Yanmar KMG Series User manual

KMG
series
OPERATION MANUAL
KMG65E-S3
KMG65E-S6
KMG65E-K3
KMG65E-K6
MARINE
GENERATOR
P/N: 0AKMG-G00100

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. We reserve
the right to make any change at any time without notice. Yanmar and are
registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other
countries.
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 storage
and retrieval systems - without the written permission of Yanmar Marine International.
© 2006 Yanmar Marine International
1106
ii KMG65E Operation Manual

TABLE OF
CONTENTS
Page
Introduction .............................................................. 1
Record of Ownership .............................................. 2
Safety ....................................................................... 3
Safety Precautions ................................................. 3
General Information ......................................... 4
Before You Operate ......................................... 4
During Operation and Maintenance ..................... 5
Product Overview ..................................................... 11
Product Overview ................................................. 11
Marine Generator Designation .......................... 13
KMG65E Models ............................................ 13
Component Identification ........................................ 15
Main Components .......................................... 15
Generator ..................................................... 16
Power Box .................................................... 18
Nameplate .......................................................... 19
Generator ..................................................... 19
Power Box .................................................... 19
Control Panel ................................................ 20
Technical Data ..................................................... 21
Operation ................................................................ 23
Marine Generator Operation .................................... 23
Daily Checks ....................................................... 24
Starting the System ........................................ 25
Checks During Operation ................................. 26
Stopping the System ....................................... 27
Maintenance ............................................................ 29
Torque Charts ...................................................... 32
KMG65E Operation Manual iii

Standard Torque Chart (Generator) .................... 32
Changing Fuses ................................................... 33
Changing Indicator LEDs ........................................ 34
Troubleshooting ....................................................... 35
Troubleshooting Chart ........................................... 35
Specifications .......................................................... 39
General Specifications ........................................... 39
Engine Speed Versus Power Output ................... 40
System Diagrams ................................................. 41
Power Box and Control Panel ........................... 41
Wiring Diagram .............................................. 42
TABLE OF CONTENTS
iv KMG65E Operation Manual

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.
To help you enjoy your Yanmar Marine
products for many years to come, please
follow these recommendations:
• Read and understand this Operation
Manual before you install / operate your
boat to ensure that you follow safe
installing / operating practices and
maintenance procedures.
• 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 Yanmar marine dealer or
distributor.
• Make sure this manual is transferred to
subsequent owners. This manual should
be considered a permanent part of the
boat and remain with it.
• Constant efforts are made to improve the
quality and performance of Yanmar
products, so some details included in this
Operation Manual may differ slightly from
your marine generating system. If you
have any questions about these
differences, please contact your
authorized Yanmar marine dealer or
distributor.
KMG65E Operation Manual 1

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:
INTRODUCTION
2KMG65E Operation Manual

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. Also, if you need to replace a
part that has a decal attached to it, make
sure you order the new part and decal at the
same time.
!
This safety alert symbol appears
with most safety statements. It
means attention, become alert,
your safety is involved! Please
read and abide by the message
that follows the safety alert
symbol.
SAFETY PRECAUTIONS
!
DANGER
Indicates a hazardous situation which, if
not avoided, will result in death or
serious injury.
!
WARNING
Indicates a hazardous situation which, if
not avoided, could result in death or
serious injury.
!
CAUTION
Indicates a hazardous situation which, if
not avoided, could result in minor or
moderate injury.
NOTICE
Indicates a situation which can cause
damage to the machine, personal property
and / or the environment or cause the
equipment to operate improperly.
KMG65E Operation Manual 3

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.
Before You Operate
!
DANGER
The safety message that follows has a
DANGER level hazard.
NEVER permit anyone to
install or operate the marine
generator without proper
training.
• Read and understand this Operation
Manual before you operate or service the
marine generator to ensure that you follow
safe operating practices and
maintenance procedures.
• Safety signs and decals are additional
reminders for safe operating and
maintenance techniques.
• See your authorized Yanmar marine
dealer or distributor for additional training.
SAFETY
4KMG65E Operation Manual

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.
Ensure that the type of fire extinguishers are
appropriate for material that might catch fire.
Check with local authorities.
Have all fire extinguishers checked
periodically for proper operation and / or
readiness.
Post evacuation routes prominently.
Periodically conduct fire drills.
Ensure that appropriate fire detection and
extinguishing equipment are installed and
checked periodically for proper operation.
Check with local authorities.
Electrical Hazard
NEVER start the engine
before the wiring is completely
installed.
ALWAYS disconnect the external power line
from the boat and shut all power box
breakers OFF before you begin to service
the marine generator.
ALWAYS check the electrical harnesses for
cracks, abrasions and damaged or
corroded connectors. ALWAYS keeps the
connectors and terminals clean.
ALWAYS have a licensed electrician
connect this system to the utility circuit.
Improper installation can cause
electrocution 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 licensed
electrician.
NEVER operate the power box near
standing water or snow.
NEVER use this system in highly conductive
areas such as on metal decking or near steel
work.
ALWAYS use grounded extension cords.
NEVER use damaged or frayed extension
cords.
NEVER ground the marine generator
system to a pipe that carries combustible
materials or gases.
NEVER touch the marine generator system
if it is wet or touch it with wet hands.
ALWAYS ground the power box. Ensure a
length of heavy wire exists between the
power box ground terminal and an external
ground.
SAFETY
KMG65E Operation Manual 5

!
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. While
the engine is running or the
battery is charging, hydrogen
gas is being produced and can
be easily ignited. Keep the area around the
battery well-ventilated and keep sparks,
open flame and any other form of ignition out
of the area.
Diesel fuel is flammable and explosive
under certain conditions.
Wipe up all spills immediately.
Fire Hazard
Avoid injury or equipment
damage from fire. Undersized
wiring systems can cause an
electrical fire.
Sever Hazard
ALWAYS ensure all
bystanders are clear of the
area before starting the
engine. Keep children and
pets away while the engine is
operating.
Alcohol and Drug Hazard
NEVER operate the engine
while under the influence of
alcohol or drugs or when
feeling ill.
SAFETY
6KMG65E Operation Manual

!
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.
Avoid personal injury. NEVER operate the
engine while wearing a headset to listen to
music or radio because it will be difficult to
hear the warning signals.
Burn Hazard
Avoid serious injury. Some of
the engine and marine gear
surfaces become very hot
during operation and shortly
after shut-down. Keep hands
and other body parts away
from hot surfaces.
Sudden Movement Hazard
Avoid personal injury. ALWAYS stop the
engine before beginning service.
ALWAYS ensure tools or appliances are
disconnected from the system before the
engine is started.
Exhaust Hazard
Avoid serious injury or death.
NEVER block windows, vents,
or other means of ventilation if
the engine is operating in an
enclosed area. All internal
combustion engines create carbon
monoxide gas during operation and special
precautions are required to avoid carbon
monoxide poisoning.
ALWAYS drain the bilge before operating
the marine generator. NEVER allow the
marine generator to get wet.
SAFETY
KMG65E Operation Manual 7

!
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.
ALWAYS wear eye protection
when servicing the engine or
when using compressed air or
high-pressure water. Dust,
flying debris, compressed air, pressurized
water or steam may injure your eyes.
NEVER open the power box. There are no
user serviceable components. Contact your
authorized Yanmar marine dealer or
distributor.
NOTICE
The safety messages that follow have
NOTICE level hazards.
It is important to perform daily checks as
listed in this Operation Manual.
Periodic maintenance prevents unexpected
downtime, reduces the number of accidents
due to poor engine or marine gear
performance and can help extend the life of
the engine and marine gear.
ALWAYS be environmentally
responsible.
Follow the guidelines of the EPA or other
governmental agencies for the proper
disposal of hazardous materials such as
lubrication oil, diesel fuel and engine
coolant. Consult the local authorities or
reclamation facility.
NEVER dispose of hazardous materials by
dumping them into a sewer, on the ground
or into ground water or waterways.
SAFETY
8KMG65E Operation Manual

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.
• Contact your authorized Yanmar marine
dealer or distributor if the marine
generator will be operated in temperature
extremes.
NEVER attempt to modify the marine
generator’s design or safety features.
Observe the following environmental
operating conditions to maintain marine
generator performance and avoid
premature 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°C
temperature rise above 15.6°C.
Most electrical appliances require more
than their rated wattage for start-up. Make
sure total wattage of electrical load does not
exceed rated wattage of the system.
This system is not rated to power an entire
home. Most home electrical service requires
more than 60A.
SAFETY
KMG65E Operation Manual 9

This Page Intentionally Left Blank
SAFETY
10 KMG65E Operation Manual

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.
KMG65E Operation Manual 11

Power box
3kVA
Power box
3kVA
Panel
Generator
To 12V battery
TV Hair Dryer PC Microwave oven
Panel
Power box
3kVA
Power box
3kVA
Panel
Generator
To 12V battery
TV Hair Dryer PC Microwave oven
Panel
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
12 KMG65E Operation Manual

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 6kVA
K3 KM35P, KM35A(2) 3kVA
K6 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
KMG65E Operation Manual 13

KM35A(2) SD50KM35A(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
14 KMG65E Operation Manual

COMPONENT IDENTIFICATION
Main 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 3
1 – Generator
2 – Power Box
3 – Control Panel
4 – Terminal Box
5 – Generator Harness
6 – Control Panel Power Harness
7 – Battery Harness
PRODUCT OVERVIEW
KMG65E Operation Manual 15

Generator
KMG65E-S3 and KMG65E-S6
(1) (2)
(7)
(11)
(14) (
(8)
(12)
(b)
(3)
(4)
(13)
(9)
(10)
(6)
(a)
(5)
0004609
Figure 4
KMG65E-K3 and KMG65E-K6
0004610
(2)
(15)
(7)
(9)
(10)
(18) (19)
(8)
(17)
(1)
(3)
(16)
Figure 5
PRODUCT OVERVIEW
16 KMG65E Operation Manual