Barrus Shire 15 15 CB Manual Download

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ORIGINAL INSTRUCTION

RDG603A13

– Issue 19

CANAL, WORK AND RIVER BOAT ENGINE

MANUAL

For the following engine models:

Shire 15 15 CB / WB / RB

HIRE

Summary of Contents for Shire 15 15 CB

Page 1: ...ORIGINAL INSTRUCTION RDG603A13 Issue 19 CANAL WORK AND RIVER BOAT ENGINE MANUAL For the following engine models Shire 15 15 CB WB RB SHIRE 15 20 CB WB RB...

Page 2: ...rt symbol appears throughout the manual It means attention be alert as your safety is involved Please read and follow the message that appears after the safety alert symbol NOTICE This indicates a sit...

Page 3: ...serial number in the space provided above Please quote the engine identification number during any enquiry or when ordering spare parts Information about the engine serial number and its location on t...

Page 4: ...pleasure Please read it carefully in conjunction with the PRM Gearbox Manual and familiarise yourself with the engine and its parts before operation The information and recommendations given in this m...

Page 5: ...ler has completed the Boat Builder Section on the Service Record Card located at the back of this manual regarding hand over and commissioning of boat Failure to complete and return the registration f...

Page 6: ...the Owner s Manual accident submersion improper installation proper installation specification and techniques are set forth in the Operations and First time running sections in this manual use of an a...

Page 7: ...ire 15 15 River Boat 17 4 Shire 15 20 River Boat 18 5 Shire 15 15 Work Boat 19 6 Shire 15 20 Work Boat 20 SECTION 4 Control Panel 21 1 Basic Control Panel 21 2 Standard Control Panel 21 3 Deluxe Contr...

Page 8: ...36 16 Calorifier 37 17 Control Cables 38 18 Domestic Battery Bank 39 19 Control Panel 40 20 Exhaust System Canal Boat 41 21 Exhaust System Work Boat River Boat 42 22 Hydraulic Drive Transmissions 44 2...

Page 9: ...Impellor Change Work Boat River Boat 60 15 Engine Heat Exchanger Tube Stack Flushing 60 16 Winterization of Seawater Cooling System Work Boat River Boat 61 SECTION 8 Service Schedule 62 1 Specificatio...

Page 10: ...ormity for Recreational Craft Propulsion Engines to the Directive No 2013 53 EU 74 2 Declaration of Incorporation of Partly Completed Machinery 75 SECTION 14 Lubricant Safety Data Sheets 79 1 Ground F...

Page 11: ...y maintenance or repairs 2 Lifting DANGER CRUSH HAZARD NEVER STAND UNDER A HOISTED ENGINE IF THE HOIST MECHANISM FAILS THE ENGINE WILL FALL ON YOU CAUSING SERIOUS INJURY OR DEATH The Lifting points su...

Page 12: ...ZARD WAIT UNTIL THE EXHAUST COOLS BEFORE YOU TOUCH IT Exhaust gases may have temperatures as high as 650 C and contain elements which are harmful if ingested It is therefore essential that exhaust sys...

Page 13: ...away from the battery NO SMOKING Batteries contain sulphuric acid if splashed on skin or eyes flush well with water and seek medical advice Keep battery tops and battery compartment ventilated at all...

Page 14: ...Boat Seawater Heat Exchanger cooled dry exhaust manifold with either a dry exhaust system same as a Canal Boat or water injected exhaust system Can also be used for sea going applications RB River Boa...

Page 15: ...from front Figure 3 Shire 15 15 CB Right Side Viewed from rear Note There are a number of optional extras that may be fitted to an engine that are not shown here Description 1 Single Thermostat Housi...

Page 16: ...e 5 Shire 15 20 CB Right Side Viewed from rear Note There are a number of optional extras that may be fitted to an engine that are not shown here Description 1 Single Thermostat Housing 2 50 Amp 12 Vo...

Page 17: ...re 7 Shire 15 15 RB Right Side Viewed from rear Note There are a number of optional extras that may be fitted to an engine that are not shown here Description 1 Seawater Pump 2 50 Amp 12 Volt Alternat...

Page 18: ...re 9 Shire 15 20 RB Right Side Viewed from rear Note There are a number of optional extras that may be fitted to an engine that are not shown here Description 1 Seawater Pump 2 50 Amp 12 Volt Alternat...

Page 19: ...ire 15 15 WB Right Side Viewed from rear Note There are a number of optional extras that may be fitted to an engine that are not shown here Description 1 Coolant Heat Exchanger 2 50 Amp 12 Volt Altern...

Page 20: ...ire 15 20 WB Right Side Viewed from rear Note There are a number of optional extras that may be fitted to an engine that are not shown here Description 1 Coolant Heat Exchanger 2 50 Amp 12 Volt Altern...

Page 21: ...ure Warning Light 4 Oil Pressure Warning Light 5 50A Alternator Charge Warning Light 6 Glow Plug Light 7 Key Flap and Ignition Switch 12 Engine Stop Description 1 Tachometer Gauge 2 Hour Meter 3 Water...

Page 22: ...15 15 WB RB Shire 15 20 WB RB Basic Control Panel Panel supplied as standard On certain engines a different control panel may be supplied as an option 5 Warning Light Procedure When the ignition is fi...

Page 23: ...first turned on for 5 8 seconds to indicate the heating system is operational When the light goes out the engine can be started Whilst the control panel is in operation all the gauges are backlit Thi...

Page 24: ...p the engine immediately Contact your local dealer Failure to stop the engine may result in permanent engine damage 5 50A Alternator Charge Warning Light This indicates that the alternator has stopped...

Page 25: ...6 Overall Dimensions of the Basic Control Panel All Dimensions are in mm Figure 17 Basic Control Panel Dimensions 7 Overall Dimensions of the Standard Control Panel All Dimensions are in mm Figure 18...

Page 26: ...RDG603A13 Issue 19 Page 26 of 97 8 Overall Dimensions of the Deluxe Control Panel All Dimensions are in mm Figure 19 Deluxe Control Panel Dimensions...

Page 27: ...and forward to the bulkhead Webs or gussets must be welded in place midway to prevent flexing 3 Cooling System Canal Boats with Skin Tanks Ensure pipe work to and from the skin tanks is of sufficient...

Page 28: ...aulic bow thruster is used Please refer to Section 5 Installation 22 Hydraulic Drive Transmission for further information 5 Engine Cooling Water Connections For Canal Boats These are on the Left hand...

Page 29: ...NJURY TIGHTEN THE HEADER TANK CAP SECURELY AFTER BEING REMOVED STEAM CAN SPURT OUT DURING ENGINE OPERATION IF THE CAP IS LOOSE The pressurised header tank should be mounted higher than the level of th...

Page 30: ...lt in excessive engine movement and premature mount failure If this is a problem put steel packing plates under the mounts Ensure that the engine has been installed for at least 24 hours before shaft...

Page 31: ...RDG603A13 Issue 19 Page 31 of 97 Figure 22 Correct Anti Vibration Mount Installation...

Page 32: ...of 97 Figure 23 Correct Anti Vibration Mount Installation Description 1 Normal mounting position 2 Alternative mounting position if engine compartment space is restricted Figure 24 Anti Vibration Mou...

Page 33: ...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 Some types of flexible shaft couplings require the...

Page 34: ...cable to the 70A alternator B terminal see wiring diagram This ensures that the 50A alternator charges the start battery and the 70A alternator charges the domestic battery removing the requirement f...

Page 35: ...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...

Page 36: ...water and 50 antifreeze Please make sure that the antifreeze used is suitable for the silicone hoses fitted to the engine Open the calorifier taps if fitted to fill the calorifier system and displace...

Page 37: ...ensure air is removed and allow a 13mm 1 2 air gap in top of manifold to allow for expansion Note Water Tap CB WB engines only on side of engine must be opened to fill engine and must be closed to the...

Page 38: ...st be incorporated in the calorifier hot water system outlet to lower the hot water temperature for domestic use 17 Control Cables Connect engine speed control cable With the engine off ensure that th...

Page 39: ...l prematurely alternators that fail due to the battery bank being over the maximum recommended size will not be covered by warranty Higher output additional alternators or travel power kits are availa...

Page 40: ...iring loom plug Turn ignition on do not start engine Press and hold black button on rear of tacho until H appears on the digital display at the bottom of the tacho on the front When pressing and holdi...

Page 41: ...e of suitable exhaust grade between the engine and the silencer or hull outlet The outlet must be above the waterline at all times The exhaust fittings and silencer if fitted must not be smaller than...

Page 42: ...r level a system such as a Lift Silencer with a siphon break system must be used to prevent sea water from flowing back down the exhaust and into the engine Lift Silencer The correct installation of t...

Page 43: ...85 degrees centigrade Normally in a well designed system the temperature of the silencer should be between 50 70 degrees centigrade Such operation will result in longer exhaust life Connections to the...

Page 44: ...ear the unit should have the small valve removed from the top and this should be thoroughly washed in warm soapy water to remove salt encrustation 2 On a pleasure vessel this should be done twice a ye...

Page 45: ...separate water circulating pump will need to be fitted for a hydraulic drive transmission Hydraulic oil coolers should be installed after the engine not before Coolers that are installed before the e...

Page 46: ...f coolant in header tank and correct ratio of antifreeze to water All air has been bled from skin tank calorifier and pipework Engine and gearbox oil levels are as specified Throttle and gear cables c...

Page 47: ...n deluxe panel Note The engine water temperature overheat warning light will only come on for a brief period of time when the ignition is first turned on as a bulb check It will then only illuminate i...

Page 48: ...Running diesel engines near there rated output maximum load regularly will disperse accumulated carbon and condensation enhancing engine life and reducing emissions Running the engine at or near maxim...

Page 49: ...ystem is in top condition This should result in many years of smooth reliable operation without the cost and inconvenience of expensive breakdowns due to poor quality fuel It has also been found that...

Page 50: ...sump Note Remember to refit the blanking plug afterwards Place a drip tray under the engine to catch the small amount of oil that will escape from the oil filter Using the strap type oil filter remova...

Page 51: ...LASH AND BURN YOU Some engines will have a gearbox sump pump fitted To change the oil in this circumstance follow the same procedures as were outlined for changing the engine oil For engines without a...

Page 52: ...g Drain Plug on Gearbox 4 Disposal of Oil and Related Items NOTICE ALWAYS BE ENVIRONMENTALLY RESPONSIBLE Please dispose of used oil and oil filters safely with due regard for the environment and take...

Page 53: ...imary fuel filter water trap Loosen the drain screw located in the bottom of the fuel filter water trap Figure 33 Drain off any water Once the water has been drained retighten the drain screw It is un...

Page 54: ...cedure Turn off the main boat fuel supply tap This is located on or near the fuel tank Place a small drip tray under the filter body Remove the fuel filter in the same way as the engine oil filter in...

Page 55: ...fter the fuel filter has been purged of air close the bleed screw Undo ALL the injector pipe connections Crank the engine over with the starter motor When fuel can be seen stop cranking Tighten the in...

Page 56: ...olant 50 clean tap water and 50 ethylene glycol based anti freeze through the expansion tank filler cap Do not use water only to top up as this weakens the coolant mix reducing the level of frost prot...

Page 57: ...ORT OR TIE BACK REMOVE ALL JEWELLERY BEFORE COMMENCING WORK CHECK BEFORE STARTING THE ENGINE THAT ANY TOOLS OR RAGS USED DURING MAINTENANCE HAVE BEEN REMOVED FROM THE AREA Ensure the ignition key is r...

Page 58: ...the top adjuster bolts and the lower mounting pivot nut and bolt Push the alternator towards the engine to loosen the belt Remove the belt Hold the belt in position over the top alternator pulley Rota...

Page 59: ...r lubricants are available Then with the battery master switch turned off operate the key switch a couple of times This will ensure the lubricant works into the mechanism 13 Sacrificial Anode Change F...

Page 60: ...For Work Boats When the engine is cold drain the water from the engine block Remove the hose from the tap and drain Drain water from the heat exchanger The drain plug is in the bottom of the heat exch...

Page 61: ...sh between the tubes to remove any dirt of scum build up Inspect the tube stack and replace if damaged Clean out the manifold if required Reassemble and refit checking the end cap O rings are in good...

Page 62: ...ons and Capacities Specification of Coolants and Lubricants to use Component Lubricant Engine SAE 10W 40 API Class CD Oil Coolant 50 Clean Water 50 Ethylene Glycol Antifreeze PRM 60 80 90 Gearbox ATF...

Page 63: ...Hours As required Check hoses for damage or leaks Replace as necessary Key Switch Lubricate Every 150 hours OR 12 Months As per instructions in Section 7 Service Procedure Sea Water Pump Impellor WB R...

Page 64: ...RDG603A13 Issue 19 Page 64 of 97 SECTION 9 Wiring Diagrams 1 Engine Wiring Diagram Shire 15 15 20 Figure 36 Shire 15 15 20 Wiring Diagram...

Page 65: ...RDG603A13 Issue 19 Page 65 of 97 2 Basic Control Panel Wiring Diagram Figure 37 Basic Control Panel Wiring Diagram...

Page 66: ...RDG603A13 Issue 19 Page 66 of 97 3 Standard Control Panel Wiring Diagram Figure 38 Standard Control Panel Wiring Diagram...

Page 67: ...RDG603A13 Issue 19 Page 67 of 97 4 Deluxe Control Panel Wiring Diagram Additional Option SS1551 Figure 39 Deluxe Control Panel Wiring Diagram...

Page 68: ...of Crankshaft Counter Clockwise View from Flywheel End Counter Clockwise View from Flywheel End Lubrication System Combination of Pressure and Splash Combination of Pressure and Splash Cooling System...

Page 69: ...Flow at Idle 0 3 Litre Min 3 Dry Weight of Engine Data Dry Weight of Engine Including Gearbox Model Dry Weight kg Shire 15 15 142kg Shire 15 20 160kg The dry weights stated are for the standard engine...

Page 70: ...399 enquiries tontomarine co uk Mobile Marine 01297 631821 mobilemarine btconnect com Darthaven Marina 01803 752242 admin darthaven co uk DORSET Purbeck Marine 01202 686592 purbeckmarine aol com Rob P...

Page 71: ...ephen Goldsbrough Boats 01564 778210 andy sgboats com WILTSHIRE Foxhangers Marine 01380 828795 info foxhangers co uk WORCESTERSHIRE J L Pinder Son 01527 876438 sales jlpinderandsons co uk Starline Nar...

Page 72: ...008 GB T12732 2008 GB T12732 2008 Air Filter Element 3011 T3 0004 3011 T3 0004 3011 T3 0004 Oil Filter 119305 35170 119305 35170 119305 35170 Sea Water Pump Impeller N A RDG010A3 RDG010A3 Sea Water Pu...

Page 73: ...DG3245 3 Engine Start Control System Fuse 15amp RDG3245 4 Glow Plug Fuse 40amp RDG3246 5 Cold Start Relay RDG5279 6 Starter Relay RDG1396 Figure 40 Fuses Relays Engine Oil Engine Oil is available from...

Page 74: ...20 CB RB WB 3M78 M78 HPiVS R1105 002 I 02 Essential Requirements Standards Other normative document method Technical file Specify in more detail Mandatory standard Annex 1 B Exhaust Emissions B 1 Eng...

Page 75: ...he engines also comply with measures against the emission of gaseous and particulate pollutants from internal combustion engines to be installed in non road mobile machinery contained in the Directive...

Page 76: ...and reliability of control systems Yes 3 No 3 3 The control systems are designed and constructed to withstand the intended operating stresses and external influences A fault in the hardware or softwar...

Page 77: ...Risks of uncontrolled movements 1 4 REQUIRED CHARACTERISTICS OF GUARDS AND PROTECTIVE DEVICES 1 4 1 General requirements No No Guards to be specified and fitted by the boat builder installer 1 4 2 1...

Page 78: ...e warning stickers are fitted on surfaces that may become hot during operation All other protection or warnings to be made by the boat builder installer 1 7 1 1 Information and information devices Yes...

Page 79: ...Details of the supplier of the safety data sheet Supplier Morris Lubricants Castle Foregate Shrewsbury SY1 2EL 08 45 17 00 GMT T 44 0 1743 232200 F 44 0 1743 353584 sds morris lubricants co uk 1 4 Eme...

Page 80: ...tion of first aid measures General information Get medical attention if any discomfort continues Inhalation If spray mist has been inhaled proceed as follows Move affected person to fresh air and keep...

Page 81: ...tering drains sewers or watercourses The product is insoluble in water and will spread on the water surface 6 3 Methods and material for containment and cleaning up Methods for cleaning up Contain spi...

Page 82: ...0 01 mg l Sediment Freshwater 132000 mg kg Sediment Marinewater 13200 mg kg Soil 263000 mg kg Fresh water 0 1 mg l Phenol dodecyl sulfurized carbonates calcium salts overbased DNEL Industry Dermal Sho...

Page 83: ...be used if the airborne contamination exceeds the recommended occupational exposure limit Thermal hazards Not anticipated under normal conditions of use The product is combustible if heated excessive...

Page 84: ...ames and other sources of ignition 10 5 Incompatible materials Materials to avoid Strong oxidising agents 10 6 Hazardous decomposition products Hazardous decomposition Oxides of carbon Oxides of nitro...

Page 85: ...re may cause skin dryness or cracking Eye contact May cause temporary eye irritation Acute and chronic health Prolonged or repeated contact with used oil may cause serious skin diseases such as Hazard...

Page 86: ...al hazards Environmentally hazardous substance marine pollutant 14 6 Special precautions for user Not applicable 14 7 Transport in bulk according to Annex II of MARPOL73 78 and the IBC Code Transport...

Page 87: ...pt Korea KECI All the ingredients are listed or exempt China IECSC All the ingredients are listed or exempt Philippines PICCS All the ingredients are listed or exempt New Zealand NZIOC All the ingredi...

Page 88: ...t Supplier Morris Lubricants Castle Foregate Shrewsbury SY1 2EL 08 45 17 00 GMT T 44 0 1743 232200 F 44 0 1743 353584 sds morris lubricants co uk 1 4 Emergency telephone number Emergency telephone 44...

Page 89: ...any discomfort continues Inhalation If spray mist has been inhaled proceed as follows Move affected person to fresh air and keep warm and at rest in a position comfortable for breathing Get medical a...

Page 90: ...tering drains sewers or watercourses The product is insoluble in water and will spread on the water surface 6 3 Methods and material for containment and cleaning up Methods for cleaning up Contain spi...

Page 91: ...tection Eyewear complying with an approved standard should be worn if a risk assessment indicates eye contact is possible The following protection should be worn Chemical splash goggles or face shield...

Page 92: ...sing properties The mixture itself has not been tested but none of the ingredient substances meet the criteria for classification as oxidising 9 2 Other information Volatile organic compound The produ...

Page 93: ...ed to be carcinogenic under IARC All of the oils in this product have been demonstrated to contain less than 3 extractables by the IP346 test Reproductive toxicity Reproductive toxicity fertility No d...

Page 94: ...ntial Bioaccumulative potential Bioaccumulation is unlikely to be significant because of the low water solubility of this product Partition coefficient Not determined log Kow 7 The above figure is typ...

Page 95: ...09 No 716 EU legislation Dangerous Preparations Directive 1999 45 EC Dangerous Substances Directive 67 548 EEC Regulation EC No 1907 2006 of the European Parliament and of the Council of 18 December 2...

Page 96: ...NOTE Lines within the margin indicate significant changes from the previous revision Issued by Regulatory Affairs Revision date 26 10 2015 Revision 2 SDS number 21439 Hazard statements in full H304 M...

Page 97: ...ssion of Boat and Hand Over to Customer Refer to the Installation Check List Page in this Manual Date Signed Dealer Stamp Actual Hours Signed Dealer Stamp Actual Hours Signed Dealer Stamp Actual Hours...

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