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RDG603A17 – Issue 1 – Shire 30_40_50 WB/RB Manual

Page 27 of 51

SECTION 5 – Service Procedure

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Содержание Shire 30 RB

Страница 1: ... 30 RB SHIRE 40 WB SHIRE 40 RB SHIRE 50 WB SHIRE 50 RB Please read in conjunction with Yanmar the PRM Gearbox Manual Optional Travel Power Manual Hybrid Manual 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 ...

Страница 2: ...re 30 3TNV 82A BDSA YD1300DNMDEC e13 97 68DA 2006 105KA 0558 11 Shire 40 50 4TNV 88 BDYE G2YDXCL0164N3N e13 97 68DA 2012 46KA 0574 24 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 R EN ISO 8178 B 3 Durability B 4 Owners Manual R ISO1024...

Страница 3: ... 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 service under this warranty does not extend the life of this warranty beyond its original expiry date To ensure tha...

Страница 4: ... pay for all related labour and material and any other expenses associated with that service 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 Owner s Manual accident submersion improper installati...

Страница 5: ...tilation 11 2 Engine Beds 11 3 Pressurised Water Header Tank 11 4 Shaft Connection and Propeller Selection 11 5 Engine Anti Vibration Mounts 11 6 Engine Alignment 13 7 Electrics 14 8 Electrical Options 15 9 Engine Oil 15 10 Fuel 15 11 Coolant 16 12 Control Cables 16 13 Domestic Battery Bank 17 14 Seawater Strainer 17 15 Control Panel 17 16 Seawater Pump Hose Minimum Inlet Size 18 17 Exhaust System...

Страница 6: ...tional RDG9210055 26 SECTION 5 Service Procedure 27 1 Engine Oil and Filer Change 28 2 Air Filter Check and Change Shire 30 40 50 WB and Shire 40 50 RB 28 3 Air Filter Check and Change Shire 30 RB 28 4 Gearbox Oil Change 29 5 Disposal of Oil and Related Items 30 6 Primary Fuel Filter Drain Shire 30 40 50 30 7 Primary and Secondary Fuel Filter Change 31 8 Fuel System Bleeding 31 9 Cooling System 31...

Страница 7: ...s 39 1 Engine Wiring Diagram Shire 30 40 50 39 2 Standard Control Panel Wiring Diagram 40 3 Deluxe Control Panel Wiring Diagram 41 4 RDG20710110 Standard Control Panel 42 5 RDG20710111 Deluxe Control Panel 42 6 Overall Dimensions of the Control Panels 43 7 8kW Travel Power Wiring Diagram and Overall Dimensions 44 SECTION 8 Technical Data 46 SECTION 9 Dealer List 47 SECTION 10 Shire Service Parts 4...

Страница 8: ... 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 C and contain elements which are harmful if ingested It is therefore essential that exhaust systems are gas tight and lagged to p...

Страница 9: ...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 or manufacturer s instructions for specific information ...

Страница 10: ...t manifold WB Work Boat Engine Seawater Heat Exchanger cooled dry exhaust manifold with either dry exhaust system same as a Canal Boat or water injected exhaust system RB River Boat Engine Can also be used for sea going applications Seawater Integral exhaust manifold heat exchanger cooled Water injected exhaust system Note There are a number of optional extras that may be fitted to an engine that ...

Страница 11: ...more than 1 metre from the engine This is to prevent cooling system air locks 4 Shaft Connection and Propeller Selection Some type of flexible coupling must be used to connect the gearbox output flange to the propeller shaft flange Various coupling flanges are widely available to assist with this Note Underperforming engines will not be covered under warranty if the cause of the poor performance i...

Страница 12: ...ation will be experienced through the hull For best results fit the front AV mounts into the front holes in the engine 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 measuring from the centre of the mount hole to the front end of the rail Note This proc...

Страница 13: ...e Alignment The gearbox output shaft flange and propeller shaft input flange must be almost perfectly aligned A maximum of 0 05mm 0 002 misalignment in any plane is acceptable Ensure alignment is recheck after the first 4 hours of running after the first month and thereafter annually Alternative mounting position if engine compartment space is Normal mounting position ...

Страница 14: ... 50A alternator and either an additional 12V 140A alternator or 240A alternator can be fitted This option is used to charge the batteries for the domestic electrical system For twin alternator engines connect the domestic battery positive cable to the 140A or 240A Alternator The 140A alternator has a B terminal and the 240A alternator has a pos out terminal see wiring diagram This ensures that the...

Страница 15: ... must be fitted to all engine installations The engines are supplied with an additional fuel pre filter water trap as standard Connect fuel feed return hoses from engine to main supply and return lines to main fuel tank ensuring they are connected the correct way around The hose to the electric fuel pump is the inlet The engine hoses are supplied with 5 16 8mm OD metal hosetails and should be secu...

Страница 16: ...ing system start and run the engine for several minutes to dispel any remaining air bubbles with the pressure cap removed Note After running 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 Figure 5 Shire 50 Coolant Filling Points For Riverboats with Water Cooled Manifold Remove filler cap on ...

Страница 17: ...e following Live aboard three times domestic alternator maximum 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 140amp domestic alternator 3 x 140 420 ampere hour maximum battery bank size Example 2 Weekend cruising or hire fleet application fitted with a 240amp domestic alternator 3...

Страница 18: ...elow table This must be set to the alternator with blue and black wire connected to it Confirm settings to tacho meter reader An optical tachometer is required to check the reading Barrus Alternator Amps Barrus Tacho reading 50 10 50 11 00 70 15 00 140 19 50 20 00 240 22 00 Alternative or non standard alternators will require calibrating and checking by trial and error with a hand held tacho until...

Страница 19: ...7 Make sure the exhaust increases then decreases in height as shown above River Boat with Water Injected Exhaust If the engine is installed low down in the boat below the outside water 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 the lift silencer ...

Страница 20: ...ed marine exhaust system The overall design of the system and choice of components will have a result on the back pressure in the exhaust which is vital to the performance and life of the engine Barrus recommend that Halyard M I Limited are used for the Lift Silencer Siphon Break and other components Contact Halyard M I Limited for further information The silencer must be drained before the boat i...

Страница 21: ...t be positioned upright well above waterline The height above waterline will vary from vessel to vessel but will be between 150mm and 2 metres Please seek guidance on this if you are unsure or if you are not familiar with the correct way to incorporate a siphon breaker into your particular exhaust system 2 The inverted U bend at the top must be connected to a hose draining into the bilge or over t...

Страница 22: ... engine coolant flow is present Oil coolers should be installed in the seawater cooling system after the engine not before Coolers that are installed before the engine will invalidate the engine warranty 19 Hydraulic Pump Drive Option Shire 30 40 50 For SAE pump 9T If a hydraulic pump is required to drive items such as bow thrusters or hydraulic winches then the following parts are required to ena...

Страница 23: ...charged Check tension of alternator belts wiring connected and belt alignment checked if removed Check fuel system is connected correctly and primed Fuel line water trap installed and water drained off Check header tank connections Work Boat are correct way round constant pipework rise to header tank Check level of coolant in header tank or manifold and correct ratio of antifreeze to water All air...

Страница 24: ...dle Speed to 850 875 rpm Check for leaks Explain Demonstrate daily weekly periodic maintenance checks Explain Demonstrate off season storage and maintenance Travel Power 230v AC systems installed by qualified electrician and to BMEA code of practice for Electrical and Electronic installation in Boats BS EN ISO 13297 ac Installer s signature Installer name company ...

Страница 25: ...t immediately release the key Key will return to on position The warning buzzer will stop and on the deluxe panel the oil pressure gauge will show an oil pressure of 3 5 4 5 bar 51 61 psi Should any warning light not go out or if there is no reading on the oil pressure gauge the buzzer will continue sounding In this case stop the engine immediately and check the relevant system Note If the charge ...

Страница 26: ...t ability are an added benefit of using this product Diesel fuel additive is available from your Shire dealer in a handy 375ml container Part Number RDG80210219 7 Exhaust Hose Sizes River Boat Use 50mm ID marine flexible exhaust hose on the Shire 30 40 and 50 engines 60mm is an option on the Shire 40 and 50 engines Do not step down to a smaller size When a PRM 260 gearbox is fitted a 60mm ID hose ...

Страница 27: ...RDG603A17 Issue 1 Shire 30_40_50 WB RB Manual Page 27 of 51 SECTION 5 Service Procedure ...

Страница 28: ...y as firmly as you can Refill the sump using the yellow oil filler cap in the rocker cover on top of the engine Oil level should be to the top mark on the dipstick Run the engine for 5 minutes before checking the oil level with the dipstick and top up if required Do not exceed the maximum oil level marker as this may cause damage to the internal components of the engine 2 Air Filter Check and Chan...

Страница 29: ... same procedures as were outlined for changing the engine oil For engines without a gearbox sump pump follow the procedure below Change the gearbox oil while it is still hot Please refer to the gearbox manual for more information Place a tray beneath the gearbox that will hold at least 2 litres Remove the drain plug and allow 5 minutes for the oil to drain thoroughly Replace the drain plug Ensure ...

Страница 30: ... 40 50 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 10 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 that the drain union is tight and that there are no leaks Do not over tighten ...

Страница 31: ...ew filter The part number for the drain screw is RDG9189022 Smear a small amount of clean fuel on all of the O ring seals that are supplied with the new filter element Screw the new element back into the filter head Tighten by hand only Turn the main boat fuel supply tap back on Ensure the system is correctly bled before attempting to start up Note The same procedure is used for both the primary a...

Страница 32: ...UTION REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT 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 the lower mounting pivot nut and bolt Pull out either using hand pressure or using the tensioning screw depending on which alternator belt i...

Страница 33: ...e belt Hold the belt in position over the top alternator pulley Rotate the engine if required by hand to guide the new belt into the vee Replace the seawater pump if required Re tension the belt as above 13 Control Panel Maintenance CAUTION REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT TURN BATTERY ISOLATION SWITCHES OFF To replace an illumination bulb Release the panel from its mou...

Страница 34: ... located on the water cooled manifold Figure 12 Figure 12 River Boat Anode Location 15 Raw Water Pump Impellor Change Work Boat River Boat The pump is located on the front of the engine It is either fitted to the Power Take Off pulley camshaft drive or bolted to the front of the engine and driven by the crankshaft Note The crank driven pump is a standard item on engines fitted with the optional 14...

Страница 35: ...e correct orientation overheating will occur which will not be covered under the warranty Refill the engine with coolant as described earlier For River Boats When the engine is cold drain the water from the engine block Remove the plug from the engine block by the starter motor Drain water from the heat exchanger The drain plug is in the bottom of the heat exchanger water cooled manifold Mark the ...

Страница 36: ...s drained from the system Alternatively run neat antifreeze through the seawater pump inlet to protect the system Ensure that the antifreeze is drained before starting the engine during the next season This is to ensure that it does not get into the marine environment Dispose of the antifreeze correctly ...

Страница 37: ...ooler Gearbox Capacity Litres Capacity Pints PRM 80 0 57 1 0 PRM 120 0 8 1 4 PRM150 1 4 2 5 PRM260 1 5 2 7 2 Service Intervals Check Change Notes Engine Oil Filter Daily Level Every 250 Hours OR 12 Months First change after 50 hours Gearbox Oil Weekly Level Every 250 Hours OR 12 Months First change after 25 hours Coolant Level Daily Level Every 24 Months Diesel Fuel Filter Primary Engine 50 hours ...

Страница 38: ...ons require it Raw Water Pump Impellor 250 Hours Every 500 hours OR 12 Months Change more frequently if operating in shallow or sandy waters Main Heat Exchanger 500 Hours Check and clean more frequently if local conditions require it Whichever occurs first If large quantities of water are found in the fuel when the filter is drained increase the frequency of draining ...

Страница 39: ...RDG603A17 Issue 1 Shire 30_40_50 WB RB Manual Page 39 of 51 SECTION 7 Wiring Diagrams 1 Engine Wiring Diagram Shire 30 40 50 Shire Work Boat River Boat Engine ...

Страница 40: ...RDG603A17 Issue 1 Shire 30_40_50 WB RB Manual Page 40 of 51 2 Standard Control Panel Wiring Diagram ...

Страница 41: ...RDG603A17 Issue 1 Shire 30_40_50 WB RB Manual Page 41 of 51 3 Deluxe Control Panel Wiring Diagram ...

Страница 42: ... Oil Pressure Warning Light 140A Alternator Charge Light 50A Alternator Charge Light Glow Plug Light Key Flap Ignition Switch 50A Alternator Voltage Output Gauge Tachometer Key Flap Ignition Switch Glow Plug Light 50A Alternator Charge Light 140 240A Alternator Charge Light Oil Pressure Warning Light Water Temperature Warning Light Oil Pressure Gauge Water Temperature Gauge Hour Meter ...

Страница 43: ... Issue 1 Shire 30_40_50 WB RB Manual Page 43 of 51 6 Overall Dimensions of the Control Panels RDG20710110 Standard Control Panel All Dimensions are in mm RDG20710111 Deluxe Control Panel All Dimensions are in mm ...

Страница 44: ... Overall Dimensions Figure 13 Travel Power wiring diagram Figure 13 shows the 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 WARNING ALL HIGH VOLTAGE WIRING SYSTEMS SHOULD BE INSTALLED BY A QUALIFIED ELECTRICIAN ...

Страница 45: ... 51 Figure 14 Travel Power dimensions These are the dimensions for Figure 14 3 5kW 5kW 7 8kW Dimension 1 65mm 65mm 55mm Dimension 2 390mm 390Mm 470mm Dimension 3 140A Alt 420mm Dimension 3 240A Alt 445mm Dimension 4 140A Alt 135mm Dimension 4 240A Alt 150mm ...

Страница 46: ...m Flywheel End Counter clockwise Viewed from Flywheel End Lubricating System Forced Lubrication with Trochoid Pump Forced Lubrication with Trochoid Pump Normal Oil Pressure at Rated Engine Speed 0 34 0 54 MPa 3 4 5 4 bar 49 78 psi 0 39 0 54 MPa 3 9 5 4 bar 56 78 psi Normal Oil Pressure at Low Idle Speed 0 068 MPa 0 68 bar 10 psi 0 068 MPa 0 68 bar 10 psi Electric Starting System Starter Motor DC12...

Страница 47: ...s Ltd 01206 305233 01255 850303 info frenchmarine com HAMPSHIRE Marine Power Ltd 0238 0403918 info marine power co uk HEREFORDSHIRE Starline Marine 01684 593443 narrowboats starline demon co uk HERTFORDSHIRE P S Marine 01923 248372 pandsmarinellp gmail com LANCASHIRE British Waterways 01257 481054 emmalene foster bwml co uk LEICESTERSHIRE Foxton Boat Services Ltd 01162 792285 tony foxton boats fre...

Страница 48: ...64 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 Narrowboats 01684 874774 narrowboats starline demon co uk YORKSHIRE Rodley Boat Centre 01132 576132 John snowdenz ntlworld com MONMOUTHSHIRE Castle Narrowboats 01873 830001 castlenarrowboats btinternet com EIRE Dun Laoghaire Marin...

Страница 49: ...r Filter Element River Boat 30 RDG906A8 Pre filter for Air Filter Element River Boat 30 3011 B1 0026 Zinc Anti Corrosive Anode Work Boat 30 40 50 119574 44150 119574 44150 119574 44150 Zinc Anti Corrosive Anode River Boat 30 RDG907A4 RDG907A4 RDG907A4 Zinc Sticker 124220 09340 124220 09340 124220 09340 Raw Water Pump Impellor for front camshaft mounted pump standard option RDG010A4 RDG010A4 RDG010...

Страница 50: ...or sub system 15amp RDG3245 Optional Relays f Cold Start Relay RDG1396 g Starter Relay RDG5279 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 375ml container Part No RDG80210219 a 40A d 15A c 40A g Starter Relay f Cold Start Relay b 15A ...

Страница 51: ...er Stamp Commission 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 Signed Dealer Stamp Actual Hours Signed Dealer Stamp Actual Hours Signed Dealer Stamp Actual Hours Signed Please refer to Owner s Manual for service intervals PDI 1st 2nd 3rd 4th 5th 6t...

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