe panels also have a:
(keel cooled) are supplied with twin
alternators:                               · 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 function
Both of these alternators work                                                       · If alternator charge problem,
independently, if the domestic battery     · Green lamp for panel power on             measure battery voltage with
system is disconnected, the engine           should function                           engine off and again with engine
will 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 engine
Standard control panels are supplied       When the engine is started, all the red   if a 2nd alternator is fitted which
with 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 this
Four lamp panels:
                                           indication lamp illuminated. The oil      connection.
A, ABV, ABVW, B, these panels utilise
                                           pressure lamp may take a few
bulbs inside sealed lamp holders
                                           seconds to switch off and the charge
Five lamp panels:                          fail lamp may remain on until engine
AB or Deluxe C, these panels also          rpm is increased to approximately                Typical start battery positive
utilise bulbs inside sealed lamp           1,000rpm (if the engine was started
holders, having an additional lamp for     at tickover).
domestic battery charge
                                           Before investigating any specific
With keyswitch* in run position &          electrical problem, always check:
engine 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

                                                               20
ELECTRICAL FAULT FINDING ­ ALL LAMP PANELS

PROBLEM                                       POSSIBLE CAUSE & SOLUTION
                                              · Battery isolation switch in off position ­switch on
                                              · Starter battery discharged ­ charge
No 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 non-functioning lamp: green/blue ­water
Non function of warning lamp    temperature, white/brown ­ oil pressure, brown/yellow ­alternator charge.
                                Reconnect wire temporarily to another warning lamp that is functioning; if
THE WATER TEMPERATURE LAMP      wire switches lamp on replace faulty lamp.
WILL NOT FUNCTION UNLESS      · Disconnect positive feed to non-functioning lamp. Reconnect temporarily
ENGINE IS OVERHEATING OR THERE with wire from another warning lamp that is functioning, if wire switches
IS 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 cold:
Water temperature warning lamp on when · Faulty wiring, check connection & continuity (small green / blue) from switch
engine 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, replace.
(Not B or Deluxe C panel see table on         If engine is warm:
following page)                               · 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
THE BUZZER WILL NOT SOUND FOR                   from illuminated warning lamp (red not green) to buzzer board.
GREEN POWER ON LAMP                           · - Faulty warning panel buzzer board ­replace.


                                              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 ­replace
Starter battery charge lamp not functioning
                                              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


                                              · -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
Tacho not functioning                           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 battery not connected
                                              · Domestic battery not connected correctly:
                                              B+ to domestic isolation block on starboard rail (port on 75 & 95hp)
Domestic charge lamp not functioning,         B- to engine earth (ground)
buzzer 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 keyswitch.

Domestic charge lamp not functioning,
                                 · No second alternator fitted to engine, domestic lamp not used
buzzer switching off with engine running
                                 · D+ (charge indication) lamp connection at rear of alternator not connected
THIS LAMP WILL NOT FUNCTION IF A · Two way plug & socket disconnected between engine harness & panel loom
SINGLE ALTERNATOR IS FITTED


                                                             21
ELECTRICAL FAULT FINDING ­ DELUXE C & WATER TEMPERATURE FUNCTION
ON B PANELS
In addition to the fault finding detailed on the previous table, the following is specific for the C deluxe panel (Also
applicable for the B panel with Murphy water temperature gauge)


PROBLEM                                        POSSIBLE CAUSE & SOLUTION
Oil pressure warning lamp not functioning,
oil pressure gauge showing maximum          · Faulty wiring ­check wire connection & continuity (small white/brown) from
deflection. Engine off and keyswitch in run   sender to panel lamp. Ensure this connection is not shorting to earth (ground).
position
Oil pressure gauge showing no movement -
even when engine is started. Warning lamp · Faulty wiring ­check oil pressure sender wire (small white / brown) is connected.
functioning correctly
                                               · Check connection to oil pressure gauge, if plug is not connected to socket on rear of
                                                 gauge reconnect.
Oil pressure showing no movement,              · If all connections are correctly made, possible faulty sender unit ­check resistance to
Warning lamp not functioning correctly           earth (ground) approx. 50. Replace if no reading or short-circuited.
                                               · If adjusted correctly & buzzer still sounding, possible faulty switch gauge unit ­
                                                 replace.

                                         Engine warm:
Oil pressure showing normal operating
pressure (0.75­5 bar). Buzzer sounding & · Incorrectly calibrated switching point for warning lamp, adjust on rear of gauge to
lamp illuminated.                          0.5 bar (minimum adjustment on gauge).
                                               · If adjusted correctly & buzzer still sounding, faulty switch gauge unit ­ replace.

                                               Engine cold / cool:
Water temperature gauge showing
120°C / 250°F                    · Faulty wiring, check water temperature sender wire is not shorting to earth
                                   (ground)
THIS ALSO APPLIES TO THE B PANEL
                                 · Faulty sender unit, ­check resistance to earth, approx. 3.5k (cold) ­ 0.5k
WITH MURPHY GAUGE
                                   (warm). Replace if notably less.
Water temperature gauge showing normal
                                               Engine warm:
operating temperature (85°C). Buzzer
sounding & lamp illuminated.     · Incorrectly calibrated switching point for warning lamp, adjust on rear of gauge to
                                   100°C/210°F.
THIS ALSO APPLIES TO THE B PANEL
                                 · If adjusted correctly & buzzer still sounding, faulty switch gauge unit ­ replace.
WITH MURPHY GAUGE
Water temperature gauge showing no
                                 · Check connection to sender, if disconnected gauge will not function.
movement, lamp not illuminated, engine
                                 · Check connection to temperature gauge, if plug is not connected to socket on
warm.                              rear of gauge reconnect.
THIS ALSO APPLIES TO THE B PANEL · If all connections are correctly made, faulty sender unit ­check resistance to
WITH MURPHY GAUGE                  earth, approx. 3.5k (cold) ­ 0.5k (warm). Replace if no reading.




                                                                   22
ELECTRICAL ­ CORRECT OPERATION OF KEYLESS PANELS

These panels control the engine with     · Green lamp for panel power on            · Green lamp for panel power on
three water resistant push buttons          should function                            should still function
instead of a keyswitch, which are less   · Buzzer should sound                      3. To stop the engine press the
prone to damage and corrosion from                                                     `STOP' push button, hold in until
                                         2. Press `START' button and hold in
sea water spray than a keyswitch.                                                      engine stops. This button also
                                            position until engine fires (see
To operate the engine:                      initial start-up section for               switches the power off to the
1. 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 re-start 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
                                            1,000rpm if the engine was
· Red lamp for low oil pressure                                                        engine.
                                            started at tickover.
    should function


ELECTRICAL FAULT FINDING ­NON BETA PANELS
Engines can be supplied wired up to         Note: Water temperature switch / sender        (Part number 200-01133)
suit VDO switch senders, usually
fitted to a non-Beta control panel.            · large spade is sender connection                 (green / blue)
If so refer to our wiring diagram 200-         · small spade is switch connection                 (blue / yellow)
60971/01 (also part number for
replacement harness)
                                            Oil pressure switch / sender                   (Part number 200-62680)
· Loom is configured differently in
  the 11-way 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
  lamps.


ELECTRICAL FAULT FINDING ­EXTENSION HARNESSES
Some installations require one of the    (and panel extension to panel on           these connections are harder to
panel extensions 11 way connectors       Deluxe C) to ensure wire colours to        distinguish between in poorly lit
to be removed to allow the cable to      each terminal match up to the correct      areas. Whilst doing this check
be passed through bulkheads etc. If      colour in its corresponding terminal.      integrity of each connection to ensure
any panel problems are experienced       Extra attention must be given to black     terminals have not become
after this may have been carried out,    (ground) and black/blue (tacho), also      damaged. Once checked, re-fit cable
visually check all 11 way connections    brown (switched positive to alternator)    tie around each connection to keep
on engine harness to panel extension     and brown/yellow (charge fail) as          them secure.




                                                         23
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 C panels)                                            600-62670
   Oil pressure sender (C panels only)                                                    200-94350
   Oil pressure switch gauge (C panels only)                                              200-96190
   Temperature switch with single terminal (on some BZ602 & BD902)                        600-62820
   Temperature switch / sender 1/8"BSP (not B or C panels)                                200-01133
   Temperature sender (B & C panels only)                                                 200-94360
   Water temperature switch gauge (B & C panels only)                                     200-96200
   Voltmeter (C 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 ABVW                            200-00072
   Tacho, 0-4000rpm with digital hour counter (all panels but A)                          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          alternators, switches for oil pressure   on the isolating solenoid. It should be
suitable for earth return installations   and engine temperature will be           connected to the terminal which is
only (where battery negative cable is     required. If your application is wired   also used for all the small black
connected directly to engine ground).     as insulated earth return and the        wires, NOT the terminal with the
For insulated earth (where battery        engine will not operate correctly,       single black wire connected
negative cable is isolated from engine    always check starter battery negative    directly to engine ground.
ground) different harnesses,              is connected to the correct terminal




                                                              24
Spanner torque settings
Tightening Torques for general use bolts and nuts


ITEM                       Size x Pitch         kgf .m     ft .lbs     N .m

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

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

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

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




Tightening Torques for special use bolts and nuts


ITEM                       Size x Pitch         kgf.m      ft.lbs      N.m

Head Bolts                 M10 x 1.25      6.5 ~7.0      47.0~50.6   63.7~68.6

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

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

Bolts 1, Bearing Case       M8 x 1.0       3.0~3.5       21.7~25.3   29.4~34.3

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

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

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

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

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

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

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




                                           25
Section 3
INSTALLATION RECOMMENDATIONS
The installation details contained herewith are basic guidelines to assist installation, due to 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         · 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.
                                                                                            combustible.



ENGINE 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 0.005" (0.127mm).
                                                                                          2. The pillar stud on the flexible
                                                                                             mount is secured into position by
                                                                                             the lower locknut, do not forget
To ensure vibration free operation, the
                                                                                             to tighten this. Also ensure that
engine must be installed on substan-
                                                                                             the stud is not screwed too far
tial beds, extending as far forward
                                                                                             through the mounting body so
and aft as possible and well braced
                                                                                             that it can touch the bearer.
to form an integral part of the hull.
                                                                                             This will cause vibration and
The engine must be installed as low                                                          knocking noises which are very
as possible on the flexible mount                                                            hard to find!!
pillar stud. This will limit vibration




ALIGNMENT
Alignment must be checked for                To obtain accurate alignment the             Once mounts are tightened,
parallel (A) and concentric (B)              flexible mountings must be adjusted          alignment must be re-checked.
misalignment using a set of feeler           until alignment is attained, and the         Coupling can now be fitted in
gauges.                                      mountings must be locked in                  accordance with instructions
                                             position.                                    supplied with coupling.


A                                                                                        B




                                                                  26
EXHAUSTS

(a) A correctly installed engine as                                                           BD1005        BV1305        BV1505
described in this handbook will meet
the exhaust emission requirements of          Standard                                             50mm     50mm           50mm
Directive 2003/44/EC amending the             Option 1 5/8" is available in SS                     1 5/8"    N/A            N/A
Recreational Craft Directive
94/25/EC.                                     High rise water injection bend SS                    50mm     50mm           50mm
(b) For compliance with exhaust               Option high rise water injection bend SS             1 5/8"    N/A            N/A
emissions requirements, engines
must have correctly installed exhaust         Cross over injection bend SS                         50mm     50mm           50mm
systems. To ensure exhaust                    to suit Volvo replacement engines.
emissions are kept within permissible
limits it is most important to reduce         measured with the exhaust system               before the water injection elbow or
exhaust back pressure to a                    connected and the engine running at            dry exhaust bellows.
minimum, whilst ensuring exhaust is           full speed, must not exceed 80mmHg
                                                                                             Wet Exhaust hose should be
adequately muffled. Back pressure             (3.1 inches Hg / 42 inches WG).
                                                                                             matched to the injection bend sizes,
increases as exhaust length increases         The correct measuring point is at the
                                                                                             see above.
and from bends in the exhaust                 position where the exhaust connects
system. The exhaust back pressure,            to the exhaust manifold. That is




TYPICAL 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 1/2" for movement of engine, see
                                               manufacturer's literature




WARNING:
                                              engine oil and a wrecked fuel pump!            supply either a T piece or an anti
(1) One of the most common
                                              Its best avoided!                              syphon valve sited at least 300mm
problems with engine installation is
                                                                                             (12 inches) above the water line and
water entering the exhaust manifold           (2) The diagram shows a typical
                                                                                             on the centre line of the boat. The
from the exhaust system by                    installation. It is essential that the
                                                                                             pipe then returns to the injection
syphoning. This can occur when the            small black rubber hose connecting
                                                                                             bend and the sea water is pumped
point of water injection (X) on the           the heat exchanger with the injection
                                                                                             down the exhaust pipe.
engine is close to or below the water         bend is removed and replaced by a
line. Water entering the pistons can          hose marked `a'. This must be of               (3) The exhaust back pressure should
cause bent con rods, emulsified               sufficient length to                           not exceed 3.1 inches of Hg.


                                                                27
FUEL SUPPLY & LEAK OFF -                      A typical system is shown below


                                                       8                                  4
                                                                                                                  10
                                                                                                 2
                                                                                3                            6
                       1                          12


                9
                                                                                             5
                           11
                                                           7
(1) Fuel tank                   (4) Injection pipe                (7) Fuel water separator       (10) Air vent
(2) Injection pump              (5) Mechanical fuel feed          (8) Overflow/leak off          (11) Stop cock
                                    pump with priming lever
(3) Injection nozzle                                              (9) Drain plug                 (12) Fuel pipe loop
                                (6) Fuel filter



Notes:                                       4. Any fuel leaks in the system are      7. Fuel lines and hoses must be
                                                likely to cause poor starting and        secured and separated or
1. 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 0.25m is
                                                                                         storage, venting and fuel supply
   required then an electric fuel lift       5. A fuel/water 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 fire
2. 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.                                                              7840:1995/A1:2000 and as
                                                                                         required by your surveyor /
3. Fuel pipe sizes are:         Supply (mm)                    Leak off (mm)             authority.
                                         8                            8




                                                                28
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                                                                         Water Level
exchanger.
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           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 3/4" minimum.                                                           will eventually fill and raw water
                                          5. If water is required for stern tube
                                                                                      will back up into the engine
3. 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 sea
4. 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




                                                          29
CALORIFIER SYSTEM
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
Calorifier tappings on this range of      supply
engine are shown.                         (BV1305 &
                                          BV1505)


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 and
   return pipes either horizontal or
   sloping down in a continuous fall
   towards the calorifier. 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     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
    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 loosen the jubilee clip
   securing the supply pipe to the
   calorifier . Air should escape.
   Refasten securely when no
   further bubbles are seen.


CAUTION
                                          Calorifier
Do not do this when the engine is         supply
hot as scalding hot water may be          (BD1005)
forced out of the pipe under pressure.


                                                         30
ELECTRICAL INSTALLATIONS
Beta has 6 panels:    A -standard            relay to overcome the voltage            clipped and protected from
                      AB or ABV              drop. (See drawing 300-58520)            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 craft
The engine harness is common to all.        invalidate the warranty.                 under normal conditions of use
1. 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 in
2. 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 carefully
3. 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 of
4. 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




                                                         31
APPENDICES ­WIRING DIAGRAMS & GENERAL ARRANGEMENTS

1. Typical starter motor ratings

2. Suggested engine starter battery size                                Page 33

3. Keyswitch terminations                                               Page 33

4. Standard harness (65 Amp)                                200-05452   Page 34

5. Standard harness (100 Amp)                               200-06077   Page 35

6. Diagram of A panel & cut-out                             200-06516   Page 36 & 37

7. Diagram of AB panel & cut-out                            200-06517   Page 38 & 39

8. Diagram of ABV panel & cut-out                           200-06519   Page 40 & 41

9. Diagram of ABVW panel & cut-out                          100-06333   Page 42 & 43

10. Diagram of B panel & cut-out                            200-06520   Page 44 & 45

11. Diagram of C Deluxe panel & cut-out                     200-06518   Page 46 & 47

12. Split charge diagram ­65 Amp alternator                 300-62210   Page 48

13. Starter booster relay                                   300-58520   Page 49

14. GA of BD1005 H/E ­ PRM 80                               100-99550   Page 50

15. GA of BD1005 H/E ­ TMC 40                               100-01939   Page 51

16. GA of BD1005 H/E ­ PRM 80 Atomic                        100-05009   Page 52

17. GA of BV13/1505 H/E ­ PRM 120                           100-98915   Page 53

18. GA of BV13/1505 H/E ­ TTMC35A                           100-06375   Page 54

19. GA of BV13/1505 H/E ­ PRM 150                           100-99660   Page 55

20. 100 Amp alternator information                          100-05471   Page 56

21. Beta Controller information                                         Page 57 & 58

22. Wiring 100 Amp & Beta Controller                        100-05475   Page 59

23. Declaration of Conformity for Recreational Craft                    Page 60 & 61

24. Maintenance record and service items                                Page 65



                                                       32
TYPICAL STARTER MOTOR RATINGS:-
Starters used in Kubota engines have the following standard capacities

          Engine             Starter capacity (kW)
   1000cc to 1500cc                    1.2


SUGGESTED MINIMUM ENGINE STARTER BATTERY SIZE:

  Engine (cc)          Typical Battery Capacity (AH)   Typical C.C.A. (A)
                              at a 20hr Rate         Cold Cranking Amperage
  BD1005                         65 ~ 75                      450 ~ 540
  BV1305                         70 ~ 75                      450 ~ 540
  BV1505                         70 ~ 75                      450 ~ 540




KEYSWITCH TERMINATIONS                       For black keyswitches, the terminal   Note: these terminals are rated at 10
                                             to achieve this ignition switched     amps maximum, since they are
The standard panel keyswitch can be
                                             positive is marked `15/54'.           already utilised for panel and
used to tap off a switched positive
                                                                                   alternator feeds Beta Marine
ignition feed to power additional            For panels without any keyswitch,
                                                                                   recommend any additional
gauges. In this way these gauges will        gauges can be driven from the 1mm2
                                                                                   requirements from these terminals
only be live whilst the engine is            brown wire which terminates at 11
                                                                                   must be fed through a relay. This
running, the engine is starting or the       way connector terminal 4. This is a
                                                                                   relay should then be connected to it's
heaters are being used.                      low power switched positive, any
                                                                                   own fused positive supply directly
                                             additional power required from this
For silver keyswitches, the terminal                                               from the engine battery. Beta drawing
                                             connection must be fed through a
to achieve this ignition switched                                                  202-06421 illustrating the wiring of
                                             relay, as noted below.
                                                                                   a typical electric fuel lift pump with
positive is marked `AC'.
                                                                                   ignition switched relay can be
                                                                                   supplied upon request.




                                                             33
34
35
36
                                                                           150.00
                         5.00       10.00                                                          10.00
                                                                                                                           10.00




                                80.00                                                                                    90.00




37
                                                                                                                           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
                                                                                                                            SOUTH WOODCHESTER,      CHECKED BY:-
                                                                      BETA MARINE                                           STROUD, GLOS. GL5 5EU                           SCALE              PAGE            DATE
                                                                     TEL: (01453) 835282   FAX: (01453) 835284                                                    LT                 NTS              2 of 2          15/11/2004
38
                                                       195.00
                   10.00                                                                  10.00



                                                                                                                 10.00




                     170.00                                                                                          180.00




39
                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
                                                                                                           SOUTH WOODCHESTER,       CHECKED BY:-
                                                        BETA MARINE                                        STROUD, GLOS. GL5 5EU                         SCALE              PAGE            DATE
                                                       TEL: (01453) 835282   FAX: (01453) 835284                                                  LT              NTS              2 of 2          15/11/2004
40
                                                                 180.0
               5.0                    10.0                                                           10.0




                     130.0                                                                                            140.0




41
                              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
                                                                                                                      SOUTH WOODCHESTER,       CHECKED BY:-
                                                                  BETA MARINE                                         STROUD, GLOS. GL5 5EU                         SCALE              PAGE             DATE
                                                                 TEL: (01453) 835282   FAX: (01453) 835284                                                   LT              NTS               2 of 2          23/11/2004
42
                                                                                           O 5.00 THRU
                                   5.00




          140.00                                                                                  120.00




43
              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
                                                                                                                        SOUTH WOODCHESTER,       CHECKED BY:-
                                                                    BETA MARINE                                         STROUD, GLOS. GL5 5EU                         SCALE              PAGE            DATE
                                                                   TEL: (01453) 835282    FAX: (01453) 835284                                                  LT              NTS              2 of 2          01/12/2004
44
                                                                   210.00

                         10.00                                                                                10.00
               5.00




                    155.00                                                                                                              165.00




45
                                                                                                                                     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
                                                                                                                      SOUTH WOODCHESTER,         CHECKED BY:-
                                                           BETA MARINE                                                STROUD, GLOS. GL5 5EU                           SCALE              PAGE              DATE
                                                          TEL: (01453) 835282   FAX: (01453) 835284                                                            LT              NTS                2 of 2          15/11/2004
46
                                                                        298.00
                  10.00                                                                                                                         10.00
           5.00



                                                                                                                                                   10.00




              156.00                                                                                                                                      166.00




47
                                                                                                                                                    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
                                                                                                                     SOUTH WOODCHESTER,      CHECKED BY:-
                                                                  BETA MARINE                                        STROUD, GLOS. GL5 5EU                          SCALE              PAGE                    DATE
                                                                 TEL: (01453) 835282   FAX: (01453) 835284                                                 LT                NTS              2 of 2                  15/11/2004
48
49
50
51
52
53
54
55
56
57
58
59
60
Emission durability.
IN RESPECT TO THE RECREATIONAL CRAFT DIRECTIVE 94/25/EC AND AMENDMENT
2003/44/EC ANNEX 1, B3.



      The engine must be installed, maintained and operated within the parameters detailed in the
      Operator's Maintenance Manual. Maintenance must use approved materials, parts and
      consumables. Should the engine lie unused for a period in excess of 6 months it must be
      inhibited otherwise it will deteriorate with resulting decrease in performance. See also the
      Winterising and Laying Up procedures in the Operator's 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 Operator's 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
      Operator's Maintenance Manual. Wet, water injected, exhaust systems must be at least the
      bore mentioned in the Operator's 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 Operator's 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.




 61
NOTES




  62
NOTES




  63
Quick Reference Parts Listing
HEAT EXCHANGER COOLED BD1005, BV1305 AND BV1505

In all cases please quote the Beta Marine WOC "K" number and engine number.


 Description                                                         Part Number   Qty per Engine

 Heat Exchanger "O" Ring                                              209-80110          2

 Wasting Zinc Anode                                                   209-61840          1

 Lubricating Oil Filter                                               211-60390          1

 Fuel Filter ­ Heat Exchanger cooling                                 211-60210          1

 Fuel Lift Pump                                                       600-67830          1

 Fuel Lift Pump Gasket                                                600-00065          1

 Air Filter Element ­ BD1005 only                                     211-62950
                                                                                         1
 Air Filter Element ­ BV1305 & BV1505 only                            211-61831

 Sea Water Pump Service Kit (includes *)                              207-61470          1

 Sea Water Pump Impellor *                                            207-79630          1

 Sea Water Pump Cover Plate "O" Ring *                                207-04206          1

 Sea Water Pump Cover Plate                                           207-05305          1

 Sea Water Pump Cover Plate Bolt                                      207-04207          3

 Sea Water Pump Seal *                                                207-02239          1

 Thermostat                                                           600-72450          1

 Thermostat Gasket                                                    600-80490          1

 40 Amp Blade Fuse - engine wiring harness                            200-00959          1

 Control Panel Key Switch                                             600-00057          1

 Control Panel standard Key                                           600-00058          1

 Water Temperature Switch (Panel A, ABV, ABVW)                        200-01133          1

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

 Oil Pressure Switch (Panel A, ABV, ABVW)                             600-62670          1

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

 Vee Belt ­ standard 65 Amp alternator                               214-63090/Q         1

 Optional Polyvee Belt ­ 100 Amp alternator                           214-00493          1




                                                       64
Service 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 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, United Kingdom

    Tel: +44 (0)1452 723492
    Fax: +44 (0)1452 883742
                                                     Beta Marine Generating Sets
    email: sales@betamarine.co.uk                    30 to 900kVA
    www.betamarine.co.uk




                                                                                   BM Doc Ref: 1640 28-37.5bhp H/E


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