Barrus SHIRE 14 30, SHIRE 14 35, SHIRE 14 38, SHIRE 14 40, SHIRE 14 45 User Manual

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

SHIRE CANAL BOAT ENGINE MANUAL

For the following engine models:

SHIRE 14 30
SHIRE 14 35
SHIRE 14 38
SHIRE 14 40
SHIRE 14 45
SHIRE 14 50

Enter your engine identification details in the spaces provided above.

E. P. BARRUS LIMITED, Launton Road, Bicester, Oxfordshire. OX26 4UR

Tel: [phone] Fax: [phone] www.barrus.co.uk

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 2 of 50

Declaration of Conformity for Recreational Craft Propulsion Engine

with the requirements of Directive 94/25/EC as amended by

2003/44/EC.

Name of Engine Manufacturer: Yanmar Co LTD.
Address: Yanmar Europe B.V, Brugplein 11, 1332 BS Almere-de Vaart, Netherlands.

Name of Authorised Representative: E.P.Barrus LTD
Address: E.P.Barrus LTD, Launton Road, Bicester, Oxon, OX26 4UR, England

Engine type approved according to: Stage II of Directive 97/68/EC, 88/77/EC

Description of Engine(s) and Essential Requirements

Engine Type: Inboard Engine Fuel Type: Diesel Combustion Cycle: 4 Stroke

Identification of Engine(s) covered by this Declaration of Conformity

Engine Model

Engine Type

Engine Family code

Type Approval Certificate Number

Shire 30 / 35

3 TNV 82 A BDSA

G2YDXCL0133MN

e13*97/68DA*2001/63*0558*06

Shire 38 / 40 / 45 / 50

4 TNV 88 DSA

5YDXL2.19K4N

e13*97/68DA*2001/63*0574*06

Shire 70

4 TNV 98 NSA

YD3300DNMGEC

e13*97/68GA*2001/63*0545*11

Essential Requirements

Standards

Other normative

document/method.

Technical

file

Specify in more detail

*= Mandatory standard.

Annex 1.B- Exhaust Emissions

B.1 Engine Identification

B.2 Exhaust emission
requirements

* EN ISO 8178- 1:1996

B.3 Durability

B.4 Owners Manual

Annex 1. C- Noise Emissions

See Declaration of Conformity of the craft in which the engine(s) has(have) been installed

This declaration of conformity is issued under the sole responsibility of the manufacturer. I declare on behalf
of the engine manufacturer that the engine(s) [is (are) in conformity with the type(s) for which above
mentioned EC type-examination or type approval certificate(s) has (have) been issued and]1 will meet the
exhaust emission requirements of Directive 94/25/EC as amended by Directive 2003/44/EC when installed in
a recreational craft, in accordance with the engine manufacturer’s supplied instructions and that t his (these)
engine(s) must not be put into service until the recreational craft which it is (they are) to be installed has been
declared in conformity with the relevant provisions of the above mentioned Directives.

Tim Hart
Sales Director
Signed: Bicester, UK

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 3 of 50

PLEASE NOTE:

This manual has been compiled to help you to operate your engine and its associated parts
with safety and pleasure. Please read it carefully and familiarise yourself with the engine
and its parts before operation.

E.P.Barrus 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.

WARNING:

THIS MANUAL FORMS AN INTEGRAL PART OF THE ENGINE IT ACCOMPANIES, IF

A TRANSFER OF TITLE OCCURS, IT MUST ALWAYS BE HANDED OVER TO THE

NEW OWNER.

WARRANTY

This Limited Warranty provides coverage for 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 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.

PRM gearboxes are covered by a three (3) year warranty for recreational users and two (2)
years for commercial users.

Engine alternator, starter motor and electrical components are only covered by a one (1)
year warranty.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 4 of 50

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.

The dealer or boat builder will then arrange for the inspection and any necessary repairs. If
the repairs carried out are not covered by the warranty, purchaser shall pay for all related
labour and material, and any other expenses associated with that service.

WHAT IS NOT COVERED

This limited warranty does not cover routine maintenance items, adjustments, normal wear
and tear, damage caused by abnormal use, operation of the product in a manner
inconsistent with the recommended operation/duty cycle section of the Owners Manual,
accident, submersion, improper installation (proper installation specification and techniques
are set forth in the Operations and First time running sections in this manual), use of an
accessory or part not manufactured or sold by us, or alteration or removal of parts.
Expenses related to crane-out, launch, towing, storage, telephone, rental, inconvenience,
slip fees, insurance coverage, loan payments, loss of time, loss of income, or any other
types of accidental or consequential damages are not covered by this warranty.

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 fuel system.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 5 of 50

Contents

SECTION 1 - Safety Precautions ................................................................... 7

1. General ................................................................................................................................................. 7

2. Lifting .................................................................................................................................................... 7

3. Rotating Shafts and Belts ..................................................................................................................... 7

4. Exhaust System ................................................................................................................................... 7

5. Launching and Lifting Boats ................................................................................................................. 7

6. Batteries ............................................................................................................................................... 8

SECTION 2 - Engine Identification ................................................................ 9

SECTION 3 - Installation .............................................................................. 10

1. Ventilation ........................................................................................................................................... 10

2. Engine Beds ....................................................................................................................................... 10

3. Cooling System .................................................................................................................................. 10

4. Skin Tanks .......................................................................................................................................... 10

5. Engine Cooling Water Inlet and Outlet Hose Connections ................................................................ 11

6. Pressurised Water Header Tank ........................................................................................................ 11

7. Shaft Connection and Propeller Selection ......................................................................................... 17

8. Engine Anti-Vibration Mounts ............................................................................................................. 17

9. Engine Alignment ............................................................................................................................... 19

10. Electrics .......................................................................................................................................... 20

11. Electrical Options ............................................................................................................................ 20

12. Engine Oil ....................................................................................................................................... 21

13. Fuel ................................................................................................................................................. 21

14. Coolant ........................................................................................................................................... 22

15. Calorifier ......................................................................................................................................... 22

16. Control Cables ................................................................................................................................ 22

17. Domestic Battery Bank ................................................................................................................... 23

18. Control Panel .................................................................................................................................. 23

19. Exhaust System .............................................................................................................................. 24

20. Hydraulic Drive Transmissions ....................................................................................................... 24

21. Hydraulic Pump Drive Option (Shire 38 / 40 / 45 / 50) ................................................................... 25

22. Installation Check list ...................................................................................................................... 26

SECTION 4 - Operation ................................ ................................................ 27

1. Starting the Engine for the First Time ................................................................................................ 27

2. Starting Procedure ............................................................................................................................. 27

3. Stopping Procedure ........................................................................................................................... 28

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 6 of 50

4. Full Load Running .............................................................................................................................. 28

5. Refuelling ........................................................................................................................................... 28

6. Twin Thermostats – Shire 45 and 50 ................................................................................................. 28

Diesel Fuel Additive ................................................................................................................................... 30

7. Exhaust Back Pressure ...................................................................................................................... 30

SECTION 5 - Service Procedure ................................................................. 30

1. Engine Oil and Filter Change ............................................................................................................. 30

2. Air Filter Check & Change .................................................................................................................. 31

3. Gearbox Oil Change .......................................................................................................................... 31

4. Disposal of Oil and Related Items ...................................................................................................... 33

5. Primary Fuel Filter Water Drain – Shire 30, 35, 40, 45 & 50.............................................................. 33

6. Primary and Secondary Fuel Filter Change ....................................................................................... 34

7. Fuel System Bleeding ........................................................................................................................ 35

8. Cooling System .................................................................................................................................. 35

9. Belt Adjustment .................................................................................................................................. 36

10. Belt Maintenance ............................................................................................................................ 36

11. Belt Replacement ........................................................................................................................... 36

12. Dash Panel Maintenance ............................................................................................................... 37

SECTION 6 - Service Schedule ................................................................... 38

Specifications and Capacities ................................................................................................................... 38

Service Intervals ........................................................................................................................................ 38

SECTION 7- Wiring Diagrams ..................................................................... 39

1. Engine Wiring Diagram Shire 30, 35, 38 & 40 ................................................................................... 39

2. Engine Wiring Diagram Shire 30 & 35 (with Glowplugs).................................................................... 40

3. Engine Wiring Diagram Shire 45, 50 & 70 (Shire 40 with optional 240A Alt)..................................... 41

4. Standard Panel Wiring Diagram ......................................................................................................... 42

5. Deluxe Panel Wiring Diagram ............................................................................................................ 43

6. RDG20710110 - Standard Panel ....................................................................................................... 44

7. RDG20710111 – Deluxe Panel .......................................................................................................... 45

SECTION 8 – Dealer List .............................................................................. 48

SECTION 9 – Shire Service Parts ............................................................... 49

Shire Service Record Card .......................................................................... 50

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 7 of 50

SECTION 1 - Safety Precautions

1. General

It is the responsibility of the installer/operator to ensure that the finished installation
complies with the relevant health & safety requirements and the recreational craft directive
before commissioning.
Ensure that the engine battery isolator switch is in the off position and the key removed
from the control panel before carrying out any maintenance or repairs.

2. Lifting

The lifting points supplied with the engine are for lifting the engine/gearbox only. A suitable
spreader bar must be employed to prevent over-stressing either bracket during any lift.

3. Rotating Shafts and Belts

The engine and its accessories are not 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

Exhaust gases may have temperatures as high as 650oC and contain elements which are
harmful if ingested.
It is therefore essential that exhaust systems are gas tight and lagged to prevent accidental
burning.

5. Launching and Lifting Boats

Care must be taken when launching or craning new boats into or out of the waterway, so
that water does not enter the engine via the exhaust system or air vents. It is
recommended that these are blocked temporarily whilst undertaking this procedure.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 8 of 50

6. Batteries

WARNING:

EXPLOSIVE GASSES / SULPHURIC ACID

 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 the battery tops and battery compartment ventilated at all times.
 If disconnecting the battery; remove the earth lead FIRST; and re-connect it last.
 If charging the battery; ensure that the charger is switched off before connecting and

disconnecting.

 Do not tip the battery on its side.
 Please see label on battery or manufacturers instructions for specific information.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 9 of 50

SECTION 2 - Engine Identification

Please quote the engine identification number during any enquiry or when ordering spare
parts. Use the space below to record these details.

This can be found engraved into the brass plate on top of the engine rocker cover and
stamped to the crankcase next to the starter motor.

An example of the engine identification plate is shown below:

Figure 2-1: Engine Identification Badge

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 Shire service parts in Section

11.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 10 of 50

SECTION 3 - Installation

1. Ventilation

 All internal combustion engines radiate heat and require cool, clean air to aid complete

combustion.

 Please ensure that adequate engine room ventilation is provided, by fitting at least two

vents of an aperture of not less than 10,000 mm2 each, (16 in2).

An allowance must be made for any grills, louvres or bends placed in the airflows
and generally an increase of 25% in area is sufficient to overcome any restriction
problems.

2. Engine Beds

 These should be a minimum of 10mm thick, extended rearward and be welded to the

hull and forward to the bulkhead. Webs or gussets must be welded in place midway to
prevent flexing.

3. Cooling System

 Ensure pipe work to and from the skin tanks is of sufficient bore. Ensure tight bends

and elbows are avoided or kept to a minimum (sizes are listed overleaf).

4. Skin Tanks

 The ideal skin tank internal thickness is between 50 and 75mm, the table below will

indicate a suitable tank size. However, volume will not compensate for lack of surface
area. It should be recognised that fitting a large calorifier will increase the theoretical
cooling capacity only until it is up to temperature. It is unlikely that a boat on the inland
waterways will operate at full power for long periods of time. The engine cooling water
outlets are on the right hand (starboard) side of the engine.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 11 of 50

Height

Length

Air Bleed Points

Coolant to
Engine

Coolant from
Engine

Figure 3-1: Skin Tank Flow Diagram

Recommended Skin Tank Size

Engine

HP

KW

Skin tank Surface

area m

2

Suggested
Height mm

Suggested Length

mm

50

50

37

1.1250

750

1500

45

45

34

1.0

721

1442

38/40

38/40

30/38

1.0

721

1442

30/35

30/35

22/26

0.85

652

1304

Note: Skin tank size must be increased by approx. 10% if a hydraulic drive transmission is
fitted

5. Engine Cooling Water Inlet and Outlet Hose Connections

These are on the right hand (starboard) side of the engine:

Shire 30, 38 28mm OD, Inlet and Outlet
Shire 35, 40 28mm OD, Inlet and Outlet
Shire 45, 50 28mm OD, Inlet and 35mm OD, Outlet

Use a good quality hose that cannot collapse or kink and is capable of working at
temperatures in excess of 100⁰C

6. Pressurised Water Header Tank

 The pressurised header tank should be mounted higher than the level of the engine, no

less than 300 mm, and no more than 1 metre from the engine, to prevent cooling

Baffles

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 12 of 50

system air locks.

 Shire 50: a single hose connects the tank to the vertical hosetail fitted into the port side

of the twin thermostat housing.

 Shire 30, 35, 38 40 and 45: Two hoses are used on these engines. One is fitted

between the smaller internal diameter (3mm) outlet (on the left hand side of the tank)
and the connection on the port side of the top of the thermostat housing (on 45 the side
of the twin thermostat housing). The second hose is connected between the larger

internal diameter outlet on the (right hand side of the tank) and the ½” hosetail

connection on the engine pipe facing forwards and upwards at 45.
Shire 30 and 35 connections.

 A constant rise on pipework is required to prevent air locks.

Figure 3-2: Shire 30/35 Header Tank Connections

Large ID hole

Small ID hole

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 13 of 50

Figure 3-3: Shire 38 Header Tank Connections

Small ID hole

Large ID hole

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 14 of 50

Figure 3-4: Shire 40 Header Tank Connections

Large ID hole

Small ID hole

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 15 of 50

Figure 3-4: Shire 45 Header Tank Connections

Small ID hole

Large ID hole

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 16 of 50

 Shire 50. There is only a single hose connected to the left hand side of the bottle (3mm) outlet.

Figure 3-5: Shire 50 Header Tank Connections

Single
Hole

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 17 of 50

7. Shaft Connection and Propeller Selection

 Some type of flexible coupling must be used to connect the gearbox output flange to the

propeller shaft flange.

 Please note, underperforming engines will not be covered under warranty if the cause

of the poor performance is found to be the use of an inappropriate propeller.

8. Engine Anti-Vibration Mounts

 Ensure that the engine feet do not end up at the top of the thread on the engine

mounts, this puts undue pressure on them and can result in excessive engine
movement and premature mount failure. If this is a problem put steel packing plates
under the mounts. Packing plates 25mm thick are available: order RDG3906 Engine
mount spacer. Alternatively they can be manufactured locally.

 Ensure that the engine has been installed for at least 24 hours before shaft alignment is

checked, to allow the mounts time to settle under the engine weight.

 Ensure that the anti-vibration mount centre screw is sufficiently raised so as not to

touch the engine bed. If this occurs, excessive engine vibration will be experienced
through the hull.

 For best results, fit the front AV mounts into the front holes in the engine rails. If engine

room space is a problem the mounts can be fitted slightly further back in the alterative
holes, and the front of the rail cut off – leaving 50mm of material to retain strength
(measuring from the centre of the mount hole to the front end of the rail). Note: this
procedure is only possible on non VDO travelpower engines, and may result in a very
slight increase in vibration.

Figure 3-6: Correct Anti-Vibration Mount Installation

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 18 of 50

Figure 3-7: Correct Anti-Vibration Mount Installation

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 19 of 50

Figure 3-8: Anti-Vibration Mount Installation Points

9. Engine Alignment

 The gearbox output shaft flange and propeller shaft input flange must be almost

perfectly aligned. A maximum of 0.05mm (.002") misalignment in any plane is
acceptable. Ensure alignment is rechecked after the first 4 hours of running, after the
first month, and thereafter annually.

 If the engine is out of alignment it will result in excessive vibration and possible damage

to the stern tube and propeller shaft.

 Boats that are fitted with fully flexible drive couplings should still have the engine and

shaft alignment as close as possible. A dummy shaft may be required for this purpose.
(Note: some types of flexible shaft couplings require the input and output to be
misaligned, check with the coupling manufacturer’s installation instructions).

 Minimum clearance of 25mm between rails and bulkhead (forward).
 Minimum clearance of 25mm between rails and engine beds

Normal mounting position.

Alternative mounting position if
engine compartment space is
restricted.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 20 of 50

10. Electrics

 Do not attach any part, hose or cable to the engine wiring harness. There is a warning

label attached to the harness to remind you of this.

 Connect the wiring extension harness multi plug to the panel plug, and the other end to

the engine.

 Connect the start battery positive cable to the engine starter motor solenoid terminal.
 The starter motor battery cable must have a cross sectional area of at least 50mm2.
 For twin alternator engines, connect the domestic battery positive cable to the 140A or

240A alternator. The 140A alternator has a B+ terminal and the 240A alternator has a
“pos out” terminal (see wiring diagram). This ensures that the 50A alternator charges
the start battery and the 140A or 240A alternator charges the domestic battery,
removing the requirement for a split charging system or relay.

 The engine is supplied with the domestic alternator belt not fitted. This is so that

domestic alternator damage does not occur if the engine is run without the domestic
battery back connected. The belt should only be fitted when domestic battery bank has
been connected to the domestic alternator. Belt fitting and tensioning instructions are in
section 5, Servicing Procedure (ensure alignment is correct).

 A cable will need to be manufactured locally and fitted between the lower 140A or 240A

alternator and domestic battery positive terminal. Cable should have a minimum cross
sectional area of 40mm² for Shire 30, 35, 38 and 40. 70mm2 for Shire 45 and 50.

 Both negative battery terminals can be connected to a common earth point.
 Note: The 240A alternator is of the insulated earth design and requires a heavy duty

earthing wire installed at all times.

11. Electrical Options

 If the engine is fitted with the optional 230V Travel Power System, refer to the manual

supplied with it for correct wiring, control box installation and operation.

 The Shire range can be supplied with an optional additional 12v or 24v alternator. This

will be supplied fitted but not wired. It is the responsibility of the boat builder to ensure
that this is correctly wired to the boats electrical system.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 21 of 50

12. Engine Oil

 All Shire engines are supplied fully run in.
 Check oil levels in engine and gearbox before starting.
 Use a good quality engine oil SAE 15W/ 40 API class CD.

WARNING:

ENGINE OIL WITH A HIGHER API CLASS THAN CD IS UNSUITABLE FOR CANAL

BOAT OPERATION AND WILL CAUSE ENGINE DAMAGE IF USED.

13. Fuel

 Ensure the main fuel tank is clear of dirt & water.
 A separate water trap is strongly advised (the Shire 30, 35, 40, 45 and 50 engine are

supplied with a fuel pre-filter water trap as standard).

 Shire 38 must have a separate water trap fitted.
 Connect fuel feed and return hoses from engine to main supply and return lines to main

fuel tank, ensuring they are connected the correct way around. The hose to the fuel
pump is the inlet.

 The engine hoses are supplied with 5/16" (8mm) OD metal hose tails and should be

securely fitted to the main supply and return pipes with compression fittings.

 The engine hoses should have sufficient slack to absorb engine movement without

placing strain on the hoses and be securely clipped to prevent accidental damage and
chafing.

 Initially fill the fuel system by turning the ignition on to operate the electric fuel pump.

Loosen the bleed screw on the top of the primary fuel filter/water trap and close when
fuel begins to flow clearly (no bubbles). It is rarely necessary to bleed the injection
pump or injectors upon installation as the engine will already have fuel in it from the
engine run in and test procedure.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 22 of 50

14. Coolant

 Prepare coolant mix of 50% clean tap water and 50% antifreeze.
 Open the calorifier taps (if fitted) to fill the calorifier system and displace air.
 To fill the cooling system for the first time, fill the boat skin tank via the inlet hose

connection or filler plug if fitted.

 Shire 30, 35, 38, 40: Fill the engine through the white plastic expansion tank.
 Shire 45: Fill the engine through the twin thermostat housing filler, then top up the white

plastic expansion tank.

 Shire 50: Fill the engine through the water-cooled exhaust manifold filler, then through

the twin thermostat housing. Top up though the white, plastic expansion tank.

 N.B. After running the engine for the first time, monitor the water level frequently as

trapped air bubbles may be expelled. Top up the system as necessary.

 Bleed skin tank

15. Calorifier

 The temperature of coolant flowing to the calorifier from the engine can be between 85

and 90C. A blender valve must be incorporated in the calorifier/hot water system outlet
to lower the hot water temperature for domestic use.

16. Control Cables

 Connect engine speed control cable. With the engine off, ensure that the engine speed

control lever achieves full travel from idle to full speed. Adjust if necessary.

 Check the gearbox shift lever selects positively and that the drive direction corresponds

with the gearshift control lever. Ensure that the gearbox control lever and the gearshift
lever are both in neutral before connection. Adjust if necessary.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 23 of 50

17. Domestic Battery Bank

Domestic battery banks that are too large create excessive loads on the domestic
alternator. Alternators running at maximum output for prolonged periods of time will
eventually fail prematurely; alternators that fail due to the battery bank being over the
maximum recommended size will not be covered by warranty.
Higher output additional alternators, or travel power kits are available; if larger battery
banks are required discuss your individual power requirements with the boat builder.

 The maximum domestic battery bank is calculated using the following:

Live aboard, three times domestic alternator, maximum output current.
Weekend cruising or hire fleet use, three and a half times domestic alternator, maximum

output current.
Example 1:
Live aboard application fitted with a 140 amp domestic alternator

3 x 140 = 420 ampere/hour maximum battery bank size
Example 2:
Weekend cruising or hire fleet application fitted with a 240 amp domestic alternator

3.5 x 240 = 840 ampere/hour maximum battery bank size

18. Control Panel

All Shire engines are supplied with high quality engine control panel that all show RPM and
hours run and include warning lights and a warning buzzer, the deluxe panels also have in
addition gauges for water temp, oil pressure and battery charging. The panels are
designed to be splash proof and are correctly installed with the gauges vertical. Do not
install so that they remain out in the open, or cover up when not in use.

The control panel engine tachometer is supplied already calibrated to measure correct
engine speed, if a new dash panel, tachometer or alternative alternator is fitted the tacho
will require re-calibrating.

Dash Panel Calibration Procedure:

 Connect dash panel plug to engine wiring loom plug
 Turn ignition on (do not start engine)
 Press and hold black button on rear of tacho until “H –“ appears on the digital display on

the bottom of the tacho (on the front).

 When pressing and holding the black button on rear of tacho, the value displayed will

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 24 of 50

increase/decrease until button is released. Then when pressed again it will
increase/decrease in the other direction, keep doing this until the digitally displayed
value on bottom of tacho reaches the correct value, according to the type of alternator
(see table). Must be set to the alternator with blue and black wire connected to it.

 Confirm settings to tacho meter reader.
 An optical tachometer is required to check the reading.

Barrus Alternator (Amps)

Barrus tacho reading

50

10.50 - 11.00

70

15.00

110

18.00

140

19.50 - 20.00

240

22.00

Alternative or non-standard alternators will require calibrating and checking by trail and
error with a hand held tacho until the engine speed and indicated tachometer speed are the
same.
Engine energise to stop systems are available as an optional extra.

19. Exhaust System

The exhaust outlet size on the engine is 1 1/2" BSP female. There must be a flexible
exhaust hose of suitable exhaust grade between the engine and the silencer or hull outlet.
The outlet must be above the waterline at all times.

 Make sure exhaust increases then decreases in height as shown above

20. Hydraulic Drive Transmissions

If an engine is to have a Hydraulic Drive Transmission attached to it, a number of points



X

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 25 of 50

must be observed.
Bobtail engines (i.e. Engines supplied without a marine gearbox), normally do not have a
gearbox oil cooler fitted, however if a cooler is supplied, this will only be suitable to cool a
conventional marine gearbox.
Hydraulic drive transmissions generate far more heat than a conventional marine gearbox,
therefore the size of oil cooler installed must be calculated by the hydraulic drive
transmission supplier; to ensure it has sufficient cooling capacity, and is sized appropriately
taking into account:

 Maximum engine power
 High ambient summer air temperature
 Summer River/Canal/Sea temperature
 No additional restriction to engine coolant flow is present

Skin tanks will also need to be increased by approx. 10% dissipate the additional heat
generated.

21. Hydraulic Pump Drive Option (Shire 38 / 40 / 45 / 50)

For SAE type pump (9T).
If a hydraulic pump is required to drive items such as bow thrusters or hydraulic winches

then the following parts are required to enable drive to be taken from the engine power
take off.

Part No. 129484-26200 incorporates:

 Packing (on gear case side): 171353-26081
 Cover: 121023 - 26070
 Cover packing: 121023-26061

Ratio: 0.903:1

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 26 of 50

22. Installation Check list

Engine alignment correct, clearance all round, check propeller turns
by hand (Ensure ignition is off battery and battery master switch is
off) Anti-Vibration mounts correct height, spacers if necessary

Exhaust system as specified

Battery leads are of correct size, tightened and start battery is
charged

Check tension of alternator belts, wiring connected and belt
alignment checked If removed

Check fuel system is connected correctly and primed

Fuel line water trap installed and water drained off

Check header tank and skin tank connections are correct way
round, constant pipework rise to header tank

Check level of coolant in header tank and correct ratio

All air has been bled from skin tank, calorifier and pipework

Engine and gearbox oil levels are as specified

Throttle and gear cables correctly adjusted and operating smoothly

All pipework and cabling supported and not chaffing, slack to allow
movement of engine

Confirm panel and warning lights operational

Check for leaks

Explain/Demonstrate off season storage and maintenance

Installer’s signature

Installer name/company

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 27 of 50

SECTION 4 - Operation

1. Starting the Engine for the First Time

 Remove ignition key.
 Ensure all oil and coolant levels are checked.
 Ensure both engine and domestic batteries are connected. Battery master switches

must be turned on.

 Check all connections and mountings are tight.

2. Starting Procedure

Note: Shire engines do not have a cold start function as standard. Therefore the glow plug
light will not illuminate.

 Ensure the gearshift control lever is set to neutral, and that persons are clear of any

moving parts.

 Insert the ignition key.
 Ensure the domestic battery isolator is turned to the on position before starting the

engine, failure to do so may damage the domestic alternator.

 Turn key to first position, on.
 Observe warning lights (and gauges on deluxe panel). N.B. the engine overheat light

will only illuminate when the water temperature exceeds the safe level

 Listen for warning buzzer.
 Turn key to second position, start, and hold to crank.
 Crank the engine for no more than 15 seconds.
 On engine start, immediately release key.
 Key will return to first position, on.
 The warning buzzer will stop and on the deluxe panel the oil pressure gauge will show

an oil pressure of 3.5 – 4.5 bar [51-65 psi].

 Should any warning light not go out, or if there is no reading on the oil pressure gauge,

the buzzer will continue sounding. In this case, stop the engine immediately and check
the relevant system (Note: if the charge light does not go out, briefly increase the
engine speed).

 Stop engine immediately if any abnormal noises are detected.
 Visually check the engine for oil, fuel and coolant leaks, (after initial start up and at

regular intervals, N.B. engine must be stopped to carry out this check).

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 28 of 50

3. Stopping Procedure

 Move speed control lever to idle position.
 Turn key to off position.

4. Full Load Running

 Running diesel engines near their rated output (maximum load) regularly will disperse

accumulated carbon and condensation enhancing engine life and reducing emissions.

 Running the engine at, or near, maximum speed whilst in gear may not be possible on

inland waterways with speed limits in place. This will have to be carried out whilst
moored up. Ensure that the mooring ropes and posts are strong enough to allow this,
and that the water is deep enough not to damage the propeller. It is recommended that
the engine is run at or near full load for 15 minutes (maximum revs, in gear) every 50
hours.

5. Refuelling

 All Shire canal boat engines run on Diesel fuel.
 Please note that when the vessel is to be left for any period of time the fuel tank should

be left full to eliminate the build up of condensation and formation of water in the fuel
tank.

 Engine to be turned off while refuelling.
 The fuel type for all Shire canal boat engines is diesel. DO NOT USE BIODIESEL.

6. Twin Thermostats – Shire 45 and 50

The twin thermostat design is a feature unique to the Shire canal boat, engine range. It
ensures that the engine warms up very quickly due to the first thermostat being closed so
that cooling water is routed through the specially designed cast iron exhaust manifold
(Shire 50 only). The waste heat from the exhaust is recycled to bring the engine up to
operating temperature even quicker than normal. This ensures efficient engine operation
with reduced fuel consumption and even cleaner exhaust emissions. It also helps in
keeping engine wear to a minimum.
The diagrams on the following page show the operation of the cooling system.
Note: Shire 30, 35, 38 and 40 have a single thermostat only.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 29 of 50

Figure 4-1: Twin Thermostat Operation

With the engine quickly up to operating
temperature, the first 71° thermostat
opens. The water now flows to the
domestic hot water tank, resulting in
hot water being rapidly available.

When the water stored in the hot water
tank has reached full temperature, the
second 88° thermostat opens and
water can then flow to the skin tank
and correctly control engine cooling.
The exhaust manifold that earlier
helped to heat engine water is now
cooled to ensure safe operation and
reduce engine compartment
temperatures.

If the load on the engine reduces and
the demand for domestic hot water
increases then the system will
automatically compensate and re­direct water to ensure that a plentiful
supply of hot water is always available.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 30 of 50

Diesel Fuel Additive

The use of diesel fuel additive is strongly recommended on Shanks & Shire engines.
The quality of the fuel available when cruising is often unknown; also the fuel may have
been in storage for long periods of time. The use of additives will ensure that your
engine fuel injection system is in top condition which should result in many years of
smooth reliable operation without the cost and inconvenience of expensive breakdowns
due to poor quality fuel. It has also been found that improvements in fuel consumption
and start ability are an added benefit of using this product.

Diesel fuel additive is available from your Shanks or Shire dealer in a handy 375ml
container, part number RDG80210219.

7. Exhaust Back Pressure

The back pressure falls within the manufacturers recommended range when using the
exhaust system supplied with the engine.

SECTION 5 - Service Procedure

1. Engine Oil and Filter Change

CAUTION:

WEAR DISPOSABLE GLOVES AND BEWARE OF HOT OIL AND ENGINE BLOCK.

REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT.

 Change the engine oil while the engine is still hot.
 Remove the blanking plug in the sump pump spout. [6mm Allen key] Note: Shire 50 has

two oil drain pumps, it is the pump mounted up higher on the engine.

 Place a plastic tube over the spout and into a container. Operate the pump handle to

empty the sump. (Remember to refit the blanking plug afterwards).

 Place a drip tray under the engine to catch the small amount of oil that will escape from

the oil filter. Using the strap type oil filter removal tool (supplied), slacken the filter from
the engine block in an anti clockwise direction, remove the tool and spin off the filter.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 31 of 50

 Lightly oil the new filter O ring seal and install the filter onto the engine. Spin it on in a

clockwise direction and finally tighten by hand only as firmly as you can.

 Refill the sump using the yellow oil filler cap in the rocker cover on top of the engine.
 Oil level should be to the top mark on the dipstick.
 Run the engine for 5 minutes to fully circulate the oil, and check for leaks, stop the

engine. Wait 5 minutes before checking the oil level with the dipstick and top up if
required.

 Do not exceed maximum oil level marker as this may cause damage to the internal

components of the engine.

2. Air Filter Check & Change

CAUTION:

WEAR DISPOSABLE GLOVES AND BEWARE OF HOT OIL AND ENGINE BLOCK.

REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT.

 Release the two spring clips, pull off the end cover to reveal the filter element. The

element simply pulls out.

 To fit the new element, slide the open end of the filter element into the main body;

gently push the element until fully seated. Refit the end cover.

 The air filter element is constructed from pleated paper; inspect it closely for dust or dirt.

The air filter cannot be cleaned and must be replaced when dirty. The engine requires
clean unrestricted air to run efficiently, failure to maintain the air filter could result in
smoke, increased fuel consumption and ultimately engine damage.

3. Gearbox Oil Change

CAUTION:

WEAR DISPOSABLE GLOVES AND BEWARE OF HOT OIL AND ENGINE BLOCK.

REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT.

NOTE: Some engines will have a gearbox sump pump fitted, to change the oil in this
circumstance, follow the same procedure as was outlined for changing the engine oil. For

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 32 of 50

engines without a gearbox sump pump, follow the procedure below.

 Change the gearbox oil while it is still hot (Please refer to gearbox manual for more

information).

 Place a tray beneath the gearbox that will hold at least 2.0 litres.
 Remove drain plug and allow 5 minutes for oil to drain thoroughly.
 Replace the drain plug, ensure that the sealing washer (if used) is still in place, and in

good condition, tighten. Fit a new washer if required.

 Refill the gearbox with oil to the upper mark on the dipstick. Screw dipstick in fully to

establish level. Refer to PRM Owner manual for more details. Section 6 contains details
of oil specifications.

 Do not overfill gearbox as this can damage the internal components.

Figure 5-2: PRM 80 and 120 Gearbox

Level dipstick /
Filler plug

Magnetic Drain Plug

(viewed from underneath)

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 33 of 50

Figure 5-3: PRM150 Gearbox

Figure 5-4: PRM260 Gearbox

4. Disposal of Oil and Related Items

 Please dispose of used oil and oil filters safely with due regard for the environment and

take to your local waste oil disposal point.

 Do not allow oil or contaminated parts to enter the inland water way system.

5. Primary Fuel Filter Water Drain – Shire 30, 35, 40, 45 & 50

CAUTION:

WEAR DISPOSABLE GLOVES.

REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT.

Note - Shire 38 is not fitted with a primary fuel filter/water trap.

Level dipstick /
Filler plug

Level dipstick /
Filler plug

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 34 of 50

 Place a small drain bowl under the primary fuel filter/water trap.
 Loosen the drain screw located in the bottom of the fuel filter/water trap (Figure 5-6).
 Drain off any water.
 Once the water has been drained - re-tighten the drain screw.
 It is unlikely the complete fuel system will require bleeding.
 Run for 5 minutes.
 Check that the drain union is tight and that there are no leaks.
 Note: the boat builder should have fitted an additional water trap in the fuel system

before the engine. Ensure that this is drained regularly.

 Do not over tighten drain screw.

Figure 5-6: Primary Fuel Filter Drain Screw

6. Primary and Secondary Fuel Filter Change

CAUTION:

WEAR DISPOSABLE GLOVES.

REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT.

 Ensure the fuel tank is at least ¾ full prior to undertaking this procedure.
 Turn off the main boat fuel supply tap, located on or near the fuel tank.
 Place a small drip tray under the filter body.
 Remove the fuel filters using the filter wrench supplied. Unscrew them until loose then

remove by hand.

 Primary fuel filter only – Retain the metal fuel filter drain screw from old filter and re-use

in the new filter. (Shire 30, 35, 40, 45 and 50 only)

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 35 of 50

 Smear a small amount of clean fuel on all of the O ring seals that are supplied with the

new filter element.

 Screw the new element back into the filter head. Tighten by hand only.
 Turn the main boat fuel supply tap back on.
 Ensure system is correctly bled before attempting start up.

The same procedure is used for both Primary and secondary fuel filter changes

7. Fuel System Bleeding

 Ensure the fuel tank is at least ¾ full prior to undertaking this procedure.
 See Fuel paragraph, Section 3, in Yanmar Engine Operation Manual.

8. Cooling System

WARNING:

DO NOT CHECK THE COOLANT LEVEL WHEN THE ENGINE IS HOT. REMOVE THE

IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT.

 To check the coolant level, ensure that the engine has been shut down for at least half

an hour.

 The coolant level can be checked visually and should between the two level marks

formed on the front of the white, plastic expansion tank.

 If required, top up the level with coolant (50% clean tap water and 50% ethylene glycol

based anti-freeze) through the expansion tank filler cap.

 Do not use water only to top up as this weakens the coolant mix, reducing the level of

frost protection and anti-corrosion protection of the coolant.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 36 of 50

9. Belt Adjustment

CAUTION:

REMOVE THE IGNITION KEY BEFORE WORKING IN THE ENGINE

COMPARTMENT.

 Depress the longest run of the drive belt to be checked. If the travel exceeds 15 -20mm

using hard finger pressure, the belt needs re-tensioning.

 Loosen the upper adjuster bolts on the alternator, and the lower mounting pivot nut and

bolt, either pull out using hand pressure or use the tensioning screw, depending on
which alternator belt is to be tensioned.

 Pull the alternator away from the engine to tighten the belt.
 Hold the alternator in position and re-tighten all the bolts.
 Note: if the belts are over tightened alternator bearing failure will occur.

10. Belt Maintenance

 Do not allow oil to contact the belt. Oil attacks the construction of the belt, reduces the

drive efficiency and will ultimately cause it to fail prematurely.

 Replace the belt if it cracks or splits and as the adjustment nears the limit of its travel.
 Note: Some boat builders may remove one or more of the alternators during the

installation of the engine. It is essential that when the alternators are re-fitted that the
alignment is perfect or premature belt wear will occur.

11. Belt Replacement

CAUTION:

REMOVE THE IGNITION KEY BEFORE WORKING IN THE ENGINE

COMPARTMENT.

 Ensure that you have the correct replacement belts before starting this procedure.

(Some engines may have been fitted with non-standard optional alternators which may
not use the belt sizes listed. Make a note of these belt sizes up on delivery).

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 37 of 50

 Loosen the top adjuster bolts, and the lower mounting pivot nut and bolt.
 Push the alternator towards the engine to loosen the belt.
 Remove the belt.
 Hold the belt in position over the top alternator pulley; rotate the engine if required, by

hand, to guide the new belt into the “vee”.

 Re-tension the belt as above.

12. Dash Panel Maintenance

CAUTION:

REMOVE THE IGNITION KEY BEFORE WORKING IN ENGINE COMPARTMENT.

TURN BATTERY ISOLATION SWITCHES OFF.

Warning Light Bulb replacement

1. Release the panel from its mounting

2. To replace an illumination bulb.

a. 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.

3. To replace any gauge

a. The gauges are accessible from rear of the panel. Unplug the wire connectors,

unscrew and pull the gauge out from the panel.

4. Periodically squirt a lubricant in to the key switch slot with key removed (a lubricant

such as WD40 – with silicon, other lubricants are available). Then with the battery
master switch turned off operate key switch a couple of times to ensure lubricant works
in to mechanism.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 38 of 50

SECTION 6 - Service Schedule

Specifications and Capacities

ENGINE OIL CAPACITY (WITH FILTER):

Engine

Capacity (litres)

Capacity (Pints)

30, 35

5.5

9.6

38, 40, 45, 50

7.4

13

GEARBOX OIL CAPACITY (EXCLUDING COOLER):

Gearbox

Capacity (Litres)

Capacity (Pints)

PRM 80

0.57

1.0

PRM 120

0.8

1.4

PRM 150

1.4

2.5

PRM 260

1.5

2.7

Engine Oil: SAE 15W 40 API Class CD.
Coolant: 50% Clean Water + 50% Ethylene Glycol Antifreeze.
PRM 80 and 120 Gearbox: ATF (Automatic Transmission Fluid) oil.
PRM 150 and 260 Gearbox: Engine Oil.

Service Intervals

Check

Change

Notes

Engine Oil & Filter

Daily (level)

Every 250 hours

Or 12 Months *

First change after 50 hrs

Gearbox Oil

Weekly

(level)

Every 250 hours

Or 12 Months *

First change after 25 hrs

Coolant level

Daily

(level)

Every 24 Months

Diesel Fuel Filter
Primary and
Secondary

50 hours

Every 500 hours

Or 12 Months *

Drain water every 50 hours,
or monthly #

Air Filter Element

250 Hours

Every 500 hours

Or 24 Months *

Sooner if required
Drive belts

Daily

As required

Adjust as necessary

Key Switch

Lubricate

Every 150 hours

Or 12 Months *

As per Instructions section 12,
Dash Panel Maintenance

* Whichever occurs first.
# If large quantities of water are found in fuel when filter drained, increase frequency of
draining

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

SECTION 7- Wiring Diagrams

1. Engine Wiring Diagram Shire 30, 35, 38 & 40

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 40 of 50

2. Engine Wiring Diagram Shire 30 & 35 (with Glowplugs)

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

3. Engine Wiring Diagram Shire 45, 50 & 70 (Shire 40 with optional 240A Alt)

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

4. Standard Panel Wiring Diagram

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

5. Deluxe Panel Wiring Diagram

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

6. RDG20710110 - Standard Panel

Tachometer

Hour Meter

Water

Temperature

Warning Light

Oil Pressure

Warning Light

140A Alternator

Charge Light

50A Alternator

Charge Light

Glow Plug Light

(Optional)

Key Flap

&

Ignition Switch

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 45 of 50

7. RDG20710111 – Deluxe Panel

50A Alternator

Charge Light

140/240A
Alternator

Charge Light

Oil Pressure

Warning Light

Water

Temperature

Warning Light

Glow Plug Light

(Optional)

Key Flap

&

Ignition Switch

Water

Temperature

Gauge

Hour Meter

Tachometer

50A Alternator Voltage

Output Gauge

Oil

Pressure

Gauge

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 46 of 50

7. 8kW Wiring Diagram and Overall Dimensions

Figure 7-1: Travelpower wiring diagram

The above diagram shows 12/24 Volt part of the wiring for the 8kW Travel Power system.
For the 230 Volt wiring diagram please refer to the Travel Power manual.

8. 5kW Travel Power System

 This unit is excited by a 12V ignition operated supply the travel power installer can

wire to a convenient plug on the existing loom for this purpose.

 When the 12V relay (RDG1396) is placed into the spare relay holder on the engine

the black two way plug becomes live.

 The wire colours in the plug are: Black - Earth

Red - Live

WARNING:

ALL HIGH VOLTAGE WIRING SYSTEMS SHOULD BE INSTALLED BY A

QUALIFIED ELECTRICIAN.

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 47 of 50

Figure 7-2: Travelpower dimension reference diagram

Sizes for the dimensions listed in figure 7-2 are as follows:

3.5 kW

5 kW

7/8 kW

Dim 1

65 mm

65 mm

55 mm

Dim 2

390 mm

390 mm

470 mm

Dim 3 (140 Amp Alt)

420 mm

Dim 3 (240 Amp Alt)

445 mm

Dim 4 (140 Amp Alt)

135 mm

Dim 4 (240 Amp Alt)

150 mm

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 48 of 50

SECTION 8 – Dealer List

Area

Company

Telephone

Email

BERKSHIRE

Bluenine Marine

01189 406482

[e-mail]

Aquatec Marine

07880793686

[e-mail]

Driveline Marine

0118 942 3877

[e-mail]

CHESHIRE

Nantwich Canal Centre

01270 625122

[e-mail]

CORNWALL

Black Dog Marine

01503 265898

[e-mail]

Cellar Marine

01326 280214

[e-mail]

DERBYSHIRE

Midland Canal Centre

01283 701933

[e-mail]

DEVON

Sleeman & Hawkin Ltd

01626 778266

[e-mail]

ESSEX

French Marine Motors Ltd

01206 305233

[e-mail]

French Marine Motors Ltd

01255 850303

[e-mail]

HAMPSHIRE

Marine Power Ltd

0238 0403918

[e-mail]

HERTFORDSHIRE

P & S Marine

01923 248372

(no email contact)

LEICESTERSHIRE

Foxton Boat Services Ltd

01162 792285

[e-mail]

NORFOLK

French Marine Motors Ltd

01603 722079

[e-mail]

NORTHAMPTON

Grand Junction Boat Co.

01604 858043

[e-mail]

NOTTINGHAM

Farndon Marina

01636 705483

[e-mail]

STAFFORDSHIRE

JD Boat Services Ltd

01902 791811

[e-mail]

Stone Boatbuilding Company

01785 812688

[e-mail]

Streethay Warf

01543 414770

[e-mail]

WARWICKSHIRE

Barry Hawkins Narrowboats

01827 711762

[e-mail]

Onboard Energy

02476 393333

[e-mail]

Valley Boat Services Ltd

07990528123

[e-mail]

WEST MIDLANDS

Stephen Goldsbrough Boats

01564 778210

[e-mail]

WORCESTERSHIRE

J L Pinder & Son

01527 876438

[e-mail]

Starline Narrowboats

01684 874774

[e-mail]

YORKSHIRE

Rodley Boat Centre

01132 576132

[e-mail]

MONMOUTHSHIRE

Castle Narrowboats

01873 830001

[e-mail]

EIRE

Dun Laoghaire Marine Services

00353 12104776

[e-mail]

EIRE

O’Sullivans Marine

003536 67124524

[e-mail]

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 49 of 50

SECTION 9 – Shire Service Parts

Model

30/35

38

40

45/50

Primary Fuel

Filter

RDG9188346

Not standard

fitment

RDG9188346

RDG9188346

Secondary

Fuel Filter

119802-55801

119802-55801

119802-55801

119802-55801

50A Alt Belt

25132-003700

RDG6079

RDG6079

RDG6079

140A Alt Belt

RDG6076

RDG6076

RDG6076

240A Alt Belt

RDG0047498

Air Filter
Element

RDG5795

RDG5795

RDG5795

RDG5795

Oil Filter

129150-35153

129150-35153

129150-35153

129150-35153

Fuses

The electrical system is fitted with three or four blade type fuses,
a. Engine start control system 25amp (RDG1152)

b. Engine stop control system 40amp (RDG3246)
c. Dash Panel supply 15amp (RDG3245)

**7/8kw Alternator sub-system 15amp (RDG3245)**

3.5kw Travel Power alternator belt is RDG0047511.
5kw Travel Power alternator belt is RDG0047511.
7/8kw Travel Power alternator belt is RDG6082.

Engine oil is available from your Shire dealer in convenient 5 litre containers -
part number RDG6110.

Diesel fuel additive is available from your Shire dealer in a handy 375ml container -
part number RDG80210219.

Starter Relay

a. 25A

b. 40A

c. 15A

RDG603A8 - Issue 1 - Shire 14 Canal Boat Complete Manual 30, 35, 38, 40, 45, 50.doc

Page 50 of 50

Shire Service Record Card