Summary of Contents for Yanmar KMG Series
- Page 1 series OPERATION MANUAL KMG65E-S3 KMG65E-S6 KMG65E-K3 KMG65E-K6 P/N: 0AKMG-G00100 MARINE GENERATOR...
- Page 2 / or exemplify a product, service or maintenance improvement. We reserve the right to make any change at any time without notice. Yanmar and registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other countries.
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Page 3: Table Of Contents
TABLE OF CONTENTS Page Introduction .............. 1 Record of Ownership ..........Safety ............... 3 Safety Precautions ..........General Information ......... Before You Operate ......... During Operation and Maintenance ..... Product Overview ............. 11 Product Overview ..........Marine Generator Designation ......KMG65E Models .......... - Page 4 TABLE OF CONTENTS Standard Torque Chart (Generator) ....Changing Fuses ........... Changing Indicator LEDs ........Troubleshooting ............35 Troubleshooting Chart ........... Specifications ............39 General Specifications ........... Engine Speed Versus Power Output ....System Diagrams ..........Power Box and Control Panel ......
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Page 5: Introduction
INTRODUCTION Welcome to the world of Yanmar Marine! Yanmar Marine offers systems and accessories for all types of boats, from runabouts to sailboats, and from cruisers to mega yachts. In marine leisure boating, the worldwide reputation of Yanmar Marine is second to none. -
Page 6: Record Of Ownership
INTRODUCTION RECORD OF OWNERSHIP Take a few moments to record the information you need when you contact Yanmar for service, parts or literature. Marine Generating System Model: Marine Generating System Serial No.: Date Purchased: Dealer: Dealer Phone: KMG65E Operation Manual... -
Page 7: Safety
SAFETY SAFETY PRECAUTIONS Yanmar considers safety of great importance and recommends that anyone that comes into close contact with its DANGER products, such as those who install, operate, maintain or service Yanmar Indicates a hazardous situation which, if products, exercise care, common sense... -
Page 8: General Information
• Safety signs and decals are additional reminders for safe operating and maintenance techniques. • See your authorized Yanmar marine dealer or distributor for additional training. KMG65E Operation Manual... -
Page 9: During Operation And Maintenance
SAFETY During Operation and ALWAYS check the electrical harnesses for Maintenance cracks, abrasions and damaged or corroded connectors. ALWAYS keeps the DANGER connectors and terminals clean. The safety messages that follow have ALWAYS have a licensed electrician DANGER level hazards. connect this system to the utility circuit. - Page 10 SAFETY DANGER WARNING NEVER connect the marine generator The safety messages that follow have output to external power (shore power). A WARNING level hazards. three-way switch must be installed by a Explosion Hazard licensed electrician to use shore power. Avoid serious personal injury or equipment damage.
- Page 11 SAFETY Exhaust Hazard WARNING Avoid serious injury or death. Exposure Hazard NEVER block windows, vents, To avoid injury, ALWAYS or other means of ventilation if wear personal protective the engine is operating in an equipment including enclosed area. All internal appropriate clothing, combustion engines create carbon gloves, work shoes, eye...
- Page 12 NEVER open the power box. There are no user serviceable components. Contact your authorized Yanmar marine dealer or distributor. KMG65E Operation Manual...
- Page 13 • If the temperature exceeds +50˚C (+122˚F), the generator or power box may overheat and cause the marine generator to shut down for protection. • Contact your authorized Yanmar marine dealer or distributor if the marine generator will be operated in temperature extremes.
- Page 14 SAFETY This Page Intentionally Left Blank KMG65E Operation Manual...
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Page 15: Product Overview
PRODUCT OVERVIEW PRODUCT OVERVIEW This marine generator system outputs alternating current (230V / 50Hz) through one or two power boxes. The current flows from the generator that is installed between the main engine and the transmission. This system can output current only when the main engine is running and all the control panels are turned ON. - Page 16 PRODUCT OVERVIEW Hair Dryer Hair Dryer Microwave oven Microwave oven Power box Power box Power box Power box 3kVA 3kVA 3kVA 3kVA Panel Panel Panel Panel To 12V battery To 12V battery Generator Generator 0004606 Figure 1 Note: Equipment such as the television (TV), hair dryer, microwave oven and personal computer (PC) are not included in this system.
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Page 17: Marine Generator Designation
Total System Output KMG65E- 3JH4E SD50 3kVA 4JH4E 6kVA KM35P, KM35A(2) 3kVA 6kVA Note: The KMG65E is only available for the engines and transmission listed above. See your authorized Yanmar marine dealer or distributor for more information. KMG65E Operation Manual... - Page 18 PRODUCT OVERVIEW KM35A(2) KM35A(2) SD50 SD50 0004607 Figure 2 Applicable Marine Gears and Sail Drives The KMG65E is available for the following marine gears and sail drives: • KM35P: All models • KM35A(2): Only models which have holes in the mounting flange (Figure 2). •...
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Page 19: Component Identification
PRODUCT OVERVIEW COMPONENT IDENTIFICATION Main Components 3kVA 0004608 6kVA Figure 3 1 – Generator 5 – Generator Harness 2 – Power Box 6 – Control Panel Power Harness 3 – Control Panel 7 – Battery Harness 4 – Terminal Box KMG65E Operation Manual... -
Page 20: Generator
PRODUCT OVERVIEW Generator KMG65E-S3 and KMG65E-S6 (10) (11) (12) (14) ( (13) 0004609 Figure 4 KMG65E-K3 and KMG65E-K6 (15) (16) (10) (17) (18) (19) 0004610 Figure 5 KMG65E Operation Manual... - Page 21 PRODUCT OVERVIEW 1 – Coupling 11 – Bolts (M8x25mm) (6 used) 2 – Generator Assembly 12 – Stud Bolts (M8) (2 used) 3 – Generator Output Cable 13 – Nuts (2 used) Bolts (M8x25mm) (4 used) 4 – Flange (Sail Drive) 14 –...
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Page 22: Power Box
PRODUCT OVERVIEW Power Box (10) 0004611 Figure 6 1 – Power Box 6 – 230V Output Port (2-pin) 2 – Input Port from Generator (3-pin) 7 – Control Signal Port from Panel (6-pin) 3 – Earth (Ground) Terminal for Input 8 –... -
Page 23: Nameplate
PRODUCT OVERVIEW NAMEPLATE Power Box The power box nameplate is installed on the Generator side of the power box. The generator nameplate is installed on the generator housing. PRODUCT No. M FG .N o. M O D EL KANZAKI KOKYUKOKI MFG CO., LTD. M FG .N o. -
Page 24: Control Panel
PRODUCT OVERVIEW Control Panel 0004614 Figure 9 1 – Insufficient Engine Speed Warning Indicator 2 – Power Box is Running Indicator 3 – Power Box Temperature Warning Indicator 4 – Generator Temperature Warning Indicator 5 – Power Box ON / OFF Switch 6 –... -
Page 25: Technical Data
PRODUCT OVERVIEW TECHNICAL DATA Installation should be done only by a qualified technician. See your authorized Yanmar marine dealer or distributor. NOTICE: The marine generator must be aligned and installed to the engine and transmission correctly or equipment damage will result. - Page 26 PRODUCT OVERVIEW This Page Intentionally Left Blank KMG65E Operation Manual...
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Page 27: Operation
When electrical load and propeller load are both operated at engine rating speed, the engine may become overloaded. Yanmar recommends operating it at less than 2500 rpm. Shift the marine gear into NEUTRAL any time the engine is at idle. -
Page 28: Daily Checks
OPERATION DAILY CHECKS CAUTION Periodic maintenance prevents unexpected Before operating the marine generating downtime, reduces the number of accidents system, make sure it is in good operating due to poor machine performance and helps condition. extend the life of the marine generator. If any problem is noted during the visual Make sure you check the following items check, the necessary corrective action... -
Page 29: Starting The System
OPERATION Starting the System Ensure the power box switch on the control panel is OFF. Start the engine and set the engine speed according to the electric equipment you will use. Note: See Engine Speed Versus Power Output on page 40 for relationship between engine speed and power output. -
Page 30: Checks During Operation
OPERATION Checks During Operation • Check the indicators on control panel(s) from time to time during operation. • Check that Power Box is Running indicator is illuminated and that no warning indicators are lit. NOTICE: NEVER allow the system to run when a warning indicator is illuminated. Damage to equipment may result. -
Page 31: Stopping The System
OPERATION Stopping the System NOTICE: NEVER turn the power box OFF and stop the engine immediately after a long period of operation at heavy load. Decrease the electrical load and allow system to cool down before shutting off the power box switch ON / OFF switch and stopping the engine. - Page 32 OPERATION This Page Intentionally Left Blank KMG65E Operation Manual...
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Page 33: Maintenance
MAINTENANCE This section of the Operation Manual DANGER describes the procedures for proper care Explosion Hazard and maintenance of this system. NEVER check the remaining battery charge by shorting out the terminals. ALWAYS use a hydrometer to check the remaining battery charge. - Page 34 MAINTENANCE Electrical Shock Hazard WARNING Avoid serious personal injury Sever Hazard or equipment damage. Rotating parts can cause ALWAYS turn off the battery severe injury or death. NEVER switch (if equipped) or wear jewelry, unbuttoned disconnect the negative cuffs, ties or loose fitting battery cable before servicing the clothing and ALWAYS tie long equipment.
- Page 35 MAINTENANCE NOTICE CAUTION Always tighten components to the specified Slipping and Tripping Hazard torque. Loose parts can cause equipment Ensure that adequate floor damage or cause it to operate improperly. space is set aside for servicing marine generator. The floor Only use replacement parts specified.
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Page 36: Torque Charts
MAINTENANCE TORQUE CHARTS Standard Torque Chart (Generator) Thread Size x Pitch mm M6x1.0 M8x1.25 M10x1.5 M12x1.75 Tightening Aluminum N·m 8.8 ± 1.0 20.6 ± 2.0 39.2 ± 2.0 70.6 ± 4.9 Torque kgf·m 0.9 ± 0.1 2.1 ± 0.2 4.0 ± 0.2 7.2 ±... -
Page 37: Changing Fuses
MAINTENANCE CHANGING FUSES Replace with a new fuse of the specified rating. There are two or four fuses in the marine Fuse Specification generator system, depending on the 250V-5A : 5mm x 20 mm number of power boxes installed. One is Install cap and tighten with a located on each control panel and one on screwdriver. -
Page 38: Changing Indicator Leds
MAINTENANCE CHANGING INDICATOR LEDS Disconnect battery cables, beginning with negative (-) cable first, or turn battery master switch (if equipped) to OFF. Disconnect the appropriate control panel harness from the LED. 0004651 Pull the LED while pushing the upper and lower tabs. Align the tabs of the new LED and install. -
Page 39: Troubleshooting
If the thermal switch is damaged, see your authorized Yanmar marine dealer or distributor. Faulty switch Check the switch. If the switch is faulty, replace the switch. - Page 40 NOTICE: NEVER allow the system to run when a warning indicator is illuminated. Damage to equipment may result. Others See your authorized Yanmar marine dealer or distributor. KMG65E Operation Manual...
- Page 41 TROUBLESHOOTING Output voltage decrease. Insufficient MORE SPEED engine speed. OVERLOAD Gen Temp. Inv Temp. MORE SPEED The lighting time varies Load is too large. according to the load size. OVERLOAD Gen Temp. Inv Temp. MORE SPEED OVERLOAD Gen Temp. Inv Temp. Temperature of The lighting time is MORE SPEED...
- Page 42 TROUBLESHOOTING This Page Intentionally Left Blank KMG65E Operation Manual...
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Page 43: Specifications
Applicable Marine Gear or Sail SD50 KM35A(2), KM35P Drive Model Applicable Engine Model 3JH4E, 4JH4E Not applicable to other Yanmar engines Permissible Input Speed of 3500 rpm Generator Applicable Standard (EMC) EC Council Directive 89/336/EEC as Last Amended By EC Directive 93/68/EEC... -
Page 44: Engine Speed Versus Power Output
SPECIFICATIONS System Specifications Items Model Number Remarks KMG65E-S3 KMG65E-S6 KMG65E-K3 KMG65E-K6 Quantity of — Connected Power Box(es) Continuous 6.0 (3.0 and 3.0) Output 6.0 (3.0 and 3.0) Power Factor — Maximum Output 6.4 (3.2 and 3.2) Output for Engine See Figure 1 Speed Start / Stop —... -
Page 45: System Diagrams
SPECIFICATIONS SYSTEM DIAGRAMS Power Box and Control Panel 340[13.39] 340[13.39] 320[14.17] 320[14.17] 100[3.94] 0004623 Figure 2 Unit: mm (inch) KMG65E Operation Manual... -
Page 46: Wiring Diagram
SPECIFICATIONS Wiring Diagram 0004624 Figure 3 KMG65E Operation Manual...
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