Beta Marine BV1305 User manual

Operator’s
Maintenance
Manual
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.
Heat Exchanger Cooled
Small Diesel Engine Range
BD1005, BV1305 and BV1505
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 1

Engine Details
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
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).
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 2

INTRODUCTION 2
Engine identification 2
Initial receipt of the engine 2
Engine storage 2
SAFETY PRECAUTIONS
TECHNICAL SPECIFICATIONS
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
T
roubleshooting 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
Contents
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 3

OPERATION AND MAINTENANCE MANUAL FOR THE FOLLOWING
BETA MARINE ENGINES BASED ON KUBOTA SUPER 5 SERIES
BD1005, BV1305, BV1505
ENGINE IDENTIFICATION
NOTE: In all communications with
the distributor or Beta Marine, the
engine number, type, and W.O.C.
number must be quoted.
BD1005, BV1305,
BV1505
The engine serial number is stamped
above starter motor on the port side
of the engine, and is shown on the
rocker cover label.
INITIAL RECEIPT
OF THE ENGINE
A full inspection of the engine must
be made immediately on deliveryto
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.
ENGINE STORAGE
The engine must be stored in a dry,
frost free area and this is best done in
its packing case. If storage 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.
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.
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 obtained from tests
carried out at the place of
manufacture and in vessels used
for development purposes. We do
not guarantee the same results will
be obtained elsewhere under
different conditions.
SAMPLE
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 4

A Keep the engine, gearbox
and surrounding area clean,
including the area immediately
below the engine
B DRIVES - Power Take Off
Areas
i) Gearbox Output Flange
The purpose of a marine diesel
propulsion engine is to provide
motive power to propel a vessel.
Accordingly the gearbox output
shaft rotates at between 280 and
2400 rev/min. This flange is
designed to be coupled to a
propeller shaft by the installer
and steps must be taken to
ensure adequate guarding.
ii) Forward End Drive
Engines are supplied with
unguarded vee belt drives to
power the fresh water pump and
battery charging alternator. The
installer must ensure that it is not
possible for injury to occur by
allowing accessibility to this area
of the engine. The three pulleys
run at high speed and can cause
injury if personnel or clothing
come in contact with the belts or
pulleys, when the engine is
running.
iii) Power Take Off Shaft
(Engine Mounted Option)
Shaft extensions are available as
an option and rotate at between
850 and 3600 rev/min. If
contact is made with this shaft
when the engine is running,
injury can occur.
C EXHAUST OUTLET
Diesel marine propulsion engines
emit exhaust gases at very high
temperatures - around 400-
500°C. Engines are supplied with
either wet exhaust outlet (water
injection bend) or dry outlet (dry
exhaust stub) - see option list. At
the outlet next to the heat
exchanger/header tank, the
exhaust outlet can become very
hot and if touched, can injure.
This must be lagged or avoided by
ensuring adequate guarding. It is
the responsibility of the installer to
lag the exhaust system if a dry
system is used. Exhaust gases
are harmful if ingested, the
installer must therefore ensure that
exhaust lines are lead 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 8 mm
compression fittings. The
installer must ensure that when
connections are made, they are
clean and free of leaks.
E OIL
The Beta propulsion is supplied
with 2 dipsticks, one for the
engine and one for the gearbox.
Ensure dipsticks are returned and
secure after checking, if not oil
leaks can cause infection when
touched. All oil must be
removed from the skin to prevent
infection.
F SCALDING
An engine running under load will
have a closed circuit fresh water
temperature of 85°to 95°C. The
pressure cap on the top of the
heat exchanger must not be
removed when the engine is
running. It can only be removed
when the engine is stopped and
has cooled down.
G TRANSPORTATION/
LIFTING
Engines are supplied on
transportable pallets. Lifting eyes
on engines are used for lifting
engine and gearbox assembly
only, not the pallet and
associated kit.
GENERAL DECLARATION
This machinery is not intended to
be put into service until it has been
incorporated into or with other
machinery. It is the responsibility of
the purchaser/installer/owner, to
ensure that the machinery is
properly guarded and that all
necessary health and safety
requirements, in accordance with
the laws of the relevant country, are
met before it is put into service.
Signed:
J A Growcoot, C.E.O,
Beta Marine Limited
NOTE: Recreational Craft
Where applicable, the
purchaser/installer/owner and operator
must be responsible for making sure
that the Recreational Craft Directive
94/25/EC is complied with.
SAFETY PRECAUTIONS!
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 5

TECHNICAL SPECIFICATIONS Maximum Angle of Installation: T
rim 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.
Standard Engines
BD1005 BV1305 BV 1505
Cylinder 344 Bore (mm) 76 76 78 Stroke (mm) 73.6 73.6 74.8
Displacement (cc) 1001 1335 1498 Combustion Cooling
Starter voltage (V) Starter output (kW)
Starter alternator output (Amps) Glow plug resistance (each) Engine speed (RPM) Power output to ISO3046 (BHP) 28.0 35.0 37.5
Declared power ISO8665 (kW) 19.2 25.7 27.1
Compression Ratio Fuel timing BTDC
Capacity of standard sump approx (litres) 67.5 7.5
Capacity of shallow sump approx (litres) 5 6.5 6.5
Nett dry weight with gearbox (kg) 150 170 170
Fuel
Coolant Coolant capacity approx (H/E litres) 5.5 77 Min. recommended battery capacity
3 Vortex
Water
12
1.2
65 (standard)
1Ω
22:1
21°
Diesel fuel oil No.2D
33%-50% maximum antifreeze / water
12V 80Ah (400CCA Min)
3,600 3,600 3,000
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 6

CAUTION
T
o 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
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
SECTION 1
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 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. Ensure Morse speed and gearbox
cables are fitted correctly and that
cable travel lengths are correct.
Gear selection lever –all
mechanical gearboxes: care
must be taken to ensure that
the remote control cable is
adjusted so that the selector lever
on the gearbox moves FULL
travel and brought “hard up”
against its end stop in both
directions. Failure to achieve the
correct adjustment will reduce
efficiency of the clutch and may
cause slippage at low revs.
Warranty will not be accepted
on gearboxes returned in the
warranty period for failure due
to incorrect adjustment.
5. Ensure engine is out of gear with
1/3 throttle - see single lever
control instruction manual.
6. Open the fuel stopcock and bleed
the fuel water separator of air as
shown in manufacturers
literature.
7. Fuel should now be at the fuel lift
pump, see diagram 1a. Open the
sea cock
INITIAL STARTUP AND
BLEEDING THE SYSTEM
(a) Open fuel bleed screw on fuel
filter assembly by 11/2turns. See
diagrams 1a & 1b.
(b) Move hand priming lever on fuel
lift pump up and down until fuel
with no bubbles comes out of the
bleed screw.
(c) Shut/tighten the bleed screw.
Clean area thoroughly with tissue
paper.
(d) Continue to hand prime for 30
seconds to push fuel through the
fuel pump.
(e) Start engine (see normal
starting).
Note the engine may have to be
turned over with the starter for a
few seconds before it fires. Do
not run the starter for more than
20 seconds. If the engine has not
started after 20 seconds then
disengage the starter and
continue to hand prime for a
further 30 seconds, then repeat.
(f) If engine does not start after 3
attempts then allow 5 minutes
for the starter to cool down before
repeating (a) to (e).
Note: The starter windings can be
burnt out with continuous cranking
Diagram 1a
Diagram 1b
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 7

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).
•T
urn off battery isolator.
Do not turn the key to the off
position when the engine is
running. This will damage the
alternator.
*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.
The Super 5 range of engines are
equipped with a mechanical stop
lever in the event of electrical system
failure. This lever is located on the
starboard side of the engine above
the speed control lever. See Fig 2e:
Stop lever
Speed lever
NORMAL STARTING (BETA
PANELS WITH SILVER KEYSWITCH,
FOR KEYLESS SEE PAGE 23)
With the engine out of gear, set speed
control lever to 1/3 throttle. Turn key anti-
clockwise to HEAT* (A) position and hold
for ten seconds, turn key clockwise to
RUN (C) position. At this stage the
instrument panel should illuminate, an
alarm buzzer will sound and two (or
three*) red warning lights will illuminate:
STARTER BATTERY CHARGE
DOMESTIC BATTERY CHARGE (D in
battery symbol - AB & C Deluxe
panels only)
*(Note: this will only illuminate if
2nd alternator is fitted)
OIL PRESSURE
and green POWER ON / RUN LIGHT
(this will stay on)
T
urn to START (D) position and engine
will motor, hold in position until
engine fires (see initial start-up section
for maximum
time starter can
be used).
Release key
(when engine
has started) to
RUN position.
Ensure alarm
buzzer is not sounding and that
warning lights are extinguished. If one
or both of the alternator warning lights
are still on, then increase engine
speed to excite the alternator - then
return to idle. The battery charge
lights should then go out. The run
light will remain on (green lamp).
Check for sea water flow. If no flow
then SWITCH OFF IMMEDIATELY
AND CHECK SEA WATER SYSTEM.
Note: for some deluxe panel with the
black keyswitch, they operate
clockwise as legend on panel (OFF –
RUN – HEAT – START). Operation for
engine start procedure is the same as
standard apart from this.
RUN
C
START
D
OFF
B
HEAT
A
Fig. 2e
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 8

7
SECTION 2
MAINTENANCE SCHEDULE
DAILY OR EVERY 8 HOURS
RUNNING
• Check engine oil level.
• Check gearbox oil level.
• Check coolant level.
• Check battery fluid.
• Check drive belt tension
• Ensure raw water inlet strainer is
clear.
• Check stern gland lubrication.
• Drain off any water in fuel water
separator.
AFTER THE FIRST 25 HOURS
RUNNING
• Change gearbox lubricant (See
separate gearbox manual).
• Check that all external nuts,
bolts and fastenings are tight.
See table for torque values.
Special attention should be paid
to the flexible mount lock nuts,
these should be checked for
tightness, starting with lower nut
first in each case. If the lower
nuts are found to be very loose,
then the alignment of the shaft
to the gearbox half coupling
should be re-checked. Poor
alignment due to loose flexible
mount nuts will cause excessive
vibration and knocking.
• Check the belt tension on any
second alternators fitted and
adjust –see page 12.
• 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.
• Check for leaks on header tank
tubestack. Tighten end cap bolt
if required.
• Drain off any water in fuel/water
separator.
EVERY 150 HOURS
• If shallow sump (option) is
fitted, change engine lubricating
oil and filter.
EVERY YEAR – OR EVERY 250
HOURS IF SOONER
• Change engine lubricating oil
(standard sump)
• Change lubricating oil filter
• Check air cleaner element
• Check sea water pump impeller
and change if worn.
• Check wasting anode condition,
replace when necessary. In
some environments this may be
6 montly or less.
• Remove heat exchanger tube
stack, by undoing the bolt each
end of the tube stack. Remove
end cover, pull out tube stack
and clean. Replace rubber ‘O’
rings and re-assemble.
Immediately engine is started
check for leaks.
• 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 – As every
250 hours plus the following:-
•Change air cleaner element.
• Change fuel filter.
• Change antifreeze.
• Change gearbox oil.
• Check electrical equipment,
condition of hoses and belts,
replace as necessary.
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 9

LUBRICATION
8
Engine oil: Engine oil should be MIL-
L-2104C or have properties of API
classification CC/CD/CE grades. The
following table gives grades of oil
required for various ambient
temperatures.
Note: A good quality 15W/40
mineral or multigrade oil as used in
most diesel car engines will meet
these requirements. Do not use
‘Turbo Diesel Oil’ or additives.
CHECKING ENGINE OIL
LEVEL
For quantities of oil required see
section marked ‘Technical
Specification’, Page 4
When checking the engine oil level,
do so before starting, or more than
five minutes after stopping.
1. To check the oil level, draw out
the dipstick, wipe it clean, re-
insert it, and draw it out again.
Check to see that the oil level lies
between the two notches.
2. If the level is too low, add new oil
to the specified level - Do not
overfill.
IMPORTANT
When using an oil of different make
or viscosity from the previous one,
drain old oil. Never mix two different
types of oil. Engine oil should be
changed after first 50 hours running
time and then every year or every
250 hours if sooner. Oil filter is a
cartridge type mounted on the port
side of the engine.
(1) Run the engine for 10 minutes to
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. T
urn the tap to
off position and replace end cap.
See diagram 2c.
(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
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.
(4) Fill the engine with new oil as
described above.
(5) Run the engine and check for oil
leaks
AMBIENT TEMP SINGLE GRADE MULTI GRADE
-30°C TO 0 0° °C C SAE 10W SAE 10W/30
-15°C TO +15°C SAE 20W SAE 15W/40
0°C TO +30°C SAE 30 SAE 15W/40
25°C AND ABOVE SAE 30 SAE 15W/40
CHANGING ENGINE OIL
Fig. 2d
Oil filter
Fig. 2b. Dip stick
Fig. 2a
Sump
pump
Oil goes
in here
End Cap
Fig. 2c
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 10

CHECKING GEARBOX OIL LEVEL
(1) The gearbox is fitted with a dip-
stick 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.
(4) The oil can be changed via the
drain plug at the bottom of the
box or sucked out with a hand
pump via the filler plug.
(5) A guide to the type of oil to be
used is as follows:
IMPORTANT
• Always fit a fuel/water separator
in the fuel supply system. Water
in the fuel can seriously damage
the injection system.
• If a fuel supply shutoff valve is
fitted do not use a taper tap, only
use a ball valve tap. The ball
valve type are more reliable and
less likely to let air into the fuel
system.
• Be sure to use a strainer when
filling the fuel tank. Dirt or sand
in the fuel may cause trouble in
the fuel injection pump.
• Always use diesel fuel.
• Do not use kerosene, which is
very low in cetane rating, and
adversely affects the engine.
• Be careful not to let the fuel tank
become empty, or air can enter
the fuel system, necessitating
bleeding before next engine start.
• The fuel lift pump will only lift
fuel through 0.25 metres. If this
is insufficient then an electric fuel
lift pump must be fitted. Drawing
202-06421, illustrating the
wiring of a typical electric fuel lift
pump with ignition switched
relay can be supplied upon
request..
FUEL FILTER REPLACEMENT
1. The fuel filter is a spin on type.
Remove by turning anti-clockwise
when viewed from below.
2. Replace the fuel filter cartridge
every 750 hours. See fig. 2g.
3. Apply fuel oil thinly over the
gasket and tighten into position -
hand tight.
4. Bleed as detailed - see initial
start up.
5. Check for leaks.
6. Do not get fuel on the flexible
mounts.
FUEL SYSTEM (see page 28 for a typical installation)
Fig. 2g
Gearbox Lubricant Capacity (approx)
TMC40M Use ATF Oil 0.2 litres
TMC60M Use ATF Oil 0.8 litres
PRM 80 Use Engine Oil 15W40 0.6 litres
PRM 120 Use Engine Oil 15W40 0.8 litres
PRM 150 Use Engine Oil 15W40 1.4 litres
PRM 260 Use Engine Oil 15W40 1.5 litres
ZF10M Use ATF Oil 0.35 litres
ZF15M Use ATF Oil 0.55 litres
TTMC 35A-2 Use Engine Oil 15W40 0.65 litres
Note: ATF is Automatic Transmission Fluid
Fig 2e
Dip
stick
Oil drain
plug
Oil
filler
plug
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 11

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
freshwater drained off. The following
instructions must be followed to fill
the system.
(a) Mix up in a clean bucket a 33 to
50% antifreeze to fresh water
solution. For the volume required
see technical specification
page 4.
(b) Check that the drain tap or plug
is turned off. (see fig 2l)
(c) Fill engine with freshwater/anti
freeze solution through the top of
the heat exchanger or header
tank with the filler cap removed.
(see fig 2m).
(d) Fill header tank to the top of the
filler neck and replace cap. Press
down firmly on filler cap and
hand tighten in a clockwise
direction.
(e) Run the engine for 5 minutes on
no load (out of gear) and check
coolant level. Top up as
necessary.
(f) Check system for leaks.
(g) If a calorifier is fitted care must
be taken to see that this is also
full of coolant and all the air is
expelled. (See calorifier fitting
notes under Section 3).
(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
pressure cap and top up the
coolant to one inch below the
filler neck.
Fig. 2m
Fig. 2l
Drain
Tap or
plug
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 12

11
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. The water
temperature alarm switch will
however be activated at 95° to
100°C. If no anti-freeze or a very
weak solution is used, then the water
temperature switch may not be
activated before coolant is lost.
IMPORTANT
Removal of the pressure cap when
the engine is hot can cause severe
injury from scalding hot water under
pressure. Always allow the engine to
cool and then use a large cloth when
turning the cap anti-clockwise to the
stop. This allows the pressure to be
released. Press firmly down on the
cap and continue to turn
anticlockwise to release the cap.
(i) Repeat (h) if coolant level is more
than one inch below the base of
the filler neck when the engine
has cooled down.
(j) Run engine on 2/3 full load for 20
minutes, check for leaks and
repeat (i).
(k) Anti-freeze solutions should be
drained off every 2 years and
replaced with a new solution.
Note: When draining fresh water
system, ensure the engine has cooled
sufficiently to prevent scalding from
hot pressurised water. Prior to
draining a cold engine, remove the
filler cap from the header tank and
then open the water drain tap. This
allows the water to drain freely from
the system.
YACHTS AND LAUNCHES WITH HEAT EXCHANGER COOLING
SEA WATER PUMP AND COOLING SYSTEM
(HEAT EXCHANGER-COOLED
ENGINES)
CAUTION
Before working on the sea water
system ensure that the sea cock is in
the off position.
(1) It is very important that the
correct sea water flow is
maintained to cool the closed
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.
(3) Check impeller for cracks in the
rubber, excessive wear or lost
vanes. Replace with a new
impeller as necessary.
Note: If any pieces of rubber
impeller are missing then they
must be found as they are most
likely to be trapped in the
entrance to the heat exchanger
cooling stack. See ‘Cleaning Tube
Stack’.
Fig. 2h
Fig. 2I
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 13

CLEANING THE HEAT EXCHANGER TUBE STACK AND REPLACING WASTING ZINC ANODE
(1) The wasting zinc anode should
be checked every six months and
replaced every year or as
necessary. The anode is attached
to the bolt inserted in the aft end
cap of the heat exchanger. See
fig. 2j.
(2) Unscrew the bolt and replace the
complete unit with a new one.
(3) Check for leaks.
(4) It is possible for fine sea weed
and other debris to get past the
inlet filter and into the tube stack.
This should be removed and
cleaned. See fig. 2k.
(5) Drain off coolant into a bucket.
(6) Unscrew the 2 end cap retaining
bolts (one each end of the tube
stack). Remove the ‘O’ rings and
pull out tube stack. Clean tube
stack and end caps.
(7) Re-assemble using new ‘O’ rings.
Do not overtighten end cap bolts
and make sure the tube stack is
the right way round.
(8) Re-fill engine with water/anti-
freeze solution and run engine up
to temperature to check for leaks.
BELT TENSION
65 AMP ALTERNATOR (HEAT EXCHANGER COOLED)
100 AMP ALTERNATOR (OPTION)
Fig. 2j
Zinc
Anode
Fig. 2k
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. These alternators are
adjusted as follows.
(2) The belt tension is adjusted by
swinging the alternator outboard
as it pivots on its power support
bolt.
(3) With the engine stopped, loosen
the support bolts and the link
adjusting bolt.
(4) Push alternator outboard to
tension and tighten link bolt.
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.
(5) Belt tension should be regularly
checked especially during the
first 20 hours of running in a
new belt, as stretching
occurs.Belt tension must only be
checked with the engine
switched off.
Link adjust bolt
Support bolts
The same method, as outlined above
applies, but final tensioning must be
by hand only. Over tensioning will
cause premature failure of
components.
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 14

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
3
2
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 31.
GENERAL MAINTENANCE
(1) The panel must be protected from
rain and sea water, see instal-
lation. Sea water entering the key
switch will eventually cause
corrosion and could result in the
starter motor being permanently
energised and burning out. Spray
key switch every month with WD
40 or equivalent.
(2) Check batteries for acid level and
top up if required. For low
maintenance and ‘gel’ batteries
see manufacturers instructions.
(3) Loose spade terminal
connections are the most
common cause for electrical
faults - check on a regular bases
(see maintenance instructions).
WINTERISING AND LAYING UP
HEAT EXCHANGER COOLED
ENGINES LEFT AFLOAT AND
ASHORE
(a) The engine oil and oil filter
should be changed at the end of
the season rather than in the
spring. See section 2.
(b) The closed circuit system should
contain a 50/50 solution of anti-
freeze (this also applies to warm
and tropical climates).
(c) For cold climates where the air or
water temperatures can fall
below 3°C, the sea water circuit
must be protected in addition to
the fresh water system. This is
best achieved as follows:
(i) Close the inlet seacock to the
engine (engine stopped).
(ii) Disconnect the sea water
inlet pipe and dip it into a small
bucket containing 50/50 anti-
freeze solution.
(iii) Start the engine (out of gear)
and run for 5 to 10 seconds until
the anti-freeze is used up and
can be seen coming out of the
exhaust outlet.
(iv) Shut engine off and
reconnect the inlet pipe to the
seacock.
The sea water or raw water
circuit is now protected by anti-
freeze.
(d) Ensure instrument panel is well
protected and give the key switch
a spray of WD 40 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 up period to
eliminate water condensation in
the tank. Water entering the fuel
injection system can cause
considerable damage.
LAYING UP ASHORE
(a) Change the engine oil before the
boat is taken out of the water.
Warm engine oil is much easier
to pump than cold!
(b) to (f) should be followed as
above.
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 15

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:
Air in fuel system:
Water in fuel:
Blocked fuel pipe:
Fuel filter clogged:
Fuel lift pump blocked:
Blocked injector:
Fuel return not fed back to the tank:
Heater plugs not working:
Stop solenoid stuck in off position.
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.
Solution
Turn fuel cock on and fill tank.
Vent air (see initial start-up)
Change fuel filter and bleed system.
Clean out and bleed system.
Change filter and bleed system.
Remove and replace.
Remove and clean.
Re-route fuel return pipe.
Check wiring to the plugs, and replace plugs if they are burnt out.
Check solenoid is free to return to run position.
PROBLEM: STARTER MOTOR WILL NOT TURN OR TURNS OVER VERY SLOWLY
Possible Cause
Battery discharged:
Starter motor flooded with sea water:
Wiring disconnected or loose:
Water in cylinders:
Engine harness fuse blown:
Solution
Charge battery or replace. Check alternator belt tension.
Remove and clean or replace.
Check circuit for loose connections.
Incorrect installation. This is serious - check engine oil for signs of water
(creamy-coloured oil). Ring your dealer.
Replace fuse (located by starter motor or above flywheel housing) and check
for wiring faults
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 16

PROBLEM: WHITE OR BLUE EXHAUST GAS
PROBLEM: BLACK EXHAUST GAS
Solution
Inspect and replace
Get the propeller
re-pitched if necessary.
Inspect and clean if required
Possible Cause
Blocked air filter element:
Over pitched propeller - engine will
not reach its full rpm:
Accumulated debris on hull:
Possible Cause
Engine oil level too high:
Blocked injector:
Piston ring and bore worn, giving a
low compression:
Check that the breather pipe is clear
and not obstructed:
Solution
Reduce the level.
Service injectors.
Get compression checked by your dealer or Kubota service agent. He will
advise action to be taken.
Remove and clean out.
PROBLEM: ERRATIC RUNNING
Possible Cause
Air in fuel supply:
Fuel lift pump faulty:
Clogged fuel filter:
Fuel return not fed back to the fuel
tank, or blocked pipe:
Air filter blocked:
Worn or blocked injector:
Engine rpm in gear is too low, this
must be 850 min:
Faulty stop solenoid:
Broken fuel injection pump spring:
Solution
Check supply system for leaks and fix.
Replace.
Replace.
Re-route pipe or clean.
Replace.
Service injectors.
Increase engine tick over speed.
Disconnect wiring to solenoid. If running improves check for a wiring fault.
Replace.
PROBLEM: LOW POWER OUTPUT
Possible Cause
Propeller is too big:
Check gearbox reduction ratio
relative to propeller size:
Solution
Change or depitch.
Change.
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 17

PROBLEM: LOW POWER OUTPUT
Possible Cause
Blocked fuel filter:
Blocked air filter:
Air in fuel system:
Governor spring incorrectly mounted:
Single lever control not operating
correctly:
The electrical load is too large on start
up.
Solution
Replace.
Replace.
Check system.
Dealer to adjust.
Disconnect speed control cable and move the lever by hand. Adjust cable.
Disconnect or reduce the load.
PROBLEM: HIGH OIL CONSUMPTION
Oil leaks:
Piston rings worn:
Valve stem and guide worn:
Piston rings gap facing the same
direction:
Check for leaks.
Overhaul required.
Overhaul required.
Shift ring gap position.
Possible Cause Solution
Core plug pushed out due to frozen
block:
Water pump seal damaged:
Service Agent to check and replace.
Service Agent to check and replace.
Possible Cause Solution
PROBLEM: WATER IN LUBRICATING OIL - (Heat exchanger cooled)
Oil goes “milky” due to sea water
entering exhaust manifold:
Check installation - has anti-siphon valve been fitted? Change engine oil and
run engine for 10 minutes each time to eliminate any water. Get fuel injection
pump and compression checked by Service Agent.
Possible Cause Solution
PROBLEM: WATER IN LUBRICATING OIL - (Keel cooled)
Oil goes “milky” due to water entering
exhaust manifold and then into the
sump:
Check installation – has dry exhaust system been fitted correctly, ensuring rain
water cannot enter the exhaust port and run back? (See DRY EXHAUST
SYSTEM) Change engine oil and run engine for 10 minutes each time to
eliminate any water. Get fuel injection pump checked by Service Agent.
Possible Cause Solution
PROBLEM: WATER IN LUBRICATING OIL - (General)
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 18

PROBLEM: LOW OIL PRESSURE WARNING LIGHT COMES ON WHEN ENGINE SPEED REDUCED TO TICK OVER:
Faulty switch sender:
Engine running too hot:
Oil relief valve stuck partially open
with dirt:
Blocked oil filter:
Wiring fault:
Insufficient oil:
Replace.
Check cooling water flow (see section 2 Cooling).
Remove and clean.
Change.
Check circuit.
Top up and check for leaks.
Possible Cause Solution
PROBLEM: ENGINE OVERHEATS
Check coolant level:
Insufficient sea water flow:
Damaged or worn pump impeller:
Blocked tube stack in heat
exchanger:
Zinc anode flakes blocking tube stack:
Pressure cap loose:
Switch sender faulty:
Inlet sea cock is too small:
High exhaust back pressure:
Air locks in cooling pipe work to keel
cooler:
Keel cooler of insufficient size:
Possible Cause Solution
No W connection to alternator.
Wiring fault:
Check power output from ‘W’ connection. Should be about 9V AC.
Check circuit.
Possible Cause Solution
PROBLEM: PANEL REV COUNTER NOT WORKING (WHEN FITTED
T
op up.
Clear blocked intake or filter.
Replace.
Remove tube stack and clean - replace ‘O’ rings.
Remove and clean tube stack as above.
Replace.
Replace.
Replace (see heat exchanger cooled seawater inlet system in section 3).
Must not exceed 3.1” of Hg.
Vent the system and top up coolant.
Contact boat builder.
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 19

The most common cause of
overheating is insufficient seawater
flow due to a blocked intake (weed
or a plastic bag!). If this happens
then clear the blockage. If the
problem is not cured then check the
system for sea water flow which
should be 6.5 litres / minute
minimum at 1,000 rpm as follows:
(a) With the boat tied up and out of
gear run the engine up to 1000 rpm.
*Hold a plastic bucket over the
exhaust outlet for 10 seconds and
measure the amount of water
collected. Multiply this value by 6 to
give the flow in litres/min. Repeat
twice and take an average. If the flow
rate is noticably less than the 6.5
litre per minute minimum, 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
removed.
(d) Check flow again as in (a).
*Note: This operation must only be
done in safe conditions, in port and
with two assistants.
Working from a rubber dinghy is
best. The person holding the bucket
should take precautions against
breathing in the exhaust gasses.
PROBLEM: KNOCKING NOISE
Propshaft touching gearbox output
coupling through split boss or Type 16
coupling:
Flexible mount stud touching engine
bed:
Drive plate broken:
Engine touching engine bed:
Adjust, giving correct clearance (10mm) between gearbox and propeller shaft.
Adjust stud to clear.
Replace / repair.
Re-align engine / modify bed.
Possible Cause Solution
PROBLEM: BATTERY QUICKLY DISCHARGES
High load and insufficient running:
Low electrolyte level:
Fan belt slipping - black dust in
engine compartment: Engine
compartment temperature too high:
Alternator defective:
Battery defective:
Poor wiring connection:
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.
T
op up.
Adjust tension / replace belt with a high temperature and/or improve engine
compartment ventilation.
Check with Agent.
Replace.
Check wiring system.
Possible Cause Solution
GENERAL -HEAT EXCHANGE ONLY:
beta small engine ref 1640.qxd 15/9/06 1:59 pm Page 20