KMG series OPERATION MANUAL KMG65E-S3 KMG65E-S6 KMG65E-K3 KMG65E-K6 P/N: 0AKMG-G00100 MARINE GENERATOR
Disclaimers: All information, illustrations and specifications in this manual are based on the latest information available at the time of publishing. The illustrations used in this manual are intended as representative reference views only. Moreover, because of our continuous product improvement policy, we may modify information, illustrations and / or specifications to explain and / or exemplify a product, service or maintenance improvement.
TABLE OF CONTENTS Page Introduction .............................................................. 1 Record of Ownership .............................................. 2 Safety ....................................................................... 3 Safety Precautions ................................................. General Information ......................................... Before You Operate ......................................... During Operation and Maintenance .....................
TABLE OF CONTENTS Standard Torque Chart (Generator) .................... 32 Changing Fuses ................................................... 33 Changing Indicator LEDs ........................................ 34 Troubleshooting ....................................................... 35 Troubleshooting Chart ........................................... 35 Specifications .......................................................... 39 General Specifications ...........................................
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.
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.
SAFETY Yanmar considers safety of great importance and recommends that anyone that comes into close contact with its products, such as those who install, operate, maintain or service Yanmar products, exercise care, common sense and comply with the safety information in this manual and on the machine’s safety decals. Keep the decals from becoming dirty or torn and replace them if they are lost or damaged.
SAFETY General Information ! DANGER There is no substitute for common sense and careful practices. Improper practices or carelessness can cause burns, cuts, mutilation, asphyxiation, other bodily injury or death. This information contains general safety precautions and guidelines that must be followed to reduce risk to personal safety. Special safety precautions are listed in specific procedures. Read and understand all of the safety precautions before operation or performing repairs or maintenance.
SAFETY During Operation and Maintenance ! DANGER The safety messages that follow have DANGER level hazards. NEVER connect medical appliances such as a life-support system. This system is not rated to power medical devices of that type. NEVER connect a welding machine to the marine generator. This marine generator system is not rated for a welding machine. Fire Hazard Keep fire extinguishers handy in case of fire. Clearly indicate the location of the fire extinguishers with a safety sign.
SAFETY ! DANGER NEVER connect the marine generator output to external power (shore power). A three-way switch must be installed by a licensed electrician to use shore power. NEVER connect tools or appliances that exceed 230V / 50 Hz to the marine generator system. If equipped with two power boxes, never connect the two boxes together. ! WARNING The safety messages that follow have WARNING level hazards. Explosion Hazard Avoid serious personal injury or equipment damage.
SAFETY ! WARNING Exposure Hazard To avoid injury, ALWAYS wear personal protective equipment including appropriate clothing, gloves, work shoes, eye and hearing protection as required by the task at hand. Entanglement Hazard NEVER leave the key in the key switch when you are servicing the marine generator. Someone may accidentally start the engine and not realize you are servicing it. Exhaust Hazard Avoid serious injury or death.
SAFETY ! CAUTION The safety messages that follow have CAUTION level hazards. Poor Lighting Hazard Avoid personal injury or equipment damage. Ensure that the work area is adequately illuminated. ALWAYS install wire cages on portable safety lamps. Tool Hazard Avoid personal injury or equipment damage. ALWAYS use tools appropriate for the task at hand and use the correct size tool for loosening or tightening machine parts. Flying Object Hazard Avoid personal injury.
SAFETY NOTICE Observe the following environmental operating conditions to maintain marine generator performance and avoid premature marine generator wear: • NEVER run the marine generator if the engine room or power box room temperature is above +50˚C (+122˚F). • 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.
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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. 12V DC are required for each power box.
PRODUCT OVERVIEW TV Hair Dryer PC Microwave oven Power box 3kVA Power box 3kVA Panel Panel 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.
PRODUCT OVERVIEW Marine Generator Designation KMG 6 5 E Specification of output E: Europe (230V / 50Hz) Size of generator Capacity of generator Design of generator KMG65E Models Model Name KMG65E- Applicable Engine Applicable Transmission Total System Output S3 3JH4E 4JH4E SD50 3kVA S6 K3 6kVA KM35P, KM35A(2) K6 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.
PRODUCT OVERVIEW KM35A(2) 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). • SD50: Only models which have holes in the mounting flange (Figure 2).
PRODUCT OVERVIEW COMPONENT IDENTIFICATION Main Components (1) (2) (4) (5) (7) (3) (7) (3) (6) 3kVA (1) (2) (2) (3) (4) (5) (6) 6kVA 1– 2– 3– 4– Generator Power Box Control Panel Terminal Box 0004608 Figure 3 5 – Generator Harness 6 – Control Panel Power Harness 7 – Battery Harness KMG65E Operation Manual 15
PRODUCT OVERVIEW Generator KMG65E-S3 and KMG65E-S6 (1) (2) (3) (4) (5) (6) (7) (8) (a) (9) (10) (b) (11) (12) (14) ( (13) 0004609 Figure 4 KMG65E-K3 and KMG65E-K6 (1) (2) (3) (15) (16) (7) (8) (9) (10) (17) 16 (18) (19) Figure 5 KMG65E Operation Manual 0004610
PRODUCT OVERVIEW 1– 2– 3– 4– 5– 6– 7– Coupling 11 – Bolts (M8x25mm) (6 used) Generator Assembly 12 – Stud Bolts (M8) (2 used) Generator Output Cable 13 – Nuts (2 used) Bolts (M8x25mm) (4 used) Flange (Sail Drive) 14 – Flexible Coupling (Vulkan Torflex Fan (Sail Drive) Boatbuilder Supplied) Plate (Sail Drive) a. Sail Drive Cooling Pipe Bolts (M8x25mm) and Washers b.
PRODUCT OVERVIEW Power Box (1) (5) (6) (7) (2) (8) (3) (9) (4) (10) 0004611 Figure 6 Power Box 6 – 230V Output Port (2-pin) Input Port from Generator (3-pin) 7 – Control Signal Port from Panel (6-pin) Earth (Ground) Terminal for Input 8 – Fuse Holder Input Port of Generator Thermal 9 – Ground (Earth) Terminal Switch 10 – Specification Decal 5 – Nameplate 1– 2– 3– 4– 18 KMG65E Operation Manual
PRODUCT OVERVIEW NAMEPLATE Power Box The power box nameplate is installed on the side of the power box. Generator The generator nameplate is installed on the generator housing. (1) PRODUCT No. M FG .N o. (2) (1) M O D EL M FG .N o. KANZAKI KOKYUKOKI MFG CO., LTD. (2) MADE IN JAPAN 0004613 Figure 8 1 – Power Box Model Number 2 – Power Box Serial Number KANZAKI KOKYUKOKI MFG CO., LTD.
PRODUCT OVERVIEW Control Panel (1) (5) (2) (6) (3) (7) (4) 0004614 Figure 9 1– 2– 3– 4– 5– 6– 7– Insufficient Engine Speed Warning Indicator Power Box is Running Indicator Power Box Temperature Warning Indicator Generator Temperature Warning Indicator Power Box ON / OFF Switch Overload Warning Indicator Fuse • Insufficient Engine Speed Warning Indicator (Figure 9, (1)): A red LED that illuminates when engine speed is too low for the load.
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.
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OPERATION MARINE GENERATOR OPERATION This section describes the procedure for performing daily checks and the operating procedures. ! WARNING Sever Hazard Rotating parts can cause severe injury or death. NEVER wear jewelry, unbuttoned cuffs, ties or loose fitting clothing and ALWAYS tie long hair back when working near moving / rotating parts such as the flywheel or PTO shaft. Keep hands, feet and tools away from all moving parts. Avoid continuous use of engine under heavy load.
OPERATION ! CAUTION Periodic maintenance prevents unexpected downtime, reduces the number of accidents due to poor machine performance and helps extend the life of the marine generator. If any problem is noted during the visual check, the necessary corrective action should be taken before you operate the marine generator. DAILY CHECKS Before operating the marine generating system, make sure it is in good operating condition.
OPERATION Starting the System 1. Ensure the power box switch on the control panel is OFF. 2. 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. 3. When tools or appliances that draw heavy loads, such as a pump or air conditioner, are started, the necessary starting current required is greater than the rated load.
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. Indicator MORE SPEED OFF GenTemp. InvTemp.
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. 1. Turn all tool or appliances OFF before shutting down the marine generator. WARNING! NEVER restart the engine without turning all tools or appliances to OFF.
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MAINTENANCE This section of the Operation Manual describes the procedures for proper care and maintenance of this system. ! DANGER Explosion Hazard NEVER check the remaining battery charge by shorting out the terminals. ALWAYS use a hydrometer to check the remaining battery charge. If the battery electrolyte is frozen, slowly warm the battery before you recharge it. ALWAYS disconnect the external power line from the boat and shut off all the power box output breakers before servicing the system.
MAINTENANCE ! WARNING Sever Hazard Rotating parts can cause severe injury or death. NEVER wear jewelry, unbuttoned cuffs, ties or loose fitting clothing and ALWAYS tie long hair back when working near moving / rotating parts such as the flywheel or PTO shaft. Keep hands, feet and tools away from all moving parts. Avoid personal injury or equipment damage. Always remove any tools or shop rags used during maintenance from the area before operation.
MAINTENANCE ! CAUTION Slipping and Tripping Hazard Ensure that adequate floor space is set aside for servicing marine generator. The floor space must be flat and free of holes. Keep floor free of dust, mud, spilled liquids and parts to help prevent slipping and tripping. NOTICE Always tighten components to the specified torque. Loose parts can cause equipment damage or cause it to operate improperly. Only use replacement parts specified. Other replacement parts may affect warranty coverage.
MAINTENANCE TORQUE CHARTS Standard Torque Chart (Generator) Thread Size x Pitch mm Tightening Torque Aluminum Cast Iron or Steel 32 M6x1.0 M8x1.25 M10x1.5 M12x1.75 N·m 8.8 ± 1.0 20.6 ± 2.0 39.2 ± 2.0 70.6 ± 4.9 kgf·m 0.9 ± 0.1 2.1 ± 0.2 4.0 ± 0.2 7.2 ± 0.5 N·m 10.8 ± 1.0 25.5 ± 2.0 49.1 ± 4.5 88.3 ± 10.0 kgf·m 1.1 ± 0.1 2.6 ± 0.2 5.0 ± 1.0 9.0 ± 1.
MAINTENANCE CHANGING FUSES 4. There are two or four fuses in the marine generator system, depending on the number of power boxes installed. One is located on each control panel and one on each power box. All fuses are rated the same. Replace with a new fuse of the specified rating. Fuse Specification 250V-5A : 5mm x 20 mm 5. Install cap and tighten with a screwdriver. Do not over-tighten. (1) 0004649 (1) 0004650 1. 2. 3.
MAINTENANCE CHANGING INDICATOR LEDS 1. 2. 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 3. 4. 5. 6. 34 Pull the LED while pushing the upper and lower tabs. Align the tabs of the new LED and install. Connect the panel harness. Connect the battery cables, beginning with negative (-) cable first, or turn the battery master switch (if equipped) to ON.
TROUBLESHOOTING TROUBLESHOOTING CHART No. 1 Problem System does not start Symptom Power Box is Running indicator does NOT light Possible Cause Corrective Action 12V DC wiring is disconnected or incorrect Check the cables and cable connections. 2 Battery is too weak Check the battery voltage. This system needs approximately 10 to 12V DC. The system can be started if there is enough battery capacity to start the engine.
TROUBLESHOOTING No. Possible Cause Corrective Action Wiring of power lines is disconnected or incorrect Check the cables and generator output and power box output cable connections. Tools or appliances do not work Check the tools or appliances. Insufficient Engine Speed indicator is illuminated Engine speed is too low Increase the engine speed until the indicator turns off.
TROUBLESHOOTING Output voltage decrease. Insufficient engine speed. MORE SPEED OFF GenTemp. InvTemp. OVERLOAD MORE SPEED OFF Load is too large. MORE SPEED OFF GenTemp. InvTemp. GenTemp. InvTemp. ON ON OVERLOAD The lighting time varies according to the load size. ON OVERLOAD Temperature of generator is too high. MORE SPEED OFF GenTemp. InvTemp. PANEL ON OVERLOAD The lighting time is a few seconds. MORE SPEED OFF GenTemp. InvTemp. ON OVERLOAD System stops.
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SPECIFICATIONS GENERAL SPECIFICATIONS Marine Generator Specifications Items Model Number KMG65E-S3 KMG65E-S6 System Output Weight Dimension of Main Components Voltage 230V AC Frequency 50 Hz Form and Phase Sine wave, Single Generator 21 kg (with fan) (46 lb with fan) 13 kg (28.6 lb) Generator SAE #5 x 105 mm Power Box 320 x 360 x 145 mm (12.6 x 14.2 x 5.7 in.
SPECIFICATIONS System Specifications Items Model Number Quantity of Connected Power Box(es) Continuous Output Power Factor KMG65E-S6 KMG65E-K6 — 1 2 kVA 3.0 6.0 (3.0 and 3.0) kW 3.0 6.0 (3.0 and 3.0) — Maximum Output 1.0 kVA Output for Engine Speed 3.2 6.4 (3.2 and 3.
SPECIFICATIONS SYSTEM DIAGRAMS 220[8.66] 320[12.60] Power Box and Control Panel 340[13.39] 86[3.39] 100[3.94] 145[5.71] 320[14.17] 100[3.
1 2 3 4 5 6 7 8 (R):U1 Ge OUTPUT (L): W1 Ge OUTPUT 42 Figure 3 KMG65E Operation Manual GENERATOR (W): V1 Ge OUTPUT (R): U2 Ge OUTPUT (W): W2 Ge OUTPUT (L): V2 Ge OUTPUT (O): THERMAL S/W (O): THERMAL S/W <#1> GROUND EARTH CACABLE (AWG16-18) <#1> (AWG 16 - 18) NAMENAME <#1> MARK:CUSTMER'S CUSTOMER’S PREPARATION PARTS <#1>MARK: PREPARATION PARTS CODE CODE 2M 196530-05340 GENERATOR HARNESS ⑥2 196530-05340 196530-05310 TERMINAL TERMINAL BOX BOX ⑥1 196530-05310 NO.
