Barrus SHIRE 14 30 WB User manual

RDG603A9 - Issue 1 - Shire 14 Workboat Owners Manual 30, 40, 50
SHIRE WORK BOAT MANUAL
SHIRE 14 30 WB
SHIRE 14 40 WB
SHIRE 14 50 WB
Please read in conjunction with
Yanmar
&
PRM Gearbox Manual.
Enter your engine identification details in the spaces provided above.
E. P. BARRUS LIMITED, Launton Road, Bicester, Oxfordshire. OX26 4UR
Tel: [phone] Fax: [phone] www.barrus.co.uk

RDG603A9 - Issue 1 - Shire 14 Workboat Owners Manual 30, 40, 50 Page 2 of 40
Declaration of Conformity for Recreational Craft Propulsion Engine
with the requirements of Directive 94/25/EC as amended by
2003/44/EC.
Name of Engine Manufacturer: Yanmar Co LTD.
Address: Yanmar Europe B.V, Brugplein 11, 1332 BS Almere-de Vaart, Netherlands.
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 II of Directive 97/68/EC, 88/77/EC
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 code
Type Approval Certificate Number
Shire 30WB
3 TNV 82A BDSA
YD1300DNMDEC
e13*97/68DA*2001/63*0574*06
Shire 40/50WB
4 TNV 88 DSA
5YDXL2.19K4N
e13*97/68GA*2001/63*0545*11
Essential Requirements
Standards
Other normative
document/method.
Technical
file
Specify in more detail
*= Mandatory standard.
Annex 1.B- Exhaust Emissions
B.1 Engine Identification
B.2 Exhaust emission
requirements
*EN ISO 8178- 1:1996
B.3 Durability
B.4 Owner’s Manual
Annex 1. C- Noise Emissions
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 mentioned
EC type-examination or type approval certificate(s) has (have) been issued and]1will 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

RDG603A9 - Issue 1 - Shire 14 Workboat Owners Manual 30, 40, 50 Page 3 of 40
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 reserves 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 three (3) years (or 2000 hours which ever
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.
PRM gearboxes are covered by a two (2) year warranty.
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.
Engine alternator, starter motor and electrical components are only covered by a one (1)
year warranty.

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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. Routine maintenance outlined in the Owners 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, 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 Owners 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.
Failure to use John Deere approved oils and coolants will invalidate any warranty (Shire 90).
Engine electrical systems fitted with alternator boost charge systems or any other electrical
management systems other than those approved by Barrus 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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Contents
SECTION 1 - Safety Precautions .......................................................................................7
1. General............................................................................................................................................. 7
2. Lifting................................................................................................................................................ 7
3. Rotating Shafts and Belts................................................................................................................. 7
4. Exhaust System ............................................................................................................................... 7
5. Launching and Lifting Boats............................................................................................................. 7
6. Batteries ........................................................................................................................................... 8
SECTION 2 - Engine Identification.....................................................................................9
SECTION 3 - Installation...................................................................................................10
1. Ventilation....................................................................................................................................... 10
2. Engine Beds................................................................................................................................... 10
3. Pressurised Water Header Tank.................................................................................................... 10
4. Shaft Connection and Propeller Selection ..................................................................................... 10
5. Engine Anti-Vibration Mounts......................................................................................................... 10
6. Engine Alignment........................................................................................................................... 13
7. Electrics.......................................................................................................................................... 13
8. Engine Oil....................................................................................................................................... 13
9. Fuel................................................................................................................................................. 13
10. Coolant........................................................................................................................................... 14
11. Control Cables............................................................................................................................. 15
12. Seawater Strainer........................................................................................................................... 15
13. Control Panel.................................................................................................................................. 15
14. Seawater Pump Hose Inlet Size .................................................................................................... 16
15. Exhaust System ............................................................................................................................. 16
17. Hydraulic Pump Drive Option (Shire 38 / 40 / 45 / 50)................................................................... 17
18. Installation Check list...................................................................................................................... 18
SECTION 4 - Operation.....................................................................................................19
1. Starting the Engine for the First Time ............................................................................................ 19
2. Starting Procedure ......................................................................................................................... 19
3. Stopping Procedure........................................................................................................................ 20
4. Refuelling ....................................................................................................................................... 20
5. Diesel Fuel Additive........................................................................................................................ 20
6. Exhaust Back Pressure.................................................................................................................. 20
SECTION 5 - Service Procedure ......................................................................................21
1. Engine Oil and Filter Change......................................................................................................... 21
2. Air Filter Check & Change.............................................................................................................. 22

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3. Gearbox Oil Change....................................................................................................................... 22
4. Primary Fuel Filter Water Drain...................................................................................................... 24
5. Primary and Secondary Fuel Filter Change................................................................................... 25
6. Bleeding the Fuel System. ............................................................................................................. 26
7. Cooling System .............................................................................................................................. 26
8. Belt Adjustment.............................................................................................................................. 26
9. Belt Maintenance............................................................................................................................ 27
10. Belt Replacement........................................................................................................................... 27
11. Panel Maintenance......................................................................................................................... 28
12. Sacrificial Anode Change............................................................................................................... 28
13. Raw Water Pump Impeller Change................................................................................................ 28
14. Engine Heat Exchanger Tube Stack Flushing. .............................................................................. 29
15. Winterization of Seawater Cooling System.................................................................................... 29
SECTION 6 - Shire Service Parts.....................................................................................30
Starter Relay............................................................................................................................................. 30
b. 40A....................................................................................................................................................... 30
a. 25A....................................................................................................................................................... 30
c. 15A ....................................................................................................................................................... 30
SECTION 7 - Service Schedule........................................................................................31
Specifications and Capacities .................................................................................................................. 31
Service Intervals....................................................................................................................................... 31
SECTION 8 - Wiring Diagrams .........................................................................................33
Harness Wiring Diagram .......................................................................................................................... 33
Panel Wiring Diagram .............................................................................................................................. 35
SECTION 9 –Dealer List...................................................................................................38
Shire Service Record Card...............................................................................................40

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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 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 600oC 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.

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6. Batteries
WARNING:
EXPLOSIVE GASES / SULPHURIC ACID.
Batteries can produce explosive gas; 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
seek medical advice.
Keep the 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 top of the engine rocker cover and
stamped to the crankcase next to the starter motor.
An example of the engine identification plate is shown below:
Note: There are a number of optional extras that may be fitted to an engine for particular
customer’s engine that are not listed here.
A list of common item service part numbers can be found in Shire service parts in Section 6.
(P 26).

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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 10,000 mm2each, (16 in2).
An allowance must be made for any grills or louvers 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. They may be steel or stainless steel glassed into a GRP hull.
3. Pressurised Water Header Tank
The pressurised header tank should be mounted higher than the level of the engine
and no more than 1 metre from the engine, to prevent cooling system air locks.
4. Shaft Connection and Propeller Selection
Some type of flexible coupling must be used to connect the gearbox output flange to
the propeller shaft flange. Various coupling flanges are widely available to assist with
this.
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.
5. 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.
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.

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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.
Care should be taken to install mounts parallel to the engine rails and washer and locknut
firmly tightened on the cover of the mount. The maximum distance from the top of the
locknut to the base of the adjusting nut must not exceed 5mm; any greater adjustment
should be made up using shims below the mount.

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RDG603A9 - Issue 1 - Shire 14 Workboat Owners Manual 30, 40, 50 Page 13 of 40
6. Engine Alignment
The gearbox output shaft flange and propeller shaft input flange must be almost
perfectly aligned. A maximum of ± 0.05mm (0.002") misalignment in any plane is
acceptable. 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.
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).
7. 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 single wire that is adjacent to the 11 pin plug
Connect the start battery positive cable to the electrical terminal post adjacent to the
sump pump.
The starter motor battery cable must have a cross sectional area of at least 50mm2.
8. Engine Oil
All Shire engines are supplied fully run in.
Check oil levels in engine and gearbox before starting.
Use a good quality engine oil SAE 15W/ 40 API class CD.
9. Fuel
Ensure the main fuel tank is clear of dirt & water.
A separate water trap is strongly advised.
Connect fuel feed and 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
fuel lift pump is the inlet.
The engine hoses are supplied with 5/16" (8mm) OD metal hose tails, 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

RDG603A9 - Issue 1 - Shire 14 Workboat Owners Manual 30, 40, 50 Page 14 of 40
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). 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.
10. Coolant
Prepare coolant mix of 50% clean tap water and 50% antifreeze.
Fill the engine cooling system for the first time through the header tank filler cap on
models 30 & 40, and through the exhaust manifold filler cap and then via the header
tank on model 50. Start and run the engine for several minutes to dispel any
remaining air bubbles, with the pressure cap removed.
N.B. After running the engine for the first time, monitor the water level frequently as
trapped air bubbles may be expelled. Top up the system as necessary.
Ensure the top header tank connection goes to the small hole connection on the tank.
Shire 50
Exhaust manifold filler cap
Header tank filler cap

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11. 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.
Ensure that when forward is engaged on the throttle that forward is engaged on the
gearbox.
12. Seawater Strainer
A bulkhead mounted seawater strainer or similar is not supplied with the engine, we
recommend that one is fitted between the seawater inlet (seacock) and the sea water
pump inlet.
13. 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 gauges for 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 in use.
Dash Panel Calibration Procedure:
Connect dash 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
on 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 button is released. Then when pressed again it will
increase/decrease in the other direction, keep doing this until the digitally displayed
value on bottom of tacho reaches the correct value, according to the type of alternator
(see table). 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.

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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
Alternative or non-standard alternators will require calibrating and checking by trail 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.
14. Seawater Pump Hose Inlet Size
Shire 30WB –20mm (approx. 3/4”)
Shire 40/50WB –25mm (approx. 1”)
15. Exhaust System
The exhaust outlet size on the engine is 1 1/2" 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.
Make sure exhaust increases then decreases in height as shown above

X

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16. Hydraulic Drive Transmissions
If an engine is to have a Hydraulic Drive Transmission attached to it, 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
conventional marine gearbox.
Hydraulic drive transmissions generate far more heat than a conventional marine
gearbox, therefore the size of 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
17. Hydraulic Pump Drive Option (Shire 38 / 40 / 45 / 50)
For SAE type 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: 0.903:1

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18. Installation Check list
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
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, constant pipework rise to header tank
Check level of coolant in header tank and correct ratio
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 panel and warning lights operational
Check for leaks
Explain/Demonstrate off season storage and maintenance
Installer’s signature
Installer name/company

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SECTION 4 - Operation
1. Starting the Engine for the First Time
Remove ignition key.
Ensure all oil and coolant levels are checked.
Ensure engine battery is connected. Battery master switch must be turned on.
Check all connections and mountings are tight.
Ensure that the raw water seacock is turned on.
2. Starting Procedure
Note: Shire engines do not have a cold start function as standard. Therefore the glow
plug light will not illuminate.
Ensure the gearshift control lever is set to neutral, and that persons are clear of any
moving parts.
Insert the ignition key and turn to the first position, on.
Observe warning lights (and gauges on deluxe panel). NB the engine overheat light
will only illuminate when the water temperature exceeds the safe level
Listen for warning buzzer.
Turn key to second position, start, and hold to crank.
Crank the engine for no more than 15 seconds.
On engine start, immediately release key.
Key will return to first position, on.
The warning buzzer will stop and on the deluxe panel the oil pressure gauge will show
an oil pressure of 3–4 bar [45-60 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, rev the
engine briefly).
Once started check that sea water is coming out of the water cooled exhaust outlet in
the hull of the boat
Stop engine immediately if any abnormal noises are detected.
Visually check the engine for oil, fuel and coolant leaks, (after initial startup and at
regular intervals, N.B. engine must be stopped to carry out this check).

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3. Stopping Procedure
Move speed control lever to idle position.
Turn key to off position.
4. Refuelling
All Shire marine engines run on diesel fuel. DO NOT USE BIODIESEL
Please note that if the vessel is to be left for any period of time the fuel tank should be
full to eliminate the build up of condensation and formation of water in the fuel tank.
5. Diesel Fuel Additive
The use of diesel fuel additive is strongly recommended on Shanks & 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 startability 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.
6. Exhaust Back Pressure
Use 50mm ID suitable marine flexible exhaust hose on the 30 model engine and
60mm on the 40 and 50 models. Do not step down to a smaller size.
The engine exhaust outlet must be at least 200mm (8”) above the outside seawater
level of the hull. If not an exhaust high rise kit and/or lock box/Swan neck must be
used to prevent sea water flowing back up the exhaust and causing engine damage.