OPERATION MANUAL - yanmar.fi · • Keep this Operation Manual in a convenient place for easy access. • If this Operation Manual is lost or damaged, order a new one from your authorized

KMGseries

OPERATION MANUALKMG65E-S3KMG65E-S6KMG65E-K3KMG65E-K6

MARINEGENERATOR

P/N: 0AKMG-G00100

Disclaimers:All information, illustrations and specifications in this manual are based on the latestinformation available at the time of publishing. The illustrations used in this manual areintended as representative reference views only. Moreover, because of our continuousproduct improvement policy, we may modify information, illustrations and / or specificationsto explain and / or exemplify a product, service or maintenance improvement. We reservethe right to make any change at any time without notice. Yanmar and areregistered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or othercountries.All Rights Reserved:No part of this publication may be reproduced or used in any form by any means - graphic,electronic, or mechanical, including photocopying, recording, taping, or information storageand retrieval systems - without the written permission of Yanmar Marine International.© 2006 Yanmar Marine International

1106

ii KMG65E Operation Manual

TABLE OFCONTENTS

PageIntroduction .............................................................. 1

Record of Ownership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Safety ....................................................................... 3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Before You Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4During Operation and Maintenance . . . . . . . . . . . . . . . . . . . . . 5

Product Overview ..................................................... 11Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Marine Generator Designation . . . . . . . . . . . . . . . . . . . . . . . . . . 13KMG65E Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Main Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Power Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Power Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Operation ................................................................ 23

Marine Generator Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Daily Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Starting the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Checks During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Stopping the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Maintenance ............................................................ 29Torque Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

KMG65E Operation Manual iii

Standard Torque Chart (Generator) . . . . . . . . . . . . . . . . . . . . 32Changing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Changing Indicator LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Troubleshooting ....................................................... 35Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Specifications .......................................................... 39General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Engine Speed Versus Power Output . . . . . . . . . . . . . . . . . . . 40System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Power Box and Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

TABLE OF CONTENTS

iv KMG65E Operation Manual

INTRODUCTIONWelcome to the world of Yanmar Marine!Yanmar Marine offers systems andaccessories for all types of boats, fromrunabouts to sailboats, and from cruisers tomega yachts. In marine leisure boating, theworldwide reputation of Yanmar Marine issecond to none.To help you enjoy your Yanmar Marineproducts for many years to come, pleasefollow these recommendations:• Read and understand this Operation

Manual before you install / operate yourboat to ensure that you follow safeinstalling / operating practices andmaintenance procedures.

• Keep this Operation Manual in aconvenient place for easy access.

• If this Operation Manual is lost ordamaged, order a new one from yourauthorized Yanmar marine dealer ordistributor.

• Make sure this manual is transferred tosubsequent owners. This manual shouldbe considered a permanent part of theboat and remain with it.

• Constant efforts are made to improve thequality and performance of Yanmarproducts, so some details included in thisOperation Manual may differ slightly fromyour marine generating system. If youhave any questions about thesedifferences, please contact yourauthorized Yanmar marine dealer ordistributor.

KMG65E Operation Manual 1

RECORD OF OWNERSHIPTake a few moments to record the information you need when you contact Yanmar forservice, parts or literature.

Marine Generating System Model:

Marine Generating System Serial No.:

Date Purchased:

Dealer:

Dealer Phone:

INTRODUCTION

2 KMG65E Operation Manual

SAFETYYanmar considers safety of greatimportance and recommends that anyonethat comes into close contact with itsproducts, such as those who install,operate, maintain or service Yanmarproducts, exercise care, common senseand comply with the safety information inthis manual and on the machine’s safetydecals. Keep the decals from becomingdirty or torn and replace them if they are lostor damaged. Also, if you need to replace apart that has a decal attached to it, makesure you order the new part and decal at thesame time.

!

This safety alert symbol appearswith most safety statements. Itmeans attention, become alert,your safety is involved! Pleaseread and abide by the messagethat follows the safety alertsymbol.

SAFETY PRECAUTIONS! DANGER

Indicates a hazardous situation which, ifnot avoided, will result in death orserious injury.

! WARNINGIndicates a hazardous situation which, ifnot avoided, could result in death orserious injury.

! CAUTIONIndicates a hazardous situation which, ifnot avoided, could result in minor ormoderate injury.

NOTICEIndicates a situation which can causedamage to the machine, personal propertyand / or the environment or cause theequipment to operate improperly.


General Information! DANGER

There is no substitute for common senseand careful practices. Improper practices orcarelessness can cause burns, cuts,mutilation, asphyxiation, other bodily injuryor death. This information contains generalsafety precautions and guidelines that mustbe followed to reduce risk to personal safety.Special safety precautions are listed inspecific procedures. Read and understandall of the safety precautions before operationor performing repairs or maintenance.

Before You Operate! DANGER

The safety message that follows has aDANGER level hazard.

NEVER permit anyone toinstall or operate the marinegenerator without propertraining.

• Read and understand this OperationManual before you operate or service themarine generator to ensure that you followsafe operating practices andmaintenance procedures.

• Safety signs and decals are additionalreminders for safe operating andmaintenance techniques.

• See your authorized Yanmar marinedealer or distributor for additional training.

SAFETY


During Operation andMaintenance

! DANGERThe safety messages that follow haveDANGER level hazards.NEVER connect medical appliances suchas a life-support system. This system is notrated to power medical devices of that type.

NEVER connect a welding machine to themarine generator. This marine generatorsystem is not rated for a welding machine.

Fire HazardKeep fire extinguishers handyin case of fire. Clearly indicatethe location of the fireextinguishers with a safetysign.

Ensure that the type of fire extinguishers areappropriate for material that might catch fire.Check with local authorities.

Have all fire extinguishers checkedperiodically for proper operation and / orreadiness.

Post evacuation routes prominently.Periodically conduct fire drills.

Ensure that appropriate fire detection andextinguishing equipment are installed andchecked periodically for proper operation.Check with local authorities.

Electrical HazardNEVER start the enginebefore the wiring is completelyinstalled.

ALWAYS disconnect the external power linefrom the boat and shut all power boxbreakers OFF before you begin to servicethe marine generator.

ALWAYS check the electrical harnesses forcracks, abrasions and damaged orcorroded connectors. ALWAYS keeps theconnectors and terminals clean.

ALWAYS have a licensed electricianconnect this system to the utility circuit.Improper installation can causeelectrocution or fire.

NEVER operate this system if:• The engine misfires often• Powered tools or appliances overheat• Electrical output drops• The generator is sparking• Engine vibration is high• Any of the electrical receptacles are

damaged• Any of the cables or wires are damaged

NEVER handle live terminals or bare wires.Power the unit down and contact a licensedelectrician.

NEVER operate the power box nearstanding water or snow.

NEVER use this system in highly conductiveareas such as on metal decking or near steelwork.

ALWAYS use grounded extension cords.NEVER use damaged or frayed extensioncords.

NEVER ground the marine generatorsystem to a pipe that carries combustiblematerials or gases.

NEVER touch the marine generator systemif it is wet or touch it with wet hands.

ALWAYS ground the power box. Ensure alength of heavy wire exists between thepower box ground terminal and an externalground.

SAFETY


! DANGERNEVER connect the marine generatoroutput to external power (shore power). Athree-way switch must be installed by alicensed electrician to use shore power.

NEVER connect tools or appliances thatexceed 230V / 50 Hz to the marine generatorsystem.

If equipped with two power boxes, neverconnect the two boxes together.

! WARNINGThe safety messages that follow haveWARNING level hazards.

Explosion HazardAvoid serious personal injuryor equipment damage. Whilethe engine is running or thebattery is charging, hydrogengas is being produced and can

be easily ignited. Keep the area around thebattery well-ventilated and keep sparks,open flame and any other form of ignition outof the area.

Diesel fuel is flammable and explosiveunder certain conditions.

Wipe up all spills immediately.

Fire HazardAvoid injury or equipmentdamage from fire. Undersizedwiring systems can cause anelectrical fire.

Sever HazardALWAYS ensure allbystanders are clear of thearea before starting theengine. Keep children andpets away while the engine is

operating.

Alcohol and Drug HazardNEVER operate the enginewhile under the influence ofalcohol or drugs or whenfeeling ill.

SAFETY


! WARNINGExposure Hazard

To avoid injury, ALWAYSwear personal protectiveequipment includingappropriate clothing,gloves, work shoes, eye

and hearing protection as required by thetask at hand.

Entanglement HazardNEVER leave the key in thekey switch when you areservicing the marinegenerator. Someone mayaccidentally start the engine

and not realize you are servicing it.

Avoid personal injury. NEVER operate theengine while wearing a headset to listen tomusic or radio because it will be difficult tohear the warning signals.

Burn HazardAvoid serious injury. Some ofthe engine and marine gearsurfaces become very hotduring operation and shortlyafter shut-down. Keep handsand other body parts away

from hot surfaces.

Sudden Movement HazardAvoid personal injury. ALWAYS stop theengine before beginning service.ALWAYS ensure tools or appliances aredisconnected from the system before theengine is started.

Exhaust HazardAvoid serious injury or death.NEVER block windows, vents,or other means of ventilation ifthe engine is operating in anenclosed area. All internal

combustion engines create carbonmonoxide gas during operation and specialprecautions are required to avoid carbonmonoxide poisoning.

ALWAYS drain the bilge before operatingthe marine generator. NEVER allow themarine generator to get wet.

SAFETY


! CAUTIONThe safety messages that follow haveCAUTION level hazards.

Poor Lighting HazardAvoid personal injury or equipment damage.Ensure that the work area is adequatelyilluminated. ALWAYS install wire cages onportable safety lamps.

Tool HazardAvoid personal injury or equipment damage.ALWAYS use tools appropriate for the taskat hand and use the correct size tool forloosening or tightening machine parts.

Flying Object HazardAvoid personal injury.ALWAYS wear eye protectionwhen servicing the engine orwhen using compressed air orhigh-pressure water. Dust,

flying debris, compressed air, pressurizedwater or steam may injure your eyes.

NEVER open the power box. There are nouser serviceable components. Contact yourauthorized Yanmar marine dealer ordistributor.

NOTICEThe safety messages that follow haveNOTICE level hazards.It is important to perform daily checks aslisted in this Operation Manual.Periodic maintenance prevents unexpecteddowntime, reduces the number of accidentsdue to poor engine or marine gearperformance and can help extend the life ofthe engine and marine gear.

ALWAYS be environmentallyresponsible.

Follow the guidelines of the EPA or othergovernmental agencies for the properdisposal of hazardous materials such aslubrication oil, diesel fuel and enginecoolant. Consult the local authorities orreclamation facility.

NEVER dispose of hazardous materials bydumping them into a sewer, on the groundor into ground water or waterways.

SAFETY


NOTICEObserve the following environmentaloperating conditions to maintain marinegenerator performance and avoidpremature marine generator wear:• NEVER run the marine generator if the

engine room or power box roomtemperature is above +50˚C (+122˚F).

• If the temperature exceeds +50˚C(+122˚F), the generator or power box mayoverheat and cause the marine generatorto shut down for protection.

• Contact your authorized Yanmar marinedealer or distributor if the marinegenerator will be operated in temperatureextremes.

NEVER attempt to modify the marinegenerator’s design or safety features.

Observe the following environmentaloperating conditions to maintain marinegenerator performance and avoidpremature marine generator wear:• Avoid operating in extremely dusty

conditions.• Avoid operating in the presence of

chemical gases or fumes.• Avoid getting the marine generator wet.• Air temperature affects the generator

output. Output drops 1% for each 10°Ctemperature rise above 15.6°C.

Most electrical appliances require morethan their rated wattage for start-up. Makesure total wattage of electrical load does notexceed rated wattage of the system.This system is not rated to power an entirehome. Most home electrical service requiresmore than 60A.

SAFETY


This Page Intentionally Left Blank

SAFETY


PRODUCT OVERVIEWPRODUCT OVERVIEWThis marine generator system outputsalternating current (230V / 50Hz) throughone or two power boxes. The current flowsfrom the generator that is installed betweenthe main engine and the transmission. Thissystem can output current only when themain engine is running and all the controlpanels are turned ON. 12V DC are requiredfor each power box.


Power box3kVA

Power box3kVA

Panel

Generator

To 12V battery

TV Hair Dryer PC Microwave oven

Panel

Power box3kVA

Power box3kVA

Panel

Generator

To 12V battery

TV Hair Dryer PC Microwave oven

Panel

0004606

Figure 1Note: Equipment such as the television(TV), hair dryer, microwave oven andpersonal computer (PC) are not included inthis system.

PRODUCT OVERVIEW


Marine Generator DesignationKMG 6 5 E Specification of output

E: Europe (230V / 50Hz)

Size of generator

Capacity of generator

Design of generator

KMG65E ModelsModel Name

KMG65E-Applicable Engine Applicable Transmission Total System Output

S3 3JH4E4JH4E

SD50 3kVAS6 6kVAK3 KM35P, KM35A(2) 3kVAK6 6kVA

Note: The KMG65E is only available for the engines and transmission listed above. See yourauthorized Yanmar marine dealer or distributor for more information.

PRODUCT OVERVIEW


KM35A(2) SD50KM35A(2) SD50

0004607

Figure 2Applicable Marine Gears and Sail DrivesThe 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 IDENTIFICATIONMain Components

(7)

6kVA

(6)

(7)

(6)

(2)

(3)

(1)

(4)

3kVA

(7)

(5)

(6)

(3)

(2)

(3)

(1)

(4)(7)

(6)(5)

(2)

0004608

Figure 31 – Generator2 – Power Box3 – Control Panel4 – Terminal Box

5 – Generator Harness6 – Control Panel Power Harness7 – Battery Harness

PRODUCT OVERVIEW


GeneratorKMG65E-S3 and KMG65E-S6

(1)(2)

(7)

(11)

(14) (

(8)

(12)

(b)

(3)

(4)

(13)

(9)

(10)

(6)

(a)

(5)

0004609

Figure 4KMG65E-K3 and KMG65E-K6

0004610

(2)

(15)

(7)

(9)

(10)

(18) (19)

(8)

(17)

(1)

(3)

(16)

Figure 5

PRODUCT OVERVIEW


1 – Coupling2 – Generator Assembly3 – Generator Output Cable4 – Flange (Sail Drive)5 – Fan (Sail Drive)6 – Plate (Sail Drive)7 – Bolts (M8x25mm) and Washers

(6 used)8 – Nameplate9 – Bolts (M8x20mm) (6 used)

Stud Bolts (M8x22mm) andNuts (M8) (2 used)

10 – Bolts (M6x16mm) (6 used)

11 – Bolts (M8x25mm) (6 used)12 – Stud Bolts (M8) (2 used)13 – Nuts (2 used)

Bolts (M8x25mm) (4 used)14 – Flexible Coupling (Vulkan Torflex -

Boatbuilder Supplied)a. Sail Drive Cooling Pipeb. Hose Clamp (35 mm) (2 used)

15 – Marine Gear Flange16 – Fan (Boatbuilder Supplied)17 – Bolts (M8 x 35mm) (6 used)18 – Damper Disk (Boatbuilder Supplied)19 – Bolts (M8x12mm) (6 used)

Note: No. 14, 16 and 18 are included withthe engine and marine gear or sail driveassemblies.

PRODUCT OVERVIEW


Power Box

(2)

(3)

(4)

(6)

(7)

(8)

(9)

(10)

(5)

(1)

0004611

Figure 61 – Power Box2 – Input Port from Generator (3-pin)3 – Earth (Ground) Terminal for Input4 – Input Port of Generator Thermal

Switch5 – Nameplate

6 – 230V Output Port (2-pin)7 – Control Signal Port from Panel (6-pin)8 – Fuse Holder9 – Ground (Earth) Terminal10 – Specification Decal

PRODUCT OVERVIEW


NAMEPLATEGeneratorThe generator nameplate is installed on thegenerator housing.

M O D EL

M FG .No.

KANZAKI KOKYUKOKI MFG CO., LTD.MADE IN JAPAN

(2)

(1)

0004612

Figure 71 – Generator Model2 – Generator Serial Number

Power BoxThe power box nameplate is installed on theside of the power box.

PRODUCT No.

M FG .No.

KANZAKI KOKYUKOKI MFG CO., LTD.MADE IN JAPAN

(2)

(1)

0004613

Figure 81 – Power Box Model Number2 – Power Box Serial Number

PRODUCT OVERVIEW


Control Panel

(1)

(2)

(3)

(4)

(5)

(6)

(7)

0004614

Figure 91 – Insufficient Engine Speed Warning Indicator2 – Power Box is Running Indicator3 – Power Box Temperature Warning Indicator4 – Generator Temperature Warning Indicator5 – Power Box ON / OFF Switch6 – Overload Warning Indicator7 – Fuse• Insufficient Engine Speed Warning Indicator (Figure 9, (1)): A red LED that illuminates

when engine speed is too low for the load.• Power Box is Running Indicator (Figure 9, (2)): A green LED that illuminates when the

power box main switch is ON.• Power Box Temperature Warning Indicator (Figure 9, (3)): A red LED that illuminates

when the power box (inverter) temperature is too high.• Generator Temperature Warning Indicator (Figure 9, (4)): A red LED that illuminates when

the generator temperature is too high.• Power Box ON / OFF Switch (Figure 9, (5)): ON / OFF switch for the power box.• Overload Warning Indicator (Figure 9, (6)): Two red LEDs illuminate when the Insufficient

Engine Speed Warning and the Power Box Temperature Warning Indicators are lit.• Fuse (Figure 9, (7)): For 12V DC LineSee Checks During Operation on page 26 for operation information.

PRODUCT OVERVIEW


TECHNICAL DATAInstallation should be done only by aqualified technician. See your authorizedYanmar marine dealer or distributor.NOTICE: The marine generator must bealigned and installed to the engine andtransmission correctly or equipmentdamage will result.

Output Voltage 230VOutput Frequency 50HzMaximum Input Speed 3500 min-1 (rpm)

PRODUCT OVERVIEW



PRODUCT OVERVIEW


OPERATIONMARINE GENERATOROPERATIONThis section describes the procedure forperforming daily checks and the operatingprocedures.

! WARNINGSever HazardRotating parts can causesevere injury or death. NEVERwear jewelry, unbuttonedcuffs, ties or loose fittingclothing and ALWAYS tie long

hair back when working near moving /rotating parts such as the flywheel or PTOshaft. Keep hands, feet and tools away fromall moving parts.

Avoid continuous use of engine under heavyload. When electrical load and propellerload are both operated at engine ratingspeed, the engine may become overloaded.Yanmar recommends operating it at lessthan 2500 rpm.

Shift the marine gear into NEUTRAL anytime the engine is at idle.


! CAUTIONPeriodic maintenance prevents unexpecteddowntime, reduces the number of accidentsdue to poor machine performance and helpsextend the life of the marine generator.If any problem is noted during the visualcheck, the necessary corrective actionshould be taken before you operate themarine generator.

DAILY CHECKSBefore operating the marine generatingsystem, make sure it is in good operatingcondition.Make sure you check the following itemsand have any repairs completed before youoperate the marine generating system:• Before operating, check all wiring

connections. Ensure the connections aretight and there is no wear or damage tothe wiring harnesses or connectors.

• Ensure no warning LEDs are illuminatedwhen the marine generator is running.

• Ensure no abnormal noise is heard whilethe marine generator is running.

CAUTION! If any problem is notedduring the visual check, the necessarycorrective action should be taken beforeyou operate the marine generator.

OPERATION


Starting the System1. Ensure the power box switch on the

control panel is OFF.2. Start the engine and set the engine

speed according to the electricequipment you will use.

Note: See Engine Speed Versus PowerOutput on page 40 for relationshipbetween engine speed and power output.

When tools or appliances that drawheavy loads, such as a pump or airconditioner, are started, the necessarystarting current required is greater thanthe rated load. Set the engine speed at2200 to 2500 rpm to handle the largerdraw.

3. Turn the power box ON / OFF switch toON. Ensure the Power Box is Runningindicator illuminates (Figure 1). Whenlit, 230V are available and the system isready for use.

0004615

Inv Temp.

MORE SPEED

OVERLOAD

OFF ON

Gen Temp.

Figure 1Note: When restarting tools or appliancesthat have a heavy draw, such as an airconditioner, ensure the engine rpm issufficient to handle the additional load. SeeGeneral Specifications on page 39.

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 State Remarks

Inv Temp.

MORE SPEED

OVERLOAD

OFF ON

Gen Temp.

0004616

Power Box isRunning Indicator

System is runningnormally

Inv Temp.

MORE SPEED

OVERLOAD

OFF ON

Gen Temp.

0004617

Insufficient EngineSpeed WarningIndicator

Insufficient enginespeed

Increase engine speedor decrease load.

Inv Temp.

MORE SPEED

OVERLOAD

OFF ON

Gen Temp.

0004618

Insufficient EngineSpeed WarningIndicator andGeneratorTemperatureWarning Indicator

Overload The timer starts and thesystem will stopautomaticallyaccording to the loadlevel.

Inv Temp.

MORE SPEED

OVERLOAD

OFF ON

Gen Temp.

0004619

GeneratorTemperatureWarning Indicator

Generator temperatureis too high

The system stopsautomatically. Correctthe problem and resetthe system.

Inv Temp.

MORE SPEED

OVERLOAD

OFF ON

Gen Temp.

0004620

Power BoxTemperatureWarning Indicator

Power box temperatureis too high

The system stopsautomatically. Correctthe problem and resetthe system.

See Troubleshooting Chart on page 35 to troubleshooting warning LEDs. If the systemstops automatically due to overload or temperature protection function, correct the problemand reset the system by turning the switch OFF and restarting.

OPERATION


Stopping the SystemNOTICE: NEVER turn the power box OFFand stop the engine immediately after a longperiod of operation at heavy load. Decreasethe electrical load and allow system to cooldown before shutting off the power boxswitch ON / OFF switch and stopping theengine.1. Turn all tool or appliances OFF before

shutting down the marine generator.WARNING! NEVER restart theengine without turning all tools orappliances to OFF. Restarting thesystem with tools or appliances ONmay cause unexpected movementof the tools or appliances.

2. Before shutting down the marinegenerator, let the system run at lowspeed for approximately 5 minutes toallow the system to cool down.

Note: Failure to properly cool down thesystem may cause a warning indicator tolight when you restart the system.3. Turn the power box ON / OFF switch on

the control panel(s) to OFF.4. Ensure that Power Box is Running

indicator is OFF.5. Turn the engine OFF.

OPERATION



OPERATION


MAINTENANCEThis section of the Operation Manualdescribes the procedures for proper careand maintenance of this system.

! DANGERExplosion Hazard

NEVER check the remaining battery chargeby shorting out the terminals. ALWAYS usea hydrometer to check the remaining batterycharge.

If the battery electrolyte is frozen, slowlywarm the battery before you recharge it.

ALWAYS disconnect the external power linefrom the boat and shut off all the power boxoutput breakers before servicing thesystem.

Crush HazardALWAYS use liftingequipment with sufficientcapacity to lift marinegenerator.

NEVER support marine generator withequipment not designed to support theweight of the marine generator such aswooden pieces, blocks or by only using ajack.


! WARNINGSever HazardRotating parts can causesevere injury or death. NEVERwear jewelry, unbuttonedcuffs, ties or loose fittingclothing and ALWAYS tie long

hair back when working near moving /rotating parts such as the flywheel or PTOshaft. Keep hands, feet and tools away fromall moving parts.

Avoid personal injury or equipment damage.Always remove any tools or shop rags usedduring maintenance from the area beforeoperation.

Stop the engine before you begin to servicethe marine generator and secure thepropeller so it will not turn.

Entanglement HazardNEVER leave the key in the key switch whenyou are servicing the engine or marinegenerator. Someone may accidentally startthe engine and not realize you are servicingit.

Avoid unexpected equipment movement.Shift the marine gear into the NEUTRALposition any time the engine is at idle.

Electrical Shock HazardAvoid serious personal injuryor equipment damage.ALWAYS turn off the batteryswitch (if equipped) ordisconnect the negative

battery cable before servicing theequipment.

Avoid personal injury or equipment damage.ALWAYS keep the electrical connectorsand terminals clean. Check the electricalharnesses for cracks, abrasions, anddamaged or corroded connectors.

MAINTENANCE


! CAUTIONSlipping and Tripping Hazard

Ensure that adequate floorspace is set aside for servicingmarine generator. The floorspace must be flat and free ofholes.

Keep floor free of dust, mud, spilled liquidsand parts to help prevent slipping andtripping.

NOTICEAlways tighten components to the specifiedtorque. Loose parts can cause equipmentdamage or cause it to operate improperly.

Only use replacement parts specified. Otherreplacement parts may affect warrantycoverage.

NEVER attempt to modify the marinegenerator’s design or safety features.Failure to comply may impair the marinegenerator’s safety and performancecharacteristics and shorten the marinegenerator’s life. Any alterations to thismarine generator may affect the warrantycoverage of your marine generator.

If you remove the battery from the marinegenerator system, insulate the terminal onthe end of the red positive (+) battery cable.Sparks may cause damage of the electroniccircuits.

When you install a battery:• ALWAYS use correct polarity when you

connect the battery cables to the battery.This system uses a negative (-) ground,12V DC starting system.

• ALWAYS ensure battery terminals areclean.

• ALWAYS ensure battery cableconnections are tight.

• ALWAYS shut down the engine beforeremoving or attaching the battery cables.

• ALWAYS disconnect the negative (-)battery cable first. Connect the negative(-) battery cable last.

MAINTENANCE


TORQUE CHARTSStandard Torque Chart(Generator)

Thread Size x Pitch mm M6x1.0 M8x1.25 M10x1.5 M12x1.75TighteningTorque

Aluminum N·m 8.8 ± 1.0 20.6 ± 2.0 39.2 ± 2.0 70.6 ± 4.9kgf·m 0.9 ± 0.1 2.1 ± 0.2 4.0 ± 0.2 7.2 ± 0.5

Cast Iron orSteel

N·m 10.8 ± 1.0 25.5 ± 2.0 49.1 ± 4.5 88.3 ± 10.0kgf·m 1.1 ± 0.1 2.6 ± 0.2 5.0 ± 1.0 9.0 ± 1.0

MAINTENANCE


CHANGING FUSESThere are two or four fuses in the marinegenerator system, depending on thenumber of power boxes installed. One islocated on each control panel and one oneach power box. All fuses are rated thesame.

(1)0004649

(1)0004650

1. Disconnect battery cables, beginningwith negative (-) cable first, or turnbattery master switch (if equipped) toOFF.

2. Turn the cap of the fuse holder with ascrewdriver.

3. Remove the fuse.

4. Replace with a new fuse of thespecified rating.

Fuse Specification250V-5A : 5mm x 20 mm

5. Install cap and tighten with ascrewdriver. Do not over-tighten.

MAINTENANCE


CHANGING INDICATORLEDS1. Disconnect battery cables, beginning

with negative (-) cable first, or turnbattery master switch (if equipped) toOFF.

2. Disconnect the appropriate controlpanel harness from the LED.

0004651

3. Pull the LED while pushing the upperand lower tabs.

4. Align the tabs of the new LED andinstall.

5. Connect the panel harness.6. Connect the battery cables, beginning

with negative (-) cable first, or turn thebattery master switch (if equipped) toON.

MAINTENANCE


TROUBLESHOOTINGTROUBLESHOOTINGCHART

No. Problem Symptom Possible Cause Corrective Action1 System

does notstart

Power Box isRunning indicatordoes NOT light

12V DC wiring isdisconnected orincorrect

Check the cables and cableconnections.

2 Battery is too weak Check the battery voltage.This system needsapproximately 10 to 12V DC.The system can be started ifthere is enough batterycapacity to start the engine.

3 Thermal switch If you are restartingimmediately after runningwith heavy load, allow thesystem to cool. Check thethermal switch cables. Ifthese cables aredisconnected or the thermalswitch is damaged, thesystem will not run. If thethermal switch is damaged,see your authorized Yanmarmarine dealer or distributor.

4 Faulty switch Check the switch. If theswitch is faulty, replace theswitch. See your authorizedYanmar marine dealer ordistributor.

5 Fuse blows out Check the fuse on the panel.Replace if necessary. If thefuse continues to blow, seeyour authorized Yanmarmarine dealer or distributor.

6 The Power Box isRunning indicator LEDblows out

Check the power box fans. Ifthe fan is running and theindicator blows out, the LEDmust be replaced. See yourauthorized Yanmar marinedealer or distributor.

7 Power box See your authorized Yanmarmarine dealer or distributor.


No. Problem Symptom Possible Cause Corrective Action8 Starting the

systemPower Box isRunning indicatorlights, but powerbox has no output

Wiring of power lines isdisconnected orincorrect

Check the cables andgenerator output and powerbox output cableconnections.

9 Tools or appliances donot work

Check the tools orappliances.

10 Duringsystemstarting orduringoperation

InsufficientEngine Speedindicator isilluminated

Engine speed is too low Increase the engine speeduntil the indicator turns off.

11 Two red warningindicators areilluminated andthe system hasstopped running

Overload Remove the load from thesystem until these LEDs turnoff.

12 GeneratorTemperatureWarning indicatoris illuminated andsystem hasstopped running

Temperature ofgenerator is too high

Investigate and repair thecause. When the generatorcools, the system can berestarted.

13 Power BoxTemperatureWarning indicatoris illuminated andthe system hasstopped running

Temperature of powerbox is too high

Investigate and repair thecause. When the power boxcools, the system can berestarted.

14 Power Box isRunning indicatordoes not light andthe power boxdoes NOT output.

Numbers 11 - 13 If able to check whichwarning indicators light,troubleshoot with Numbers11 - 13. If the warningindicators cannot bechecked, remove the loadand restart the system.NOTICE: NEVER allow thesystem to run when awarning indicator isilluminated. Damage toequipment may result.

15 Others See your authorized Yanmarmarine dealer or distributor.

TROUBLESHOOTING


Inv Temp.

MORE SPEEDOFF ON

Gen Temp.

Inv Temp.

MORE SPEEDOFF ON

Gen Temp.

Inv Temp.

MORE SPEEDOFF ON

Gen Temp.

Inv Temp.

MORE SPEED

OVERLOAD

OFF ON

Gen Temp.

Inv Temp.

MORE SPEEDOFF ON

Gen Temp.

Inv Temp.

MORE SPEED

OVERLOAD

OFF ON

Gen Temp.

The lighting time variesaccording to the load size.

Output voltage decrease.

Load is too large.

Temperature of generator is too high.

Temperature of power box is too high.

The lighting time is

The lighting time is

System stops.

PANEL

Insufficientengine speed.

PANEL

a few seconds.

a few seconds.

0004621

OVERLOAD

OVERLOAD

OVERLOAD

OVERLOAD

Figure 1

TROUBLESHOOTING



TROUBLESHOOTING


SPECIFICATIONSGENERAL SPECIFICATIONS

Marine Generator SpecificationsItems Model Number Remarks

KMG65E-S3KMG65E-S6

KMG65E-K3KMG65E-K6

System Output Voltage 230V AC Frequency 50 Hz Form andPhase

Sine wave, Single The distortion<5%

Weight Generator 21 kg (with fan)(46 lb with fan)

20.5 kg (without fan)(45.2 lb without fan)

Power Box 13 kg(28.6 lb)

Dimension ofMainComponents

Generator SAE #5 x 105 mm Power Box 320 x 360 x 145 mm

(12.6 x 14.2 x 5.7 in.)

Power Consumption of thePower Box

< 3A (12V DC)

Applicable Marine Gear or SailDrive Model

SD50 KM35A(2), KM35P

Applicable Engine Model 3JH4E, 4JH4E Not applicable toother Yanmarengines

Permissible Input Speed ofGenerator

3500 rpm

Applicable Standard (EMC) EC Council Directive 89/336/EEC as LastAmended By EC Directive 93/68/EEC


System SpecificationsItems Model Number Remarks

KMG65E-S3KMG65E-K3

KMG65E-S6KMG65E-K6

Quantity ofConnected PowerBox(es)

— 1 2

ContinuousOutput

kVA 3.0 6.0 (3.0 and 3.0) kW 3.0 6.0 (3.0 and 3.0)

Power Factor — 1.0 Maximum Output kVA 3.2 6.4 (3.2 and 3.2) Output for EngineSpeed

See Figure 1

Start / Stop — ON / OFF Switch on Control Panel Warning Signal LED Light

ONGenerator Temperature (Stator) Power Box Temperature Overload See Figure 1Insufficient Engine Speed

Self Protection Function Auto Stop for Overheat and Overload

Engine Speed Versus Power Output

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

0 500 1000 1500 2000 2500 3000 3500

Engine Speed

Out

put

A

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

Out

putk

VAMaximum output

Continuous output

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

0 500 1000 1500 2000 2500 3000 3500

Engine Speed RPM

Overload

Out

put

A

0.0

0.5

1.0

1.5

2.0

2.5

3.0

3.5

Out

putk

VAMaximum output

Continuous output Maximum outputContinuous output

POWER CAN BE SUPPLIED

SPEED IS INSUFFICIENT

0004622

Figure 1

SPECIFICATIONS


SYSTEM DIAGRAMSPower Box and Control Panel

320[14.17]

320[

12.6

0]

220[

8.66

]

340[13.39]

145[

5.71

]

320[14.17]340[13.39]

100[3.94]

100[

3.94

]

86[3

.39]

0004623

Figure 2Unit: mm (inch)

SPECIFICATIONS


Wiring Diagram

1

2

3

4

5

6

7

8

RE

D

BLA

CK

BLU

E

YE

LLO

W

OR

AN

GE

BR

OW

N

R B L Y O BN

2M 6M 2M

NO

TE

PAN

EL

AS

SY

PO

WE

R B

OX

TER

MIN

AL

BO

X

NA

ME

1965

30-0

5590

1965

30-0

5500

1965

30-0

5610

1965

30-0

5200

1965

30-0

5340

1965

30-0

5310

CO

DE

8 7 ⑥ ⑥ ⑥ ⑥ ⑥ ⑥ NO

.

<#1>

EA

RTH

CA

(AW

G16

-18)

<#1>

OU

TPU

T C

AB

LE (M

AX

10M

/ S

IZE

A 1

4)

CO

LOR

CO

DIN

G

<#1>

MA

RK

: CU

STM

ER

'S P

RE

PAR

ATIO

N P

AR

TS

Y B

NB O W L

1

2

3

4

5

6

7

8

RE

D

BLA

CK

BLU

E

BR

OW

N

R B L Y O BN

2M 6M 2M

NO

TE

PAN

EL

AS

SY

PO

WE

R B

OX

TE

RM

INA

L B

OX

NA

ME

1965

30-0

5590

1965

30-0

5500

1965

30-0

5610

1965

30-0

5200

1965

30-0

5340

1965

30-0

5310

CO

DE

8 7 NO

.

CO

LOR

CO

DIN

G

CO

NT

RO

L PA

NE

L P

OW

ER

HA

RN

ES

S

BAT

TE

RY

HA

RN

ES

S

GE

NE

RAT

OR

HA

RN

ES

S

0004624

YE

LLO

W

OR

AN

GE

6 5 4 3 2 1

<#1

> O

UT

PU

T C

AB

LE (

MA

X 1

0M /

SIZ

E A

WG

14)

<#1

> M

AR

K: C

US

TOM

ER

’S P

RE

PAR

ATIO

N P

AR

TS

(B):

BATT

.-(R

): 12

VD

C

GE

NE

RAT

OR

(R):

PO

WE

R B

OX

INP

UT

(L):

PO

WE

R B

OX

INP

UT

(W):

PO

WE

R B

OX

INP

UT

(Y):

TH

ER

MA

L S

WIT

CH

(Y):

TH

ER

MA

L S

WIT

CH

(R):

PO

WE

R B

OX

INP

UT

(L):

PO

WE

R B

OX

INP

UT

(W):

PO

WE

R B

OX

INP

UT

(Y):

TH

ER

MA

L S

WIT

CH

(Y):

TH

ER

MA

L S

WIT

CH

ONL

Y K

MG

65E

-S6,

K6

(4):

MO

RE

SP

EE

D(6

): G

ener

ator

Tem

p.(2

): G

ND

(1):

12V

DC

(5):

Inve

rter

Tem

p.(3

): R

UN

NIN

G

(*):

CA

BLE

NO

.

(4):

MO

RE

SP

EE

D(6

): G

ener

ator

Tem

p.(2

): G

ND

(1):

12V

DC

(5):

Inve

rter

Tem

p.(3

): R

UN

NIN

G

1.5M

(R):U1 Ge OUTPUT

(L): W1 Ge OUTPUT

(W): V1 Ge OUTPUT(R): U2 Ge OUTPUT

(L): V2 Ge OUTPUT

(W): W2 Ge OUTPUT

(O): THERMAL S/W(O): THERMAL S/W

<#1

> G

RO

UN

D C

AB

LE (

AW

G 1

6 -

18)

Figure 3

SPECIFICATIONS


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