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Страница: 11 / 96

RDG603A73 - Issue 3

Page 11 of 96

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, the relevant Health & Safety requirements and the recreational craft

directive 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.

Содержание Shire 43 WB

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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