Barrus Shire 90 Operation instructions

ORIGINAL INSTRUCTION
RDG603A23 –Issue 20
CANAL ENGINE MANUAL
For the following engine model*:
Shire 90
*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 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
To access the Shire Engine Manuals and Shire Parts Books on the internet type the
following short links into your search engine:
https://www.barrus.co.uk/shire-manuals/
https://www.barrus.co.uk/shire-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 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 John Deere and PRM Gearbox
Manuals and familiarise yourself with the engine and its parts before operation. The PRM
Gearbox Manual is also available from the PRM website:
www.prm-newage.com
If the engine is fitted with an E-Kit 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
The Shire UK Limited Warranty provides coverage for up to five years or 2000 hours
(whichever occurs first) for recreational users and three years or 2000 hours (whichever
occurs first) for commercial users from the date of warranty commencement. This is
dependent on the following conditions.
This covers the majority of Shire Engine components with the exception of the items as stated
in this document.
To ensure that you have been registered for your warranty, please detach and fill in the form
on the back of this manual.
Return it to the address given or email it to Richa[email protected]
The Warranty will only apply if the following have been carried out and the registration form
has been completed and returned to Barrus.
The warranty period begins when either the owner registers the engine or it is triggered
automatically. A discretionary period of 6 months is given following the delivery of the engine
(to allow for installation and commissioning), following this the warranty period will
automatically start.
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.
TERMS
It is the responsibility of the boat builder or owner to ensure the Shire Engine is registered for
warranty.
The Warranty will only apply if the following have been carried out:
•The installation is in full compliance with the requirements defined in the manual and
the checklist completed and signed by the engine installer.
•The boat builder or engine installer has completed the Boat Builder Section on the
Service Record Card (located at the back of the manual) regarding hand over and
commissioning of boat.
•The engine and ancillary systems are installed in compliance with current and
applicable national and international standards.
•The maintenance has been completed to the full requirements, using genuine parts
and recorded in the manual.
SAFETY
E.P Barrus staff or their representatives can only carry out warranty repairs if there is suitable
and safe access to the boat and engine room.

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PRM GEARBOXES
PRM Gearboxes are covered by a three year warranty for recreation users and two years for
commercial users.
ELECTRICAL SYSTEMS
Shire Engine alternator, starter motor and electrical components are subject to a limited one
year warranty.
FUEL SYSTEMS
Fuel injection and supply equipment including the injectors and pump(s) are subject to a
limited one year warranty.
It is a condition of the warranty that a separate water trap is fitted between the fuel tank and
the engine fuel lines (in addition to the filters fitted to the engine). The fuel tank should always
be kept clear of dirt, water and any other contamination. It is not recommended that the fuel
tank be run completely empty as this will induce air into the fuel system and can cause fuel
injection or starting system damage- which would not be covered by the warranty.
Upon installation the fuel system should be pressure or vacuum tested to ensure no leaks
are present. Poor quality fuel systems can cause engine fuel injection system damage which
is not covered by the warranty. The fuel system should be fully primed ahead of engine
starting- failure to do so can cause damage to the engine starting system and fuel system-
this damage is not covered by the warranty.
POOR QUALITY FUEL
Poor running (including smoking) engines that are being run (or have been run) on low quality
or contaminated fuel are not covered by the warranty. Any replacement parts that are
required as a consequence of using incorrect or low quality fuel are not covered by warranty.
Engine and fuel equipment is not covered by warranty if bio-diesel that does not comply with
EN15940 is used (See 5. Refuelling of Section 6 –Operation).
Only fuel fully compliant with EN590 or EN15940 should be used in Shire Engines. Failure
to comply with this may invalidate the warranty.
CONDITIONS THAT MUST BE MET IN ORDER TO OBTAIN WARRANTY COVERAGE
Warranty coverage is only available from EP Barrus Ltd.
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 to an
insufficient level, Barrus reserves the right to withdraw warranty coverage.

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WARRANTY CLAIMS
Warranty claims must be made by either an authorised dealer or directly to EP Barrus.
The dealer or boat builder will 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.
Any claim should be made as soon as possible, and no later than two weeks after the initial
discovery of the defect. No agent outside the EP Barrus Ltd network should be instructed
before the defect has been reported and agreement made with EP Barrus Ltd.
WHAT IS NOT COVERED
This limited warranty does not cover the following:
•Routine maintenance and service items,
•Adjustments,
•Normal wear and tear,
•Damage caused by abnormal or incorrect use,
•Operation of the product in a manner inconsistent with the recommended
operation/duty cycle,
•Accident, submersion,
•Improper installation (i.e. an installation not consistent with the requirements laid
out),
•Systems using or affected by an accessory or part not manufactured or sold by EP
Barrus Ltd,
•Systems that have been altered or modified (including addition of electrical systems
such as charge boosters or other electrical management products),
•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 loss or damages,
Engine and engine starting systems are not covered by warranty if it is found that the engine
start battery or supply circuit/system is not of the correct specification. Or if the engine start
battery is partially or fully discharged.
Damage due to rust or corrosion, submersion, or unreasonable exposure to the environment,
such as exposure to high humidity, rain fall, or seawater, or conditions resulting in the freezing
of cooling water are not covered.
Water ingression of any kind into the engine via any means (other than the cooling system)
will void the warranty. It is the responsibility of the owner/installer to ensure that no water
can enter the engine during use or storage.

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The standard alternators fitted to Shire Engines are not suitable for charging lithium-ion
batteries. If the standard alternators are used for charging lithium-ion batteries, they will not
be covered under warranty. If lithium-ion batteries are to be used a specialist alternator will
be required.
FREQUENT RUNNING
To ensure ongoing and reliable operation, Engines should not be left without running for
periods of more than two weeks at any one time. If not required to run, every two weeks the
engine should be started and run under load until correct operating temperature is reached-
this should then be maintained for a minimum of 15 minutes.
TRANSFER OF WARRANTY
The warranty is valid for the first owner of the Shire engine and is transferrable only at the
discretion of EP Barrus Ltd.
River Canal Rescue Membership
RCR offer a number of support packages and services to give the inland boater peace of
mind in the event of an incident, breakdown or emergency. They offer year round 24/7
national breakdown and recovery assistance for members on the inland waterways.
Please see RCR leaflet included with the other engine documents for more details. The leaflet
is stamped and RCR will offer a first year 20% discount to all new Shire engine owners. To
gain this discount please call RCR on 01785785680. Please have ready to hand your Shire
warranty registration date.
Note: This does not affect the normal Shire engine warranty arrangement.

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Index
Page
SECTION 1 –Safety Precautions .....................................................................................12
2. Lifting .........................................................................................................................12
3. Rotating Shafts and Belts ..........................................................................................12
4. Exhaust System.........................................................................................................13
5. Launching and Lifting Boats.......................................................................................13
6. Batteries.....................................................................................................................13
SECTION 2 –Engine Identification...................................................................................15
SECTION 3 –Component Identification...........................................................................16
1. Shire 90 .....................................................................................................................16
SECTION 4 –Control Panel ..............................................................................................17
1. Deluxe Control Panel.................................................................................................17
2. Control Panel Overview .............................................................................................17
3. Warning Light Procedure ...........................................................................................17
4. Overall Dimensions of the Deluxe Control Panel .......................................................20
SECTION 5 –Installation...................................................................................................21
1. Ventilation..................................................................................................................21
2. Engine Beds ..............................................................................................................21
3. Cooling System..........................................................................................................21
4. Skin Tanks.................................................................................................................21
5. Engine Cooling Water Inlet and Outlet Hose Connections ........................................22
6. Pressurised Water Header Tank................................................................................23
7. Shaft Connection and Propeller Selection .................................................................23
8. Engine Anti-Vibration Mounts ....................................................................................24
9. Engine Alignment.......................................................................................................27
10. Engine Inclination ......................................................................................................27
11. Electrics .....................................................................................................................28
12. Electrical Options.......................................................................................................28
13. Engine Oil ..................................................................................................................29
14. Fuel............................................................................................................................29
15. Coolant ......................................................................................................................30

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16. Calorifier ....................................................................................................................30
17. Control Cables...........................................................................................................31
18. Domestic Battery Bank ..............................................................................................31
19. Control Panel.............................................................................................................32
20. Exhaust System.........................................................................................................33
21. Hydraulic Drive Transmissions ..................................................................................34
22. PRM 280DP Gearbox with Power Take Off (Option –RDG914A198).......................35
23. Electric Start Motor ....................................................................................................35
24. Installation Check List................................................................................................36
SECTION 6 –Operation.....................................................................................................37
1. Starting the engine for the first time ...........................................................................37
2. Starting Procedure.....................................................................................................37
3. Stopping Procedure ...................................................................................................38
4. Full Load Running......................................................................................................38
5. Refuelling...................................................................................................................38
6. Diesel Fuel Additive ...................................................................................................39
7. Exhaust Back Pressure .............................................................................................39
8. Hybrid System (For engine with Hybrid System fitted)...............................................39
9. Single Shift Control Lever Side Mount Operation - Optional (RDG9210055).............40
SECTION 7 –Service Procedure ......................................................................................41
1. Engine Oil and Filter Change.....................................................................................41
2. Air Filter Check and Change......................................................................................42
3. Gearbox Oil Change ..................................................................................................42
4. Disposal of Oil and Related Items..............................................................................43
5. Primary Fuel Filter Drain (RDG9188346)...................................................................44
6. Primary Fuel Filter Change........................................................................................45
7. Secondary Fuel Filter Change ...................................................................................45
8. Fuel System Bleeding................................................................................................46
9. Cooling System..........................................................................................................46
10. Belt Adjustment..........................................................................................................47
11. Belt Maintenance .......................................................................................................47
12. Belt Replacement ......................................................................................................48

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13. Control Panel Maintenance........................................................................................49
SECTION 8 –Service Schedule ........................................................................................50
1. Specifications and Capacities ....................................................................................50
2. Service Intervals ........................................................................................................51
SECTION 9 –Wiring Diagrams .........................................................................................52
1. Engine Wiring Diagram Shire 90................................................................................52
2. Deluxe Control Panel Wiring Diagram .......................................................................53
3. 5kW ‘E’ Kit System ....................................................................................................54
4. Prestolite 24 Volt 120 Amp Alternator Wiring Diagram ..............................................54
SECTION 10 –Technical Data ..........................................................................................56
1. Engine Data...............................................................................................................56
2. Return Diesel System ................................................................................................56
3. Dry Weight of Engine Data ........................................................................................56
SECTION 11 –Dealer List .................................................................................................57
SECTION 12 –Shire Parts.................................................................................................59
SECTION 13 –Afterlife Recycling ....................................................................................61
SECTION 14 –Declarations ..............................................................................................62
1. Declaration of Conformity for Recreational Craft Propulsion Engine with the
requirements of Directive 2013/53/EU.................................................................................62
2. Declaration of Conformity for Recreational Craft Propulsion Engine with the
requirements of the Recreational Craft Regulations 2017 (UKCA Marking). .......................63
3. Declaration of Incorporation of Partly Completed Machinery.....................................64
4. EU Declaration of Conformity with the Exhaust Emissions Requirements of Directive
2013/53/EU..........................................................................................................................68
SECTION 15 –Lubricant Safety Data Sheets ..................................................................69
1. Torq-Gard Supreme 15W40 ......................................................................................69
2. Cool Gard ..................................................................................................................77
SECTION 16 –Shire Service Record Card.......................................................................84

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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, UKCA Marking, relevant Health & Safety requirements, the Recreational
Craft Directive and or any other legislative requirements 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
*Note: There are a number of other 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:
WB = Work Boat
D = Deluxe Panel
3 = 3:1 Ratio Gearbox
E = 3.5kW ‘E’ Kit
SHIRE
90-XXXXX-D

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SECTION 3 –Component Identification
1. Shire 90
Figure 2: Shire 90 Left Side (Viewed from front)
Figure 3: Shire 90 Right Side (Viewed from rear)
*Note: There are a number of other optional extras that may be fitted to an engine that are
not shown here.
Description*
1
120 Amp 12 Volt Alternator
2
150 Amp 12 Volt Alternator
Description*
3
Gearbox
4
Primary Fuel Filter
5
Gearbox Drain Pump
6
Oil Cooler
7
Secondary Fuel Filter
8
Engine Sump Pump

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SECTION 4 –Control Panel
1. Deluxe Control Panel
Figure 4: Deluxe Control Panel
2. 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 90
Deluxe Control Panel
* Panel supplied as standard. On certain engines a different control panel may be supplied
as an option
3. 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.
Description
1
Tachometer Gauge
2
Hour Meter
3
Water Temperature Warning Light
4
Oil Pressure Warning Light
5
150A Alternator Charge Warning
Light
6
120 Alternator Charge Warning
Light
7
Glow Plug Light
8
Key Flap and Ignition Switch
9
120A Alternator Output Gauge
10
Oil Pressure Gauge
11
Water Temperature Gauge

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•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

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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 9. Cooling System of SECTION 7
- SERVICE PROCEDURE). If the coolant level is
incorrect, fill it to the correct level (refer to 9.
Cooling System of SECTION 7 - SERVICE
PROCEDURE)and restart the engine. If the
coolant level is correct and the fault is still present
please, 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
150A 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
120 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.
7
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.
8
Key Flap and Ignition Switch
-
9
120A Alternator Output Gauge
-
10
Oil Pressure Gauge
-
11
Water Temperature Gauge
-
*Only applicable if a second alternator is fitted to the engine

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4. Overall Dimensions of the Deluxe Control Panel
(All Dimensions are in mm)
Figure 5: Deluxe Control Panel Dimensions