Beta Marine Beta 30, Operator'S Maintenance Manual

Page 1: ...Operators Maintenance Manual Operators Maintenance Manual Keel Cooled Mid Diesel Engine Range Beta 43 Beta 50 Beta 60 Keel Cooled Mid Diesel Engine Range Beta 43 Beta 50 Beta 60 ...

Page 2: ...Typical Keel Cooling System ...

Page 3: ... advice or parts we ask you to always provide the WOC Works Order Card number and or the engine serial number Please refer to page 4 Engine Type Power bhp Speed rpm BETA WOC NO K Gearbox Type Purchased From Invoice Number Date Commissioned Specification Special Details ...

Page 4: ...ial Start Up and Bleeding the Fuel System 21 Normal Starting and Stopping 24 SECTION 3 MAINTENANCE AND SERVICE GUIDELINES 28 Maintenance Schedule 29 Lubrication Checking and Changing Oil 30 Fuel System Fuel Water Separator Fuel Lift Pump Fuel Filter 33 Belt Tensioning Adjustment 35 Air Filter Inspection Replacement 36 Electrical Maintenance 36 Laying Up Winterising 37 SECTION 4 TROUBLESHOOTING 38 ...

Page 5: ...and we will be pleased to provide further advice or technical assistance All information and recommendations given in this publication are based on the latest information available at the time of publication and are subject to alteration at any time The information given is subject to the company s current conditions of Tender and Sale is for the assistance of users and is based upon results obtai...

Page 6: ...rage is to be more than six months then the engine must be inhibited contact your dealer or Beta Marine Failure to inhibit the engine may result in the formation of rust in the injection system and the engine bores this could invalidate the warranty ENGINE STORAGE IMPORTANT To ensure you receive the correct advice or parts we ask you to always provide the WOC Works Order Card number and or the eng...

Page 7: ...herefore ensure that exhaust pipes are led overboard and that leakage in the vessel does not occur D Fuel i Fuel Lines Diesel engines are equipped with high pressure fuel injection pumps if leakages occur or if pipes fracture fuel at a high pressure can harm personnel Skin must be thoroughly cleaned in the event of contact with diesel fuel ii Fuel Supply Connections Engines are supplied with 8mm c...

Page 8: ...wers Declared power outputs are subject to the stated tolerance band 2 Operation at parameters outside the test parameters may affect the outputs powers Standard Engines Beta 43 Beta 50 Beta 60 Cylinders 4 4 4 Bore mm 83 87 87 Stroke mm 92 4 92 4 102 4 Displacement cc 1999 2197 2434 Combustion Naturally Naturally Naturally aspirated aspirated aspirated Power Output EN ISO 8665 kW 32 6 36 0 41 0 Po...

Page 9: ...spection and or servicing must be readily accessible The insulating materials inside engine spaces shall be non combustible INSTALLATION RECOMMENDATIONS VENTILATION An engine will produce radiated heat approximately equal to 1 3 of the engine output power Additionally larger Amp starter battery and or domestic battery bank charging alternators create high amounts of heat building ambient temperatu...

Page 10: ...e bearers extending as far forward and aft as possible well braced and securely fastened to form an integral part of the hull The engine must be installed as low as possible on the flexible mount pillar stud This will limit vibration and extend the life of the flexible mount To assist with engine replacement Beta Marine can offer optional Special Engine Feet manufactured to your dimensions to suit...

Page 11: ... replace the oil filter post installation refill the engine with the correct quantity of oil as indicated within the table on page 6 and allow time for the oil to settle Remove the dipstick wipe clean and reinsert Carefully remove the dipstick so the engine oil on it is not disturbed Once removed note the wet dry line then score or engrave this new correct level on it for future use If in doubt pl...

Page 12: ...nment method involves measuring with either feeler gauges or a DTI Dial Test Indicator mounted on a magnetic foot so that they are aligned within 0 125mm 0 005 The propeller shaft must be centered in the stern tube and running true through the cutless bearing if the propeller shaft is not correctly centered vibration will be experienced ALIGNMENT Angular Mis alignment Engine gearbox flange Propell...

Page 13: ...ling design is able to absorb high torsional shocks and loads These couplings are complete and replace the need for both a R D flexible coupling and clamp coupling above FLEXIBLE OUTPUT COUPLINGS 11 CentaFlex Type 12 16 Couplings 10 R D Clamp Couplings Optional 9 R D Flexible Couplings NB If a constant velocity drive shaft is being considered for fitting then it maybe necessary to have the standar...

Page 14: ...Back pressure should be measured with the complete exhaust system connected and the engine running at full speed The correct measuring point is before the injection bend at the manifold flange Engine Exhaust Back Pressure Beta 10 to Beta 25 Max 70 mm Hg Beta 30 to Beta 60 Max 80 mm Hg Beta 75 Beta 90 Max 90 mm Hg Beta 90T Beta 105T Beta 115T 85 to 115 mm Hg There must be a propeller clearance betw...

Page 15: ...ep them straight Hydraulic lock occurs when water is allowed to enter the combustion chamber via the exhaust and hydraulics against the rising piston with the consequences possible being a bent con rod s an emulsified engine oil and or a damaged fuel pump It is imperative that it is avoided always ensure that canal river or sea water cannot enter the exhaust port and run back down the pipe floodin...

Page 16: ...to the outer skin and to one end as shown and should be as close as posisble to the inner skin d The tank should be thin in section C 30 mm to 40 mm as it is the most efficient heat transfer to the canal river or sea water that is important e The engine coolant for keel cooling is the same 50 50 ratio of fresh water anti freeze solution as heat exchanger cooling and flows around the engine then th...

Page 17: ... Baffle Hot Water In Cold Water Out C B A Baffle Gap Baffle Side wall of cooling tank Baffle Gap SWIM STERN 16 Ideal Keel Cooling Tank A X B SURFACE AREA MUST BE BELOW WATER LEVEL C TANK PROFILE 11 4 11 2 30MM 40 MM ...

Page 18: ...must be secured separated and protected from any source of significant heat The filling storage venting fuel supply arrangements and installation must be designed and installed so as to minimise the risk of fire When connecting the engine to the fuel supply and return lines marine grade flexible fuel hoses are highly recommended 6 Any fuel leaks in the system when static are likely to cause poor s...

Page 19: ... to see if the pipe going to the calorifier is getting warm Top up the water level as required and run for another ten minutes then repeat 4 If the water level is steady but no warm water is getting to the Calorifier then with engine stopped very carefully remove the pressure filler cap using a large rag cloth to protect you hand from scalding Now very carefully open the Calorifier bleed valve see...

Page 20: ...drop in the starter battery cable circuit should not exceed 0 8 volt and in any circuit should not exceed 1 2 volts 2 Starter batteries should be as close to the engine as practically possible The reason for this is to ensure that the maximum voltage from the battery is available to the starter motor The longer the cable run the more the voltage drop will be due to resistance within the cables 3 F...

Page 21: ...p to Beta 45T 100 0 00017V 4 7m Up to Beta 50 120 0 00017V 3 9m Up to Beta 60 170 0 00017V 2 8m Up to Beta 115T 210 250 0 00017V Not suitable Beta 150 333 0 00017V Not suitable 35mm2 2 AWG Cable Engine Cranking Amp Cable Volt drop Max length both cables added together Up to Beta 45T 100 0 00013V 6 2m Up to Beta 50 120 0 00013V 5 2m Up to Beta 60 170 0 00013V 3 6m Up to Beta 115T 210 250 0 00013V 2...

Page 22: ... cable for connection to the engine wiring loom Extension looms of 5m or more are available should your installation require it or you wish to relocate your existing panel s all looms include a start relay to overcome the voltage drop 3 For standard wiring diagrams see diagram index page 52 4 All electrical equipment must be protected from sea water Sea water or rust in the starter motor will inva...

Page 23: ...jection pump b Open the fuel tank stop tap valve and then bleed the fuel water separator of air as shown in manufacturer s literature c Fuel should now arrive at the fuel lift pump d Open the fuel bleed bolt on top of the fuel filter by 1 to 2 turns please refer to image 23 e Move the hand priming lever on fuel lift pump up and down please refer to image 23 until fuel with no bubbles come out of t...

Page 24: ...continue to hand prime the engine with the fuel lift pump lever for a further 30 seconds then repeat If engine does not start after 3 attempts then allow 5 minutes for the starter to cool down before repeating 6 b to 8 9 If the engine does not easily start at the first or second attempt do not over crank the engine with the seawater inlet seacock turned on This problem may have been caused by air ...

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Page 26: ...le alarm for low oil pressure high water temperature and engine alternator not charging Optional Control Panel B Is key switch controlled for engine preheat start push button controlled for engine stop has a tachometer with running hour recorder and a water temperature gauge Green light indicator for power on red warning light indicators audible alarm for low oil pressure high water temperature an...

Page 27: ...ith running hour recorder green light indicator for power on red warning light indicators audible alarm for low oil pressure high water temperature and engine alternator not charging Optional Control Panel CW Is push button controlled for engine preheat start stop has a tachometer with running hour recorder oil pressure voltmeter water temperature gauges Green light indicator for power on red warn...

Page 28: ...ey to START and hold in position until the engine fires please refer to guidelines for initial engine start up for maximum time starter can be operated Release key when the engine has started and allow to return to the RUN position All red panel warning lights should stop illuminating and the audible buzzer should cease The low oil pressure light may take a few seconds to stop illuminating and the...

Page 29: ...tion Then for all engines regardless of control panel type isolate the starter battery When leaving the vessel for an extended period turn off the sea cock if heat exchanger cooled and isolate the starter battery WARNING DO NOT leave the key in the OFF position when engine is running This will not allow the alternator to charge and will damage the alternator DO NOT depress the stop lever for more ...

Page 30: ...will cause excessive vibration and knocking Check and adjust all drive belt tensions please refer to page 35 Check ball joint nyloc nuts for tightness on both gearbox and speed control levers Grease both fittings all over AFTER FIRST 50 HOURS Change engine lubricating oil Change oil filter Drain off any water in fuel water separator AFTER 150 HOURS If shallow sump option is fitted change engine lu...

Page 31: ...on Drain off any water in fuel water separator Change gearbox oil See separate gearbox manual Check all external nuts bolts and fastenings are tight Check belt tension and alternator bolts Check for leaks Change engine oil Change oil filter Lubricate keyswitch on control panel with Vaseline or WD40 Check general condition Check air cleaner element and change if required Change air cleaner element ...

Page 32: ...30 ENGINE LUBRICANT COOLANT Engine oil Engine oil quality should have the minimum properties of the American Petroleum Institute API classification CF with multi grade SAE ratings as listed in the following table NB An acceptable alternative is a mineral based semi synthetic lubricating oil with a content mix no greater than 30 being synthetic based Do not mix two different types of oil or SAE rat...

Page 33: ...the oil into a bucket Turn the tap to off position and replace end cap Please refer to image 27 3 Unscrew the oil filter and replace with a new one Please refer to image 28 NB It is best to have a plastic bag wrapped round the filter to catch any oil left in the system and help with keeping the bilge clean Before screwing in the new filter spread a thin film of oil round the rubber gasket to ensur...

Page 34: ...efore refilling the gearbox with new oil as recommended 5 Run the engine to allow oil to circulate then stop and allow the oil to settle Re check the oil level and top up if necessary 6 Ensure dipstick and cap are firmly secured and check for oil leaks especially around the output shaft oil seal and gasket sealing surfaces NB ATF is Automatic Transmission Fluid Gearbox operator manuals can be down...

Page 35: ...t changes to fuel specifications allow the addition of FAME fatty acid methyl ester Biodiesel EN14214 2009 to diesel fuel but please be aware that Biodiesel does allow bacteria to grow more easily in the fuel and this can clog your fuel tank pipes and filters If you experience an outbreak of bacterial growth you can either empty and clean out your fuel pipes and tank or use biocide additives and f...

Page 36: ...alorifier is fitted care must be taken to see that this is also full of coolant and all the air is expelled Please refer to Calorifier Connection on page 17 h Run the engine on one third load for 15 minutes preferably with the boat tied up As the system warms up coolant may be expelled from the overflow pipe into the bilge Stop the engine and allow the engine to cool down before removing the press...

Page 37: ...oard by hand to tension the belt then tighten link bolt 4 Check that the depression of the belt at position shown is approximately 1 2 or 12 mm when pushed down firmly by thumb Tighten support bolts Please refer to image 34 5 Belt tension should be regularly checked especially during the first 20 hours of running in a new belt as stretching occurs SECONDARY DOMESTIC BATTERY CHARGING ALTERNATOR The...

Page 38: ... could result in the starter motor being permanently energised and burning out Spray key switch every month with WD40 or equivalent or apply Vaseline 2 Check batteries for acid level and top up if required For low maintenance and gel batteries please refer to manufacturers instructions 3 Loose spade terminal connections are the most common cause for electrical faults check on a regular basis pleas...

Page 39: ...ent panel is well protected and give the key switch a spray of WD40 Petroleum Jelly or equivalent e With the engine stopped disconnect the battery always disconnect the negative cable first and re connect the negative cable last and take it ashore for trickle charging and top up as necessary If AC power is available then this can be done on the boat f Fuel tanks should be kept full during the lay ...

Page 40: ...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 alterna...

Page 41: ...y hand Adjust cable The electrical load is too large on start up Disconnect or reduce the load Problem Erratic running hunting Possible Cause Solution Air in fuel supply Check supply system for leaks and fix Fuel lift pump faulty Replace Clogged fuel filter Replace Fuel return not fed back to the fuel tank or blocked pipe Re route pipe or clean Air filter blocked Replace Worn or blocked injector S...

Page 42: ... not obstructed Remove and clean out Problem Black exhaust gas Possible Cause Solution Blocked air filter element Inspect and replace Over pitched propeller engine will not reach its full rpm Get the propeller re pitched if necessary Accumulated debris on hull Inspect and clean if required Problem Low oil pressure warning light on when underway Possible Cause Solution Oil frothing due to high inst...

Page 43: ...ible Cause Solution Oil goes milky due to seawater entering Check installation has an anti syphon valve been fitted exhaust manifold Change engine oil and run engine for 10 minutes each time to eliminate any water Get fuel injection pump and compression checked by dealer or service agent Problem Water in lubricating oil keel cooled Possible Cause Solution Oil goes milky due to water entering Check...

Page 44: ...y 6 to give the flow in litres minute Repeat twice and take an average If the flow rate is noticeably less than the 18 litre per minute minimum at 1 500 rpm then b Check impeller in sea water pump if worn replace c If impeller has a vane missing then this will be lodged either in the pipe to the heat exchanger or in the end of the exchanger This must be located and removed d Check flow again as in...

Page 45: ...cracked or broken feet Problem Knocking noise Possible Cause Solution Propshaft touching gearbox output coupling Adjust giving correct clearance give 5mm 10mm through split boss or Type 16 coupling between gearbox and propeller shaft Flexible mount stud touching engine bed Adjust stud to clear Drive plate broken Replace repair Engine touching engine bed Re align engine modify bed Injectors blocked...

Page 46: ...charges 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 Adjust tension replace belt with a high temperature engine compartment temperature too...

Page 47: ...is additionally available Keel Cooled Engines Standard Greenline keel cooled engines are supplied with a single starter battery alternator a secondary domestic battery bank alternator is additionally included as standard for the Beta 30 and above For the Beta 38 and above it is possible to specify both a secondary domestic battery bank alternator a 3 5kVA travel power alternator inverter 5kVA for ...

Page 48: ... or flywheel housing and replace if necessary Check for wiring faults Non function of warning light The water temperature Disconnect switch wire to non functioning light green light will not function unless engine is overheating blue water temperature white brown oil pressure or there is a wiring fault brown yellow alternator charge Reconnect wire temporarily to another warning light that is funct...

Page 49: ...If alternator connected properly faulty panel warning light replace If tacho not functioning Check connections on rear of tacho especially black blue wire terminal 4 Check connection of black blue wire on rear of 1st alternator W connection usually a bullet on flying lead or lowest connection on alternators with 3 pin coupler Check continuity of black blue wire from alternator to tacho Measure vol...

Page 50: ... AND CW CONTROL PANELS In addition to the fault finding detailed on the previous pages the following is specific for control panels as listed above Problem Possible Cause and Solution Oil pressure warning light not functioning oil pressure Faulty wiring check wire connection and continuity gauge showing maximum deflection Engine off and small white brown from sender to panel light keyswitch in run...

Page 51: ...5k Ω warm Replace if notably less Water temperature gauge showing normal operating Engine warm temperature 85 C Buzzer sounding and light illuminated Incorrectly calibrated switching point for warning This also applies to the B Panel with Murphy gauge light adjust on rear of gauge to 100 C 210 F If adjusted correctly and buzzer still sounding faulty switch gauge unit replace Water temperature gaug...

Page 52: ...as these connections are harder to distinguish between in poorly lit areas Whilst doing this check integrity of each connection to ensure terminals have not become damaged Once checked re fit cable tie around each connection to keep them secure ELECTRICAL TROUBLE SHOOTING INSULATED EARTH If your application is wired as insulated earth return and the engine will not operate correctly always check s...

Page 53: ... 4 2 8 17 4 20 3 M10 10 MM 48 1 55 9 4 9 5 7 35 4 41 2 M12 12 MM 77 5 90 2 7 9 9 2 57 1 66 5 ITEM SIZE X PITCH N M KGF M LBF FT FT LBS CYLINDER HEAD BOLT M11 X 1 25 93 2 98 0 9 5 10 0 68 8 72 3 CONNECTING ROD BOLT M8 X 1 0 45 0 49 0 4 5 5 0 33 0 36 0 FLYWHEEL BOLT M12 X 1 25 98 1 107 0 10 0 11 0 72 4 79 5 MAIN BEARING CAP BOLT 1 M9 X 1 25 46 0 50 0 4 7 5 2 34 0 37 0 MAIN BEARING CAP BOLT 2 M10 X 1...

Page 54: ...f Deluxe panel CW cut out Page 68 69 13 GA of Beta 43 50 K C PRM 150 Page 70 14 GA of Beta 43S 50S K C PRM 150 Page 71 15 GA of Beta 43 50 K C PRM 280 Page 72 16 GA of Beta 43S 50S K C PRM 280 Page 73 17 GA of Beta 43 60 K C TM345 Page 74 18 GA of Beta 43 60 K C F12 40 Hydraulic Pump Page 75 19 Starter relay wiring over 4 metres Page 76 20 Electric fuel lift pump Page 77 21 Diagram of extension ha...

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Page 57: ... P I R C S E D V E R NOTES APP D DATE DRAWN DRAWN BY CHECKED BY SCALE PAGE SIZE TITLE DWG NO DATE REV NTS A4 2 of 2 200 06305 05 09 2008 A PANEL TW LT MATL 01 10 10 150 10 10 90 5 140 5 80 62 ADD 30mm FOR WIRES 20 41 CHANGED KEY SWITCH 05 09 08 LT TW ...

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Page 59: ... C S E D V E R NOTES APP D DATE DRAWN DRAWN BY CHECKED BY SCALE PAGE SIZE TITLE DWG NO DATE REV NTS A4 2 of 2 200 06304 05 10 2007 AB PANEL TW LT MATL 01 10 10 195 10 10 180 63 ADD 30mm FOR WIRES 23 41 5 185 5 170 O 5 THRU CHANGED KEY SWITCH 05 09 08 LT TW ...

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Page 61: ... D V E R NOTES APP D DATE DRAWN DRAWN BY CHECKED BY SCALE PAGE SIZE TITLE DWG NO DATE REV NTS A4 2 of 2 200 06320 01 05 10 2007 ABV PANEL timw LT MATL 00 140 10 180 10 10 O 5 THRU 5 5 170 130 20 20 23 63 ALLOW 30mm FOR WIRES 41 CHANGED KEY SWITCH 05 09 08 LT TW ...

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Page 73: ...AIR OUTLET MUST BE VENTED OUT OF ENGINE ROOM AIR OUTLET GEARBOX MORSE CABLE FROM SKIN TANK O 28mm TO SKIN TANK O 28mm FROM CALORIFIERS TO CALORIFIERS ENGINE AND DOMESTIC BATTERY CONNECTIONS 8mm 215 816 203 TYPE 16 COUPLING 241 6 5 6 5 143 REDESIGN TO MATCH 7kW HOUSING 01 03 04 LT TW REDESIGN FOR BETTER SOUND INSULATION 14 03 07 LT TW 02 INSPECTION COVER REMOVED ADDED INSPECTION COVER AND EXHAUST C...

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Page 81: ...79 Notes ...

Page 82: ...ying the engine the engine will meet i the exhaust emission requirement of this Directive ii the limits of Directive 97 68 EC as regards engines type approved in accordance with Directive 97 68 EC which are in compliance with Stage IIIA Stage IIIB or Stage IV emission limits for CI engines used in other application than propulsion of inland waterways vessels locomotives and railcars as provided fo...

Page 83: ...east 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 has proven that properly installed and maintained engines hold their performance without major mishap even when running hours exceed those men...

Page 84: ...ore 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 The air induction system and air cleaner supplied with the engine must be used and maintained within the limits specified in the Operator s Maintenance Manual For Emis...

Page 85: ...ntial to cause skin cancer In the case of contact immediately rinse skin with plenty of water for several minutes and then wash contact area with soap and water Keep out of reach of children The rules regulations for the disposal of waste oil and or antifreeze solutions in the UK varies by location and whether you are a business or a private individual To find your nearest disposal bank or learn m...

Page 86: ... 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 Every Year Every 750 hours if sooner 10 11 12 13 14 15 16 ...

Page 87: ...Service Date Responsible 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 ...

Page 88: ...Beta Marine Limited Davy Way Waterwells Quedgeley Gloucester GL2 2AD UK Tel 44 0 1452 723492 Fax 44 0 1452 883742 Email sales betamarine co uk Website www betamarine co uk Ref OM 221 04307 REV 00 0118 ...