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Beta Marine Beta 28 Operator's Maintenance Manual

Heat exchanger cooled small diesel engine range
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Heat Exchanger Cooled
Heat Exchanger Cooled
Small Diesel Engine Range
Small Diesel Engine Range
Beta 28, Beta 30, Beta 35 & Beta 38
Beta 28, Beta 30, Beta 35 & Beta 38
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.
Operator's
Operator's
Maintenance
Maintenance
Manual
Manual

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Summary of Contents for Beta Marine Beta 28

  • Page 1 Small Diesel Engine Range Small Diesel Engine Range Beta 28, Beta 30, Beta 35 & Beta 38 Beta 28, Beta 30, Beta 35 & Beta 38 CALIFORNIA - Proposition 65 Warning: Diesel engine exhaust and some of its constituents are known to the state of...
  • Page 2 Fig 1 Heat Exchanger Cooling System...

  • Page 3: Engine Details (To Be Completed Now)

    Engine Details Please fill in these details at moment of purchase - it really will help you! IMPORTANT! (and it will really help us specify the correct spare parts for you). Engine Type: Power: Speed: BETA WOC NO: Gearbox Type: Purchased From: Invoice No.: Date Commissioned:...

  • Page 4: Table Of Contents

    Contents Engine details (to be completed now) Introduction Engine identification Initial receipt of the engine Engine storage Safety precautions Technical specifications SECTION 1: INSTALLATION GUIDELINES Engine mounting Engine alignment - drives, flanges, flexible couplings Exhausts and mounting exhausts Cooling - sea water inlet system Fuel supply and "leak off"...

  • Page 5: Introduction

    Beta 28, Beta 30, Beta 35 & Beta 38 WELCOME TO BETA MARINE Thank you for purchasing a Beta Marine Engine. We have made this manual to provide you with important information and recommendations to ensure trouble free and economical operation of the engine.

  • Page 6: Engine Identification

    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. A photograph would always help.

  • Page 7: Safety Precautions

    Exhaust gases are harmful if ingested, the installer must therefore ensure that exhaust lines are led overboard and that leakage in the vessel does not occur. J A Growcoot, C.E.O, Beta Marine Limited. D Fuel i) Fuel Lines NOTE: Recreational Craft...

  • Page 8: Technical Specifications

    Technical Specifications Standard Engines Beta 28 Beta 30 Beta 35 Beta 38 Cylinder Bore (mm) Stroke (mm) 73.6 78.4 78.4 78.4 Displacement (cc) 1001 1123 1498 1498 Combustion 3 Vortex, naturally aspirated, indirect injection Cooling Water / Antifreeze 50:50 Starter voltage (V)

  • Page 9: Section 1: Installation Guidelines

    Therefore Beta Marine can accept no responsibility for any damage or injury incurred during the installation of a Beta • Engine parts and accessories that require frequent Marine Engine whilst following these guidelines.

  • Page 10: Engine Mounting

    ENGINE INSTALLATION AT AN ANGLE Beta Marine propulsion engines can be installed at angles When our engines are installed at varying angles of up to a maximum of 15° flywheel up or flywheel down inclination the normal markings on the dipstick should be when static, or can be run at up to 25°...
  • Page 11 ALIGNMENT To obtain accurate alignment the flexible mountings must (Dial Test Indicator) mounted on a magnetic foot so that be adjusted until alignment is attained, and the they are aligned within 0.125mm (0.005”). (Obviously mountings must be locked in position. The engine / the propeller shaft must be centered in the stern tube and gearbox unit has to be aligned with the propeller shaft in running true - through the cutless bearing;...

  • Page 12: Engine Alignment - Drives, Flanges, Flexible Couplings

    FLEXIBLE OUTPUT COUPLINGS A flexible coupling is mounted on the gearbox output flange and is strongly recommended in almost every case. Flexible couplings do not resolve bad alignment, they are designed to absorb torsional vibrations from the propeller (transmitted along the propeller shaft). We normally offer two types: R&D with a flexible nylon disc and optional Clamp Coupling –...

  • Page 13: Exhausts And Mounting Exhausts

    EXHAUST SYSTEMS There are two main types of exhaust system: We recommend care when designing your exhaust system. The most important aspect is to ensure that water • Standard yacht - wet exhaust system with a water cannot enter the engine's combustion chamber from the injection bend and waterlock silencer exhaust system (this applies to both wet and dry exhaust •...
  • Page 14 HIGH-RISE EXHAUST In yachts, engines are mostly installed low down and If this is still not enough then you have to fit an often below the water line. There are several ways to ‘antisyphon’ / vacuum valve 50 cms above the 'loaded' avoid cooling water entering the engine.
  • Page 15 WATERLOCK / SILENCER You must always fit a waterlock / silencer to stop any injection bend, being as low as reasonably possible, so water in the exhaust system back filling the engine. The that all the water can drain down into it. The waterlock water lock should always be fitted at least 30 cms away should have sufficient capacity to hold an exhaust system from the injection bend and at least 30 cms below the...

  • Page 16: Cooling - Sea Water Inlet System

    SEA WATER INLET FOR HEAT EXCHANGER COOLED ENGINES Your engine is fitted with a gear driven sea water pump 3. Good access to the inlet sea cock from inside your which sucks in seawater (raw water) to cool the closed boat is essential so that plastic bags or seaweed circuit system via the heat exchanger.
  • Page 17 EXHAUST BACK PRESSURE Keep exhaust systems to a minimum length and have Engine Exhaust Back Pressure gradual bends (NOT right angle elbows). Exhaust back Beta 10 to Beta 25 70 mm Hg pressure should be as low as possible; it is increased by long exhaust length and sharp bends.
  • Page 18 STERN GEAR LUBRICATION A cooling water ‘bleed’ for stern gear lubrication of the Stern Bleed Feed cutlass bearing can be taken from the engine as it leaves the heat exchanger. Standard Exhaust with Stern Bleed Stern Bleed with Anti-syphon Valve Beta 10 to Beta 60 - can be connected to the heat Beta 75 upwards - need a ‘T’...
  • Page 19 DRY EXHAUST INSTALLATION a) An engine correctly installed in accordance with this The engine is fitted with a 1 ” BSP male connector handbook will meet the emission requirements of the stub as standard - Valid for exhaust systems up to 3 RCD (see back of manual).

  • Page 20: Fuel Supply And Leak Off

    When connecting the engine fitted (ask your dealer or Beta Marine). to the fuel supply and return lines, flexible fuel hoses must be used (next to the engine) and must meet the 3.

  • Page 21: Calorifier Connections (If Fitted)

    CALORIFIER SYSTEM All Beta engines can be fitted with the calorifier Heat Exchanger Calorifier System connections 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 connections on this range of engine are shown.

  • Page 22: Electrical Installation

    ELECTRICAL INSTALLATIONS All our engines are supplied with 12 volt electric starting Care must be taken when pushing the two halves of as standard. We therefore supply the main components: the plug together to ensure that individual pins do not starter motor, battery charging alternator, fuel control fall out.
  • Page 23 4. Battery size depends upon your requirements. For 5. If you require a domestic battery bank you will need to starter motor batteries the battery size should be based calculate your power requirements, and then multiply upon the starter motor requirements - table below, and that by the number of hours you will need this power never be of less capacity than the battery (before you are able to re-charge the batteries).
  • Page 24 BATTERY CABLES 1. Starter batteries should be as close to the engine as If the correct battery is selected but the engine will not practically possible. The reason for this is to ensure crank at sufficient speed after the inrush then that the maximum voltage from the battery is available (assuming battery cables are the correct size) the to the starter motor.
  • Page 25 In this way these gauges will only be live whilst the alternator feeds Beta Marine recommend any additional engine is running, the engine is starting or the heaters are requirements from these terminals must be fed through a being used.

  • Page 26: Section 2: Guidelines For Operation Of The Engine

    Section 2 GUIDELINES FOR OPERATION OF ENGINE IMPORTANT! CHECKS PRIOR TO INITIAL USE 1. Generally, a new engine has the oil and anti-freeze removed after the works test. Fill the engine with the correct oil and antifreeze (see sections on Engine oil and Cooling).
  • Page 27 8. Start engine (see normal starting). Note the engine CAUTION: may have to be turned over with the starter for a few seconds before it fires. TO AVOID PERSONAL INJURY! Do not run the starter for more than 20 seconds. If the •...

  • Page 28: Starting And Stopping

    NORMAL STARTING BETA CONTROL PANELS - ABV, A, AB, B AND C DELUXE - WITH KEYSWITCH. To operate the engine: with the engine out of gear, set 3. Turn to ‘START’ position and engine will motor, hold in speed control lever to throttle.
  • Page 29 NORMAL STARTING BETA CONTROL PANEL ABVW - KEYLESS (WITHOUT KEYSWITCH) This panel controls the engine with three water resistant 2. Press ‘START’ button and hold in position until engine push buttons instead of a keyswitch, and is less prone to fires (see initial start-up section for maximum time damage and corrosion from sea water spray.
  • Page 30 STOPPING Every propulsion engine is fitted with a stop solenoid. When leaving the boat for an extended period: To stop the engine simply press stop push button, hold in • Turn off sea-cock (heat exchanger cooled engines). until engine stops, then turn key from ‘RUN’ to ‘OFF’ •...

  • Page 31: Section 3: Maintenance & Service Guidelines

    Section 3 MAINTENANCE SCHEDULE DAILY OR EVERY 8 HOURS RUNNING AFTER 150 HOURS • Check engine oil level. • If shallow sump (option) is fitted, change engine lubricating oil and filter. • Check gearbox oil level. • Check coolant level. EVERY YEAR OR 250 HOURS IF •...

  • Page 32: Maintenance Schedule

    Maintenance Schedule Daily or After After Every Every Year Every every 8hrs first first 150hrs with or 250hrs 750hrs running 25hrs 50hrs shallow sump if sooner Check engine oil level Check gearbox oil level Check engine coolant level Check battery fluid Check drive belt tension Ensure raw water inlet strainer is clear...

  • Page 33: Lubrication - Checking And Changing Oil

    LUBRICATING OILS Engine oil: Engine oil quality should have the minimum The following table gives grades of oil viscosity required properties of the American Petroleum Institute “API” for various ambient temperature ranges. classification CF (CD and CE have been superseded by Ambient Temp.
  • Page 34 CHANGING THE ENGINE OIL 1. Run the engine for 10 minutes to warm up the oil. Note: It is best to have a plastic bag wrapped round the filter to catch any oil left in the system. (Always 2. Your engine is provided with a sump drain pump. keep your bilges clean!) Before screwing in the new Unscrew the end cap on the end of the pump spout, filter spread a thin film of oil round the rubber gasket...
  • Page 35 Gearbox Lubricant Capacity (approx.) Gearbox Lubricant Capacity (approx.) TMC40 0.2 L PRM 80 0.6 L TMC60/A 0.8 L PRM 120 0.8 L TMC260 1.2 L PRM 150 1.4 L TM345/A 1.6 L PRM 260 1.5 L TM93/A 2.4 L PRM 500 2.5 L TM170/A 2.8 L...

  • Page 36: Fuel System - Fuel / Water Separator, Fuel Lift Pump, Fuel Filter

    IMPORTANT! system. Beta Marine warranty will not cover fuel equipment • Be sure to use a strainer when filling the fuel tank. when more than 7% Biodiesel is used.

  • Page 37: Cooling - Fresh Water System, Heat Exchanger

    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). Heat Exchanger Cooled Engines Sea Water Level...
  • Page 38 FILLING THE FRESH WATER SYSTEM New engines are supplied with the fresh water ‘coolant’ (e) Run the engine for 5 minutes on no load (out of gear) drained off. The following instructions must be followed to and check coolant level, this will help remove air from fill the system.

  • Page 39: Sea Water Pump, Heat Exchanger

    YACHTS AND LAUNCHES WITH HEAT EXCHANGER COOLING It is essential that a solution of fresh water and anti-freeze is The anti-freeze in the fresh water system enables the boiling used as engine coolant. The amount of anti-freeze must be point of water to rise to 124°C with a 13 psi pressure cap between 33% to 50%.

  • Page 40: Tube Stack And 'Wasting Zinc Anode

    HEAT EXCHANGER TUBE STACK AND ‘WASTING ZINC ANODE’ 1. The wasting zinc anode should be checked regularly at least every six months and replaced every year or sooner, as necessary. The anode is attached to the bolt inserted in the end cap of the heat exchanger. Zinc anode See photo 46.

  • Page 41: Belt Tensioning Adjustment

    BELT TENSION WARNING! Adjuster bolt Belt tension must only be checked with the engine switched off. 65 AMP ALTERNATOR (HEAT EXCHANGER COOLED) These engines are fitted as standard with a single belt that drives both the 65 Amp battery charging alternator and the fresh water / engine coolant circulating pump.

  • Page 42: Air Filter Inspection / Replacement

    AIR 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. ELECTRICAL MAINTENANCE WARNING! UNDER NO CIRCUMSTANCES SHOULD THE BATTERY BE DISCONNECTED OR SWITCHED OFF WHEN THE ENGINE IS RUNNING.

  • Page 43: Laying Up - Winterising

    WINTERISING AND LAYING UP • a) The engine lubricating oil and lubricating oil filter Start the engine (out of gear) and run for 5 to 10 should be changed at the end of the season rather seconds until the anti-freeze is used up and can be than in the spring.

  • Page 44: Troubleshooting

    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.
  • Page 45 Fit electric fuel lift pump. Problem: Hunting at idle Possible Cause Solution Idle adjustment screw may need adjusting: speak to Beta Marine for advice with idle adjustment - discuss problem. Problem: Hunting at higher speeds Possible Cause Solution Fuel supply problem:...
  • Page 46 Problem: Low oil pressure warning light on when underway Possible Cause Solution Oil frothing due to high installation angle or too high oil level: Refer to Beta Marine for advice Problem: Low oil pressure warning light on when engine speed reduced to tick over Possible Cause...
  • Page 47 Problem: Water in lubricating oil - general Possible Cause Solution Core plug pushed out due to frozen block: Service Agent to check and replace. Water pump seal damaged: Service Agent to check and replace. Problem: Water in lubricating oil - heat exchanger cooled Possible Cause Solution Oil goes "milky"...
  • Page 48 Problem: Engine overheats - Keel cooling only Sometimes overheating is caused by: (a) Not fully venting the engine cooling system of air. It is necessary to remove all air from the cooling system - including the “skin” tanks and (if fitted) the Calorifier and associated piping. (b) Incorrectly sized “skin”...
  • Page 49 Problem: Vibrations Possible Cause Solution Poor alignment to shaft: The alignment must be accurate even if a flexible coupling is used (see section 1, Alignment). Flexible mounts not adjusted correctly to take even weight: Check relative compression of each mount. Flexible mount rubber perished: Replace.
  • Page 50 SUPPLIED WITH FOUR OR FIVE LAMPS. engines. If your engine was built before July 2005, Four lamp panels: A, ABV, B these panels utilise contact Beta Marine for the relevant electrical trouble bulbs inside sealed lamp holders. shooting guide. Five lamp panels: AB and C; these panels also utilise...
  • Page 51 ELECTRICAL FAULT FINDING - ENGINES AFTER JULY 2005 ONLY ABVW - KEYLESS FOUR LAMP PANEL 2. Press ‘START’ button and hold in position until (WITHOUT KEYSWITCH) engine fires (see initial start-up section for maximum time starter can be operated). Release This panel controls the engine with three water button (when engine has started).
  • Page 52 ELECTRICAL FAULT FINDING - ALL LAMP PANELS Problem Possible Cause and Solution No warning lamps or • Battery isolation switch in off position - switch on buzzer functioning, engine • Starter battery discharged - charge will not start or stop •...
  • Page 53 ELECTRICAL FAULT FINDING - C DELUXE AND B PANELS In addition to the fault finding detailed on the previous table, the following is specific for the deluxe panel (Also applicable for the B panel with Murphy water temperature gauge) Problem Possible Cause and Solution Oil pressure warning lamp not functioning, •...
  • Page 54 ELECTRICAL FAULT FINDING - NON-BETA PANEL Engines can be supplied wired up to suit VDO switch Note: Water temperature switch/sender senders, usually fitted to a non-Beta control panel. If so (Part number 200-01133) refer to our wiring diagram 200-60971/01 (also part Large spade is sender connection (green/blue) number for replacement harness)

  • Page 55: Torque Settings

    Spanner Torque Settings SPANNER TORQUE SETTINGS - GENERAL NUTS & BOLTS ITEM SIZE X PITCH KGF M LBF FT (FT LBS) M6 (7T) : 6MM (0.24IN) 9.8~11.3 1.0~1.15 7.2~8.3 M8 (7T) : 8MM (0.31) 23.5~27.5 2.4~2.8 17.4~20.3 M10 (7T) : 10MM (0.39IN) 49.0~55.9 5.0~5.7 36.2~41.2...

  • Page 56: Wiring Diagrams And General Arrangement Drawings Index

    200-06520 & 200-06303 Page 68 & 69 14. Diagram of Deluxe panel ‘C’ & cut-out 200-06518 & 200-06306 Page 70 & 71 15. GA of Beta 28/30 H/E TMC 40 100-01939 Page 71 16. GA of Beta 28/30 H/E PRM 80 100-99550 Page 72 17.

  • Page 85: Exhaust Emission - Durability

    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.

  • Page 86: Fast Moving Parts Listing

    Fast Moving Parts List Heat Exchanger and Keel Cooled Beta 28, Beta 30, Beta 35 & Beta 38 engines. In all cases please quote Beta Marine WOC “K” number and Engine type. Description Part Number Qty per Engine Voltmeter (C panels only) 200-96210 Green power on indicator lamp &...
  • Page 87 Fast Moving Parts List Heat Exchanger and Keel Cooled Beta 28, Beta 30, Beta 35 & Beta 38 engines. In all cases please quote Beta Marine WOC “K” number and Engine type. Description Part Number Qty per Engine Wasting Zinc Anode 209-61840 Heat Exchanger ‘O’...

  • Page 88: Maintenance Record

    Service Record Service Date Responsible Commissioned First 25 hours First 50 hours Every 150 hours with shallow sump Every Year / Every 250 hours if sooner Every 750 hours...
  • Page 89 Fig 2 Fuel Supply & Leak Off Fig 3 Keel Cooling System...
  • Page 90 Heat Exchanger Cooled Keel Cooled 10 to 150bhp 10 to 150bhp Marine Generating Sets 4 to 40kVA Sail Drives 13.5 to 56bhp Beta Marine Limited Tel: 01452 723492 Davy Way, Waterwells Fax: 01452 883742 Quedgeley, Gloucester Email: sales@betamarine.co.uk GL2 2AD, UK. www.betamarine.co.uk...

This manual is also suitable for:

Beta 30Beta 35Beta 38

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