Barrus Shire 38 User manual

ORIGINAL INSTRUCTION
RDG603A20 - Issue 10
CANAL ENGINE MANUAL
For the following engine models:
Shire 38
Shire 40
Shire 45
Shire 50

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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 Serial 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.
Shire Engine Manuals and Shire Parts Books

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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 Canal Boat Marine 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
Manuals and familiarise yourself with the engine and its parts before operation. If the engine
is fitted with Travel Power and/or Hybrid options please also read the supplied manuals for
them carefully.
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.
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 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.

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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 the fuel system.

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Index Page
SECTION 1 –Safety Precautions .....................................................................................11
1. General......................................................................................................................11
2. Lifting.........................................................................................................................11
3. Rotating Shafts and Belts ..........................................................................................11
4. Exhaust System.........................................................................................................12
5. Launching and Lifting Boats.......................................................................................12
6. Batteries.....................................................................................................................12
SECTION 2 –Engine Identification...................................................................................14
SECTION 3 –Component Identification...........................................................................15
1. Shire 38 .....................................................................................................................15
2. Shire 40 .....................................................................................................................16
3. Shire 45 .....................................................................................................................17
4. Shire 50 .....................................................................................................................18
SECTION 4 –Control Panel ..............................................................................................19
1. Standard Control Panel..............................................................................................19
2. Deluxe Control Panel.................................................................................................19
3. Control Panel Overview.............................................................................................20
4. Warning Light Procedure...........................................................................................20
5. Overall Dimensions of the Standard Control Panel....................................................22
6. Overall Dimensions of the Deluxe Control Panel.......................................................22
SECTION 5 –Installation...................................................................................................23
1. Ventilation..................................................................................................................23
2. Engine Beds ..............................................................................................................23
3. Cooling System..........................................................................................................23
4. Skin Tanks.................................................................................................................23
5. Engine Cooling Water Inlet and Outlet Hose Connections ........................................24
6. Pressurised Water Header Tank................................................................................25
7. Calorifier ....................................................................................................................26

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8. Shaft Connection and Propeller Selection .................................................................27
9. Engine Anti-Vibration Mounts ....................................................................................28
10. Engine Alignment.......................................................................................................30
11. Engine Inclination ......................................................................................................31
12. Electrics.....................................................................................................................31
13. Electrical Options.......................................................................................................32
14. Engine Oil..................................................................................................................33
15. Fuel............................................................................................................................33
16. Coolant ......................................................................................................................34
17. Control Cables...........................................................................................................35
18. Domestic Battery Bank ..............................................................................................35
19.Control Panel.............................................................................................................36
20. Exhaust System.........................................................................................................37
21. Hydraulic Drive Transmissions ..................................................................................38
22. Hydraulic Pump Drive Option (Shire 38, 40, 45, 50)..................................................39
23. Centa Coupling CF-M-160 (RDG2779)......................................................................39
24. PRM 280DP Gearbox with Power Take Off (Option).................................................40
25. Installation Check List................................................................................................41
SECTION 6 –Operation.....................................................................................................42
1. Starting the engine for the first time...........................................................................42
2. Starting Procedure.....................................................................................................42
3. Stopping Procedure...................................................................................................43
4. Full Load Running......................................................................................................43
5. Refuelling...................................................................................................................43
6. Twin Thermostats –Shire 45 and 50.........................................................................44
7. Diesel Fuel Additive...................................................................................................46
8. Exhaust Back Pressure .............................................................................................46
9. Hybrid System (For engine with Hybrid System fitted)...............................................46
10. Single Shift Control Lever Side Mount Operation - Optional (RDG9210055).............46
SECTION 7 –Service Procedure ......................................................................................47

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1. Engine Oil and Filter Change.....................................................................................47
2. Air Filter Check and Change......................................................................................48
3. Gearbox Oil Change..................................................................................................48
4. Disposal of Oil and Related Items..............................................................................49
5. Primary Fuel Filter Drain –Shire 40, 45 & 50 ............................................................50
6. Primary and Secondary Fuel Filter Change...............................................................51
7. Fuel System Bleeding................................................................................................51
8. Cooling System..........................................................................................................52
9. Belt Adjustment..........................................................................................................53
10. Belt Maintenance.......................................................................................................54
11. Belt Replacement ......................................................................................................54
12. Control Panel Maintenance........................................................................................55
SECTION 8 –Service Schedule........................................................................................57
1. Specifications and Capacities....................................................................................57
2. Service Intervals........................................................................................................58
SECTION 9 –Wiring Diagrams .........................................................................................59
1. Engine Wiring Diagram Shire 38, 40, 45 & 50 ...........................................................59
2. Standard Control Panel Wiring Diagram....................................................................60
3. Deluxe Control Panel Wiring Diagram .......................................................................61
SECTION 10 –Technical Data ..........................................................................................62
1. Engine Data...............................................................................................................62
2. Return Diesel System................................................................................................62
3. Dry Weight of Engine Data ........................................................................................63
SECTION 11 –Dealer List .................................................................................................64
SECTION 12 –Shire Parts.................................................................................................66
SECTION 13 –Declarations..............................................................................................68
1. Declaration of Conformity for Recreational Craft Propulsion Engine with the
requirements of Directive 2013/53/EU.......................................................................68
2. Declaration of Incorporation of Partly Completed Machinery.....................................69
3. EU Declaration of Conformity with the Exhaust Emissions Requirements of Directive

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2013/53/EU................................................................................................................73
SECTION 14 –Lubricant Safety Data Sheets ..................................................................74
1. Golden Film Running In Oil........................................................................................74
2. Ground Force 10W-40...............................................................................................82
3. Liquimatic Super ATF ................................................................................................91
SECTION 15 –Shire Service Record Card.....................................................................100

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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 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 –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. The 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):
Figure 1: Engine Identification Badge
Description of Models:
Abbreviation
Type of Engine
Description*
CB
Canal Boat
Keel cooled dry exhaust manifold
WB
Work Boat
Seawater/Heat Exchanger cooled, dry exhaust manifold
with either a dry exhaust system (same as a Canal Boat)
or water injected exhaust system. Can also be used for
sea going applications
RB
River Boat
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.
A list of common item service part numbers can be found in Section 12, Shire Parts.
Description
1
Engine Model
2
Serial Number
3
Indicates Model Type or Optional Extras:
RB = River Boat
WB = Work Boat
D = Deluxe Panel
3 = 3:1 Ratio Gearbox
SHIRE
50-XXXXX-D

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SECTION 3 –Component Identification
1. Shire 38
Figure 2: Shire 38 Left Side (Viewed from front)
Figure 3: Shire 38 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
Single Thermostat Housing
2
50 Amp 12 Volt Alternator
3
125 Amp 12 Volt Alternator
4
Dry Exhaust
Description*
5
Air Filter
6
Gearbox
7
Oil Filter
8
Engine Fuel Filter
9
Engine Sump Pump

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2. Shire 40
Figure 4: Shire 40 Left Side (Viewed from front)
Figure 5: Shire 40 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
Single Thermostat Housing
2
50 Amp 12 Volt Alternator
3
150 Amp 12 Volt Alternator
4
Dry Exhaust
Description*
5
Primary Fuel Filter
6
Air Filter
7
Gearbox
8
Oil Cooler
9
Oil Filter
10
Secondary Fuel Filter
11
Engine Sump Pump

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3. Shire 45
Figure 6: Shire 45 Left Side (Viewed from front)
Figure 7: Shire 45 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
Twin Thermostat Housing
2
50 Amp 12 Volt Alternator
3
240 Amp 12 Volt Alternator
4
Dry Exhaust
Description*
5
Primary Fuel Filter
6
Air Filter
7
Gearbox
8
Oil Cooler
9
Oil Filter
10
Secondary Fuel Filter
11
Engine Sump Pump

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4. Shire 50
Figure 8: Shire 50 Left Side (Viewed from front)
Figure 9: Shire 50 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
Twin Thermostat Housing
2
50 Amp 12 Volt Alternator
3
240 Amp 12 Volt Alternator
4
Water Cooled Manifold
5
Gearbox Drain Pump
Description*
6
Primary Fuel Filter
7
Air Filter
8
Gearbox
9
Oil Cooler
10
Oil Filter
11
Secondary Fuel Filter
12
Engine Sump Pump

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SECTION 4 –Control Panel
1. Standard Control Panel
Figure 10: Standard Control Panel
2. Deluxe Control Panel
Figure 11: Deluxe Control Panel
Description
1
Tachometer Gauge
2
Hour Meter
3
Water Temperature Warning Light
4
Oil Pressure Warning Light
5
50A Alternator Charge Warning
Light
6
150/240A Alternator Charge
Warning Light
7
Glow Plug Light
8
Key Flap and Ignition Switch
Description
1
Tachometer Gauge
2
Hour Meter
3
Water Temperature Warning Light
4
Oil Pressure Warning Light
5
50A Alternator Charge Warning
Light
6
150/240A Alternator Charge
Warning Light
7
Glow Plug Light
8
Key Flap and Ignition Switch
9
50A Alternator Output Gauge
10
Oil Pressure Gauge
11
Water Temperature Gauge

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3. Control Panel Overview
All Shire engines are supplied with a control panel.
Depending on the model of Shire engine, the control panel will either be a standard
control panel or a deluxe control panel. The following table shows which panel comes
with each type of engine as standard. Please note that on certain Shire engines a
different type of control panel can be ordered as an option.
Engine
Control Panel Supplied*
Shire 38, 40
Standard Control Panel
Shire 45, 50
Deluxe Control Panel
* Panel supplied as standard. On certain engines a different control panel may be supplied
as an option
4. 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 operationall the gauges arebacklit. 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