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RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

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7. 8kW Wiring Diagram and Overall Dimensions

Figure 7-1: Travelpower wiring diagram

The above diagram shows 12/24 Volt part of the wiring for the 8kW Travel Power system.

For the 230 Volt wiring diagram please refer to the Travel Power manual.

8. 5kW Travel Power System



This unit is excited by a 12V ignition operated supply the travel power installer can

wire to a convenient plug on the existing loom for this purpose.



When the 12V relay (RDG1396) is placed into the spare relay holder on the engine

the black two way plug becomes live.



The wire colours in the plug are: Black - Earth

Red - Live

WARNING:

ALL HIGH VOLTAGE WIRING SYSTEMS SHOULD BE INSTALLED BY A

QUALIFIED ELECTRICIAN.

Summary of Contents for SHIRE 14 30

Page 1: ...INE MANUAL For the following engine models SHIRE 14 30 SHIRE 14 35 SHIRE 14 38 SHIRE 14 40 SHIRE 14 45 SHIRE 14 50 Enter your engine identification details in the spaces provided above E P BARRUS LIMITED Launton Road Bicester Oxfordshire OX26 4UR Tel 01869 363636 Fax 01869 363610 www barrus co uk ...

Page 2: ...EC e13 97 68GA 2001 63 0545 11 Essential Requirements Standards Other normative document method Technical file Specify in more detail Mandatory standard Annex 1 B Exhaust Emissions B 1 Engine Identification B 2 Exhaust emission requirements EN ISO 8178 1 1996 B 3 Durability B 4 Owners Manual Annex 1 C Noise Emissions See Declaration of Conformity of the craft in which the engine s has have been in...

Page 3: ...ENGINE IT ACCOMPANIES IF A TRANSFER OF TITLE OCCURS IT MUST ALWAYS BE HANDED OVER TO THE NEW OWNER WARRANTY This Limited Warranty provides coverage for five 5 years or 2000 hours whichever occurs first for recreational users and three 3 years or 2000 hours whichever occurs first for commercial users from the date of warranty registration The repair or replacement of parts or the performance of ser...

Page 4: ...WHAT IS NOT COVERED This limited warranty does not cover routine maintenance items adjustments normal wear and tear damage caused by abnormal use operation of the product in a manner inconsistent with the recommended operation duty cycle section of the Owners Manual accident submersion improper installation proper installation specification and techniques are set forth in the Operations and First ...

Page 5: ...er Inlet and Outlet Hose Connections 11 6 Pressurised Water Header Tank 11 7 Shaft Connection and Propeller Selection 17 8 Engine Anti Vibration Mounts 17 9 Engine Alignment 19 10 Electrics 20 11 Electrical Options 20 12 Engine Oil 21 13 Fuel 21 14 Coolant 22 15 Calorifier 22 16 Control Cables 22 17 Domestic Battery Bank 23 18 Control Panel 23 19 Exhaust System 24 20 Hydraulic Drive Transmissions ...

Page 6: ...Filter Change 34 7 Fuel System Bleeding 35 8 Cooling System 35 9 Belt Adjustment 36 10 Belt Maintenance 36 11 Belt Replacement 36 12 Dash Panel Maintenance 37 SECTION 6 Service Schedule 38 Specifications and Capacities 38 Service Intervals 38 SECTION 7 Wiring Diagrams 39 1 Engine Wiring Diagram Shire 30 35 38 40 39 2 Engine Wiring Diagram Shire 30 35 with Glowplugs 40 3 Engine Wiring Diagram Shire...

Page 7: ...event over stressing either bracket during any lift 3 Rotating Shafts and Belts The engine and its accessories are not intended to be put into operation until they are integrated into the boat as a whole No person should be in the engine compartment and the engine cover or deck hatches should be closed whilst the engine is running 4 Exhaust System Exhaust gases may have temperatures as high as 650...

Page 8: ...ulphuric acid if splashed on skin or eyes flush well with water and seek medical advice Keep the battery tops and battery compartment ventilated at all times If disconnecting the battery remove the earth lead FIRST and re connect it last If charging the battery ensure that the charger is switched off before connecting and disconnecting Do not tip the battery on its side Please see label on battery...

Page 9: ... these details This can be found engraved into the brass plate on top of the engine rocker cover and stamped to the crankcase next to the starter motor An example of the engine identification plate is shown below Figure 2 1 Engine Identification Badge Note There are a number of optional extras that may be fitted to an engine that are not listed here A list of common item service part numbers can b...

Page 10: ...rearward and be welded to the hull and forward to the bulkhead Webs or gussets must be welded in place midway to prevent flexing 3 Cooling System Ensure pipe work to and from the skin tanks is of sufficient bore Ensure tight bends and elbows are avoided or kept to a minimum sizes are listed overleaf 4 Skin Tanks The ideal skin tank internal thickness is between 50 and 75mm the table below will ind...

Page 11: ...ze must be increased by approx 10 if a hydraulic drive transmission is fitted 5 Engine Cooling Water Inlet and Outlet Hose Connections These are on the right hand starboard side of the engine Shire 30 38 28mm OD Inlet and Outlet Shire 35 40 28mm OD Inlet and Outlet Shire 45 50 28mm OD Inlet and 35mm OD Outlet Use a good quality hose that cannot collapse or kink and is capable of working at tempera...

Page 12: ...rnal diameter 3mm outlet on the left hand side of the tank and the connection on the port side of the top of the thermostat housing on 45 the side of the twin thermostat housing The second hose is connected between the larger internal diameter outlet on the right hand side of the tank and the hosetail connection on the engine pipe facing forwards and upwards at 45 Shire 30 and 35 connections A con...

Page 13: ...RDG603A8 Issue 1 Shire 14 Canal Boat Complete Manual 30 35 38 40 45 50 doc Page 13 of 50 Figure 3 3 Shire 38 Header Tank Connections Small ID hole Large ID hole ...

Page 14: ...RDG603A8 Issue 1 Shire 14 Canal Boat Complete Manual 30 35 38 40 45 50 doc Page 14 of 50 Figure 3 4 Shire 40 Header Tank Connections Large ID hole Small ID hole ...

Page 15: ...RDG603A8 Issue 1 Shire 14 Canal Boat Complete Manual 30 35 38 40 45 50 doc Page 15 of 50 Figure 3 4 Shire 45 Header Tank Connections Small ID hole Large ID hole ...

Page 16: ...hire 14 Canal Boat Complete Manual 30 35 38 40 45 50 doc Page 16 of 50 Shire 50 There is only a single hose connected to the left hand side of the bottle 3mm outlet Figure 3 5 Shire 50 Header Tank Connections Single Hole ...

Page 17: ...der RDG3906 Engine mount spacer Alternatively they can be manufactured locally Ensure that the engine has been installed for at least 24 hours before shaft alignment is checked to allow the mounts time to settle under the engine weight Ensure that the anti vibration mount centre screw is sufficiently raised so as not to touch the engine bed If this occurs excessive engine vibration will be experie...

Page 18: ...RDG603A8 Issue 1 Shire 14 Canal Boat Complete Manual 30 35 38 40 45 50 doc Page 18 of 50 Figure 3 7 Correct Anti Vibration Mount Installation ...

Page 19: ...t of alignment it will result in excessive vibration and possible damage to the stern tube and propeller shaft Boats that are fitted with fully flexible drive couplings should still have the engine and shaft alignment as close as possible A dummy shaft may be required for this purpose Note some types of flexible shaft couplings require the input and output to be misaligned check with the coupling ...

Page 20: ...t domestic alternator damage does not occur if the engine is run without the domestic battery back connected The belt should only be fitted when domestic battery bank has been connected to the domestic alternator Belt fitting and tensioning instructions are in section 5 Servicing Procedure ensure alignment is correct A cable will need to be manufactured locally and fitted between the lower 140A or...

Page 21: ...om engine to main supply and return lines to main fuel tank ensuring they are connected the correct way around The hose to the fuel pump is the inlet The engine hoses are supplied with 5 16 8mm OD metal hose tails and should be securely fitted to the main supply and return pipes with compression fittings The engine hoses should have sufficient slack to absorb engine movement without placing strain...

Page 22: ...up though the white plastic expansion tank N B After running the engine for the first time monitor the water level frequently as trapped air bubbles may be expelled Top up the system as necessary Bleed skin tank 15 Calorifier The temperature of coolant flowing to the calorifier from the engine can be between 85 and 90 C A blender valve must be incorporated in the calorifier hot water system outlet...

Page 23: ...mum battery bank size Example 2 Weekend cruising or hire fleet application fitted with a 240 amp domestic alternator 3 5 x 240 840 ampere hour maximum battery bank size 18 Control Panel All Shire engines are supplied with high quality engine control panel that all show RPM and hours run and include warning lights and a warning buzzer the deluxe panels also have in addition gauges for water temp oi...

Page 24: ...ding 50 10 50 11 00 70 15 00 110 18 00 140 19 50 20 00 240 22 00 Alternative or non standard alternators will require calibrating and checking by trail and error with a hand held tacho until the engine speed and indicated tachometer speed are the same Engine energise to stop systems are available as an optional extra 19 Exhaust System The exhaust outlet size on the engine is 1 1 2 BSP female There...

Page 25: ... it has sufficient cooling capacity and is sized appropriately taking into account Maximum engine power High ambient summer air temperature Summer River Canal Sea temperature No additional restriction to engine coolant flow is present Skin tanks will also need to be increased by approx 10 dissipate the additional heat generated 21 Hydraulic Pump Drive Option Shire 38 40 45 50 For SAE type pump 9T ...

Page 26: ... removed Check fuel system is connected correctly and primed Fuel line water trap installed and water drained off Check header tank and skin tank connections are correct way round constant pipework rise to header tank Check level of coolant in header tank and correct ratio All air has been bled from skin tank calorifier and pipework Engine and gearbox oil levels are as specified Throttle and gear ...

Page 27: ...first position on Observe warning lights and gauges on deluxe panel N B the engine overheat light will only illuminate when the water temperature exceeds the safe level Listen for warning buzzer Turn key to second position start and hold to crank Crank the engine for no more than 15 seconds On engine start immediately release key Key will return to first position on The warning buzzer will stop an...

Page 28: ... Diesel fuel Please note that when the vessel is to be left for any period of time the fuel tank should be left full to eliminate the build up of condensation and formation of water in the fuel tank Engine to be turned off while refuelling The fuel type for all Shire canal boat engines is diesel DO NOT USE BIODIESEL 6 Twin Thermostats Shire 45 and 50 The twin thermostat design is a feature unique ...

Page 29: ...tored in the hot water tank has reached full temperature the second 88 thermostat opens and water can then flow to the skin tank and correctly control engine cooling The exhaust manifold that earlier helped to heat engine water is now cooled to ensure safe operation and reduce engine compartment temperatures If the load on the engine reduces and the demand for domestic hot water increases then the...

Page 30: ...part number RDG80210219 7 Exhaust Back Pressure The back pressure falls within the manufacturers recommended range when using the exhaust system supplied with the engine SECTION 5 Service Procedure 1 Engine Oil and Filter Change CAUTION WEAR DISPOSABLE GLOVES AND BEWARE OF HOT OIL AND ENGINE BLOCK REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT Change the engine oil while the engine i...

Page 31: ...LOCK REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT Release the two spring clips pull off the end cover to reveal the filter element The element simply pulls out To fit the new element slide the open end of the filter element into the main body gently push the element until fully seated Refit the end cover The air filter element is constructed from pleated paper inspect it closely fo...

Page 32: ... 5 minutes for oil to drain thoroughly Replace the drain plug ensure that the sealing washer if used is still in place and in good condition tighten Fit a new washer if required Refill the gearbox with oil to the upper mark on the dipstick Screw dipstick in fully to establish level Refer to PRM Owner manual for more details Section 6 contains details of oil specifications Do not overfill gearbox a...

Page 33: ... with due regard for the environment and take to your local waste oil disposal point Do not allow oil or contaminated parts to enter the inland water way system 5 Primary Fuel Filter Water Drain Shire 30 35 40 45 50 CAUTION WEAR DISPOSABLE GLOVES REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT Note Shire 38 is not fitted with a primary fuel filter water trap Level dipstick Filler plug...

Page 34: ... trap in the fuel system before the engine Ensure that this is drained regularly Do not over tighten drain screw Figure 5 6 Primary Fuel Filter Drain Screw 6 Primary and Secondary Fuel Filter Change CAUTION WEAR DISPOSABLE GLOVES REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT Ensure the fuel tank is at least full prior to undertaking this procedure Turn off the main boat fuel supply ...

Page 35: ... procedure See Fuel paragraph Section 3 in Yanmar Engine Operation Manual 8 Cooling System WARNING DO NOT CHECK THE COOLANT LEVEL WHEN THE ENGINE IS HOT REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT To check the coolant level ensure that the engine has been shut down for at least half an hour The coolant level can be checked visually and should between the two level marks formed on ...

Page 36: ...ver tightened alternator bearing failure will occur 10 Belt Maintenance Do not allow oil to contact the belt Oil attacks the construction of the belt reduces the drive efficiency and will ultimately cause it to fail prematurely Replace the belt if it cracks or splits and as the adjustment nears the limit of its travel Note Some boat builders may remove one or more of the alternators during the ins...

Page 37: ... TURN BATTERY ISOLATION SWITCHES OFF Warning Light Bulb replacement 1 Release the panel from its mounting 2 To replace an illumination bulb a The bulbs are accessible from the rear of the panel Remove the wires unscrew the nut and pull out the bulb housing from the panel 3 To replace any gauge a The gauges are accessible from rear of the panel Unplug the wire connectors unscrew and pull the gauge ...

Page 38: ...150 and 260 Gearbox Engine Oil Service Intervals Check Change Notes Engine Oil Filter Daily level Every 250 hours Or 12 Months First change after 50 hrs Gearbox Oil Weekly level Every 250 hours Or 12 Months First change after 25 hrs Coolant level Daily level Every 24 Months Diesel Fuel Filter Primary and Secondary 50 hours Every 500 hours Or 12 Months Drain water every 50 hours or monthly Air Filt...

Page 39: ...RDG603A8 Issue 1 Shire 14 Canal Boat Complete Manual 30 35 38 40 45 50 doc SECTION 7 Wiring Diagrams 1 Engine Wiring Diagram Shire 30 35 38 40 ...

Page 40: ...RDG603A8 Issue 1 Shire 14 Canal Boat Complete Manual 30 35 38 40 45 50 doc Page 40 of 50 2 Engine Wiring Diagram Shire 30 35 with Glowplugs ...

Page 41: ...RDG603A8 Issue 1 Shire 14 Canal Boat Complete Manual 30 35 38 40 45 50 doc 3 Engine Wiring Diagram Shire 45 50 70 Shire 40 with optional 240A Alt ...

Page 42: ...RDG603A8 Issue 1 Shire 14 Canal Boat Complete Manual 30 35 38 40 45 50 doc 4 Standard Panel Wiring Diagram ...

Page 43: ...RDG603A8 Issue 1 Shire 14 Canal Boat Complete Manual 30 35 38 40 45 50 doc 5 Deluxe Panel Wiring Diagram ...

Page 44: ... Manual 30 35 38 40 45 50 doc 6 RDG20710110 Standard Panel Tachometer Hour Meter Water Temperature Warning Light Oil Pressure Warning Light 140A Alternator Charge Light 50A Alternator Charge Light Glow Plug Light Optional Key Flap Ignition Switch ...

Page 45: ...DG20710111 Deluxe Panel 50A Alternator Charge Light 140 240A Alternator Charge Light Oil Pressure Warning Light Water Temperature Warning Light Glow Plug Light Optional Key Flap Ignition Switch Water Temperature Gauge Hour Meter Tachometer 50A Alternator Voltage Output Gauge Oil Pressure Gauge ...

Page 46: ...g diagram please refer to the Travel Power manual 8 5kW Travel Power System This unit is excited by a 12V ignition operated supply the travel power installer can wire to a convenient plug on the existing loom for this purpose When the 12V relay RDG1396 is placed into the spare relay holder on the engine the black two way plug becomes live The wire colours in the plug are Black Earth Red Live WARNI...

Page 47: ...f 50 Figure 7 2 Travelpower dimension reference diagram Sizes for the dimensions listed in figure 7 2 are as follows 3 5 kW 5 kW 7 8 kW Dim 1 65 mm 65 mm 55 mm Dim 2 390 mm 390 mm 470 mm Dim 3 140 Amp Alt 420 mm Dim 3 240 Amp Alt 445 mm Dim 4 140 Amp Alt 135 mm Dim 4 240 Amp Alt 150 mm ...

Page 48: ...85 tony foxton boats freeserve co uk NORFOLK French Marine Motors Ltd 01603 722079 info frenchmarine com NORTHAMPTON Grand Junction Boat Co 01604 858043 grandjunco talk21 com NOTTINGHAM Farndon Marina 01636 705483 info farndonmarina co uk STAFFORDSHIRE JD Boat Services Ltd 01902 791811 jdboats btinternet com Stone Boatbuilding Company 01785 812688 sales stonebuilding co uk Streethay Warf 01543 414...

Page 49: ...29150 35153 129150 35153 129150 35153 129150 35153 Fuses The electrical system is fitted with three or four blade type fuses a Engine start control system 25amp RDG1152 b Engine stop control system 40amp RDG3246 c Dash Panel supply 15amp RDG3245 7 8kw Alternator sub system 15amp RDG3245 3 5kw Travel Power alternator belt is RDG0047511 5kw Travel Power alternator belt is RDG0047511 7 8kw Travel Pow...

Page 50: ...RDG603A8 Issue 1 Shire 14 Canal Boat Complete Manual 30 35 38 40 45 50 doc Page 50 of 50 Shire Service Record Card ...

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