BETA Marine OPERATOR 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. Operator’s Maintenance Manual Heat Exchanger Cooled Mid Diesel Engine Range Beta 43, Beta 50 & Beta 60 Operator’s Maintenance Manual Heat Exchanger Cooled Mid Diesel Engine Range Beta 43, Beta 50 & Beta 60 Downloaded from www.Manualslib.com manuals search engine

Engine 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). Engine Type: Power: bhp Speed: rpm BETA WOC NO: K Gearbox Type: Purchased From: Invoice No.: Date Commissioned: Specification / Special Details: Downloaded from www.Manualslib.com manuals search engine

1 My engine details (to be completed now) Inside front cover Introduction Engine identification 2 Initial receipt of the engine 2 Engine storage 2 Safety precautions 3 Technical specifications 4 Section 1: Installation guidelines Engine mounting 5 Engine alignment - drives, flanges, flexible couplings 6 Exhausts and mounting exhausts 7 Fuel supply and "leak off" 8 Cooling - sea water inlet system 9 Calorifier connections (if fitted) 9 Electrical Installation 10 Section 2: Guidelines for operation of the engine Important checks prior to initial use 11 Initial start-up and bleeding the fuel system 11 Starting and stopping 13 Section 3: Maintenance & Service guidelines Maintenance schedule 14 Lubrication - checking and changing oil 16 Fuel system - fuel/water separator, fuel lift pump, fuel filter 18 Cooling - fresh water system, heat exchanger 19 Sea water pump, heat exchanger 20 Belt tensioning adjustment 21 Air filter inspection / replacement 22 Electrical maintenance 22 Laying up - winterising 23 Troubleshooting 24 Torque settings 34 Wiring diagrams and general arrangement drawings index 35 Exhaust Emission - Declaration of Conformity 61 Exhaust Emission - Durability 62 Fast Moving Parts Listing 63 Maintenance record Inside back cover Contents Downloaded from www.Manualslib.com manuals search engine

Engine Identification NOTE: In all communications with the distributor or Beta Marine, the W.O.C. and engine number must be quoted. Beta 43, Beta 50 and Beta 60 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 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. 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 SERIES Beta 43, Beta 50 & Beta 60 2 1 2 This manual has been compiled to provide the user with important information and recommendations to ensure trouble free and economical operation of the engine. As manufacturers we have obviously written this “Operators Maintenance Manual’ from our ‘involved technical viewpoint’ assuming a certain amount of understanding of marine engineering. We wish to help you, so if you do not fully understand any phrase or terminology or require any explanations please contact Beta Marine Limited or its distributors 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 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. Downloaded from www.Manualslib.com manuals search engine

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 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 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 access 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 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 compression fittings. The installer must ensure that when connections are made, they are clean and free of leaks. E Oil The Beta propulsion unit 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! Downloaded from www.Manualslib.com manuals search engine

Maximum Angle of Installation: Trim 15°; Roll 25° (intermittent) or 20° continuous, see page 6. Rotation: Anti-clockwise on flywheel, clockwise on output gearbox flange for use with right hand propeller 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 API Classification CF (CD or CE), See section 2 for details Gearbox - see gearbox 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 ISO8665:1996 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 Beta 43 Beta 50 Beta 60 Cylinder 4 4 4 Bore (mm) 83 87 87 Stroke (mm) 92.4 92.4 102.4 Displacement (cc) 1999 2197 2434 Combustion 3 Vortex 3 Vortex 3 Vortex Cooling Water Water Water Starter voltage (V) 12 12 12 Starter output (kW) 1.4 1.4 2.0 Starter alternator output (Amps) 65 (standard) 65 (standard) 65 (standard) Glow plug resistance (each) 1Ω 1Ω 1Ω Engine speed (RPM) 2,800 2,800 2,700 Power output to ISO3046 (BHP) 43.0 50.0 56.0 Declared power ISO8665 (kW) 31.0 36.1 40.6 Compression Ratio 23.0:1 23.0:1 23.0:1 Fuel timing BTDC 18° 18° 18° Capacity of standard sump approx. (litres) 9.5 9.5 9.5 Capacity of shallow sump approx. (litres) 7.0 7.0 7.0 Nett dry weight with gearbox (kg) 270 300 310 Fuel Diesel fuel oil No.2D Coolant 33%-50% maximum antifreeze:water Coolant capacity approx.. (H/E litres) 7.4 7.4 7.4 Min. recommended battery capacity 12V, 120Ah (600 CCA Min) 4 Technical Specifications Downloaded from www.Manualslib.com manuals search engine

5 Installation Recommendations The installation details are basic guidelines to assist installation, however due to the great diversity of marine craft it is impossible to give definitive instructions. Therefore Beta Marine can accept no responsibility for any damage or injury incurred during the installation of a Beta Marine Engine whilst following these guidelines. Engine Mounting To ensure vibration free operation, the engine must be installed and correctly aligned on substantial beds, 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 we offer ‘Special Engine Feet’ manufactured to your dimensions, as an optional extra to suit your existing engine bearers and shaft alignment/installation. Warning (1) Do not set the engine feet high up the flexible mount pillar stud. This will cause excessive engine movement and vibration. Pack under the flexible mount with steel shims securely bolted into the engine bearer. (2) The pillar stud on the flexible mount is secured into position by the lower locknut, do not forget to tighten this. Also ensure that the stud is not screwed too far through the mounting body so that it can touch the bearer. This will cause vibration and knocking noises which are very hard to find! Section 1 Flexible Output Couplings A flexible coupling should be mounted on the gearbox output flange and is strongly recommended in almost every case. Flexible couplings do not accommodate bad alignment, they are designed to absorb torsional vibrations from the propeller (transmitted along the propeller shaft). 3 • All engines shall be placed within an enclosure separated from living quarters and installed so as to minimise the risk of fires or spread of fires as well as hazards from toxic fumes, heat, noise or vibrations in the living quarters. • Unless the engine is protected by a cover or its own enclosure, exposed moving or hot parts of the engine that could cause personal injury shall be effectively shielded. • Engine parts and accessories that require frequent inspection and / or servicing must be readily accessible. • The insulating materials inside engine spaces shall be non-combustible. • Adequate ventilation must be included with every engine installation. It is very important that the engine compartment is ventilated, as the engine will produce radiated heat - approximately equal to 1 / 3 of the engine output power. Also the 65 and/or 100 amp battery charging alternator/s create lots of heat. In yachts we recommend forced ventilation using an extraction fan to draw out the hot air and limit the maximum engine compartment /room temperature to 60°C. This can be checked with a thermometer on a hot day - the cooler the engine compartment the better. A symptom of overheating problems is black belt dust. It is normally best with two ventilation holes; an inlet of at least 300 cm 2 allowing colder air to enter near to the alternator and drive belts and a second outlet (a third bigger than the inlet) for the hot air to rise and ventilate out from the top of the engine compartment using the cooling fan. Downloaded from www.Manualslib.com manuals search engine

4 Angular Mis-alignment Angular Mis-alignment Engine / gearbox flange Propeller shaft Alignment To obtain accurate alignment the flexible mountings must be adjusted until alignment is attained, and the mountings must be locked in position. The engine/gearbox unit has to be aligned with the propeller shaft in two ways. The traditional engine alignment 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 engine mountings and the couplings must now be tightened in position and the alignment re-checked. 6 Engine Installation at an Angle Beta Marine propulsion engines can be installed at angles up to a maximum of 15° flywheel up or flywheel down when static, or can be run at up to 25° when heeling. When our engines are installed at varying angles of inclination the normal markings on the dipstick should be disregarded. It is probably better to totally drain the lubricating oil from the sump, replacing the oil filter with a new one; then add the recommended amount of lubricating oil – noting its position on the dipstick – and then marking the dipstick. If in doubt ask Beta Marine. Angular Alignment 5 Parallel Mis-alignment Parallel Mis-alignment Engine / gearbox flange Propeller shaft Parallel Alignment Downloaded from www.Manualslib.com manuals search engine

Typical Yacht Exhaust Installation Warning (1) One of the most common problems with engine installations (and possibly expensive), is water entering the engine exhaust manifold from the exhaust system by syphoning when the engine is switched off. This can occur when the point of water injection "X" on the engine is close to or below the water line. Water entering the pistons can cause bent con rods, emulsified engine oil and a wrecked fuel pump! It’s best avoided! (2) This diagram shows a typical exhaust installation. The rubber hose connecting the heat exchanger to the injection bend must be replaced by a hose (a) of sufficient length, connecting to a "T" piece or anti-syphon valve that is above the maximum seawater level when heeled (at least 30 cms / 12 inches above the water line) on the centre line of the boat. The pipe then returns to the injection bend and the seawater is pumped down the exhaust pipe. (3) The exhaust back pressure should NOT exceed 62 mm Hg (2.4 inches Hg). Exhausts (a) An engine correctly installed in accordance with this handbook will meet the emission requirements of the RCD (see page 64). (b) Keep dry exhaust systems to a minimum length and have swept bends (NOT right angle elbows). Exhaust back pressure is increased by longer exhaust length and sharp bends. Back pressure should be measured; with the complete exhaust system connected and the engine running at full speed; and should NOT exceed 62 mm Hg (2.4 inches Hg). The correct measuring point is before the injection bend (at the manifold flange). Wet Exhaust hose should be matched to the injection bend sizes detailed below. 7 Exhaust Beta 43 Beta 50 Beta 60 Standard 50 mm 50 mm 50 mm High rise water 50 mm 50 mm 50 mm injection bend SS Cross over water 50 mm 50 mm 50 mm injection bend SS Normal Seawater Level Anti syphon valve or T piece fitted here Propeller Clearance: between tip of propeller blade and underside of hull should be at least 10 percent of the propeller blade diameter If a rope cutter is fitted, allow approximately 1/2” for movement of engine, see manufacturer’s literature 30 cm minimum Maximum Seawater level when heeled (measured on the centre line of the boat) 40 cm minimum a X 5 cm minimum Waterlock Silencer 6 Downloaded from www.Manualslib.com manuals search engine

8 Fuel supply & leak off Fuel tank Stop tap/valve Fuel/water separator Fuel filter Fuel lift pump Fuel injection pump Engine (All Fuel Connections Supplied) Flexible Fuel Connections to be used Fuel injectors 7 Notes: 1) A fuel/water separator must be installed. 2) The mechanical fuel lift pump is fitted to all engines as standard, but if a suction head of 0.25m or more is required, then an electric fuel lift pump must be fitted (ask your dealer or Beta Marine). 3) It is very important that the excess fuel from the injectors is fed back to the fuel tank and not back to any point in the supply line. This will help prevent air getting into the system. 4) The fuel return (leak off) pipe must loop down to be level with the bottom of the tank before it enters the top of the tank – see drawing. This prevents fuel ‘drain down’. 5) Fuel lines and hoses connecting the fuel tank to the engine, 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, flexible fuel hoses must be used (next to the engine) and must meet the requirements set in standard ISO7840:1995/A1:2000 and/or as required by your surveyor / authority. 6) Any fuel leaks in the system when static are likely to cause poor starting and erratic running and must be corrected immediately. These leaks will allow air to be sucked in when the engine is running. Engine Connections Actual Connector: Required Pipe Size: Fuel supply and fuel leaf-off connections are 8 mm conex with olives 8 mm O.D piping for both with flexible section Seawater cooling pump connections are 28 mm OD Engine Inlet = 28 mm I.D hose Water injected exhaust elbow outlet 50 mm OD Flexible exhaust rubber pipe to correct quality - 50 mm OD Vent Downloaded from www.Manualslib.com manuals search engine

BETA Marine OPERATOR Maintenance Manual

You're Reading a Preview

Recently Viewed