Barrus Shire 39 Manual Download

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ORIGINAL INSTRUCTION

RDG603A63 - Issue 10

CANAL ENGINE

MANUAL

For the following engine model*:

Shire 39
Shire 43
Shire 49

*Standard Model, there may be a number of optional extras, or alternative components, that
might be fitted to an engine that are not shown in this book.

Summary of Contents for Shire 39

Page 1: ...sue 10 CANAL ENGINE MANUAL For the following engine model Shire 39 Shire 43 Shire 49 Standard Model there may be a number of optional extras or alternative components that might be fitted to an engine...

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: ...enquiry or when ordering spare parts Information about the engine serial number and its location on the engine can be found in SECTION 2 of the manual Shire Engine Manuals and Shire Parts Books To acc...

Page 4: ...lf with the engine and its parts before operation The PRM Gearbox Manual is also available from the PRM website www prm newage com If the engine is fitted with an E Kit and or Hybrid options please al...

Page 5: ...o allow for installation and commissioning following this the warranty period will automatically start The repair or replacement of parts or the performance of service under this warranty does not ext...

Page 6: ...use engine fuel injection system damage which is not covered by the warranty The fuel system should be fully primed ahead of engine starting failure to do so can cause damage to the engine starting sy...

Page 7: ...not consistent with the requirements laid out Systems using or affected by an accessory or part not manufactured or sold by EP Barrus Ltd Systems that have been altered or modified including addition...

Page 8: ...e maintained for a minimum of 15 minutes TRANSFER OF WARRANTY The warranty is valid for the first owner of the Shire engine and is transferrable only at the discretion of EP Barrus Ltd River Canal Res...

Page 9: ...19 SECTION 4 Control Panel 20 1 Basic Control Panel 20 2 Standard Control Panel 20 3 Deluxe Control Panel 21 4 Control Panel Overview 21 5 Warning Light Procedure 21 6 Overall Dimensions of the Basic...

Page 10: ...st System 39 21 Hydraulic Drive Transmissions 40 22 Centa Coupling CF M 160 RDG2779 40 23 PRM 280DP Gearbox with Power Take Off Optional Extra 41 24 Engine Start Battery 41 25 Installation Check List...

Page 11: ...Maintenance 54 SECTION 8 Service Schedule 56 1 Specifications and Capacities 56 2 Service Intervals 57 SECTION 9 Wiring Diagrams 58 1 Engine Wiring Diagram Shire 39 43 49 58 2 Shire 39 43 49 Cold Sta...

Page 12: ...EU 80 2 Declaration of Conformity for Recreational Craft Propulsion Engine with the requirements of the Recreational Craft Regulations 2017 UKCA Marking 81 3 Declaration of Incorporation of Partly Co...

Page 13: ...l before carrying out any 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 DEA...

Page 14: ...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 15: ...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 16: ...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 going...

Page 17: ...Side Viewed from rear Note There are a number of other optional extras that may be fitted to an engine that are not shown here Description 1 Single Thermostat Housing 2 40 Amp 12 Volt Alternator 3 12...

Page 18: ...rear Note There are a number of other optional extras that may be fitted to an engine that are not shown here Description 1 Single Thermostat Housing 2 40 Amp 12 Volt Alternator 3 150 Amp 12 Volt Alte...

Page 19: ...rear Note There are a number of other optional extras that may be fitted to an engine that are not shown here Description 1 Single Thermostat Housing 2 40 Amp 12 Volt Alternator 3 150 Amp 12 Volt Alte...

Page 20: ...Ignition Switch 2 150 240A Alternator Charge Warning Light 3 Water Temperature Warning Light 4 Oil Pressure Warning Light 5 50A Alternator Charge Warning Light 6 Glow Plug Light Description 1 Tachome...

Page 21: ...erent control panel may be supplied as an option 5 Warning Light Procedure When the ignition is first turned on the control panel warning lights will come on as a bulb check When the engine is started...

Page 22: ...ke repairs on the engine Description Procedure for Warning Light 1 Tachometer Gauge 2 Hour Meter 3 Water Temperature Warning Light Reduce the engine revs and stop the engine within one or two minutes...

Page 23: ...system is operating If the light fails to illuminate during the starting procedure contact your local dealer 8 Key Flap and Ignition Switch 9 40A Alternator Output Gauge 10 Oil Pressure Gauge 11 Water...

Page 24: ...Overall Dimensions of the Standard Control Panel All Dimensions are in mm Figure 12 Standard Control Panel Dimensions 8 Overall Dimensions of the Deluxe Control Panel All Dimensions are in mm Figure...

Page 25: ...o 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 av...

Page 26: ...ol the hydraulic oil Please refer to Section 5 Installation 21 Hydraulic Drive Transmission for further information 5 Engine Cooling Water Inlet and Outlet Hose Connections These are on the left hand...

Page 27: ...LOOSE The pressurised header tank should 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 39 43 49 Two ho...

Page 28: ...mperature 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 water temperat...

Page 29: ...mounts this puts undue pressure on them and can result in excessive engine movement and premature mount failure If this is a problem put steel packing plates under the mounts Packing plates 25mm thic...

Page 30: ...f the rail cut off leaving 50mm of material to retain strength measuring from the centre of the mount hole to the front end of the rail Note This procedure is only possible on non E Kit engines and ma...

Page 31: ...1 of 104 Figure 18 Correct Anti Vibration Mount Installation Description 1 Normal mounting position 2 Alternative mounting position if engine compartment space is restricted Figure 19 Anti Vibration M...

Page 32: ...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 33: ...belt not fitted This is so that domestic alternator damage does not occur if the engine is run without the domestic battery back connected The belt should only be fitted when the domestic battery bank...

Page 34: ...ty of the boat builder to ensure that this is correctly wired to the boats electrical system 14 Engine Oil WARNING BURN HAZARD WAIT UNTIL THE ENGINE COOLS BEFORE YOU DRAIN THE ENGINE OIL HOT ENGINE OI...

Page 35: ...sion fittings The engine hoses should have sufficient slack to absorb engine movement without placing strain on the hoses and be securely clipped to prevent accidental damage and chafing Initially fil...

Page 36: ...ng the engine for the first time stop the engine and monitor the water level frequently as trapped air bubbles may be expelled Top up the system as necessary 17 Control Cables Connect engine speed con...

Page 37: ...dividual power requirements with the boat builder or engine supplier The maximum domestic battery bank is calculated using the following Live aboard three times domestic alternator maximum output curr...

Page 38: ...ug 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 holding the black...

Page 39: ...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 1 BSP Exhaust silencers flexible ex...

Page 40: ...to approx 10 to dissipate the additional heat generated when a hydraulic drive system or hydraulic bow thruster is used Or An additional separate skin tank of suitable capacity with separate water ci...

Page 41: ...ub The propeller thrust or propeller pull in reverse drive is safely transmitted via the coupling from the propeller shaft to the gearbox but the design of the coupling is such that the rubber must be...

Page 42: ...tio 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 smoothl...

Page 43: ...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 Wait f...

Page 44: ...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 Refuelling WARNING DIESEL FUEL IS FLAMMABLE...

Page 45: ...ty 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 7 Exhaust Back Pressure The back pressure fall...

Page 46: ...mber 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 removal tool supplie...

Page 47: ...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 the engine oil Fo...

Page 48: ...2 Location of Dipstick Filler Plug 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 reg...

Page 49: ...TION EQUIPMENT IS WORN 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 23 Drain off any water Once t...

Page 50: ...ll prior to undertaking this procedure 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 filters using the f...

Page 51: ...NT IS WORN Ensure the fuel tank is at least full prior to undertaking this procedure Open the bleed screw on top of the engine fuel filter Figure 24 Operate the electric fuel pump by turning the ignit...

Page 52: ...ENGINE COOLANT HOT ENGINE COOLANT MAY SPLASH AND BURN YOU 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...

Page 53: ...er mounting pivot nut and bolt Pull out either using hand pressure or using the tensioning screw depending on which alternator belt is to be tensioned Pull the alternator away from the engine to tight...

Page 54: ...D DURING MAINTENANCE HAVE BEEN REMOVED FROM THE AREA Ensure the ignition key is removed before replacing any belts Turn the battery master switch to the off position before replacing any belts Ensure...

Page 55: ...anel from its mounting The gauges are accessible from the rear of the panel Unplug the wire connectors unscrew and pull the gauge out of the panel Replace the gauge and refit Reattach the wiring conne...

Page 56: ...ENT IS WORN 1 Specifications and Capacities Specification of Coolants and Lubricants to use Component Lubricant Engine SAE 15W 40 API Class CH 4 CF 4 Oil Coolant 50 Clean Water 50 Ethylene Glycol Anti...

Page 57: ...12 Months If large quantities of dirt or water are found in the Primary Fuel Filter then change at 250 hours Air Filter Element 250 Hours Every 750 hours OR 24 Months Sooner if required Drive Belts Da...

Page 58: ...RDG603A63 Issue 10 Page 58 of 104 SECTION 9 Wiring Diagrams 1 Engine Wiring Diagram Shire 39 43 49 Figure 25 Shire 39 43 49 Wiring Diagram...

Page 59: ...RDG603A63 Issue 10 Page 59 of 104 2 Shire 39 43 49 Cold Start Wiring Diagram Figure 26 Shire 39 43 49 Cold Start Wiring Diagram...

Page 60: ...RDG603A63 Issue 10 Page 60 of 104 3 Basic Control Panel Wiring Diagram Figure 27 Basic Control Panel Wiring Diagram Twin Alternator Engines...

Page 61: ...RDG603A63 Issue 10 Page 61 of 104 4 Standard Control Panel Wiring Diagram Figure 28 Standard Control Panel Wiring Diagram...

Page 62: ...RDG603A63 Issue 10 Page 62 of 104 5 Deluxe Control Panel Wiring Diagram Figure 29 Deluxe Control Panel Wiring Diagram...

Page 63: ...D or AVI147J3113HD models so does not need connecting on those two models The W Tacho is an option when a rev counter is fitted and is not required for alternator functionality The DFM Field Monitor u...

Page 64: ...can be used The alternator is earth return grounded Ensure there is a good earth connection to the engine A 12v ignition operated relay may be required to switch on the 24v supply to Terminal 15 if t...

Page 65: ...t 2 449L Rated Output Speed Shire 39 29kW 39hp at 2000rpm Shire 43 32kW 43hp at 2300rpm Shire 49 36 5kW 49hp at 3000rpm Low Idling 875 900 rpm High Idling Shire 39 2200 25 rpm Shire 43 2500 25 rpm Shi...

Page 66: ...n Bearing Cap Bolts M10 x 1 Grade 10 9 First time 30 1 Second time 60 3 Cylinder Head Bolts M11 x 1 5 Grade 10 9 First time 30 Second time 50 Third time 60 Fourth time 60 Connecting Rod Bolts M8 x 1 G...

Page 67: ...nt Turn all the cylinder head bolts 60 clockwise following the sequence shown in Figure 31 Turn all the cylinder head bolts a further 60 clockwise following the sequence shown in Figure 31 The bolts c...

Page 68: ...he unlocked position Loosen the three nuts securing the fuel injection pump to the engine Make sure the fuel injection pump is in the middle of its adjustment on the slots When the fuel injection pump...

Page 69: ...RDG603A63 Issue 10 Page 69 of 104 Remove the front cover from the engine Make sure the pump timing gear is loose on the pump shaft Front cover Pump timing gear...

Page 70: ...3 Issue 10 Page 70 of 104 Remove the timing window cover from the fuel injection pump Make sure the line on the shaft and the line on the pump body line up Timing window cover Two lines which need to...

Page 71: ...o rotate the pump shaft when the pump shaft timing is locked Rotate the engine make sure the pump timing gear is rotating freely on the pump shaft until the timing marks line up with 6 btdc with cylin...

Page 72: ...e 72 of 104 Torque the pump timing gear to 25Nm on the pump shaft using a torque wrench Put the timing lock pin on the fuel injection pump back into the unlocked position Pump timing gear Lock pin in...

Page 73: ...RDG603A63 Issue 10 Page 73 of 104 Torque the pump timing gear to 50Nm on the pump shaft using a torque wrench Refit the front cover from the engine Pump timing gear Front cover...

Page 74: ...RDG603A63 Issue 10 Page 74 of 104 Refit the timing window cover from the fuel injection pump Torque the screws to 1 5 2 5Nm Timing window cover...

Page 75: ...Lee Valley Marina 01920 870499 01920 293101 stansteadmarina vibrantpartnerships co uk Keypart Ltd 01923 276000 sales keypart com LEICESTERSHIRE Foxton Boat Services Ltd 01162 792285 foxtonboats btinte...

Page 76: ...386 768500 info eveshammarina co uk Starline Narrowboats 01531 632003 enquiries starlinenarrowboats co uk YORKSHIRE Rodley Boat Centre 01132 576132 rodleyboatcentre msn com MONMOUTHSHIRE Castle Narrow...

Page 77: ...Belt If 240A Alternator is fitted GB T12732 1996 GB T12732 1996 GB T12732 1996 125A Alternator 128990 77250 128990 77250 125A Alternator Belt From Serial No xx 02798 RDG6076 RDG6076 150A Alternator R...

Page 78: ...s available from your Shire Dealer in a 20 litre container Part Number VC83070 020 Diesel Fuel Additive Diesel fuel additive is available from your Shire Dealer in a handy 500ml container Part No RDG8...

Page 79: ...the environment Contact local recycling centres or garages or check their websites to find out whether they take or recycle engine fluids If they don t they may be able to direct you to your nearest...

Page 80: ...ssions B C B D B E B F G H Other Community Directives applied Essential Requirements Standards Other normative document method Technical file Specify in more detail Mandatory standard Annex 1 B Exhaus...

Page 81: ...4D24 HPiUK R1105 T007 I 01 00 Essential Requirements Standards Other normative document method Technical file Specify in more detail Mandatory standard Annex 1 B Exhaust Emissions B 1 Engine Identific...

Page 82: ...e Engine BS1522 4 The essential health and safety requirements of the Directive 2006 42 EC Annex I relating to the design and construction of the engine have been applied and fulfilled as shown in Ann...

Page 83: ...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 84: ...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 85: ...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 86: ...ainst the emission of gaseous and particulate pollutants from internal combustion engines The engines comply with Directive 2013 53 EU Recreational Craft Directive Article 6 part 4 in that the engine...

Page 87: ...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 88: ...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 89: ...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 90: ...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 91: ...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 92: ...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 93: ...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 94: ...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 95: ...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 96: ...lowing components Highly refined mineral oil Name CAS EINECS Proportion Hazard R Phrase Zinc alkyl dithiophos phate 68649 42 3 272 028 3 1 2 49 Xi N R38 R41 R51 53 Other Information See Section 16 Oth...

Page 97: ...bricants is not usually necessary unless a large amount has been ingested or some other compound has been dissolved in the product If this is indicated for example when there is rapid onset of central...

Page 98: ...formation Polyethylene containers should not be exposed to high temperatures because of possible risk of distortion 8 EXPOSURE CONTROLS PERSONAL PROTECTION Exposure Limits Substance Regulations Exposu...

Page 99: ...ugh time should be used with care and a margin of safety should be applied HSE guidance on protective gloves recommends a 75 safety factor to be applied to any figures obtained in a laboratory test Ni...

Page 100: ...an inhalation hazard under normal conditions of use Eye Irritation Expected to be slightly irritating Skin Irritation Expected to be slightly irritating Respiratory Irritation If mists are inhaled sl...

Page 101: ...city Poorly soluble mixture May cause physical fouling of aquatic organisms Product is expected to be practically non toxic to aquatic organisms LL EL50 100 mg l LL EL50 expressed as the nominal amoun...

Page 102: ...ers of Vehicles Carrying Dangerous Goods Regulations Reporting of Injuries Diseases and Dangerous Occurences Regulations Health and Safety First Aid Regulations 1981 Personal Protective Equipment EC D...

Page 103: ...sheet directive 2001 58 EC Department of the Environment Waste Management The Duty of Care A Code of Practice Concawe Boulevard du souverain 165 B 1160 Brussels Belgium www concawe be Restrictions Th...

Page 104: ...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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