Barrus Shire 43 WB Original Instruction Download

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ORIGINAL INSTRUCTION

RDG603A73 - Issue 3

WORK BOAT ENGINE

MANUAL

For the following engine models:

Shire 43 WB
Shire 49 WB

Summary of Contents for Shire 43 WB

Page 1: ...ORIGINAL INSTRUCTION RDG603A73 Issue 3 WORK BOAT ENGINE MANUAL For the following engine models Shire 43 WB Shire 49 WB...

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: ...nquiry 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 acce...

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

Page 5: ...short link into your search engine https www barrus co uk shire registration form The Warranty will only apply if the following have been carried out 1 The Installation Check List in the Installation...

Page 6: ...ed 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 dut...

Page 7: ...SECTION 4 Control Panel 17 1 Standard Control Panel 17 2 Deluxe Control Panel 17 3 Control Panel Overview 18 4 Warning Light Procedure 18 5 Overall Dimensions of the Standard Control Panel 20 6 Overa...

Page 8: ...st 38 SECTION 6 Operation 39 1 Starting the engine for the first time 39 2 Starting Procedure 39 3 Stopping Procedure 40 4 Full Load Running 40 5 Refuelling 40 6 Diesel Fuel Additive 40 7 Exhaust Back...

Page 9: ...Wiring Diagram Shire 43 49 55 2 Shire 43 49 Cold Start Wiring Diagram 56 3 Standard Control Panel Wiring Diagram 57 4 Deluxe Control Panel Wiring Diagram 58 SECTION 10 Technical Data 59 1 Engine Data...

Page 10: ...EU Declaration of Conformity with the Exhaust Emissions Requirements of Directive 2013 53 EU 78 SECTION 14 Lubricant Safety Data Sheets 79 1 Ground Force 10W 40 79 2 Torq Gard Supreme 15W 40 88 SECTIO...

Page 11: ...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 sup...

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: ...y 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 goin...

Page 15: ...ight 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 40 Amp 12 Volt Alternator 3 Dry...

Page 16: ...rom 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 40 Amp 12 Volt Alternator 3 Dry Exhaust Outlet 4 C...

Page 17: ...Warning Light 5 40A 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 Temp...

Page 18: ...perature warning light and glow plug light operate slightly differently The water temperature warning light will only come on for a brief period of time when the ignition is first turned on as a bulb...

Page 19: ...he engine immediately Contact your local dealer Failure to stop the engine may result in permanent engine damage 5 40A Alternator Charge Warning Light This indicates that the alternator has stopped ch...

Page 20: ...Overall Dimensions of the Standard Control Panel All Dimensions are in mm Figure 8 Standard Control Panel Dimensions 6 Overall Dimensions of the Deluxe Control Panel All Dimensions are in mm Figure 9...

Page 21: ...be a minimum of 10mm thick extended 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 Pressurised Water Header Tank WAR...

Page 22: ...be used to connect the gearbox output flange to the propeller shaft flange Please note underperforming engines will not be covered under warranty if the cause of the poor performance is found to be th...

Page 23: ...rails If the engine room space is a problem the mounts can be fitted slightly further back in the alternative holes and the front of the rail cut off leaving 50mm of material to retain strength measur...

Page 24: ...ing position 2 Alternative mounting position if engine compartment space is restricted Figure 13 Anti Vibration Mount Installation Points 6 Engine Alignment The gearbox output shaft flange and propell...

Page 25: ...se 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 manufacturer s installation i...

Page 26: ...ges the domestic battery This removes the requirement for a split charging system or relay The engine is supplied with the domestic alternator belt not fitted This is so that domestic alternator damag...

Page 27: ...rical system 10 Engine Oil WARNING BURN HAZARD WAIT UNTIL THE ENGINE COOLS BEFORE YOU DRAIN THE ENGINE OIL HOT ENGINE OIL MAY SPLASH AND BURN YOU NOTICE ENGINE OIL WITH A HIGHER API CLASS THAN CD IS U...

Page 28: ...k to absorb engine movement without placing strain on the hoses and be securely clipped to prevent accidental damage and chafing Initially fill the fuel system by turning the ignition on to operate th...

Page 29: ...r bubbles may be expelled Top up the system as necessary 13 Control Cables Connect engine speed control cable With the engine off ensure that the engine speed control lever achieves full travel from i...

Page 30: ...output current Weekend cruising or hire fleet use three and a half times domestic alternator maximum output current Example 1 Live aboard application fitted with a 150amp domestic alternator 3 x 150 4...

Page 31: ...ho the value displayed will increase decrease until the button is released Then when pressing again it will increase decrease in the other direction Keep doing this until the digitally displayed value...

Page 32: ...itable 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 1 BSP E...

Page 33: ...t silencer correctly Note Halyard M I Limited have given Barrus permission to use the diagram Figure 16 Correct Installation of the Lift Silencer 1 The swan neck must reach at least 450mm 18 above the...

Page 34: ...A minimum of 2 hose clips must be used Securely tighten all hose clamps but be careful not to overtighten The silencer should be positioned within 300mm of the centre line of the vessel or to the eng...

Page 35: ...e Transmissions If an engine is to have a hydraulic drive transmission attached to it instead of a conventional marine gearbox a number of points must be observed Bobtail engines i e Engines supplied...

Page 36: ...st be tightened alternately in several steps until the required tightening torque is reached Finally the tightening torque of all fasteners must be checked all round TIGHTENING TORQUE M12x40 is 79Nm T...

Page 37: ...B specification The maximum power which can be transmitted is 22kW 29 5hp per 1000rpm The power take off operates in the opposite direction to the gearbox input shaft The output of the live power tak...

Page 38: ...header tank and correct ratio of antifreeze to water All air has been bled from calorifier and pipework Engine and gearbox oil levels are as specified Throttle and gear cables correctly adjusted and...

Page 39: ...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 in the cas...

Page 40: ...ONAL PROTECTION EQUIPMENT IS WORN All Shire boat engines run on 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 bui...

Page 41: ...r lock box swan neck must be used to prevent sea water flowing back up the exhaust and causing engine damage The back pressure falls within the manufacturers recommended range when using the optional...

Page 42: ...ber 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 supplied...

Page 43: ...OT OIL MAY SPLASH AND BURN YOU Some engines may have an optional gearbox sump pump fitted To change the oil in this circumstance follow the same procedures as were outlined for changing the engine oil...

Page 44: ...ALWAYS BE ENVIRONMENTALLY RESPONSIBLE Please dispose of used oil and oil filters safely with due regard for the environment and take to your local waste oil disposal point Do not allow oil or contamin...

Page 45: ...fuel filter water trap Figure 18 Drain off any water Once the water has been drained retighten the drain screw It is unlikely the complete fuel system will require bleeding Run for 5 minutes Check tha...

Page 46: ...strap wrench 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 The part number for the dra...

Page 47: ...he 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 injector...

Page 48: ...e front of the white plastic expansion tank If required top up the level with coolant 50 clean tap water and 50 ethylene glycol based anti freeze through the expansion tank filler cap Do not use water...

Page 49: ...VING ROTATING PARTS WEAR TIGHT FITTING CLOTHING AND KEEP YOUR HAIR SHORT OR TIE BACK REMOVE ALL JEWELLERY BEFORE COMMENCING WORK CHECK BEFORE STARTING THE ENGINE THAT ANY TOOLS OR RAGS USED DURING MAI...

Page 50: ...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 51: ...inlet end of the main heat exchanger Figure 20 Figure 20 Work Boat Anode Location 14 Raw Water Pump Impellor Change Remove the pump cover plate Remove the pump impeller special tools are available fr...

Page 52: ...aps O rings are in good condition Ensure the end caps are fitted in the correct orientation If they are not in the correct orientation overheating will occur which will not be covered under the warran...

Page 53: ...TION EQUIPMENT 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...

Page 54: ...er if required Drive Belts Daily As required Adjust as necessary All Hoses 50 Hours As required Check hoses for damage or leaks Replace as necessary Key Switch Lubricate Every 150 Hours OR 12 Months A...

Page 55: ...RDG603A73 Issue 3 Page 55 of 96 SECTION 9 Wiring Diagrams 1 Engine Wiring Diagram Shire 43 49 Figure 21 Shire 43 49 Wiring Diagram...

Page 56: ...RDG603A73 Issue 3 Page 56 of 96 2 Shire 43 49 Cold Start Wiring Diagram Figure 22 Shire 43 49 Cold Start Wiring Diagram...

Page 57: ...RDG603A73 Issue 3 Page 57 of 96 3 Standard Control Panel Wiring Diagram Figure 23 Standard Control Panel Wiring Diagram...

Page 58: ...RDG603A73 Issue 3 Page 58 of 96 4 Deluxe Control Panel Wiring Diagram Figure 24 Deluxe Control Panel Wiring Diagram...

Page 59: ...49L Rated Output Speed Shire 43 32kW 43hp at 2300rpm Shire 49 36 5kW 49hp at 3000rpm Low Idling 875 900 rpm High Idling Shire 43 2500 25 rpm Shire 49 3200 25 rpm Direction of Rotation Anti clockwise V...

Page 60: ...g 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 Grade 12...

Page 61: ...nt Turn all the cylinder head bolts 60 clockwise following the sequence shown in Figure 25 Turn all the cylinder head bolts a further 60 clockwise following the sequence shown in Figure 25 The bolts c...

Page 62: ...e 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 63: ...RDG603A73 Issue 3 Page 63 of 96 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 64: ...73 Issue 3 Page 64 of 96 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 l...

Page 65: ...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 cylind...

Page 66: ...e 66 of 96 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 t...

Page 67: ...RDG603A73 Issue 3 Page 67 of 96 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 68: ...RDG603A73 Issue 3 Page 68 of 96 Refit the timing window cover from the fuel injection pump Torque the screws to 1 5 2 5Nm Timing window cover...

Page 69: ...99 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 Pe...

Page 70: ...n 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 Narrowb...

Page 71: ...is fitted GB T12732 1996 GB T12732 1996 125A Alternator 125A Alternator Belt 150A Alternator Option RDG20110201 RDG20110201 150A Alt Belt Option RDG2254 RDG2254 Air Filter Element RDG5795 RDG5795 Oil...

Page 72: ...Relays Engine Oil Engine Oil is 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 han...

Page 73: ...sions 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 Exhaust...

Page 74: ...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 Anne...

Page 75: ...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 softwa...

Page 76: ...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 77: ...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 78: ...inst 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 w...

Page 79: ...etails 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 Emer...

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: ...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 Shor...

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: ...e 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 Hazards...

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: ...owing 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 Othe...

Page 89: ...ricants 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 90: ...ormation Polyethylene containers should not be exposed to high temperatures because of possible risk of distortion 8 EXPOSURE CONTROLS PERSONAL PROTECTION Exposure Limits Substance Regulations Exposur...

Page 91: ...gh 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 Nit...

Page 92: ...n 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 slig...

Page 93: ...ty 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 amount...

Page 94: ...rs 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 Di...

Page 95: ...et 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 This p...

Page 96: ...sion 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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Barrus Shire 43 WB, Original Instruction

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