Barrus Shire 65, Original Instruction

Page 1: ...ORIGINAL INSTRUCTION RDG603A31 Issue 4 CANAL ENGINE MANUAL For the following engine models Shire 60 Shire 65...

Page 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...

Page 3: ...serial number in the space provided above Please quote the engine identification number during any enquiry or when ordering spare parts Information about the engine serial number and its location on t...

Page 4: ...Gearbox Manual and familiarise yourself with the engine and its parts before operation If the engine is fitted with Travel Power and or Hybrid options please also read the supplied manuals for them c...

Page 5: ...ual regarding hand over and commissioning of boat Failure to complete and return the registration form to E P Barrus will result in the warranty period starting from the date of engine manufacture NOT...

Page 6: ...tion and techniques are set forth in the Operations and First time running sections in this manual use of an accessory or part not manufactured or sold by us or alteration or removal of parts Expenses...

Page 7: ...ol 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 Overall Dimensions of...

Page 8: ...r Take Off Optional Extra 37 24 Installation Check List 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 R...

Page 9: ...ring Diagram 55 3 Standard Control Panel Wiring Diagram 56 4 Deluxe Control Panel Wiring Diagram 57 SECTION 10 Technical Data 58 1 Engine Data 58 2 Return Diesel System 58 3 Dry Weight of Engine Data...

Page 10: ...RDG603A31 Issue 4 Page 10 of 88 SECTION 14 Lubricant Safety Data Sheets 71 1 Ground Force 10W 40 71 2 Torq Gard Supreme 15W 40 80 SECTION 15 Shire Service Record Card 88...

Page 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...

Page 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...

Page 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...

Page 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...

Page 15: ...ht 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 3 150 Am...

Page 16: ...m 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 50 Amp 12 Volt Alternator 3 150 Amp 12 Volt Alternat...

Page 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...

Page 18: ...ature 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 che...

Page 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...

Page 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...

Page 21: ...e 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 avoide...

Page 22: ...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 port side of the...

Page 23: ...he 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 60 65 Two hoses are us...

Page 24: ...rature 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...

Page 25: ...sult in excessive engine movement and premature mount failure If this is a problem put steel packing plates under the mounts Packing plates 25mm thick are available Order RDG3906 Engine mount spacer A...

Page 26: ...tain strength measuring from the centre of the mount hole to the front end of the rail Note This procedure is only possible on non 230V Power system engines and may result in a very slight increase in...

Page 27: ...tallation Description 1 Normal mounting position 2 Alternative mounting position if engine compartment space is restricted Figure 15 Anti Vibration Mount Installation Points 10 Engine Alignment The ge...

Page 28: ...he 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 input and output to be misaligned check with the co...

Page 29: ...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 damage does not occur if the engine is run...

Page 30: ...ine 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 UNSUITABLE FOR CANAL...

Page 31: ...fing Initially fill the fuel system by turning the ignition on to operate the electric fuel pump Loosen the bleed screw on the top of the primary fuel filter water trap and close when fuel begins to f...

Page 32: ...ck 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 neutra...

Page 33: ...840 ampere hour maximum battery bank size 19 Control Panel CAUTION All Shire engines are supplied with an engine control panel that shows RPM and hours run and include warning lights and a warning bu...

Page 34: ...s 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 Engine energise to stop systems are available as an...

Page 35: ...umber of points must be observed Bobtail engines i e Engines supplied without a marine gearbox normally do not have a gearbox oil cooler fitted However if a cooler is supplied this will only be suitab...

Page 36: ...y in the tapered bore of the coupling hub and on the outside of the clamping hub DO NOT USE SOLVENTS Mount the coupling onto the gearbox output flange Note The M10 tapped holes in the coupling are 15...

Page 37: ...ling would be subject to a pulling force when sailing forward The coupling uses a bonded rubber element and care should be taken not to contaminate the rubber by indiscriminate use of solvents or anae...

Page 38: ...io 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 smoothly...

Page 39: ...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 case of the engine coolant temperature exceeding the maximum safety level W...

Page 40: ...nough to allow this and that the water is 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 Ref...

Page 41: ...bility 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...

Page 42: ...w when pumping to empty the sump Note Remember 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...

Page 43: ...THE GEARBOX 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 en...

Page 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...

Page 45: ...fuel filter water trap Figure 19 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...

Page 46: ...ap wrench supplied 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 th...

Page 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...

Page 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...

Page 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...

Page 50: ...p 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 Rotate the...

Page 51: ...hen the key has been removed see Section 8 Service Schedule A lubricant such as WD40 with silicon would be suitable Other lubricants are available Then with the battery master switch turned off operat...

Page 52: ...EQUIPMENT IS WORN 1 Specifications and Capacities Specification of Coolants and Lubricants to use Component Lubricant Engine SAE 15W 40 API Class CD Oil Coolant 50 Clean Water 50 Ethylene Glycol Antif...

Page 53: ...Months If large quantities of dirt or water are found in the Primary Fuel Filter then change at 350 hours Air Filter Element 250 Hours Every 700 hours OR 24 Months Sooner if required Drive Belts Dail...

Page 54: ...RDG603A31 Issue 4 Page 54 of 88 SECTION 9 Wiring Diagrams 1 Engine Wiring Diagram Shire 60 65 Figure 21 Shire 60 65 Wiring Diagram...

Page 55: ...RDG603A31 Issue 4 Page 55 of 88 2 Shire 60 65 Cold Start Wiring Diagram Figure 22 Shire 60 65 Cold Start Wiring Diagram...

Page 56: ...RDG603A31 Issue 4 Page 56 of 88 3 Standard Control Panel Wiring Diagram Figure 23 Standard Control Panel Wiring Diagram...

Page 57: ...RDG603A31 Issue 4 Page 57 of 88 4 Deluxe Control Panel Wiring Diagram Figure 24 Deluxe Control Panel Wiring Diagram...

Page 58: ...Output Speed Shire 60 44kW 60hp at 2500rpm Shire 65 48kW 65hp at 2600rpm Low Idling 875 900 rpm High Idling 2700 25 rpm Direction of Rotation Anti clockwise Viewed from Flywheel End Lubricating Syste...

Page 59: ...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 Gra...

Page 60: ...in Figure 25 Tighten all the cylinder head bolts to 50Nm following the sequence shown in Figure 25 Put a paint mark on each bolt as reference point Turn all the cylinder head bolts 60 clockwise follow...

Page 61: ...r Ltd 0238 0403918 sales marine power co uk HERTFORDSHIRE Lee Valley Marina 01920 870499 01920 293101 stansteadmarina vibrantpartnerships co uk Keypart Ltd 01923 276000 sales keypart com LEICESTERSHIR...

Page 62: ...ts btconnect com Evesham Marina 01386 768500 info eveshammarina co uk YORKSHIRE Rodley Boat Centre 01132 576132 rodleyboatcentre msn com MONMOUTHSHIRE Castle Narrowboats 01873 830001 info castle narro...

Page 63: ...00037010003 R300037010003 40A Alt Belt R300037010001 R300037010001 150A Alternator RDG20110201 RDG20110201 150A Alt Belt RDG2254 RDG2254 240A Alternator Option RDG2019682 RDG2019682 240A Alt Belt Opti...

Page 64: ...3245 3 Engine Start Control System Fuse 15amp RDG3245 4 Glow Plug Fuse 40amp RDG3246 5 Cold Start Relay RDG5279 6 Starter Relay RDG1396 Figure 26 Fuses Relays Engine Oil Engine Oil is available from y...

Page 65: ...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 Emissions...

Page 66: ...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 Annex A of this Declaration The relevant...

Page 67: ...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...

Page 68: ...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...

Page 69: ...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...

Page 70: ...ion 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 will continue t...

Page 71: ...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...

Page 72: ...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...

Page 73: ...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...

Page 74: ...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...

Page 75: ...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...

Page 76: ...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...

Page 77: ...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...

Page 78: ...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...

Page 79: ...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...

Page 80: ...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...

Page 81: ...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...

Page 82: ...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...

Page 83: ...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...

Page 84: ...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...

Page 85: ...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...

Page 86: ...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...

Page 87: ...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...

Page 88: ...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...