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Barrus Shire 30 WB Manual

Work boat and river boat engine
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SH
IRE
WORK BOAT AND RIVER BOAT ENGINE MANUAL
Enter your engine identification details in the spaces provided above.
E. P. BARRUS LIMITED, Launton Road, Bicester, Oxfordshire. OX26 4UR
Tel: 01869-363636
RDG603A17 – Issue 1 – Shire 30_40_50 WB/RB Manual
For the following engine models:
S
HIRE
S
HIRE
S
HIRE
S
HIRE
S
HIRE
S
HIRE
Please read in conjunction with
Yanmar & the PRM Gearbox Manual
Optional:
Travel Power Manual, Hybrid Manual
Fax: 01869-363610
30 WB
30 RB
40 WB
40 RB
50 WB
50 RB
www.barrus.co.uk

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  • Page 1 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 RDG603A17 – Issue 1 – Shire 30_40_50 WB/RB Manual...
  • Page 2 Declaration of Conformity for Recreational Craft Propulsion Engine with the requirements of Directive 2013/53/EU. Name of Engine Manufacturer: Yanmar Co., LTD. Name of Authorised Representative: E.P.Barrus LTD Address: E.P.Barrus LTD, Launton Road, Bicester, Oxon, OX26 4UR, England Engine type approved according to: Stage IIIB of Directive 97/68/EC, 88/77/EC...
  • Page 3 Please read it carefully and familiarise yourself with the engine and its parts before operation. E.P.Barrus reserve the right to change the specification of its products and manuals without prior notice. Depending upon the equipment specification of the engine and accessories fitted, there may be discrepancies with the information presented in this handbook.
  • Page 4 Routing maintenance outlined in the Owner’s Manual must be performed using genuine parts in order to maintain warranty coverage. If the customer performs maintenance, Barrus reserves the right to make future warranty coverage possible only with proof of proper maintenance.

  • Page 5: Table Of Contents

    Index Page SECTION 1 – Safety Precautions ..............8 General ......................... 8 Lifting ..........................8 Rotating Shafts and Belts ..................... 8 Exhaust System ......................8 Launching and Lifting Boats ..................8 Batteries ........................8 SECTION 2 – Engine Identification .............. 10 SECTION 3 –...
  • Page 6 20. Calorifiers ........................22 21. Control Cables ......................22 22. Installation Check List ....................23 SECTION 4 – Operation ................. 24 Starting the engine for the first time ................24 Starting Procedure ..................... 25 Stopping Procedure ....................25 Full Load Running ...................... 25 Refuelling ........................
  • Page 7 17. Winterization of Seawater Cooling System (Work Boat & River Boat) ....... 35 SECTION 6 – Service Schedule ..............37 Specifications and Capacities ..................37 Service Intervals ......................37 SECTION 7 – Wiring Diagrams ..............39 Engine Wiring Diagram Shire 30, 40, & 50 ..............39 Standard Control Panel Wiring Diagram ..............

  • Page 8: Section 1 - Safety Precautions

    SECTION 1 – Safety Precautions 1. General It is the responsibility of the installer/operator to ensure that the finished installation complies with 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.
  • Page 9 seek medical advice. • Keep battery tops and battery compartment 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.

  • Page 10: Section 2 - Engine Identification

    SECTION 2 – Engine Identification Please quote the engine identification number during any enquiry or when ordering spare parts. Use the space below to record these details. This can be found engraved into the brass plate on the top of the engine rocker cover and stamped to the crankcase next to the starter motor.

  • Page 11: Section 3 - Installation

    Packing plates 25mm thick are available: Order RDG3906 Engine mount spacer. Alternatively they can be manufactured locally. • On the Shire 30 WB/RB there are two different sizes of Anti-Vibration Mounts used. The small mounts are used at the front of the engine along with spacer blocks. The RDG603A17 –...
  • Page 12 large mounts are used on the back of the engine. • Ensure that the engine has been installed for at least 24 hours before shaft alignment is checked, to allow the mounts time to settle under the engine weight. • Ensure that the anti-vibration mount centre screw is sufficiently raised so as not to touch the engine bed.

  • Page 13: Engine Alignment

    Figure 3: Correct Anti-Vibration Mount Installation Alternative mounting position engine compartment space Normal mounting position Figure 4: Anti-Vibration Mount Installation Points 6. Engine 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.

  • Page 14: Electrics

    • If the engine is out of alignment it will result in excessive vibration and possible damage to the stern tube and propeller shaft. • Boats that are fitted with fully flexible drive couplings should still have the engine and shaft alignment as close as possible.

  • Page 15: Electrical Options

    cable installed at all times. 8. Electrical Options • If the engine is fitted with the optional 230V Travel Power System, refer to the manual supplied with it for correct wiring, control box installation and operation. • The Shire range can be supplied with other optional additional 12V or 24V alternators.

  • Page 16: Coolant

    11. Coolant • Prepare coolant mix of 50% clean tap water and 50% antifreeze. For Workboats: • Ensure the top header tank connection goes to the small hole connection on the tank. • To fill the engine cooling system for the first time: •...

  • Page 17: Domestic Battery Bank

    speed control lever achieves full travel from idle to full speed. Adjust if necessary. • Check the gearbox shift lever selects positively and that the drive direction corresponds with the gearshift control lever. Ensure that the gearbox control lever and the gearshift lever are both in neutral before connection. Adjust if necessary. 13.

  • Page 18: Seawater Pump Hose Minimum Inlet Size

    (see below 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 10.50 – 11.00 15.00 19.50 –...
  • Page 19 The correct installation of the lift silencer is vital to safety, and to avoid back flooding of the engine. Figure 6 shows how to install the lift silencer correctly (Note: Halyard (M&I) Limited have given Barrus permission to use the diagram). RDG603A17 – Issue 1 – Shire 30_40_50 WB/RB Manual...
  • Page 20 Barrus recommend that Halyard (M&I) Limited are used for the Lift Silencer, Siphon Break and other components.
  • Page 21 approved by Lloyds and DNV. Do not use oil or grease to lubricate hoses when installing, wetting the inside of the hoses with water will help them slip more easily over the silencer spigots. A minimum of 2 hose clips must be used. Securely tighten all hose clamps, but be careful not to overtighten.

  • Page 22: Hydraulic Drive Transmissions

    18. Hydraulic Drive 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 without a marine gearbox), normally do not have a gearbox oil cooler fitted.

  • Page 23: Installation Check List

    speed control lever achieves full travel from idle to full speed. Adjust if necessary. • Check the gearbox shift lever selects positively and that the drive direction corresponds with the gearshift control lever. Ensure that the gearbox control lever and the gearshift lever are both in neutral before connection. Adjust if necessary. 22.

  • Page 24: Section 4 - Operation

    Check & Set the Engine Idle 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 Boats: BS EN ISO 13297 (ac) Installer’s signature Installer name/company...

  • Page 25: Starting Procedure

    • Ensure all oil and coolant levels are checked. • Ensure both the engine and domestic batteries are connected. Both battery master switches must be turned on. Failure to do so may damage the domestic alternator. • Ensure that the raw water seacock is turned on. 2.

  • Page 26: Refuelling

    5. Refuelling • 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 build-up of condensation and formation of water in the fuel tank.

  • Page 27: Section 5 - Service Procedure

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

  • Page 28: Engine Oil And Filer Change

    CAUTION: WEAR DISPOSABLE GLOVES AND BEWARE OF HOT OIL AND ENGINE BLOCK. REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT. 1. Engine Oil and Filer Change • Change the engine oil while the engine is still hot. • Remove the blanking plug in the sump pump spout (6mm Allen key). Note: Shire 50 has two oil drain pumps, it is the pump mounted up higher on the engine.

  • Page 29: Gearbox Oil Change

    • To fit a new air filter, loosen the jubilee clip which secures the old air filter to the engine. Remove the old air filter and fit the new air filter in its place. Re-tighten the jubilee clip. • The air filter is constructed from pleated paper. Inspect it closely for dust or dirt. The air filter cannot be cleaned and must be replaced when dirty.

  • Page 30: Disposal Of Oil And Related Items

    Level dipstick / Filler Plug Figure 8: PRM150 Gearbox Level dipstick / Filler Plug Figure 9: PRM260 Gearbox 5. Disposal of Oil and Related Items Please dispose of used oil and oil filters safely with due regard for the environment •...

  • Page 31: Primary And Secondary Fuel Filter Change

    Figure 10: Primary Fuel Filter Drain Screw 7. Primary and Secondary Fuel Filter Change Ensure the fuel tank is at least ¾ full prior to undertaking this procedure. • Turn off the main boat fuel supply tap. This is located on or near the fuel tank. •...

  • Page 32: Belt Adjustment

    To check the coolant level, ensure that the engine has been shut down for at least • half an hour. For Work Boats The coolant level can be checked visually and should be between the two level • marks formed on the front of the white plastic expansion tank. For River Boats Remove the lid from the water cooled exhaust manifold/heat exchanger.

  • Page 33: Belt Replacement

    of the engine. It is essential that when the alternators are refitted that the alignment is perfect or premature belt wear will occur. 12. Belt Replacement CAUTION: REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT. • Ensure that you have the correct replacement belts before starting this procedure. Some engines may have been fitted with non-standard optional alternators which may not use the belt sizes listed.

  • Page 34: Sacrificial Anode Change

    Note: Periodically squirt a lubricant into the key switch slot when the key has been removed. A lubricant such as WD40 – with silicon, would be suitable. Other lubricants are available. Then with the battery master switch turned off, operate the key switch a couple of times.

  • Page 35: Engine Heat Exchanger Tube Stack Flushing

    • Replace the impellor. • Replace the cover plate gasket if damaged. • Replace any other worn components as necessary. 16. Engine Heat Exchanger Tube Stack Flushing For Work Boats • When the engine is cold, drain the water from the engine block. Remove the hose from the tap and drain.
  • Page 36 freezing, ensure all seawater or raw water is 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.

  • Page 37: Section 6 - Service Schedule

    SECTION 6 – Service Schedule 1. Specifications and Capacities Specification of Coolants and Lubricants to use: Component Lubricant Engine SAE 10W 40 API Class CD Oil Coolant 50% Clean Water + 50% Ethylene Glycol Antifreeze PRM 80 and 120 Gearbox ATF (Automatic Transmission Fluid) Oil PRM 150 and 260 Gearbox Engine Oil...
  • Page 38 Check and change more Every 500 hours Sacrificial Anodes 250 Hours frequently if local conditions OR 12 Months* require it Change more frequently if Raw Water Pump Every 500 hours 250 Hours operating in shallow or sandy Impellor OR 12 Months* waters Check and clean more Main Heat Exchanger...

  • Page 39: Section 7 - Wiring Diagrams

    SECTION 7 – Wiring Diagrams 1. Engine Wiring Diagram Shire 30, 40, & 50 RDG603A17 – Issue 1 – Shire 30_40_50 WB/RB Manual Page 39 of 51...

  • Page 40: Standard Control Panel Wiring Diagram

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

  • Page 41: Deluxe Control Panel Wiring Diagram

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

  • Page 42: Rdg20710110 - Standard Control Panel

    4. RDG20710110 – Standard Control Panel Tachometer Hour Meter Water Temperature Warning Light Key Flap & Ignition Switch Oil Pressure Glow Plug Light 140A Alternator 50A Alternator Warning Light Charge Light Charge Light 5. RDG20710111 – Deluxe Control Panel Tachometer Hour Meter Water 50A Alternator...

  • Page 43: Overall Dimensions Of The Control Panels

    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) RDG603A17 – Issue 1 – Shire 30_40_50 WB/RB Manual Page 43 of 51...

  • Page 44: Kw Travel Power Wiring Diagram And Overall Dimensions

    7. 8kW Travel Power Wiring Diagram and 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.
  • Page 45 Figure 14: Travel Power dimensions These are the dimensions for Figure 14: 3.5kW 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 RDG603A17 –...

  • Page 46: Section 8 - Technical Data

    SECTION 8 – Technical Data Engine Model 3TNV82A BDSA 4TNV88 BDYED SH Type Vertical In-Line Diesel Engine Vertical In-Line Diesel Engine Combustion Indirect Injection Indirect Injection System Aspiration Natural Natural Number of Cylinders Bore x Stoke 82 x 84mm 88 x 90mm Displacement 1.331L 2.190L...

  • Page 47: Section 9 - Dealer List

    SECTION 9 – Dealer List Area Company Telephone Email Bluenine Marine 01189 406482 bluenine@marine7957.fsnet.co.uk BERKSHIRE Aquatec Marine 07880793686 sales@aquatecmarine.com Driveline Marine 0118 942 3877 tam@drivelinemarine.com CHESHIRE Nantwich Canal Centre 01270 625122 info@nantwichcc.com Black Dog Marine 01503 265898 blackdogmarine@googlemail.com CORNWALL Cellar Marine 01326 280214 john@cellarmarine.com G B Smith &...
  • Page 48 Onboard Energy 02476 393333 sales@onboardenergy.com Springwood Haven Leisure Ltd 0845 4566572 enquiries@springwoodhaven.co.uk Valley Boat Services Ltd 07990528123 enquiries@valleycruises.co.uk WEST MIDLANDS Stephen Goldsbrough Boats 01564 778210 andy@sgboats.com WILTSHIRE Foxhangers Marine 01380 828795 info@foxhangers.co.uk J L Pinder & Son 01527 876438 sales@jlpinderandsons.co.uk WORCESTERSHIRE Starline Narrowboats 01684 874774...

  • Page 49: Section 10 - Shire Service Parts

    SECTION 10 – Shire Service Parts Model Primary Fuel Filter RDG9188346 RDG9188346 RDG9188346 Engine Fuel Filter 119802-55801 119802-55801 119802-55801 Oil Filter 129150-35153 129150-35153 129150-35153 50A Alternator Belt 25132-003700 RDG004A4 RDG004A4 70A Alternator Belt 25132-003700 25132-003700 25132-003700 Optional 140A Alternator Belt RDG6076 RDG6076 RDG6076...
  • Page 50 b) Control Panel supply: 15amp (RDG3245) c) Engine start control system: 40amp (RDG3246) d) Glow Plug Fuse: 40amp (RDG3246) e) 7/8kw Alternator sub-system: 15amp (RDG3245) - Optional Relays: f) Cold Start Relay: (RDG1396) g) Starter Relay: (RDG5279) b) 15A d) 15A c) 40A a) 40A g) Starter Relay...

  • Page 51: Rdg603A17 - Issue 1 - Shire 30_40_50 Wb/Rb Manual

    SECTION 11 – Shire Service Record Card SERVICE RECORD CARD Model: ……………………………………………………………………… Engine No: ……………………………………………………………….. Carried out by E.P.Barrus Boat Builder Stamp: Print Name: Commission of Boat and Hand Over to Customer. (Refer to the Installation Check List Page in this Actual Hours: Manual).

This manual is also suitable for:

Shire 30 rbShire 40 wbShire 40 rbShire 50 wbShire 50 rb

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