Barrus SHIRE 15 YM DB BARNES Operation instructions

ORIGINAL INSTRUCTION
RDG603A62 –Issue 2
15 YM DB BARNES ENGINE MANUAL
For the following engine model*:
Shire 15 YM DB BARNES
Addendum to the Yanmar Marine Engines Manual
*Standard Model, there may be a number of optional extras, or alternative components, that
might be fitted to an engine that are not shown in this book.

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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 meansattention, 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.

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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 15 YM DB Barnes 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 Manual 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 three (1) years (or 1000 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.
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. Routine maintenance outlined in the Owner’s Manual must be performed using
genuine parts in order to maintain warranty coverage. If the customerperforms 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.

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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.
Damage due to rust or corrosion, submersion, or unreasonable exposure to the environment,
such as exposure tohigh humidity, rain fall, orseawater, or conditions resulting in thefreezing
of cooling water are also not covered.
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 .................................................................8
1. General...................................................................................................8
2. Lifting......................................................................................................8
3. Rotating Shafts and Belts........................................................................8
4. Exhaust System......................................................................................9
5. Launching and Lifting Boats....................................................................9
6. Batteries..................................................................................................9
SECTION 2 –Control Panel ........................................................................11
1. Standard Control Panel.........................................................................15
2. Control Panel Overview ........................................................................11
3. Warning Light Procedure ......................................................................11
4. Overall Dimensions of the Standard Control Panel ...............................12
SECTION 3 –Operation...............................................................................13
1. Starting the engine for the first time.......................................................14
2. Starting Procedure................................................................................14
3. Stopping Procedure ..............................................................................15
4. Diesel Fuel Additive ..............................................................................15
5. Engine Overheat Protection..................................................................15
SECTION 4 –Service Procedure................................................................16
1. Control Panel Maintenance...................................................................16
SECTION 5 –Wiring Diagrams...................................................................17
1. Shire to Yanmar Extension Loom..........................................................17
2. Standard Control Panel Wiring Diagram ...............................................18
SECTION 6 –Afterlife Recycling ................................................................19

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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 andflames away from the battery.
NO SMOKING
•Batteries contain sulphuric acid; if splashed on skin or eyes, flush well with water and
seek medical advice.
•Keep battery tops and battery compartment ventilated at all 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 –Control Panel
1. Control Panel Overview
•The Shire 15 YM engine are supplied with a standard control panel.
•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.
2. 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.
•Whilst the control panel is in operation all the gauges are backlit. This does not indicate
a fault and is a normal function for the control panel.
•If any of the warning lights on the control panel come on whilst the engine is running,
please follow the correct procedure as shown in the following table.
In the event of a fault, only trained and qualified personnel should undertake
repairs on the engine
Description
Procedure for Warning Light
1
Tachometer Gauge
-
2
Hour Meter
-
3
Water Temperature Warning Light
Reduce the engine revs and stop the engine
within one or two minutes. Check the coolant
level (refer to Yanmar Marine Engine Manual). If
the coolant level is incorrect, fill it to the correct
level (refer to Yanmar Marine Engine Manual)

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and restart the engine. If the coolant level is
correct and the fault is still present, or there is a
coolant leak, please contact your local dealer.
4
Oil Pressure Warning Light
Stop the engine immediately. Contact your local
dealer. Failure to stop the engine may result in
permanent engine damage.
5
Alternator Charge Warning Light
This indicates that the alternator has stopped
charging. The engine can still be operated for a
short period of time. Contact your local dealer.
6
Glow Plug Light
This indicates that the cold start system is
operating. If the light fails to illuminate during the
starting procedure contact your local dealer.
7
Heat Start Button
When operated the button will cause the glow
plug light to illuminate - This is a normal function
of the panel.
8
Key Flap and Ignition Switch
-
9
Stop Button
-
10
Oil Pressure Gauge
-
11
Water Temperature Gauge
-
*Only applicable if fitted to the engine
3. Overall Dimensions of the Standard Control Panel
(All Dimensions are in mm)

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Figure 1: Standard Control Panel Dimensions
SECTION 3 –Operation

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NOTICE:
REFER TO THE YANMAR MANUAL PRIOR TO STARTING THE ENGINE.
1. Starting the engine for the first time
•Remove ignition key.
•Ensure all oil and coolant levels are checked.
•Ensure both the engine and domestic batteries are connected. All battery master
switches must be turned on. Failure to do so may damage the domestic alternator.
•Ensure that the raw water seacock is turned on.
2. Starting Procedure
•Ensure there is no one in the engine compartment.
•Ensure the engine compartment door is closed.
•Ensure the gearshift control level is set to neutral and that all persons are clear of any
moving parts.
•Insert ignition key.
•Turn key to on position.
•Press the heat start button for 10 seconds, the glow plug light will illuminate.
•Observe warning lights (and gauges on deluxe panel). Note: The engine water
temperature overheat 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.
•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 continuesounding. 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).
•Once started check that water is coming out of the water cooled exhaust outlet in the
hull of the boat.
•Stop engine if any abnormal noises are detected.
•Visually check the engine for oil, fuel and coolant leaks, after initial start-up and at

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regular intervals. Note: Engine must be stopped to carry out this check).
•Standard Control Panel
Figure 2: Standard Control Panel
3. Stopping Procedure
•Move speed control lever to idle position.
•Press the stop button
•Turn key to off position.
4. 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 500ml
container, Part Number RDG80210219.
5. Engine Overheat Protection
To prevent engine damage, if the coolant temperature is too high then the engine will
automatically sense this and stop. Before investigating the cause of the problem let the
engine cool down. Once the problem has been rectified the engine can be restarte
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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SECTION 4 –Service Procedure
NOTICE:
REFER TO THE YANMAR MANUAL PRIOR TO CARRYING OUT ANY SERVICE OR
MAINTENANCE WORK.
WARNING:
PRIOR TO CARRYING OUT ANY SERVICE OR MAINTENANCE WORK MAKE SURE
THE RELEVANT PERSONAL PROTECTION EQUIPMENT IS WORN.
1. Control Panel Maintenance
WARNING:
REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT.
TURN BATTERY ISOLATION SWITCHES OFF.
•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.
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.

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SECTION 5 –Wiring Diagrams
1. Shire to Yanmar Extension Loom

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2. Standard Control Panel Wiring Diagram

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SECTION 6 –Afterlife Recycling
When it becomes necessary to dispose of your engine. This may be possible at recycling
centre; however, it will likely require careful disassembly first before disposal. For further
information please contact your local recycling centres for disposal advice to see what they
will accept for disposal.
Engines are primarily made up of steel, cast iron and aluminium; and are recyclable after
removal of other parts. Larger components such as the engine block may only be handleable
by a few centres, unlike say smaller plastic components.
Most of the other parts require special disposal as they include hazardous waste, and must
be separated and declared upon disposal, including:
Fluid Disposal
You must make sure that all unused oil, fuel and coolant is drained out carefully and disposed
of correctly at a local recycling centre. Under NO circumstance must any oil, fuel or coolant
be put down any drains or leaked into waterways or the environment.
Contact local recycling centres or garages, or check their websites to find out whether they
take or recycle engine fluids. If they don't, they may be able to direct you to your nearest
drop-off point depending on the volume. Recycle your coolant/oil/fuel in distinct well-sealed
containers that are clearly labelled.
Waste Electrical Electronic Equipment (WEEE) and Battery recycling
Parts contain WEEE waste or batteries should not be disposed of in your
domestic waste. You should recycle WEEE or batteries in accordance with your
local authority or recycling centre’s directions. Batteries will need declaring
separately for safety purposes.
Packaging materials that are unwanted should be sorted, with
cardboard, wood, and paper recycled where possible. Some Local
Authorities and recycling centres may accept plastic bags, films and
bubble wrap for recycling. Polystyrene is very rarely recycled and may
have to be disposed of in general rubbish, inside bags.
For further information about disposal please contact your Local Authority. You can also get
more advice and guidance about recycling in your area at the following website
http://www.recycle-more.co.uk.
Reduce, Reuse,
Recycle