rdg603a15 issue 3 shire 30 32 33 35 38 40 45 50 canal boat manual

SH
IRE CANAL ENGINE MANUAL
For the following engine models:
SHIRE 30
SHIRE 32
SHIRE 33
SHIRE 35
SHIRE 38
SHIRE 40
SHIRE 45
SHIRE 50
Please read in conjunction with
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
RDG603A15 – Issue 3 – Shire 30_32_33_35_38_40_45_50 Canal Boat Manual
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
Name of Notified Body for exhaust emission assessment: United States Environmental Protection Agency
Address: Office of Transportation and Air Quality
Town: Michigan
Post Code: 48105
Country: USA
ID Number: BCHCL1.12AAA-002
Conformity assessment module used for exhaust emissions: B+C B+D B+E B+F G H
Or engine type-approved according to: R stage II of Directive 97/68/EC R Directive 88/77/EC
Other Community Directives applied:
Description of Engine(s) and Essential Requirements
Engine Type: Inboard Engine
Fuel Type: Diesel
Combustion Cycle: 4 Stroke
Identification of Engine(s) covered by this Declaration of Conformity
Engine Model
Engine Type
Engine
Family Type Approval Certificate Number
code
Shire 30 / 32 / 33 / 35
Shire 38 / 40 / 45 50
4TNV 88 BDYE
G2YDXCL0164N3N
e13*97/68DA*2012/46KA*0574*24
Essential Requirements
Annex 1.B- Exhaust Emissions
B.1 Engine Identification
B.2 Exhaust emission
requirements
B.3 Durability
B.4 Owners Manual
Annex 1. C- Noise Emissions
Standards
Other normative
document/method.
*
R
Technical
file
Specify in more detail
*= Mandatory standard.
* EN ISO 8178
R
ISO10240
See Declaration of Conformity of the craft in which the engine(s) has(have) been installed
This declaration of conformity is issued under the sole responsibility of the manufacturer. I declare on behalf
of the engine manufacturer that the engine(s) [is (are) in conformity with the type(s) for which above
1
mentioned EC type-examination or type approval certificate(s) has (have) been issued and] will meet the
exhaust emission requirements of Directive 94/25/EC as amended by Directive 2003/44/EC when installed in
a recreational craft, in accordance with the engine manufacturer’s supplied instructions and that this (these)
engine(s) must not be put into service until the recreational craft which it is (they are) to be installed has been
declared in conformity with the relevant provisions of the above mentioned Directives.
Tim Hart
Sales Director
Signed: Bicester, UK
Date: 16/01/2016
RDG603A15 – Issue 3 – Shire 15 Canal Boat Manual 30_32_33_35_38_40_45_50
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PLEASE NOTE:
This manual has been compiled to help you to operate your engine and its associated parts
with safety and pleasure. 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. No claims may be
pursued in this respect.
WARNING:
THIS MANUAL FORMS AN INTEGRAL PART OF THE ENGINE IT ACCOMPANIES, IF
A TRANSFER OF TITLE OCCURS, IT MUST ALWAYS BE HANDED OVER TO THE
NEW OWNER.
WARRANTY
This Limited Warranty provides coverage for five (5) years (or 2000 hours whichever occurs
first) for recreational users and three (3) years (or 2000 hours whichever occurs first) for
commercial users from the date of warranty registration. The repair or replacement of parts,
or the performance of service under this warranty, does not extend the life of this warranty
beyond its original expiry date.
To ensure that you have been registered for your warranty, please ask your Boat Builder or
Engine Supplier to provide your portion of the registration form.
The Warranty will only apply if the following have been carried out:
1/ The Installation Check List in the Installation Section has been fully completed.
2/ The boat builder or engine installer has completed the Boat Builder Section on the
Service Record Card (located at the back of this manual) regarding hand over and
commissioning of boat.
3/ The registration form has been completed and returned to E.P Barrus.
PRM Gearboxes are covered by a three (3) year warranty for recreation users and two (2)
RDG603A15 – Issue 3 – Shire 15 Canal Boat Manual 30_32_33_35_38_40_45_50
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years for commercial users.
Engine alternator, starter motor and electrical components are only covered by a one (1)
year warranty.
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE
Warranty coverage is only available from an authorised dealer in the country in which the
sale occurred. 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.
WARRANTY CLAIMS
Warranty claims shall be made by an authorised dealer or boat builder.
The dealer or boat builder will then arrange for the inspection and any necessary repairs. If
the repairs carried out are not covered by the warranty, the purchaser shall pay for all
related labour and material, and any other expenses associated with that service.
WHAT IS NOT COVERED
This limited 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/duty cycle section of the Owner’s Manual,
accident, submersion, improper installation (proper installation specification 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 related to crane-out, launch, towing, storage, telephone, rental, inconvenience,
slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other
types of accidental or consequential damages are not covered by this warranty.
Engine electrical systems fitted with alternator boost charge systems or any other electrical
management systems are not covered by warranty.
Engine and fuel equipment is not covered by warranty if bio-diesel is used in the fuel
system. Also if no type of water trap is incorporated into fuel system.
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Index
Page
SECTION 1 – Safety Precautions ........................................................................................ 8
1.
General......................................................................................................................... 8
2.
Lifting ............................................................................................................................ 8
3.
Rotating Shafts and Belts ............................................................................................. 8
4.
Exhaust System ........................................................................................................... 8
5.
Launching and Lifting Boats ......................................................................................... 8
6.
Batteries ....................................................................................................................... 8
SECTION 2 – Engine Identification ..............................................................10
SECTION 3 – Installation ...............................................................................11
1.
Ventilation................................................................................................................... 11
2.
Engine Beds ............................................................................................................... 11
3.
Cooling System .......................................................................................................... 11
4.
Skin Tanks.................................................................................................................. 11
5.
Engine Cooling Water Inlet and Outlet Hose Connections......................................... 12
6.
Pressurised Water Header Tank ................................................................................ 12
7.
Shaft Connection and Propeller Selection.................................................................. 15
8.
Engine Anti-Vibration Mounts ..................................................................................... 16
9.
Engine Alignment ....................................................................................................... 17
10.
Electrics ...................................................................................................................... 18
11.
Electrical Options ....................................................................................................... 18
12.
Engine Oil ................................................................................................................... 19
13.
Fuel ............................................................................................................................ 19
14.
Coolant ....................................................................................................................... 19
15.
Calorifier ..................................................................................................................... 20
16.
Control Cables............................................................................................................ 20
17.
Domestic Battery Bank ............................................................................................... 20
18.
Control Panel.............................................................................................................. 21
19.
Exhaust System ......................................................................................................... 22
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20.
Hydraulic Drive Transmissions ................................................................................... 22
21.
Hydraulic Pump Drive Option (Shire 38, 40, 45, 50) .................................................. 23
22.
Centa Coupling CF-M-160 (RDG2779) ...................................................................... 23
23.
Installation Check List ................................................................................................ 24
SECTION 4 – Operation .................................................................................25
1.
Starting the engine for the first time ........................................................................... 25
2.
Starting Procedure ..................................................................................................... 26
3.
Stopping Procedure.................................................................................................... 26
4.
Full Load Running ...................................................................................................... 26
5.
Refuelling ................................................................................................................... 27
6.
Twin Thermostats – Shire 45 and 50 ......................................................................... 27
7.
Diesel Fuel Additive.................................................................................................... 28
8.
Exhaust Back Pressure .............................................................................................. 28
9.
Hybrid System (For engine with Hybrid System fitted) ............................................... 29
10.
Single Lever Side Mount Operation - Optional (RDG9210055) ................................. 29
SECTION 5 – Service Procedure ..................................................................29
1.
Engine Oil and Filer Change ...................................................................................... 29
2.
Air Filter Check and Change ...................................................................................... 30
3.
Gearbox Oil Change................................................................................................... 30
4.
Disposal of Oil and Related Items .............................................................................. 32
5.
Primary Fuel Filter Drain – Shire 30, 33, 35, 40, 45 & 50........................................... 32
6.
Primary and Secondary Fuel Filter Change ............................................................... 32
7.
Fuel System Bleeding ................................................................................................ 33
8.
Cooling System .......................................................................................................... 33
9.
Belt Adjustment .......................................................................................................... 33
10.
Belt Maintenance........................................................................................................ 34
11.
Belt Replacement ....................................................................................................... 34
12.
Control Panel Maintenance ........................................................................................ 34
SECTION 6 – Service Schedule ....................................................................35
1.
Specifications and Capacities .................................................................................... 35
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2.
Service Intervals ......................................................................................................... 36
SECTION 7 – Wiring Diagrams .....................................................................38
1.
Engine Wiring Diagram Shire 30, 32, 33, 35, 38, 40, 45 & 50.................................... 38
2.
Standard Control Panel Wiring Diagram .................................................................... 39
3.
Deluxe Control Panel Wiring Diagram........................................................................ 40
4.
RDG20710110 – Standard Control Panel .................................................................. 41
5.
RDG20710111 – Deluxe Control Panel ..................................................................... 41
6.
Overall Dimensions of the Control Panels.................................................................. 42
7.
8kW Travel Power Wiring Diagram and Overall Dimensions ..................................... 43
SECTION 8 – Technical Data ........................................................................45
SECTION 9 – Dealer List ...............................................................................46
SECTION 10 – Shire Service Parts ...............................................................48
SECTION 11 – Shire Service Record Card ..................................................49
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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.
2. Lifting
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
The engine and its accessories are not intended to be put into operation until they are
integrated into the boat as a whole. No person should be in the engine compartment and
the engine cover or deck hatches should be closed whilst the engine is running.
4. Exhaust System
Exhaust gases may have temperatures as high as 650°C and contain elements which are
harmful if ingested.
It is therefore essential that exhaust systems are gas tight and lagged to prevent accidental
burning.
5. Launching and Lifting Boats
Care must be taken when launching or craning new boats into or out of the waterway, so
that water does not enter the engine via the exhaust system or air vents. It is recommended
that these are blocked temporarily whilst undertaking this procedure.
6. Batteries
WARNING:
EXPLOSIVE GASSES / SULPHURIC ACID
•
•
Batteries can produce explosive gases; keep sparks and flames away from the
battery.
NO SMOKING
Batteries contain sulphuric acid; if splashed on skin or eyes, flush well with water and
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•
•
•
•
•
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.
Do not tip the battery on its side.
Please see label on battery or manufacturer’s instructions for specific information.
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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.
Note: Canal Boat Engines (CB) do not have identification initials on the engraved plate.
An example of the engine identification plate is shown below (Figure 1):
SHIRE
1550DXXXXX
Serial Number
Build Number
Engine Model
Indicates Model Type or Optional Extras:
RB = River Boat
WB = Work Boat
D = Deluxe Panel
3 = 3:1 Ratio Gearbox
Figure 1: Engine Identification Badge
Description of Models:
CB: Canal Boat Engine: Keel cooled dry exhaust manifold.
WB: Work Boat Engine: Seawater / Heat Exchanger cooled, dry exhaust manifold
with either dry exhaust system (same as a Canal Boat) or
water injected exhaust system.
RB: River Boat Engine: Can also be used for sea going applications. Seawater / Integral
exhaust manifold, heat exchanger cooled. Water injected exhaust system.
Note: There are a number of optional extras that may be fitted to an engine that are not
listed here.
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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 (16in2).
An allowance must be made for any grills, louvres or bends placed in the airflows
and generally an increase of 25% in area is sufficient to overcome any restriction
problems.
2. Engine Beds
• These should 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. Cooling System
• Ensure pipe work to and from the skin tanks is of sufficient bore. Ensure tight bends
and elbows are avoided or kept to a minimum (sizes are listed overleaf).
4. Skin Tanks
The ideal skin tank internal thickness is between 50 and 75mm, the table below will indicate
a suitable tank size. However, volume will not compensate for lack of surface area. It
should be recognised that fitting a large calorifier will increase the theoretical cooling
capacity only until it is up to temperature. It is unlikely that a boat on the inland waterways
will operate at full power for long periods of time. The engine cooling water outlets are on
the right hand (starboard) side of the engine.
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Air Bleed Points
Height
Coolant from
Engine
Coolant to
Engine
Length
Figure 2: Skin Tank Flow Diagram
Recommended Skin Tank Size
Suggested
Height mm
Suggested Length mm
Engine
HP
KW
Skin tank surface
area m2
50
50
37
1.1250
750
1500
45
45
34
1.0
721
1442
38-40
38-40 30-38
1.0
721
1442
30-35
30-35 22-26
0.85
652
1304
Note: Skin tank size must be increased by approx. 10% if a hydraulic drive transmission is
fitted.
5. Engine Cooling Water Inlet and Outlet Hose Connections
These are on the right hand (starboard) side of the engine:
• Shire 30, 32, 33, 38
28mm OD, Inlet and Outlet
• Shire 35, 40
28mm OD, Inlet and Outlet
• Shire 45, 50
28mm OD, inlet and 35mm OD, Outlet
Use a good quality hose that cannot collapse or kink and is capable of working at
temperature in excess of 100°c.
6. Pressurised Water Header Tank
• 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 50: A single hose connects the tank to the vertical hosetail fitted into the port
side of the twin thermostat housing. Shire 50 Connections are shown on (Figure 7).
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•
•
Shire 30, 32, 33, 35, 38, 40 and 45: Two hoses are used on these engines. One is
fitted between the smaller internal diameter (3mm) outlet (on the left hand side of the
tank) and the connection on the port side of the top of the thermostat housing (on 45
the side of the twin thermostat housing). The second hose is connected between the
larger internal diameter outlet on the right hand side of the tank and the ½“ hosetail
connection on the engine pipe facing forwards and upwards at 45°. Shire 30, 32, 33,
35 Connections are shown on (Figure 3). Shire 38 Connections are shown on
(Figure 4). Shire 40 Connections are shown on (Figure 5). Shire 45 Connections
are shown on (Figure 6).
A constant rise on pipework is required to prevent air locks
Large ID Hole
Small ID Hole
Figure 3: Shire 30/32/33/35 Header Tank Connections
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Large ID Hole
Small ID Hole
Figure 4: Shire 38 Header Tank Connections
Large ID Hole
Small ID Hole
Figure 5: Shire 40 Header Tank Connections
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Large ID Hole
Small ID Hole
Figure 6: Shire 45 Header Tank Connections
Single Hole (3mm Outlet)
Figure 7: Shire 50 Header Tank Connections
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.
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8. Engine Anti-Vibration Mounts
• Ensure that the engine feet do not end up at the top of the thread on the engine
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 thick are available: Order RDG3906 Engine
mount spacer. Alternatively they can be manufactured locally.
• On the Shire 30, 32, 33, 35 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 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. If this occurs, excessive engine vibration will be experienced
through the hull.
• For best results, fit the front AV mounts into the front holes in the engine 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 (measuring from the centre of the mount hole to the front end of the rail).
Note: This procedure is only possible on non VDO Travel Power engines, and may
result in a very slight increase in vibration. AV mount installation points are shown
on (Figure 10)
Figure 8: Correct Anti-Vibration Mount Installation
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Figure 9: Correct Anti-Vibration Mount Installation
Alternative
position
compartment
mounting
if
engine
space
Normal mounting position
Figure 10: Anti-Vibration Mount Installation Points
9. 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. Ensure alignment is recheck after the first 4 hours of running, after the
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is
•
•
•
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.
Boats that are fitted with 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. Note: Some types of flexible shaft couplings require the input and output to
be misaligned, check with the coupling manufacturer’s installation instructions.
Minimum clearance of 25mm between rails and engine beds.
10. Electrics
• Do not attach any part, hose or cable to the engine wiring harness. There is a
warning label attached to the harness to remind you of this.
• Connect the wiring extension harness multi plug to the panel plug and the other end
to the engine.
• Connect the start battery positive cable to the engine starter motor solenoid terminal.
• The starter motor battery cable must have a cross sectional area of at least 50mm2.
• Shire 32 is a single alternator engine.
• For twin alternator engines, connect the domestic battery positive cable to the 140A
or 240A Alternator. The 140A alternator has a B+ terminal and the 240A alternator
has a “pos out” terminal (see wiring diagram). This ensures that the 50A alternator
charges the start battery and the 140A or 240A alternator charges 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 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 has been connected to the domestic alternator. Belt fitting and tensioning
instructions are in Section 5 – Service Procedure. Make sure the alignment is
correct.
• A cable will need to be manufactured locally and fitted between the lower 140A or
240A alternator and domestic battery positive terminal. The cable should have a
minimum cross sectional area of:
40mm² for Shire 30, 33, 35, 38 and 40.
70mm² for Shire 45 and 50.
• Both negative battery terminals can be connected to a common earth point.
Note: The 240A alternator is of the insulated earth design and requires a heavy duty earth
cable installed at all times.
11. Electrical Options
• If the engine is fitted with the optional 230V Travel Power System, refer to the
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•
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. This will be supplied fitted but not wired. It is the responsibility of the
boat builder to ensure that this is correctly wired to the boats electrical system.
12. Engine Oil
• All Shire engines are supplied fully run in.
• Check oil levels in engine and gearbox before starting
• Use good quality engine oil SAE 10W / 40 API class CD.
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. The Shire 30, 33, 35,
40, 45 and 50 engines are supplied with an additional fuel pre-filter water trap as
standard.
• Connect fuel feed return hoses from engine to main supply and return lines to main
fuel tank, ensuring they are connected the correct way around. The hose to the
electric fuel pump is the inlet.
• The engine hoses are supplied with 5/16” (8mm) OD metal hosetails and should be
securely fitted to the main supply and return pipes with compression 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 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 flow clearly (no bubbles). The rest of the process is done
automatically by the engine. It is rarely necessary to bleed the injection pump or
injectors upon installation as the engine will already have fuel in it from the engine
run in and test procedure.
14. Coolant
• Prepare coolant mix of 50% clean tap water and 50% antifreeze.
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Open the calorifier taps (if fitted) to fill the calorifier system and displace air.
To fill the cooling system for the first time, fill the boat skin via the inlet hose
connection or filler plug if fitted.
• Shire 30, 32, 33, 35, 38, 40: Fill the engine through the white plastic expansion tank.
• Shire 45: Fill the engine through the twin thermostat housing filler, then top up the
white plastic expansion tank.
• Shire 50: Fill the engine through the water-cooled exhaust manifold filler, then
through the twin thermostat housing. Top up through the white plastic expansion
tank.
• Bleed skin tank.
Note: After running 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.
•
•
15. Calorifier
• 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. Control Cables
• Connect engine speed control cable. With the engine off, ensure that the engine
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.
17. Domestic Battery Bank
Domestic battery banks that are too large create excessive loads on the domestic
alternator. Alternators running at maximum output for prolonged periods of time will
eventually fail prematurely; alternators that fail due to the battery bank being over the
maximum recommended size will not be covered by warranty.
Higher output additional alternators, or travel power kits are available: if larger battery
banks are required discuss your individual 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 current.
- Weekend cruising or hire fleet use, three and a half times domestic
alternator, maximum output current.
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Example 1:
Live aboard application fitted with a 140amp domestic alternator
3 x 140 = 420 ampere/hour maximum battery bank size
Example 2:
Weekend cruising or hire fleet application fitted with a 240amp domestic alternator
3.5 x 240 = 840 ampere/hour maximum battery bank size.
18. Control Panel
All Shire engines are supplied with high quality engine control panel that all show RPM and
hours run and include warning lights and a warning buzzer. The deluxe panels also have
additional gauges for the water temp, oil pressure and battery charging. The panels are
designed to be splash proof and are correctly installed with the gauges vertical. Do not
install so that they remain out in the open, or cover up when not on use.
The control panel engine tachometer is supplied already calibrated to measure correct
engine speed. If a new control panel, tachometer or alternative alternator is fitted, the tacho
will require re-calibrating.
Control Panel Calibration Procedure:
• Connect control panel plug to engine wiring loom plug.
• 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 button on rear of tacho, 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 on the bottom of tacho reaches the correct value, according to the
type of alternator (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
50
10.50 – 11.00
70
15.00
110
18.00
140
19.50 – 20.00
240
22.00
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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.
Engine energise to stop systems are available as an optional extra.
19. Exhaust System
The exhaust outlet size on the engine is 1½” BSP female. There must be a flexible exhaust
hose of suitable 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 1½” BSP. Exhaust silencers, flexible exhaust hose connections
and lagging blanket are all available as optional extras:
Part Description
Part Number
Exhaust Coupling 1½” x 1½” BSP
RDG1916
Exhaust Silencer DSA-38
RDG1911
Flexible Exhaust Hose (18”)
RDG1879
Blanket 18” Flexy Exhaust
RDG2477
ü
•
X
Make sure the exhaust increases then decreases in height as shown above.
20. 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. However if a cooler is supplied, this will only be suitable to cool a
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conventional marine gearbox.
Hydraulic drive transmissions generate far more heat than a conventional marine gearbox.
Therefore the size of the oil cooler installed must be calculated by the hydraulic drive
transmission supplier: to ensure it has sufficient cooling capacity and is sized appropriately
taking into account:
• Maximum engine power.
• High ambient summer air temperature.
• Summer River/Canal/Sea temperature.
• No additional restriction to engine coolant flow is present.
Skin tanks will also need to be increased by approx. 10% to dissipate the additional heat
generated.
Oil coolers should be installed after the engine, not before. Coolers that are installed before
the engine will invalidate the engine warranty.
21. Hydraulic Pump Drive Option (Shire 38, 40, 45, 50)
For SAE pump (9T)
If a hydraulic pump is required to drive items such as bow thrusters or hydraulic winches
then the following parts are required to enable drive to be taken from the engine power take
off:
Part No 129484-26200 incorporates:
• Packing (on gear case side): 171353-26081
• Cover: 121023-26070
• Cover packing: 121023-26061
Ratio: 0.90:1
22. Centa Coupling CF-M-160 (RDG2779)
Centa have given Barrus permission to use the following instruction on how to fit the
coupling:
When assembling the coupling all the bolts and nuts must be tightened to the correct torque
using a torque wrench. Tightening by “feel” will not give a satisfactory result.
•
•
•
Remove the clamping bush from the coupling.
Degrease the propeller shaft and the bore of the clamping hub. Leave the special
grease only 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
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•
•
the coupling are 15/17mm, so care must be taken to use screws or studs of the
correct length. Centa recommend the use of M10 x 25 screws or M10 x 40 studs. If
using studs the shorter (10mm) screwed portion should be inserted into the coupling.
TIGHTENING TORQUE IS 45Nm
Push the clamping hub fully onto propeller shaft.
Connect the clamping hub/propeller shaft onto the coupling. The connecting screws
of the clamping bush must 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
CAUTION: The tightening of the connecting screws between the clamping bush and the
hub means that the clamping hub/propeller shaft will be dragged into the coupling by a few
millimetre’s, thereby effectively shortening the installation length. Sufficient free space
(minimum 10mm) should be available between the outer bearing and the propeller hub.
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 compressed when sailing in the forward direction. The coupling is not
suitable for use with vee-drive gearboxes having outputs of the quill-shaft arrangement
where the coupling 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 anaerobic liquids.
23. 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
Check tension of alternator belts, wiring connected and belt alignment
checked if removed
Check fuel system is connected correctly and primed
Fuel line water trap installed and water drained off
Check header tank and skin tank connections are correct way round,
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constant pipework rise to header tank
Check level of coolant in header tank and correct ratio 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
All pipework and cabling supported and not chaffing, slack to allow
movement of engine
Confirm engine control panel, gauges and warning lights are all
operational
Run the engine for 20 minutes with the boat tied up and in gear (at ½
speed). Check for leaks and that all systems operate correctly
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 in
Boats: BS EN ISO 13297 (ac)
Installer’s signature
Installer name/company
SECTION 4 – Operation
1. Starting the engine for the first time
• Remove ignition key.
• Ensure all oil and coolant levels are checked.
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•
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.
• Insert ignition key.
• Turn key to on position. The glow plug light will illuminate.
• Observe warning lights (and gauges on deluxe panel). Note: The engine overheat
light will only illuminate when the water temperature exceeds the safe level. The
buzzer will also come on.
• Wait for the glow plug warning light to go out.
• Turn key to start and hold to crank.
• Crank the engine for no more than 15 seconds.
• Upon engine start, immediately release the key.
• Key will return to on position.
• The warning buzzer will stop and on the deluxe panel, the oil pressure gauge will
show an oil pressure of 3.5 - 4.5 bar (51 – 61 psi).
• Should any warning light not go out, or if there is no reading on the oil pressure
gauge, the buzzer will continue sounding. In this case, stop the engine immediately
and check the relevant system (Note: If the charge light does not go out, briefly
increase the engine speed).
• Stop engine if any abnormal noises are detected.
• Visually check the engine for oil, fuel and coolant leaks, after initial start-up and at
regular intervals. Note: Engine must be stopped to carry out this check).
3. Stopping Procedure
• Move speed control lever to idle position.
• Turn key to off position.
4. Full Load Running
• Running diesel engines near there rated output (maximum load) regularly will
disperse accumulated carbon and condensation, enhancing engine life and reducing
emissions.
• Running the engine at, or near maximum speed whilst in gear may not be possible
on inland waterways with speed limits in place. This will have to be carried out whilst
moored up. Ensure that the mooring ropes and posts are strong enough 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)
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With the engine quickly up to
operating temperature, the first 71°
thermostat opens. The water now
flows to the domestic hot water tank,
resulting in hot water being rapidly
available.
every 50 hours.
5. Refuelling
• All Shire canal 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.
• Engine to be turned off while refuelling
• The fuel type for all Shire canal boat engines is diesel. DO NOT USE BIODIESEL.
6. Twin Thermostats – Shire 45 and 50
The twin thermostat design is a feature unique to the Shire canal boat engine range. It
ensures that the engine warms up very quickly due to the first thermostat being closed so
that cooling water is routed through the specially designed cast iron exhaust manifold (Shire
50 only). The waste heat from the exhaust is recycled to bring the engine up to operating
temperature even quicker than normal. This ensures efficient engine operation with
reduced fuel consumption and even cleaner exhaust emissions. It also helps in keeping
engine wear to a minimum.
Figure 11 shows the operation of the cooling system. Note: Shire 30, 32, 33, 35, 38 and 40
have a single thermostat only.
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When the water stored in the hot water
tank has reached full temperature, the
second 88° thermostat opens and
water can then flow to the skin tank
and correctly control engine cooling.
The exhaust manifold that earlier
helped to heat engine water is now
cooled to ensure safe operation and
reduce engine compartment
temperatures.
If the load on the engine reduces and
the demand for domestic hot water
increases then the system will
automatically compensate and redirect water to ensure that a plentiful
supply of hot water is always
available.
7. Diesel Fuel Additive
The use of diesel fuel additive is strongly recommended on Shire engines. The quality of
the fuel available when cruising is often unknown. Also the fuel may have been in storage
for long periods of time. The use of additives will ensure that your engine fuel injection
system is in top condition which should result in many years of smooth reliable operation,
without the cost and inconvenience of expensive breakdowns due to poor quality fuel. It
has also been found that improvements in fuel consumption and start ability are an added
benefit of using this product. Diesel fuel additive is available from your Shire dealer in a
handy 375ml container, Part Number RDG80210219.
8. Exhaust Back Pressure
The back pressure falls within the manufacturers recommended range when using the
optional exhaust system (see Figure 11: Twin Thermostat Operation “19. Exhaust System”
from
“Section
3
–
Installation”) with the
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engine.
9. Hybrid System (For engine with Hybrid System fitted)
Refer to the separate Hybrid Operation Manual for more details on the system.
10. Single Lever Side Mount Operation - Optional (RDG9210055)
To engage forward or reverse gear:
• Lift the safety latch under the handle before shifting.
To rev the engine in neutral:
• Pull the lever out sideways from the main body.
• Lift the safety latch under the handle then shift.
SECTION 5 – Service Procedure
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.
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•
•
•
•
•
•
•
Place a plastic tube over the spout and into a container. Operate the pump handle
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 strap type oil filter removal tool supplied with the engine
(except the Shire 38), slacken the filter from the engine block in an anti-clockwise
direction. Remove the tool and spin off the filter.
Lightly oil the new filter O ring seal and install the filter onto the engine. Spin it on in
a clockwise direction and finally tighten by hand only as firmly as you can.
Refill the sump using the yellow oil filler cap in the rocker cover on top of the engine.
Oil level should be to the top mark on the dipstick.
Run the engine for 5 minutes before checking the oil level with the dipstick and top
up if required.
Do not exceed the maximum oil level marker as this may cause damage to the
internal components of the engine.
2. Air Filter Check and Change
• Release the two spring clips. Pull off the end cover to reveal the filter element. 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. The engine requires
clean unrestricted air to run efficiently. Failure to maintain the air filter could result in
smoke, increased fuel consumption and ultimately engine damage.
3. Gearbox Oil Change
Note: 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. For
engines without a gearbox sump pump follow the procedure below.
•
•
•
•
•
•
Change the gearbox oil while it is still hot (Please refer to the gearbox manual for
more information).
Place a tray beneath the gearbox that will hold at least 2 litres.
Remove the drain plug and allow 5 minutes for the oil to drain thoroughly.
Replace the drain plug. Ensure that the sealing washer (if used) is still in place and
in good condition before tightening. Fit a new washer if required.
Refill the gearbox with oil to the upper mark on the dipstick. Screw the dipstick in
fully, to establish level. Refer to the PRM owner manual for more details. Section 6
in this manual contains details of oil specifications.
Do not overfill the gearbox as this can damage the internal components.
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Level dipstick / Filler Plug
Magnetic
Drain
Plug
(viewed
from
Figure 12: PRM 80 and 120 Gearbox
Level dipstick / Filler Plug
Figure 13: PRM150 Gearbox
Level dipstick / Filler Plug
Figure 14: PRM260 Gearbox
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4. Disposal of Oil and Related Items
• 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 contaminated parts to enter the inland water way system.
5. Primary Fuel Filter Drain – Shire 30, 33, 35, 40, 45 & 50
Note: Shire 32 and 38 are not fitted with a primary fuel filter / water trap.
• 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 15)
• 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 that the drain union is tight and that there are no leaks.
• Do not over tighten the drain screw.
Note: The boat builder should have fitted an additional water trap in the fuel system.
Ensure that this is drained regularly.
Figure 15: Primary Fuel Filter Drain Screw
6. 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.
• Place a small drip tray under the filter body.
• Remove the fuel filters using the filter strap wrench supplied (not supplied with the
Shire 38). 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 (Shire 30, 33, 35, 40, 45 and 50 only). The part number for the
drain screw is RDG9189022.
Smear a small amount of clean fuel on all of the O ring seals that are supplied with
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the new filter element.
• Screw the new element back into the filter head. Tighten by hand only.
• Turn the main boat fuel supply tap back on.
• Ensure the system is correctly bled before attempting to start up.
Note: The same procedure is used for both the primary and secondary fuel filter changes.
7. Fuel System Bleeding
• Ensure the fuel tank is at least ¾ full prior to undertaking this procedure.
• See the fuel paragraph in Section 3 of the Yanmar engine operation manual.
8. Cooling System
CAUTION:
DO NOT CHECK THE COOLANT LEVEL WHEN THE ENGINE IS HOT. REMOVE THE
IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT.
•
•
•
•
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 should be between the two level
marks formed on the 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 only to top up as this weakens the coolant mix, reducing the level
of frost protection and anti-corrosion protection of the coolant.
9. Belt Adjustment
CAUTION:
REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT.
•
•
Depress the longest run of the drive belt to be checked. If the travel exceeds 1520mm using hard finger pressure, the belt needs re-tensioning.
Loosen the upper adjuster on the alternator. Loosen the lower mounting pivot nut
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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 tighten the belt.
• Hold the alternator in position and retighten all the bolts
Note: If the belts are over tightened, alternator bearing failure will occur.
10. 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.
• Replace the belt if it cracks or splits and as the adjustment nears the limit of travel.
Note: Some boat builders may remove one or more of the alternators during the installation
of the engine. It is essential that when the alternators are refitted that the alignment is
perfect or premature belt wear will occur.
11. 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. Make a note of these belt sizes upon delivery.
Loosen 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. Rotate the engine if required
by hand, to guide the new belt into the “vee”.
Re-tension the belt as above.
12. Control Panel Maintenance
CAUTION:
REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT.
TURN BATTERY ISOLATION SWITCHES OFF.
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To replace an illumination bulb: Release the panel from its mounting. The bulbs
are accessible from the rear of the panel. Remove the wires, unscrew the nut and
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. Replace the gauge and refit. Reattach the wiring
connectors.
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. This will ensure the lubricant works into the mechanism.
•
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
Engine Oil Capacity (with Filter):
Engine
Capacity (Litres)
Capacity (Pints)
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30, 32, 33, 35
5.5
9.6
38, 40, 45, 50
7.4
13
Gearbox
Capacity (Litres)
Capacity (Pints)
PRM 80
0.57
1.0
PRM 120
0.8
1.4
PRM150
1.4
2.5
PRM260
1.5
2.7
Gearbox Oil Capacity (Excluding Cooler):
2. Service Intervals
Check
Change
Notes
Engine Oil & Filter
Daily (Level)
Every 250 Hours
OR 12 Months*
First change after 50 hours
Gearbox Oil
Weekly
(Level)
Every 250 Hours
OR 12 Months*
First change after 25 hours
Coolant Level
Daily (Level)
Every 24 Months
-
Diesel Fuel Filter –
Primary & Engine
50 hours
Every 500 hours
OR 12 Months*
Drain water every 50 hours
OR Monthly**
Air Filter Element
250 Hours
Every 500 hours
OR 24 Months*
Sooner if required
Drive Belts
Daily
As required
Adjust as necessary
Key Switch
Lubricate
Every 150 hours
OR 12 Months*
As per instructions in Section
12 - Control Maintenance
* Whichever occurs first.
** If large quantities of water are found in the fuel when the filter is drained, increase the
frequency of draining.
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SECTION 7 – Wiring Diagrams
1. Engine Wiring Diagram Shire 30, 32, 33, 35, 38, 40, 45 & 50
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2. Standard Control Panel Wiring Diagram
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3. Deluxe Control Panel Wiring Diagram
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4. RDG20710110 – Standard Control Panel
Tachometer
Hour Meter
Water
Temperature
Warning Light
Key Flap &
Ignition Switch
Oil Pressure
Warning Light
50A Alternator
Charge Light
140A Alternator Glow Plug Light
Charge Light
5. RDG20710111 – Deluxe Control Panel
Tachometer
Hour Meter
50A Alternator
Water
Voltage Output
Temperature
Gauge
Gauge
Oil Pressure
Gauge
Water
Temperature
Key Flap &
Warning Light
Ignition Switch
Oil Pressure
Warning Light
50A Alternator 140/240A Alternator Glow Plug Light
Charge Light
Charge Light
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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)
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7. 8kW Travel Power Wiring Diagram and Overall Dimensions
Figure 16: Travel Power wiring diagram
Figure 16 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.
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Figure 17: Travel Power dimensions
These are the dimensions for Figure 17:
3.5kW
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
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SECTION 8 – Technical Data
Engine Model
3TNV82A
4TNV88 BDYED SH
Vertical In-Line Diesel Engine
Vertical In-Line Diesel Engine
Indirect Injection
Indirect Injection
Natural
Natural
3
4
Bore x Stoke
82 x 84mm
88 x 90mm
Displacement
1.331L
2.190L
Low Idling
850 - 875 rpm
850 - 875 rpm
High Idling
3180 ±25 rpm
3210 ±25 rpm
Direction of
Counter clockwise Viewed from Flywheel
Type
Combustion
System
Aspiration
Number of
Cylinders
Rotation
Lubricating
System
End
Counter clockwise Viewedfrom Flywheel End
Forced Lubrication with Trochoid Pump
Forced Lubrication with Trochoid Pump
0.34 – 0.54 MPa / 3.4 – 5.4 bar / 49 – 78 psi
0.39 – 0.54 MPa / 3.9 – 5.4 bar / 56 – 78 psi
0.068 MPa / 0.68 bar / 10 psi
0.068 MPa / 0.68 bar / 10 psi
Starter Motor: DC12V
Starter Motor: DC12V
Starter Capacity: 1.7kW
Starter Capacity: 2.3kW
Recommended Start Battery Capacity: 12V 55Ah
Recommended Start Battery Capacity: 12V 65Ah
0.64 ± 0.06mm
0.73 ± 0.06mm
0.15 – 0.25mm
0.15 – 0.25mm
Normal Oil
Pressure at
Rated Engine
Speed
Normal Oil
Pressure at Low
Idle Speed
Electric Starting
System
Top Clearance
(Piston to Head
Clearance at
tdc)
Valve
Clearances
(Exhaust and
Inlet)
RDG603A15 – Issue 3 – Shire 15 Canal Boat Manual 30_32_33_35_38_40_45_50
Page 45 of 50
SECTION 9 – Dealer List
Area
Company
Telephone
Email
Bluenine Marine
01189 406482
bluenine@marine7957.fsnet.co.uk
Aquatec Marine
07880793686
sales@aquatecmarine.com
Driveline Marine
0118 942 3877
tam@drivelinemarine.com
Nantwich Canal Centre
01270 625122
info@nantwichcc.com
Black Dog Marine
01503 265898
blackdogmarine@googlemail.com
Cellar Marine
01326 280214
john@cellarmarine.com
G B Smith & Son
01208 862815
info@gbsmithandson.co.uk
CUMBRIA
Windermere Aquatic Ltd
01539 442121
service@aquaticboatcentres.com
DERBYSHIRE
Midland Canal Centre
01283 701933
info@mccboats.co.uk
Sleeman & Hawkin Ltd
01626 778266
keith@sleeman-hawkin.co.uk
Tonto Marine
01803 844399
enquiries@tontomarine.co.uk
Mobile Marine
01297 631821
mobilemarine@btconnect.com
Darthaven Marina
01803 752242
admin@darthaven.co.uk
BERKSHIRE
CHESHIRE
CORNWALL
DEVON
01206 305233
ESSEX
French Marine Motors Ltd
HAMPSHIRE
Marine Power Ltd
0238 0403918
info@marine-power.co.uk
HEREFORDSHIRE
Starline Marine
01684 593443
narrowboats@starline.demon.co.uk
HERTFORDSHIRE
P & S Marine
01923 248372
pandsmarinellp@gmail.com
LANCASHIRE
British Waterways
01257 481054
@emmalene.foster@bwml.co.uk
LEICESTERSHIRE
Foxton Boat Services Ltd
01162 792285
tony@foxton-boats.freeserve.co.uk
LONDON
De La Hunty Marine
02089 792121
delahuntymarine@btinternet.com
NORFOLK
French Marine Motors Ltd
01603 722079
info@frenchmarine.com
NORTHAMPTON
Grand Junction Boat Co.
01604 858043
grandjunco@talk21.com
NOTTINGHAM
Farndon Marina
01636 705483
info@farndonmarina.co.uk
OXFORDSHIRE
Service Engine UK
01993 835157
info@serviceenginesuk.co.uk
SHROPSHIRE
Maestermyn (Marine) Ltd
01691 662424
enquiries@maestermyn.co.uk
JD Boat Services Ltd
01902 791811
jdboats@btinternet.com
Stone Boatbuilding Company
01785 812688
sales@stonebuilding.co.uk
Streethay Warf
01543 414770
pat@streethaywarf.freeserve.co.uk
Barry Hawkins Narrowboats
01827 711762
boats@hawkinsyard.freeserve.co.uk
STAFFORDSHIRE
WARWICKSHIRE
01255 850303
info@frenchmarine.com
RDG603A15 – Issue 3 – Shire 15 Canal Boat Manual 30_32_33_35_38_40_45_50
Page 46 of 50
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
Starline Narrowboats
01684 874774
narrowboats@starline.demon.co.uk
YORKSHIRE
Rodley Boat Centre
01132 576132
John.snowdenz@ntlworld.com
MONMOUTHSHIRE
Castle Narrowboats
01873 830001
castlenarrowboats@btinternet.com
Dun Laoghaire Marine Services
00353 12104776
info@dlms.ie
O’Sullivans Marine
003536 67124524
brian@sulliansmarine.com
WORCESTERSHIRE
EIRE
RDG603A15 – Issue 3 – Shire 15 Canal Boat Manual 30_32_33_35_38_40_45_50
Page 47 of 50
SECTION 10 – Shire Service Parts
Model
32
30/33/35
38
Primary
Fuel Filter
Engine Fuel
Filter
Not standard
fitment
11980255801
25132003700
RDG91883
46
11980255801
25132003700
Not standard
fitment
11980255801
-
50A Alt Belt
140A Alt
Belt
240A Alt
Belt
Air Filter
Element
Pre Air
Filter Cover
Oil Filter
40
45/50
RDG9188346
RDG9188346
11980255801
11980255801
RDG6079
RDG6079
RDG6079
RDG6076
RDG6076
RDG6076
-
-
-
-
-
RDG0047498
RDG906A8
RDG5795
RDG5795
RDG5795
RDG5795
-
-
-
-
12915035153
12915035153
12915035153
12915035153
3011-B10026
12915035153
Travel Power:
3.5kw Travel Power alternator belt is RDG0047511.
5kW Travel Power alternator belt is RDG0047511.
7/8kW Travel Power alternator belt is RDG6082.
Fuses:
The electrical system is fitted with three or four blade type fuses:
a) Engine stop control system:
40amp (RDG3246)
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:
g) Starter Relay:
(RDG1396)
(RDG5279)
RDG603A15 – Issue 3 – Shire 15 Canal Boat Manual 30_32_33_35_38_40_45_50
Page 48 of 50
b) 15A
d) 15A
c) 40A
a) 40A
g) Starter Relay
f)
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).
SECTION 11 – Shire Service Record Card
RDG603A15 – Issue 3 – Shire 15 Canal Boat Manual 30_32_33_35_38_40_45_50
Page 49 of 50
SERVICE RECORD CARD
Model: ………………………………………………………………………
Engine No: ………………………………………………………………..
Carried out by E.P.Barrus
Print Name:
Actual Hours:
PDI
Boat Builder Stamp:
Commission of Boat and Hand Over to Customer.
(Refer to the Installation Check List Page in this
Manual).
Signed:
Date:
Signed:
Dealer Stamp:
Dealer Stamp:
Actual Hours:
Signed:
1st
Dealer Stamp:
Actual Hours:
Signed:
Signed:
Signed:
2nd
Dealer Stamp:
3rd
Dealer Stamp:
Actual Hours:
Actual Hours:
Actual Hours:
Signed:
4th
Dealer Stamp:
5th
Actual Hours:
Signed:
6th
Please refer to Owner’s Manual for service intervals
RDG603A15 – Issue 3 – Shire 15 Canal Boat Manual 30_32_33_35_38_40_45_50
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