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Barrus Shire 15 15 CB Manual

Canal, work and river boat engine
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SHIR
CANAL, WORK AND RIVER BOAT
ENGINE MANUAL
For the following engine models:
Shire 15 15 CB / WB / RB
S
15 20 CB / WB / RB
HIRE
Please read in conjunction with the PRM Gearbox 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

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  • Page 1 15 20 CB / WB / RB HIRE Please read in conjunction with the PRM Gearbox 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...
  • Page 2 Name of Engine Manufacturer: E.P.Barrus LTD Name of Authorised Representative: E.P.Barrus LTD Address: E.P.Barrus LTD, Launton Road, Bicester, Oxon, OX26 4UR, England Name of Notified Body for exhaust emission assessment: HPi Verification Services Ltd Address: The Manor House, Howbery Park...
  • 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. Exhaust System (Work Boat / River Boat) ..............22 21. Hydraulic Drive Transmissions ................... 24 22. Installation Check List ....................25 SECTION 4 – Operation ................. 26 Starting the engine for the first time ................26 Starting Procedure ..................... 27 Stopping Procedure ....................
  • Page 7 Specifications and Capacities ..................38 Service Intervals ......................38 SECTION 7 – Wiring Diagrams ..............40 Engine Wiring Diagram Shire 15 15/20 ..............40 Standard Control Panel Wiring Diagram ..............41 Deluxe Control Panel Wiring Diagram (Additional Option – SS1551) ......42 RDG20710110 –...

  • 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

    A list of common item service part numbers can be found in Section 11, Shire service parts. SECTION 3 – Installation 1. Ventilation • All internal combustion engines radiate heat and require cool, clean air to aid complete combustion. • Please Ensure that adequate engine room ventilation is provided, by fitting at least two vents of an aperture of not less than 10,000mm2 each (16in An allowance must be made for any rills, louvres or bends placed in the airflows and generally an increase of 25% in area is sufficient to overcome any restriction...

  • Page 12: Engine Cooling Water Connections

    Air Bleed Points Coolant from Engine Coolant to Engine Length Figure 2: Skin Tank Flow Diagram Recommended Skin Tank Size Suggested Length mm Skin tank surface Suggested Engine area m Height mm 0.75m 1000 0.75 1250 Note: Skin tank size must be increased by approx. 10% if a hydraulic drive transmission is fitted.
  • Page 13 make sure they are connected the correct way around as per Figure 3 and Figure 4. Note: Not fitted to RB engines Large ID Hole Small ID Hole Figure 3: Shire 15 20 Canal Boat Header Tank Connections Large ID Hole Small ID Hole Figure 4: Shire 15/20 Work Boat Header Tank Connections RDG603A13 –...

  • Page 14: Shaft Connection And Propeller Selection

    7. Shaft Connection and Propeller Selection • Some type of flexible coupling must 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 the use of an inappropriate propeller. 8.

  • Page 15: Engine Alignment

    Figure 6: Correct Anti-Vibration Mount Installation Alternative mounting position engine compartment space Normal mounting position Figure 7: Anti-Vibration Mount Installation Points 9. Engine Alignment • The gearbox output shaft flange and propeller shaft input flange must be almost RDG603A13 – Issue 7 – Shire 15 Manual 15_20 – CB_WB_RB Page 15 of 55...

  • Page 16: Electrics

    perfectly aligned. A maximum of 0.05mm (0.002”) misalignment in any plane is acceptable. Ensure alignment is rechecked after the first 4 hours of running, after the first month and thereafter annually. • If the engine is out of alignment it will result in excessive vibration and possible damage to the stern tube and propeller shaft.

  • Page 17: Fuel

    WARNING: ENGINE OIL WITH A HIGHER API CLASS THAN CD IS UNSUITABLE FOR CANAL BOAT OPERATION AND WILL CAUSE ENGINE DAMAGE IF USED. 13. Fuel • Ensure the main fuel tank is clear of dirt and water. • A separate water trap must be fitted to all engine installations. •...

  • Page 18: Calorifier

    Riverboats with Water Cooled Manifold: Remove filler cap on top of water cooled exhaust manifold and fill cooling system through here. Run engine at idle for a few minutes with cap removed to ensure air is removed and allow a 13mm (1/2”) air gap in top of manifold to allow for expansion.

  • Page 19: Control Cables

    For River Boats: The calorifiers are positioned as per (Figure 11) • Outlet Inlet Figure 11: Position of Calorifiers on a River Boat WARNING: The temperature 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 temperature for domestic use 16.

  • Page 20: Control Panel

    Example 1: Live aboard application fitted with a 70amp domestic alternator 3 x 70 = 210 ampere/hour maximum battery bank size Example 2: Weekend cruising or hire fleet application fitted with 50amp domestic alternator 3.5 x 50 = 175 ampere/hour maximum battery bank size. Note: For boats with single alternators and using domestic batteries, it is strongly advised to use a split charge relay system and separate batteries.

  • Page 21: Exhaust System (Canal Boat)

    Barrus Alternator (Amps) Barrus Tacho reading 10.50 – 11.00 15.00 50 & 70 (Twin Alts) Only the 50 Amp alternator requires calibration Alternative or non-standard alternators will require calibrating and checking by trial and error, with a hand held tacho until the engine speed and indicated tachometer speed are the same.

  • Page 22: Exhaust System (Work Boat / River Boat)

    The correct installation of the lift silencer is vital to safety, and to avoid back flooding of the engine. Figure 13 shows how to install the lift silencer correctly (Note: Halyard (M&I) Limited have given Barrus permission to use the diagram). Figure 13: Correct Installation of the Lift Silencer 1.
  • Page 23 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 is craned or transported and during the winter.

  • Page 24: Hydraulic Drive Transmissions

    sealed container, such as a bottle due to the risk of back siphoning. After fitting, run the engine and check the unions for leaks. Check again after 5 running hours. 3. The siphon break is equally suitable for use with a marine toilet water inlet. 4.

  • Page 25: Installation Check List

    22. Installation Check List Please tick box ! Engine alignment correct, clearance all round, check propeller turns by hand (Ensure ignition is off battery and battery master switch is off) Anti-Vibration mounts correct height, spacers if necessary. Make sure all nuts are tight Exhaust system as specified Battery leads are of correct size, tightened and start battery is charged...

  • Page 26: Section 4 - Operation

    Explain/Demonstrate off season storage and maintenance Installer’s signature Installer name/company SECTION 4 – Operation 1. Starting the engine for the first time • Remove ignition key. RDG603A13 – Issue 7 – Shire 15 Manual 15_20 – CB_WB_RB Page 26 of 55...

  • Page 27: 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. 2. Starting Procedure • Ensure the gearshift control level is set to neutral and that persons are clear of any moving parts.

  • Page 28: Refuelling

    4. Refuelling • All Shire engines run on diesel fuel. DO NOT USE BIODIESEL • 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 29: Section 5 - Service Procedure

    SECTION 5 – Service Procedure CAUTION: REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT. 1. Daily Maintenance • Check the oil level in the sump. Make sure it lies between the upper and lower mark lines on the dipstick. •...

  • Page 30: Gearbox Oil Change

    The element simply pulls out. • To fit the new element, slide the open end of the filter element into the main body. Gently push the element until fully seated. Refit the end cover. • 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 31: Disposal Of Oil And Related Items

    Level dipstick / Filler Plug Figure 15: PRM 80 Level dipstick / Filler Plug Figure 16: PRM150 Gearbox (Optional) 5. Disposal of Oil and Related Items Please dispose of used oil and oil filters safely with due regard for the environment •...

  • Page 32: Fuel Filter Change

    Drain Screw Figure 17: Fuel Filter Drain Screw 7. 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 33: Belt Adjustment

    CAUTION: DO NOT CHECK THE COOLANT LEVEL WHEN THE ENGINE IS HOT. REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT. For All Models To check the coolant level, ensure that the engine has been shut down for at least •...

  • Page 34: Belt Maintenance

    Note: If the belts are over tightened, alternator bearing failure will occur. 11. Belt Maintenance • Do not allow oil to contact the belt. Oil attacks the construction of the belt. This reduces the drive efficiency and ultimately cause it to fail prematurely. •...

  • Page 35: Sacrificial Anode Change

    pull out the bulb housing from the panel. Remove the bulb and replace. Refit bulb housing, screw the nut back up and refit the wires. • To replace any gauge: Release the panel 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.

  • Page 36: Engine Heat Exchanger Tube Stack Flushing

    • Note: Do not lever against the front of the pulley housing as it is easily damaged. • Inspect the pump housing and front housing for damage or wear. • Replace the impellor. • Replace the cover plate gasket if damaged. •...

  • Page 37: Winterization Of Seawater Cooling System (Work Boat & River Boat)

    17. Winterization of Seawater Cooling System (Work Boat & River Boat) • To prevent frost damage to the seawater cooling circuit components due to water 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.

  • Page 38: 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 60 Gearbox ATF (Automatic Transmission Fluid) Oil PRM 80 Gearbox ATF (Automatic Transmission Fluid) Oil PRM 150 Gearbox...
  • Page 39 Sea Water Pump Every 300 hours 150 Hours Sooner if required Impellor (WB/RB Only) OR 24 Months* Check and change more Every 450 hours Sacrificial Anodes 150 Hours frequently if local conditions OR 12 Months* require it Or check more frequently if local conditions require it.

  • Page 40: Section 7 - Wiring Diagrams

    SECTION 7 – Wiring Diagrams 1. Engine Wiring Diagram Shire 15 15/20 RDG603A13 – Issue 7 – Shire 15 Manual 15_20 – CB_WB_RB Page 40 of 55...

  • Page 41: Standard Control Panel Wiring Diagram

    2. Standard Control Panel Wiring Diagram RDG603A13 – Issue 7 – Shire 15 Manual 15_20 – CB_WB_RB Page 41 of 55...

  • Page 42: Deluxe Control Panel Wiring Diagram (Additional Option - Ss1551)

    3. Deluxe Control Panel Wiring Diagram (Additional Option – SS1551) RDG603A13 – Issue 7 – Shire 15 Manual 15_20 – CB_WB_RB Page 42 of 55...

  • Page 43: 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 50A Alternator Optional Additional Warning Light Charge Light 70 amp Alternator 5. RDG20710111 – Deluxe Control Panel (Additional Option – SS1551) Tachometer Hour Meter Water...

  • Page 44: 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) RDG603A13 – Issue 7 – Shire 15 Manual 15_20 – CB_WB_RB Page 44 of 55...

  • Page 45: Section 8 - Technical Data

    SECTION 8 – Technical Data Model Shire 15 15 Shire 15 20 Type In Line, Water Cooled, 4 Stroke In Line, Water Cooled, 4 Stroke Combustion Chamber Swirl Chamber Swirl Chamber Type of Cylinder Liner Number of Cylinders Bore (mm) Stroke (mm) 78.4 78.4...
  • Page 46 Fuel Injector Model Axis Needle Type Fuel Injection Pump Type Plunger Type Plunger Diameter (mm) Lube Oil Pump Type Inner and Outer Rotors Cooling Water Pump Type Centrifugal Type Speed (r/min) 4000 Flow (L/min) Lift (mW.G) Starting Motor Type QDY1257A Power (kW) Voltage (V) Alternator...

  • Page 47: Section 9 - General Arrangement Drawings

    SECTION 9 – General Arrangement Drawings 1. General Arrangement Shire 15 15 Canal Boat RDG603A13 – Issue 7 – Shire 15 Manual 15_20 – CB_WB_RB Page 47 of 55...

  • Page 48: General Arrangement Shire 15 15 River Boat

    2. General Arrangement Shire 15 15 River Boat RDG603A13 – Issue 7 – Shire 15 Manual 15_20 – CB_WB_RB Page 48 of 55...

  • Page 49: General Arrangement Shire 15 20 Canal Boat

    3. General Arrangement Shire 15 20 Canal Boat RDG603A13 – Issue 7 – Shire 15 Manual 15_20 – CB_WB_RB Page 49 of 55...

  • Page 50: General Arrangement Shire 15 20 River Boat

    4. General Arrangement Shire 15 20 River Boat RDG603A13 – Issue 7 – Shire 15 Manual 15_20 – CB_WB_RB Page 50 of 55...

  • Page 51: Section 10 - Dealer List

    SECTION 10 – 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 52 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 53: Section 11 - Shire Service Parts

    SECTION 11 – Shire Service Parts Model 15/20 CB 15/20 WB 15/20 RB Fuel Filter RDG906A3 RDG906A3 RDG906A3 50A Alt Belt GB/T12732-2008 GB/T12732-2008 GB/T12732-2008 70A Alt Belt (Single GB/T12732-2008 GB/T12732-2008 GB/T12732-2008 Alt Engine) 70A Alt Belt (Twin Alt Engine) Air Filter Element 3011-T3-0004 3011-T3-0004 3011-T3-0004...

  • Page 54: Section 12 - Shire Service Record Card

    a) 15A b) 15A d) 40A c) 40A Starter Relay e) Cold Start Relay 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).
  • Page 55 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). Date: Signed: Signed:...

This manual is also suitable for:

Shire 15 15 wbShire 15 15 rbShire 15 20 cbShire 15 20 rbShire 15 20 wb

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