Barrus Shire 15 Work Boat YM Operation instructions

ORIGINAL INSTRUCTION
RDG603A24 –Issue 13
WORK BOAT YM ENGINE MANUAL
For the following engine models:
Shire 15,20,25,30 WB YM
Addendum to the Yanmar Marine Engines Manual & PRM Owners
Handbook / Technodrive Operating Manual

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SAFETY
E.P. Barrus is concerned for your safety. We use safety statements throughout the manual
to call your attention to the potential hazards associated with the operation of your Shire
engine.
Follow the precautions listed throughout the manual before operation, during operation and
during servicing/maintenance procedures for your safety, the safety of others and to protect
the performance of your engine.
Safety alert symbol appears throughout the manual. It means attention, be alert as your safety
is involved. Please read and follow the message that appears after the safety alert symbol.
NOTICE:
This indicates a situation which can cause damage to the
machine, personal property and/or the environment or cause the
equipment to operate improperly
CAUTION:
This indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
WARNING:
This indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
DANGER:
This indicates a hazardous situation which, if not avoided, will
result in death or serious injury.

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Engine Details
Engine Number:
Please enter your engine serial number in the space provided above. Please quote the
engine identification number during any enquiry or when ordering spare parts. Information
about the engine serial number and its location on the engine can be found in SECTION 2 of
the manual.

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Operators Manual
NOTICE:
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.
Thank you for purchasing this Shire Work Boat YM Engine from E.P.Barrus. This manual has
been compiled to help you to operate your engine and its associated parts with safety and
pleasure. Please read it carefully in conjunction with the Yanmar and PRM Gearbox /
Technodrive Gearbox Manuals and familiarise yourself with the engine and its parts before
operation.
The information and recommendations given in this manual are based on the latest
information available at the time of publication. 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.

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WARRANTY
This UK 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 warranty is for non-
serviceable items. 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.
Failure to complete and return the registration form to E.P Barrus will result in
the warranty period starting from the date of engine manufacture NOT from the date
of purchase.
PRM Gearboxes are covered by a three (3) year warranty for recreation users and two (2)
years for commercial users.
Technodrive Gearboxes are covered by a two (2) year warranty for recreation users and one
(1) year for commercial users.
Engine alternator, starter motor and electrical components are onlycovered 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. Routine 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.

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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 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 the fuel system.

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Index Page
SECTION 1 –Safety Precautions ...................................................................................... 9
1. General....................................................................................................................... 9
2. Lifting.......................................................................................................................... 9
3. Rotating Shafts and Belts ........................................................................................... 9
4. Exhaust System.........................................................................................................10
5. Launching and Lifting Boats.......................................................................................10
6. Batteries.....................................................................................................................10
SECTION 2 –Engine Identification...................................................................................12
SECTION 3 –Component Identification...........................................................................13
1. Shire 15 Work Boat YM .............................................................................................13
2. Shire 20 Work Boat YM .............................................................................................14
3. Shire 25 Work Boat YM .............................................................................................15
4. Shire 30 Work Boat YM .............................................................................................16
5. Shire 30 Work Boat M YM .........................................................................................17
6. Engine Mounts...........................................................................................................18
SECTION 4 –Control Panel ..............................................................................................19
1. Basic Control Panel...................................................................................................19
2. Standard Control Panel..............................................................................................19
3. Deluxe Control Panel.................................................................................................20
4. Control Panel Overview.............................................................................................20
5. Warning Light Procedure...........................................................................................20
6. Overall Dimensions of the Basic Control Panel .........................................................23
7. Overall Dimensions of the Standard Control Panel....................................................23
8. Overall Dimensions of the Deluxe Control Panel.......................................................24
SECTION 5 –Operation.....................................................................................................25
1. Starting the engine for the first time...........................................................................25
2. Starting Procedure.....................................................................................................25
3. Stopping Procedure...................................................................................................26

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4. Diesel Fuel Additive...................................................................................................26
5. Single Shift Control Lever Side Mount Operation - Optional (RDG9210055).............26
SECTION 6 –Service Procedure ......................................................................................27
1. Engine Oil and Filter Change.....................................................................................27
2. Gearbox Oil Change..................................................................................................27
3. Disposal of Oil and Related Items..............................................................................30
4. Primary Fuel Filter Drain............................................................................................30
5. Primary Fuel Filter Change........................................................................................31
6. Control Panel Maintenance........................................................................................32
SECTION 7 –Service Schedule........................................................................................33
1. Specifications and Capacities....................................................................................33
2. Service Intervals........................................................................................................34
SECTION 8 –Wiring Diagrams .........................................................................................35
1. Shire to Yanmar Extension Loom ..............................................................................35
2. Basic Control Panel Wiring Diagram..........................................................................36
3. Standard Control Panel Wiring Diagram....................................................................37
4. Deluxe Control Panel Wiring Diagram .......................................................................38
SECTION 9 –Technical Data ............................................................................................39
1. Dry Weight of Engine Data ........................................................................................39
SECTION 10 –Dealer List .................................................................................................40
SECTION 11 –Shire Parts.................................................................................................42
SECTION 12 –Shire Service Record Card.......................................................................44

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SECTION 1 –Safety Precautions
1. General
NOTICE:
NEVER PERMIT ANYONE TO OPERATE THE ENGINE WITHOUT PROPER
TRAINING.
It is the responsibility of the installer/operator to ensure that the finished installation complies
with CE Marking, 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
DANGER:
CRUSH HAZARD! NEVER STAND UNDER A HOISTED ENGINE. IF THE HOIST
MECHANISM FAILS, THE ENGINE WILL FALL ON YOU, CAUSING SERIOUS INJURY
OR DEATH.
The Lifting points 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
WARNING:
SEVERE HAZARD! KEEP HANDS AND OTHER BODY PARTS AWAY FROM
MOVING/ROTATING PARTS. WEAR TIGHT FITTING CLOTHING AND KEEP YOUR
HAIR SHORT OR TIE BACK. REMOVE ALL JEWELLERY BEFORE COMMENCING
WORK. CHECK BEFORE STARTING THE ENGINE THAT ANY TOOLS OR RAGS
USED DURING MAINTENANCE HAVE BEEN REMOVED FROM THE AREA.

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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
WARNING:
EXHAUST HAZARD! NEVER OPERATE ENGINE IN A BOATS ENGINE BAY
WITHOUT PROPER VENTILATION. NEVER BLOCK VENTS OR OTHER MEANS OF
VENTILATION. ALL COMBUSTION ENGINES CREATE CARBON MONOXIDE GAS
DURING OPERATION. ACCUMULATION OF THIS GAS COULD CAUSE ILLNESS OR
EVEN DEATH.
WARNING:
BURN HAZARD! WAIT UNTIL THE EXHAUST COOLS BEFORE YOU TOUCH IT.
Exhaust gases may have temperatures as high as 650°C and contain elements which are
harmful if ingested.
It is therefore essential that exhaust systems are gas tight and lagged to prevent accidental
burning and inhalation of exhaust gases when inside the boat cabin.
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
DANGER:
EXPLOSION HAZARD! NEVER SHORT OUT THE BATTERY TERMINALS,
INCLUDING WHEN CHECKING THE REMAINING BATTERY CHARGE THIS WILL
RESULT IN A SPARK AND MAY CAUSE AN EXPLOSION OR FIRE.

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WARNING:
BURN HAZARD! BATTERIES CONTAIN SULPHURIC ACID. NEVER ALLOW
BATTERY FLUID TO COME IN CONTACT WITH SKIN, EYES OR CLOTHING. SEVERE
BURNS COULD RESULT. MAKE SURE THE CORRECT PERSONAL PROTECTION
EQUIPMENT IS WORN.
Batteries can produce explosive gases; keep sparks and flames awayfrom the battery.
NO SMOKING
Batteries contain sulphuric acid; if splashed on skin or eyes, flush well with water and
seek medical advice.
Keep battery tops and battery compartment ventilated at all 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
The engine serial number 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.
An example of the engine identification plate is shown below (Figure 1):
Figure 1: Engine Identification Badge
Description of Models:
Abbreviation
Type of Engine
Description*
WB
Work Boat
Seawater/Heat Exchanger cooled, dry exhaust manifold
with either a dry exhaust system (same as a Canal Boat)
or water injected exhaust system. Can also be used for
sea going applications
*Note: There are a number of optional extras that may be fitted to an engine that are not
listed here.
A list of Shire part numbers can be found in Section 10, Shire Parts.
Description
1
Engine Model
2
Serial Number
3
Indicates Model Type or Optional Extras:
WB = Work Boat
D = Deluxe Panel
3 = 3:1 Ratio Gearbox
SHIRE
30-XXXXX-WB

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SECTION 3 –Component Identification
1. Shire 15 Work Boat YM
Figure 2: Shire 15 Left Side (Viewed from front)
Figure 3: Shire 15 Right Side (Viewed from rear)
*Note: There are a number of optional extras that may be fitted to an engine that are not
shown here.
Description*
1
Water Pump
Description*
2
Gearbox
3
Primary Fuel Filter
4
Engine Sump Pump

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2. Shire 20 Work Boat YM
Figure 4: Shire 20 Left Side (Viewed from front)
Figure 5: Shire 20 Right Side (Viewed from rear)
*Note: There are a number of optional extras that may be fitted to an engine that are not
shown here.
Description*
1
Water Pump
Description*
2
Gearbox
3
Primary Fuel Filter
4
Engine Sump Pump

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3. Shire 25 Work Boat YM
Figure 6: Shire 25 Left Side (Viewed from front)
Figure 7: Shire 25 Right Side (Viewed from rear)
*Note: There are a number of optional extras that may be fitted to an engine that are not
shown here.
Description*
1
Water Pump
Description*
2
Gearbox
3
Primary Fuel Filter
4
Engine Sump Pump

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4. Shire 30 Work Boat YM
Figure 8: Shire 30 Left Side (Viewed from front)
Figure 9: Shire 30 Right Side (Viewed from rear)
*Note: There are a number of optional extras that may be fitted to an engine that are not
shown here.
Description*
1
Water Pump
Description*
2
Zinc Anode
3
Gearbox
4
Primary Fuel Filter
5
Engine Sump Pump
6
Oil Cooler

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5. Shire 30 Work Boat M YM
Figure 10: Shire 30 M Left Side (Viewed from front)
Figure 11: Shire 30 M Right Side (Viewed from rear)
*Note: There are a number of optional extras that may be fitted to an engine that are not
shown here.
Description*
1
Water Pump
Description*
2
Gearbox
3
Primary Fuel Filter
4
Engine Sump Pump

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6. Engine Mounts
There are two different types of engine mounts fitted to the engine. The engine mounts fitted
to the front and the rear of the engine have different numbers stamped on them. The front
mounts have a 100 stamped on them and the rear mounts have a 75 stamped on them. The
mounts should not be changed front to rear or rear to front as they are designed to carry
different loads.
Figure 12: Engine Mounts
Front of engine
Rear of engine

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SECTION 4 –Control Panel
1. Basic Control Panel
Figure 13: Basic Control Panel
2. Standard Control Panel
Figure 14: Standard Control Panel
Description
3
Water Temperature Warning Light
4
Oil Pressure Warning Light
5
Alternator Charge Warning Light
6
Glow Plug Light
7
Heat Start Button
8
Key Flap and Ignition Switch
9
Stop Button
Description
1
Tachometer Gauge
2
Hour Meter
3
Water Temperature Warning Light
4
Oil Pressure Warning Light
5
Alternator Charge Warning Light
6
Glow Plug Light
7
Heat Start Button
8
Key Flap and Ignition Switch
9
Stop Button

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3. Deluxe Control Panel
Figure 15: Deluxe Control Panel
4. Control Panel Overview
The Shire Work Boat YM engine are supplied with a standard control panel. Please
note that a deluxe control panel can be ordered as an option.
The control panel is splash proof but is NOT fully water proof. The control panel needs
to be installed in a position where it is protected from water.
5. Warning Light Procedure
When the ignition is first turned on, the control panel warning lights will come on as a
bulb check. When the engine is started the warning lights will go out. Please note that
the water temperature warning light and glow plug light operate slightly differently.
The water temperature warning light will only come on for a brief period of time when
the ignition is first turned on as a bulb check. It will then only illuminate in the case of
the engine coolant temperature exceeding the maximum safety level.
The glow plug light will come on when the ignition is first turned on for 5 –8 seconds
to indicate the heating system is operational. When the light goes out the engine can
be started.
Description
1
Tachometer Gauge
2
Hour Meter
3
Water Temperature Warning Light
4
Oil Pressure Warning Light
5
50A Alternator Charge Warning
Light
6
Glow Plug Light
7
Heat Start Button
8
Key Flap and Ignition Switch
9
Stop Button
10
50A Alternator Output Gauge
11
Oil Pressure Gauge
12
Water Temperature Gauge