Operator’s Maintenance Manual Heat Exchanger Cooled Mid Diesel Engine Range 43 and 50 bhp CALIFORNIA – Proposition 65 Warning: Diesel engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects and other reproductive harm.
CONTENTS Introduction Engine identification 2 Initial receipt of the engine 2 Engine storage 2 Safety precautions 3 Technical specifications 4 Section 1: Guidelines for operation of the engine Important checks prior to initial use 5 Initial start-up and bleeding the fuel system 5 Starting / stopping 5 Section 2: Maintenance and service guidelines Maintenance schedule 6 Lubrication –checking and changing oil 7 Fuel system - pumps, filter, fuel/water separator 8 Cooling – fresh water sys
OPERATION AND MAINTENANCE MANUAL FOR THE FOLLOWING BETA MARINE ENGINES BASED ON KUBOTA SUPER 3 SERIES BV1903, BV2203 This manual has been compiled to provide the user with important information and recommendations to ensure a trouble free and economical operation of the engine. For further advice or technical assistance, application should be made to BETA MARINE LIMITED or its distributors.
SAFETY PRECAUTIONS! A. Keep the engine, gearbox and surrounding area clean, including the area immediately below the engine B. Drives - Power Take Off Areas ii). Fuel Supply Connections Engines are supplied with 8mm compression fittings. The installer must ensure that when connections are made, they are clean and free of leaks. i). Gearbox Output Flange The purpose of a marine diesel propulsion engine is to provide motive power to propel a vessel.
TECHNICAL SPECIFICATIONS (Standard Engines) Standard Engines BD1703 BV1903 BV2203 Standard Engines Cylinder Bore (mm) Stroke (mm) Displacement (cc) Combustion Cooling Starter voltage (V) Starter output (kW) Alternator output (Amps) Glow plug resistance (each) Engine speed (RPM) Power output ISO3046 (BHP) Declared power ISO8665 (kW) Compression Ratio Fuel timing BTDC Capacity of standard sump (litres) Capacity of shallow sump (litres) Nett dry weight with std gearbox (kg) Fuel Coolant Approx Coolant capacit
SECTION 1 IMPORTANT CHECKS PRIOR TO INITIAL USE 1. Generally, a new engine has the oil and anti-freeze removed after the works test. Fill the engine with the correct oil and anti-freeze (see sections on ENGINE OIL and COOLING). Check gearbox oil level - see separate operator's hand book. 2. Ensure the engine is free to turn without obstructions. 3. Ensure battery is fully charged and connected (the isolator is in the 'ON' position). 4.
STOPPING Every propulsion engine is fitted with a stop solenoid which is energised to stop. To stop engine simply press stop push button, hold in until engine stops, then turn key from ‘RUN’ to ‘OFF’ position. When leaving the boat for an extended period, • Turn off sea-cock (heat exchanger cooled engines). • Turn off battery isolator. Do not turn the key to the off position when the engine is running. This will damage the alternator.
• • • Spray the key switch with WD40 or equivalent to lubricate the barrel. Check that all external nuts, bolts and fastenings are tight. See table for torque values. Check ball joint nyloc nuts for tightness on both gearbox and speed control levers. Grease both fittings all over. Every 750 Hours • Change air cleaner element. • Change fuel filter. • Change antifreeze. • Change gearbox oil. • Check electrical equipment, condition of hoses and belts, replace as necessary.
CHECKING GEARBOX OIL LEVEL (1) The gearbox is fitted with a dipstick and oil filler plug, see fig 2e. (2) Each engine is supplied with a gearbox operators manual which specifies the type of lubricating oil to be used, the capacity and frequency of changing of the oil. (3) New engines are normally supplied with the gearbox topped up with lubricant but Check the level before starting the engine for the first time.
HEATING EXCHANGER COOLED Heat Exchanger Cooled Fresh 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 freshwater drained off. The following instructions must be followed to fill the system. (a) Mix up in a clean bucket a 33 to 50% anti-freeze to freshwater solution (see page 10).
Yachts and Launches with Heat Exchanger Cooling It is essential that a 33% to 50% anti-freeze/water mixture is used. This not only stops freezing up in winter, but it prevents overheating and corrosion. The warranty is invalid unless the correct ratio is used. Concentration of ethylene should not exceed 50%. The anti-freeze in the fresh water system enables the boiling point of water to rise to 124°C with a 13 psi pressure cap fitted.
BELT TENSION ADJUSTING BOLTS 65 AMP ALTERNATOR (Heat Exchanger Cooled) WARNING Belt tension must only be checked with the engine switched off. (1) On heat exchanger cooled engines a single 65 amp is fitted as standard. This alternator is adjusted as follows. (2) The belt tension is adjusted by swinging the alternator outboard as it pivots on its support bolts. (3) With the engine stopped, loosen the support bolts and the link adjusting bolt. (4) Push alternator outboard to tension and tighten link bolt.
MAINTENANCE - ELECTRICAL WARNING Under no circumstances should the battery be disconnected or switched off when the engine is running. This will seriously damage the alternator PANELS AND WIRING See installation notes, page 27. General maintenance (1) The panel must be protected from rain and sea water, see installation. Sea water entering the key switch will eventually cause corrosion and could result in the starter motor being permanently energised and burning out.
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 No fuel: Solution 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.
Problem: Erratic running Possible Cause Air in fuel supply: Solution Check supply system for leaks and fix. Fuel lift pump faulty: Replace. Clogged fuel filter: Replace. Fuel return not fed back to the fuel tank, or blocked pipe: Re-route pipe or clean. Air filter blocked: Replace. Worn or blocked injector: Service injectors. Engine rpm in gear is too low, this must be 850 min: Increase engine tick over speed.
Problem: High oil consumption Possible Cause Solution Oil leaks: Check for leaks. Piston rings worn: Overhaul required. Valve stem and guide worn: Overhaul required. Piston rings gap facing the same direction: Shift ring gap position.
Problem: Engine overheats Possible Cause Solution Check coolant level: Top up. Insufficient sea water flow: Clear blocked intake or filter. Damaged or worn pump impeller: Replace. Blocked tube stack in heat exchanger: Remove tube stack and clean – replace ‘O’ rings. Zinc anode flakes blocking tube stack: Remove and clean tube stack as above. Pressure cap loose: Replace. Switch sender faulty: Replace.
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 engine compartment, engine compartment temperature too Adjust tension / replace belt with a high temperature type and / high: or improve engine compartment ventilation.
Electrical fault finding & trouble shooting –engines built after July 2005 only The following chart is compiled to aid diagnosis of electrical faults, based on the Beta 10-90hp range of engines. If your engine was built before July 2005, contact Beta Marine for the relevant electrical trouble shooting guide. Standard sea specification engines (heat exchanger cooled) are supplied with a single alternator, mounted port side, supplying power to starter battery and control panel.
Electrical fault finding –all lamp panels Problem No warning lamps or buzzer functioning, engine will not start or stop Non function of warning lamp THE WATER TEMPERATURE LAMP WILL NOT FUNCTION UNLESS ENGINE IS OVERHEATING OR THERE IS A WIRING FAULT Water temperature warning lamp on when engine is not over temperature (Not 2B or 2C deluxe panel see table on following page) Buzzer not functioning THE BUZZER WILL NOT SOUND FOR GREEN POWER ON LAMP Starter battery charge lamp not functioning Tacho not funct
Electrical fault finding –2c’d’ & water temperature function on 2b panels In addition to the fault finding detailed on the previous table, the following is specific for the 2c’d’ type deluxe panel (Also applicable for the 2b panel with Murphy water temperature gauge) Problem Oil pressure warning lamp not functioning, oil pressure gauge showing maximum deflection. Engine off and keyswitch in run position Oil pressure gauge showing no movement -even when engine is started.
Electrical fault finding –Non Beta Panels Engines can be supplied wired up to suit VDO switch senders, usually fitted to a non-Beta control panel. If so refer to our wiring diagram 200-60971/01 (also part number for replacement harness) • • • Loom is configured differently in the 11-way plug to accommodate the extra wiring. Small brown wire (battery sensed alternator feed) fitted with bullet connection beside harness plug.
SPANNER TORQUE SETTINGS Tightening Torques for general use bolts and nuts 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 ITEM Tightening Torques for special use bolts and nuts ITEM Size x Pitch kgf.m ft.lbs N.m Head Bolts M11 x 1.25 9.5 ~10.0 68.7~72.3 93.1~98.0 M8 x 1.0 4.
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.
Typical Yacht Installation Maximum sea water level when healed (on the centre line of the boat) 300mm minimum Normal sea water level Allow at least 10% of propeller diameter for tip clearance to hull If a rope cutter is fitted, allow approximately ½” for movement of engine, see manufacturer’s literature WARNING: (1) One of the most common problems with engine installation is water entering the exhaust manifold from the exhaust system by syphoning.
1. The mechanical fuel lift pump is fitted to all engines as standard, but if a suction head of 0.25m is required then an electric fuel lift pump must be fitted (ask your dealer or Beta Marine). 2. It is very important that the excess fuel from the injectors is fed back to the fuel tank and not back to any point on the supply line. This will help prevent air getting into the system. 3. Fuel pipe sizes are: Supply (mm) Leak off (mm) 8 8 4.
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 tappings on this range of engine are shown. 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.
APPENDICES Wiring diagrams & General Arrangements 1. Typical starter motor ratings 2. Suggested engine starter battery size 3. Keyswitch terminations 4. Standard engine harness (65 Amp) 5. Standard engine harness (100 Amp) 6. Diagram of 2a panel & cut-out 7. Diagram of 2ab’d’ panel & cut-out 8. Diagram of 2ab’V’ panel & cut-out 9. Diagram of 2ab’V’W panel & cut-out 10. Diagram of 2b panel & cut-out 11. Diagram of 2c’d’ deluxe panel & cut-out 12. Diagram of domestic extension harness 13.
01 REV DESCRIPTION 5.00 80.00 10.00 DATE APP'D DRAWN 10.00 MATL: TEL: (01453) 835282 FAX: (01453) 835284 BETA MARINE DIMENSIONS IN MM (INCH) DO NOT SCALE NOTES 140.00 150.00 BETA MARINE LTD, MERRETTS MILLS, BATH ROAD, SOUTH WOODCHESTER, STROUD, GLOS. GL5 5EU TITLE SCALE A4 SIZE 36.68 20.12 TW CHECKED BY:LT DRAWN BY:- 50.32 ADD 30mm FOR WIRES 5.00 10.00 90.00 10.00 NTS DWG NO.
01 REV 5.00 DESCRIPTION 5.00 170.00 10.00 DATE APP'D DRAWN 10.00 MATL: TEL: (01453) 835282 FAX: (01453) 835284 BETA MARINE DIMENSIONS IN MM (INCH) DO NOT SCALE NOTES 185.00 195.00 BETA MARINE LTD, MERRETTS MILLS, BATH ROAD, SOUTH WOODCHESTER, STROUD, GLOS. GL5 5EU O 5.00 THRU 10.00 180.00 10.00 TW CHECKED BY:LT DRAWN BY:- TITLE SCALE A4 SIZE NTS DWG NO. 50.32 ADD 30mm FOR WIRES PAGE 2 of 2 200-06304 2AB PANEL 22.62 36.
01 REV 130.0 DESCRIPTION 5.0 5.0 20.0 DATE APP'D 20.0 10.0 DRAWN 10.0 MATL: TEL: (01453) 835282 FAX: (01453) 835284 BETA MARINE DIMENSIONS IN MM (INCH) DO NOT SCALE NOTES 170.0 180.0 TW CHECKED BY:LT DRAWN BY:- TITLE SCALE A4 SIZE 50.3 ALLOW 30mm FOR WIRES BETA MARINE LTD, MERRETTS MILLS, BATH ROAD, SOUTH WOODCHESTER, STROUD, GLOS. GL5 5EU O 5.0 THRU 10.0 140.0 NTS DWG NO. PAGE 2 of 2 200-06320/01 ABV PANEL 36.7 22.
01 REV 5.00 140.00 DESCRIPTION DATE 180.00 APP'D 5.00 160.00 5.00 DRAWN 20.00 10.00 TEL: (01453) 835282 FAX: (01453) 835284 BETA MARINE MATL: BETA MARINE LTD, MERRETTS MILLS, BATH ROAD, SOUTH WOODCHESTER, STROUD, GLOS. GL5 5EU 50.50 ALLOW 30mm FOR WIRES AS USED ON K14744 DIMENSIONS IN MM (INCH) DO NOT SCALE NOTES 10.00 20.00 5.00 120.00 O 5.00 THRU TITLE TW CHECKED BY:LT DRAWN BY:- 22.62 SCALE A4 SIZE NTS DWG NO.
01 REV 10.00 DESCRIPTION 5.00 155.00 5.00 DATE APP'D DRAWN MATL: 10.00 TEL: (01453) 835282 FAX: (01453) 835284 BETA MARINE DIMENSIONS IN MM (INCH) DO NOT SCALE NOTES 200.00 210.00 BETA MARINE LTD, MERRETTS MILLS, BATH ROAD, SOUTH WOODCHESTER, STROUD, GLOS. GL5 5EU 10.00 165.00 TW CHECKED BY:LT DRAWN BY:- TITLE SCALE A4 SIZE NTS DWG NO. 2B PANEL PAGE 2 of 2 200-06303 50.32 ALLOW 30mm FOR WIRES 22.62 36.
01 REV 156.00 5.00 10.00 DESCRIPTION DATE APP'D DRAWN MATL: TEL: (01453) 835282 FAX: (01453) 835284 BETA MARINE DIMENSIONS IN MM (INCH) DO NOT SCALE NOTES 288.00 298.00 BETA MARINE LTD, MERRETTS MILLS, BATH ROAD, SOUTH WOODCHESTER, STROUD, GLOS. GL5 5EU SCALE A4 SIZE NTS DWG NO. 36.68 22.62 PAGE 2 of 2 200-06306 2C PANEL DELUXE 50.32 ADD 30mm FOR WIRES TW CHECKED BY:LT DRAWN BY:- TITLE 5.00 10.00 166.00 10.00 10.
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BETA CONTROLLER SEA SPEC ENGINES The BETA CONTROLLER is an integrated battery charging external regulator. It is designed to be used with Beta s 70 and 100am p Iskra alternators. The system utilises a three stage charging characteristic which optimises the rapid charge of battery systems. The first stage (A mode) is a boost charge, which is indicated by the indicator LED showing red.
The graphs below illustrate charging voltages for different battery types.
Date Service carried out APPENDICES 23.
Sail Drives 13.5 to 50bhp Heat Exchanger Cooled 10 to 90bhp Beta Marine Generating Sets 3.7 to 40kVA www.mono-studio.co.uk Keel Cooled 10 to 90bhp Beta Marine Limited Davy Way, Waterwells, Quedgeley, Gloucester GL2 2AD, U.K. Tel: 01452 723492 Fax: 01452 883742 www.betamarine.co.uk Technical Spares email: spares@betamarine.co.uk Technical Warranty email: adrian@betamarine.co.
