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RDG603A63 - Issue 10

Page 13 of 104

SECTION 1

–

Safety Precautions

1. General

NOTICE:

NEVER PERMIT ANYONE TO OPERATE THE ENGINE WITHOUT PROPER

TRAINING.

It is the responsibility of the installer/operator to ensure that the finished installation complies
with CE Marking, UKCA Marking, relevant Health & Safety requirements, the Recreational
Craft Directive and or any other legislative requirements before commissioning.
Ensure that the engine battery isolator switch is in the off position and the key removed from
the control panel 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 DEATH.

The Lifting points supplied with the engine are for lifting the engine/gearbox only. A suitable
spreader bar must be employed to prevent over-stressing either bracket during any lift.

3. Rotating Shafts and Belts

WARNING:

SEVERE HAZARD!

KEEP HANDS AND OTHER BODY PARTS AWAY FROM

MOVING/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 MAINTENANCE HAVE BEEN REMOVED FROM THE AREA.

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Содержание Shire 39

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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