Barrus Shire 38 Manual Download Page 67

Page: 67 / 100

RDG603A20 - Issue 10

Page 67 of 100

Hybrid System:

48 Volt Alternator Belt

(up to Serial No xx-02638)

RDG004A200

48 Volt Alternator Belt (Port)

(from Serial No xx-02639)

RDG004A219

48 Volt Alternator Belt (Starboard)

(from Serial No xx-02639)

RDG004A220

Fuses & Relays:

The electrical system is fitted with three or four blade type fuses:

Engine Stop Control System Fuse

40amp

RDG3246

Control Panel Supply Fuse

15amp

RDG3245

Engine Start Control System Fuse

15amp

RDG3245

Glow Plug Fuse

40amp

RDG3246

7/8kw Alternator Sub-System Fuse (Optional)

15amp

RDG3245

Cold Start Relay

RDG5279

Starter Relay

RDG1396

Figure 28: Fuses & Relays

Engine Oil:

Engine Oil is available from your Shire Dealer in convenient 5 litre containers (Part Number

RDG6110).

Diesel Fuel Additive:

Diesel fuel additive is available from your Shire Dealer in a handy 500ml container (Part No

RDG80210219).

Summary of Contents for Shire 38

Page 1: ...ORIGINAL INSTRUCTION RDG603A20 Issue 10 CANAL ENGINE MANUAL For the following engine models Shire 38 Shire 40 Shire 45 Shire 50...

Page 2: ...ert 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 si...

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...

Page 4: ...nd PRM Gearbox Manuals and familiarise yourself with the engine and its parts before operation If the engine is fitted with Travel Power and or Hybrid options please also read the supplied manuals for...

Page 5: ...oat 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 form to E P Barrus will...

Page 6: ...oper installation proper installation specification and techniques are set forth in the Operations and First time running sections in this manual use of an accessory or part not manufactured or sold b...

Page 7: ...Shire 40 16 3 Shire 45 17 4 Shire 50 18 SECTION 4 Control Panel 19 1 Standard Control Panel 19 2 Deluxe Control Panel 19 3 Control Panel Overview 20 4 Warning Light Procedure 20 5 Overall Dimensions o...

Page 8: ...Hydraulic Pump Drive Option Shire 38 40 45 50 39 23 Centa Coupling CF M 160 RDG2779 39 24 PRM 280DP Gearbox with Power Take Off Option 40 25 Installation Check List 41 SECTION 6 Operation 42 1 Startin...

Page 9: ...and Capacities 57 2 Service Intervals 58 SECTION 9 Wiring Diagrams 59 1 Engine Wiring Diagram Shire 38 40 45 50 59 2 Standard Control Panel Wiring Diagram 60 3 Deluxe Control Panel Wiring Diagram 61 S...

Page 10: ...20 Issue 10 Page 10 of 100 2013 53 EU 73 SECTION 14 Lubricant Safety Data Sheets 74 1 Golden Film Running In Oil 74 2 Ground Force 10W 40 82 3 Liquimatic Super ATF 91 SECTION 15 Shire Service Record C...

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: ...AZARD 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 sy...

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: ...ry exhaust manifold WB Work 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 goi...

Page 15: ...Shire 38 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 Volt Alterna...

Page 16: ...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 Volt Alternator 3 150 Amp 12 Volt Alternator 4 Dr...

Page 17: ...Note There are a number of optional extras that may be fitted to an engine that are not shown here Description 1 Twin Thermostat Housing 2 50 Amp 12 Volt Alternator 3 240 Amp 12 Volt Alternator 4 Dry...

Page 18: ...a number of optional extras that may be fitted to an engine that are not shown here Description 1 Twin Thermostat Housing 2 50 Amp 12 Volt Alternator 3 240 Amp 12 Volt Alternator 4 Water Cooled Manifo...

Page 19: ...e Warning Light 5 50A Alternator Charge Warning Light 6 150 240A Alternator Charge Warning Light 7 Glow Plug Light 8 Key Flap and Ignition Switch Description 1 Tachometer Gauge 2 Hour Meter 3 Water Te...

Page 20: ...rted the warning lights will go out Please note that the water temperature warning light and glow plug light operate slightly differently The water temperature warning light will only come on for a br...

Page 21: ...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 c...

Page 22: ...Overall Dimensions of the Standard Control Panel All Dimensions are in mm Figure 12 Standard Control Panel Dimensions 6 Overall Dimensions of the Deluxe Control Panel All Dimensions are in mm Figure...

Page 23: ...d 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...

Page 24: ...hydraulic oil if a hydraulic bow thruster is used Please refer to Section 5 Installation 21 Hydraulic Drive Transmission for further information 5 Engine Cooling Water Inlet and Outlet Hose Connection...

Page 25: ...be mounted higher than the level of the engine no less than 300mm and no more than 1m from the engine to prevent cooling system air locks Shire 50 A single hose connects the tank to the vertical hoset...

Page 26: ...ier 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 to lower the hot wate...

Page 27: ...d Propeller Selection Some type of flexible coupling must be used to connect the gearbox output flange to the propeller shaft flange Please note underperforming engines will not be covered under warra...

Page 28: ...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 w...

Page 29: ...RDG603A20 Issue 10 Page 29 of 100 Figure 17 Correct Anti Vibration Mount Installation...

Page 30: ...stallation Description 1 Normal mounting position 2 Alternative mounting position if engine compartment space is restricted Figure 19 Anti Vibration Mount Installation Points 10 Engine Alignment The g...

Page 31: ...and shaft alignment as close as possible A dummy shaft may be required for this purpose Some types of flexible shaft couplings require the input and output to be misaligned check with the coupling man...

Page 32: ...gine is run without the domestic battery back connected The belt should only be fitted when the domestic battery bank has been connected to the domestic alternator Belt fitting and tensioning instruct...

Page 33: ...ING DIESEL FUEL IS FLAMMABLE AND EXPLOSIVE UNDER CERTAIN CONDITIONS WARNING DIESEL FUEL IS HARMFUL TO SKIN MAKE SURE THE RELEVANT PERSONAL PROTECTION EQUIPMENT IS WORN Ensure the main fuel tank is cle...

Page 34: ...will already have fuel in it from the engine run in and test procedure 16 Coolant WARNING SCALD HAZARD NEVER REMOVE THE COOLANT BOTTLE CAP IF THE ENGINE IS HOT STEAM AND HOT COOLANT WILL SPURT OUT AND...

Page 35: ...ft lever selects positively and that the drive direction corresponds with the gearshift control lever Ensure that the gearbox control lever and the gearshift lever are both in neutral before connectio...

Page 36: ...40 840 ampere hour maximum battery bank size 19 Control Panel CAUTION All Shire engines are supplied with an engine control panel that shows RPM and hours run and include warning lights and a warning...

Page 37: ...rnators will require calibrating and checking by trial 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...

Page 38: ...number of points must be observed Bobtail engines i e Engines supplied without a marine gearbox normally do not have a gearbox oil cooler fitted However if a cooler is supplied this will only be suita...

Page 39: ...given Barrus permission to use the following instruction on how to fit the coupling When assembling the coupling all the bolts and nuts must be tightened to the correct torque using a torque wrench T...

Page 40: ...uch that the rubber must be compressed when sailing in the forward direction The coupling is not suitable for use with vee drive gearboxes having outputs of the quill shaft arrangement where the coupl...

Page 41: ...io 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 correctly adjusted and operating smoothly...

Page 42: ...y come on for a brief period of time when the ignition is first turned on as a bulb check It will then only illuminate in the case of the engine coolant temperature exceeding the maximum safety level...

Page 43: ...enough to allow this and that the water is deep enough not to damage the propeller It is recommended that the engine is run at or near full load for 15 minutes maximum revs in gear every 50 hours 5 Re...

Page 44: ...a feature unique to some of the Shire canal boat engine range It ensures that the engine warms up very quickly due to the first thermostat being closed so that cooling water is routed through the spe...

Page 45: ...nd 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 operatio...

Page 46: ...bility are an added benefit of using this product Diesel fuel additive is available from your Shire dealer in a handy 500ml container Part Number RDG80210219 8 Exhaust Back Pressure The back pressure...

Page 47: ...ntainer Operate the pump handle to empty the 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...

Page 48: ...AIN THE GEARBOX OIL HOT OIL MAY SPLASH 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 th...

Page 49: ...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 t...

Page 50: ...r water trap Place a small drain bowl under the primary fuel filter water trap Loosen the drain screw located in the bottom of the fuel filter water trap Figure 24 Drain off any water Once the water h...

Page 51: ...upplied Unscrew them until loose then remove by hand Primary fuel filter only Retain the metal fuel filter drain screw from the old filter and reuse in the new filter Shire 40 45 and 50 only The part...

Page 52: ...OUT DURING ENGINE OPERATION IF THE CAP IS LOOSE WARNING BURN HAZARD WAIT UNTIL THE ENGINE COOLS BEFORE YOU DRAIN THE ENGINE COOLANT HOT ENGINE COOLANT MAY SPLASH AND BURN YOU To check the coolant lev...

Page 53: ...stments Depress the longest run of the drive belt to be checked If the travel exceeds 15 20mm using hard finger pressure the belt needs re tensioning Loosen the upper adjuster on the alternator Loosen...

Page 54: ...l prematurely Replace the belt if it cracks or splits and as the adjustment nears the limit of travel Ensure the belt is correctly aligned using a straight edge Misaligned belts will cause excessive b...

Page 55: ...the correct replacement belts before starting this procedure Some engines may have been fitted with non standard optional alternators which may not use the belt sizes listed Make a note of these belt...

Page 56: ...irt a lubricant into the key switch slot when the key has been removed see Section 8 Service Schedule A lubricant such as WD40 with silicon would be suitable Other lubricants are available Then with t...

Page 57: ...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 90 and 120 Gearbox ATF Autom...

Page 58: ...r are found in the Primary Fuel Filter then change at 350 hours Air Filter Element 175 Hours Every 700 hours OR 24 Months Sooner if required Drive Belts Daily As required Adjust as necessary The Shire...

Page 59: ...RDG603A20 Issue 10 Page 59 of 100 SECTION 9 Wiring Diagrams 1 Engine Wiring Diagram Shire 38 40 45 50 Figure 25 Shire 38 40 45 50 Wiring Diagram...

Page 60: ...RDG603A20 Issue 10 Page 60 of 100 2 Standard Control Panel Wiring Diagram Figure 26 Standard Control Panel Wiring Diagram...

Page 61: ...RDG603A20 Issue 10 Page 61 of 100 3 Deluxe Control Panel Wiring Diagram Figure 27 Deluxe Control Panel Wiring Diagram...

Page 62: ...Shire 40 30kW 40hp at 2400rpm Shire 45 33kW 45hp at 2600rpm Shire 50 37kW 50hp at 3000rpm Low Idling 850 875 rpm High Idling 3210 25 rpm Direction of Rotation Counter clockwise Viewed from Flywheel En...

Page 63: ...f Engine Including Gearbox Model Dry Weight kg Shire 38 260kg Shire 40 270kg Shire 45 278kg Shire 50 284kg The dry weights stated are for the standard engine in each model range If a different gearbox...

Page 64: ...er Ltd 0238 0403918 sales marine power co uk HERTFORDSHIRE Lee Valley Marina 01920 870499 01920 293101 stansteadmarina vibrantpartnerships co uk Keypart Ltd 01923 276000 sales keypart com LEICESTERSHI...

Page 65: ...ats btconnect com Evesham Marina 01386 768500 info eveshammarina co uk YORKSHIRE Rodley Boat Centre 01132 576132 rodleyboatcentre msn com MONMOUTHSHIRE Castle Narrowboats 01873 830001 info castle narr...

Page 66: ...No xx 02663 125A Alt Belt RDG0047511 from Serial No xx 02663 150A Alternator RDG20110201 up to Serial No xx 02662 RDG20110201 150A Alt Belt RDG6076 up to Serial No xx 02662 RDG6076 240A Alternator RD...

Page 67: ...e Stop Control System Fuse 40amp RDG3246 2 Control Panel Supply Fuse 15amp RDG3245 3 Engine Start Control System Fuse 15amp RDG3245 4 Glow Plug Fuse 40amp RDG3246 7 8kw Alternator Sub System Fuse Opti...

Page 68: ...4N3N HPiVS R1105 005 I 01 Essential Requirements Standards Other normative document method Technical file Specify in more detail Mandatory standard Annex 1 B Exhaust Emissions B 1 Engine Identificatio...

Page 69: ...EC Annex I relating to the design and construction of the engines have been applied and fulfilled as shown in Annex A of this Declaration The relevant technical documentation is compiled in accordance...

Page 70: ...y 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 softw...

Page 71: ...9 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 72: ...ce 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 Ye...

Page 73: ...2006 42 EC Annex I relating to the design and construction of the engines have been applied and fulfilled as shown in Annex A of this Declaration The relevant technical documentation is compiled in a...

Page 74: ...0 GMT T 44 0 1743 232200 F 44 0 1743 353584 sds morris lubricants co uk 1 4 Emergency telephone number 44 0 1743 232200 08 45 17 00 hrs GMT SECTION 2 HAZARDS IDENTIFICATION 2 1 Classification of the s...

Page 75: ...RST AID MEASURES 4 1 Description of first aid measures General information Get medical attention if any discomfort continues Inhalation In case of inhalation of spray mist Move person into fresh air a...

Page 76: ...rs 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 Contain spillage with sand or earth Use sealed contai...

Page 77: ...ial Eye protection If risk of splashing wear safety goggles or face shield Other Protection Use barrier creams to prevent skin contact Hygiene measures Wash promptly with soap water if skin becomes co...

Page 78: ...cal effects Acute toxicity Acute Toxicity Oral LD50 2000 mg kg Rat Not expected to be highly toxic based on information of ingredients Based on available data the classification criteria are not met A...

Page 79: ...as dangerous for the environment 12 1 Toxicity Acute Fish Toxicity Based on available data the classification criteria are not met Not considered toxic to fish Based on available data the classificati...

Page 80: ...fety at Work Act 1974 Environmental Listing The Pollution Prevention and Control Act 1999 Special Waste regulations 1996 Control of Pollution Oil Storage England Regulations 2001 Statutory Instruments...

Page 81: ...3 08 2010 Risk Phrases In Full R53 May cause long term adverse effects in the aquatic environment R43 May cause sensitisation by skin contact NC Not classified R41 Risk of serious damage to eyes R51 5...

Page 82: ...ier 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 Emergency telephone num...

Page 83: ...ption 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 kee...

Page 84: ...ntering 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 sp...

Page 85: ...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 86: ...t 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 excessiv...

Page 87: ...lames 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 nitr...

Page 88: ...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 89: ...tal 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 90: ...mpt 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 ingred...

Page 91: ...et 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 92: ...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 93: ...ntering 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 sp...

Page 94: ...otection 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 shiel...

Page 95: ...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 96: ...red 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...

Page 97: ...ential 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 ty...

Page 98: ...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 99: ...s 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...

Page 100: ...ission 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 Hour...

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