Beta 10 BZ482 Beta 16 BD722 and Beta 25 Marine Engine Complete Workshop Service Repair 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 and Keel Cooled Small Diesel Engine Range: Beta 10, BZ482, Beta 16, BD722 & Beta 25

Engine Details Engine Type: Power: bhp Speed: rpm BETA WOC NO: K Gearbox Type: Purchased from: Invoice No: 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).

1 INTRODUCTION 2 Engine Identification 2 Initial Receipt of the engine 2 Engine Storage 2 SAFETY PRECAUTIONS 3 TECHNICAL SPECIFICATIONS 4 SECTION 1: GUIDELINES FOR OPERATION OF ENGINE Important checks prior to initial use 5 Initial Start-up and Bleeding The Fuel System 5 Starting/Stopping 6 SECTION 2: MAINTENANCE AND SERVICE GUIDELINES Maintenance Schedule: 7 Lubrication – Checking and changing oil 8 Fuel System - Pumps, Filter, fuel/water separator 9 Cooling - Fresh water system, Keel Cooling, Heat Exchanger 10 Sea Water Pump, Heat Exchanger 12 Belt Tensioning 13 Air Filter 13 Electrical 14 Laying up - Winterising 14 Troubleshooting 15 Torque Settings 26 SECTION 3: INSTALLATION GUIDELINES Engine Mounting 27 Alignment - Drives, Flanges, Flexible Drives 27 Exhausts & Bends 28 Mounting Exhausts 28 Fuel Supply 29 Cooling 30 Calorifier System 31 Electrical installations 32 Appendices –wiring diagrams and general arrangements 32 Component identification at rear of manual. 63 Maintenance Record 65 Contents

ENGINE IDENTIFICATION NOTE: In all communications with the distributor or Beta Marine, the engine number, type, and W.O.C. number must be quoted. BETA 10, BZ482, BETA 16, BD722 & BETA 25 The engine serial number is stamped above the fuel lift pump on the starboard 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 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. 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. OPERATION AND MAINTENANCE MANUAL FOR THE FOLLOWING BETA MARINE ENGINES BASED ON KUBOTA MINI SERIES Beta 10, BZ482, Beta 16 (BZ602), BD722 & Beta 25 (BD902) 2 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

3 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 300 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!

TECHNICAL SPECIFICATIONS MINI SERIES – STANDARD ENGINES Maximum Angle of Installation: Trim 15°, Roll 30° (intermittent) Rotation: ANTI CLOCK ON FLYWHEEL, CLOCKWISE ON OUTPUT GEARBOX FLANGE FOR USE WITH RIGHT HAND PROP IN AHEAD 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. 4 BETA 10 BZ482 Beta 16 BD722 Beta 25 Cylinder 2 2 2 3 3 Bore (mm) 67 67 72 67 72 Stroke (mm) 68 68 73.6 68 73.6 Displacement (cc) 479 479 599 719 898 Combustion 3 Vortex E-TVCS Cooling Water Starter voltage (V) 12 Starter output (kW) 0.8 Starter alternator output (Amps) 40 (standard) Glow plug resistance (each) 1Ω Engine speed (RPM) 3,000 3,600 Power output to ISO3046 (BHP) 10.0 13.3 16.7 20.0 24.8 Declared power ISO8665 (kW) 7.4 8.7 11.0 13.1 16.3 Fuel timing BTDC 21° Capacity of standard sump approx (litres) 2.0 - 2.5 2.4 - 2.9 3.1 - 3.8 3.7 – 4.5 Capacity of shallow sump approx (litres) 2.2 2.6 3.4 3.8 Nett dry weight with gearbox (kg) 87.2 94.1 101.7 110.6 Fuel Diesel oil class A1 / A2 Coolant 33%-50% maximum antifreeze / water Coolant capacity approx (H/E litres) 2.25 3.00 3.25 Min. recommended battery capacity 12V, 40Ah 12V, 75Ah

INITIAL STARTUP AND BLEEDING THE SYSTEM (a) Open fuel bleed screw on injection pump by 1 1 /2 turns. See diagram 1a. (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 star ter windings can be burnt out with continuous cranking CAUTION To avoid personal injury: • Do not bleed a hot engine as this could cause fuel to spill onto a hot exhaust manifold creating a danger of fire. • Do not mix gasoline or alcohol with diesel fuel. This mixture can 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 Diagram 1a 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 antifreeze (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. 8. Open the sea cock.

6 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 not allow the alternator to charge. *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. NOTES FOR ALL PANEL TYPES: Do not depress the stop button for more than ten seconds as this will lead to overheating and failure of the solenoid. The Mini 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 illustration below: Stop lever Stop lever Speed lever Speed lever NORMAL STARTING (ALL BETA PANELS WITH SILVER KEYSWITCH) 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 PANELS ONLY) *(Note: this will only illuminate if 2nd alternator is fitted) OIL PRESSURE and green POWER ON / RUN LIGHT (this will stay on) Turn 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 LED). Note: for panels without keyswitches see seperate instruction sheet (page 24). RUN C START D OFF B HEAT A

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 11 • 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.

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 (option on Beta Ten, see note below). Unscrew the end cap on the end of the pump (if fitted), turn the tap to ‘on’. Use the hand pump as shown to pump out the oil into a bucket. Turn the tap to off position and replace end cap. See diagram 2c. (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. Note: On the Beta Ten not fitted with a sump drain pump the engine oil must be drained off by unscrewing the sump drain plug (see diagram 100-00030 at rear of book). This is best done with the oil filler cap removed. Replace the plug and tighten firmly. (4) Fill the engine with new oil as described above. LUBRICATION AMBIENT TEMP SINGLE GRADE MULTI GRADE -30°C TO 0°C SAE 10W S AE 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. 2b. Dip stick Fig. 2a Oil goes in here Sump pump Tap Oil filter End Cap Fig. 2c Fig. 2d

Beta 10 BZ482 Beta 16 BD722 and Beta 25 Marine Engine Complete Workshop Service Repair Manual

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