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TORQUE CHARTS

Standard Torque Chart

(Generator)

Thread Size x Pitch mm

M6x1.0

M8x1.25

M10x1.5

M12x1.75

Tightening

Torque

Aluminum

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

Cast Iron or

Steel

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 ± 1.0

MAINTENANCE

32

KMG65E Operation Manual

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Summary of Contents for KMG Series

Page 1: ...KMG series OPERATION MANUAL KMG65E S3 KMG65E S6 KMG65E K3 KMG65E K6 MARINE GENERATOR P N 0AKMG G00100 ...

Page 2: ...nd 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 tap...

Page 3: ...verview 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 ...

Page 4: ...ging 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 ...

Page 5: ...rating 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 improv...

Page 6: ...ents 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 2 KMG65E Operation Manual ...

Page 7: ...al 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 resu...

Page 8: ...etyprecautionsbeforeoperation 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 pr...

Page 9: ... 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 ofte...

Page 10: ...tery is charging hydrogen gasisbeingproducedandcan 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 Sev...

Page 11: ...e 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 wind...

Page 12: ...en 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 e...

Page 13: ...y 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 e...

Page 14: ...This Page Intentionally Left Blank SAFETY 10 KMG65E Operation Manual ...

Page 15: ...hrough 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 ...

Page 16: ...en 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 ...

Page 17: ...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 ...

Page 18: ...l 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 ...

Page 19: ...ents 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 ...

Page 20: ...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 ...

Page 21: ... 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 Pipe b Hose Clamp 35 mm 2 used 15 Marine Gear Flange 16 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 with the engine and marine gear or sail drive...

Page 22: ...rom Generator 3 pin 3 Earth Ground Terminal for Input 4 Input Port of Generator Thermal Switch 5 Nameplate 6 230V Output Port 2 pin 7 Control Signal Port from Panel 6 pin 8 Fuse Holder 9 Ground Earth Terminal 10 Specification Decal PRODUCT OVERVIEW 18 KMG65E Operation Manual ...

Page 23: ...ADE IN JAPAN 2 1 0004612 Figure 7 1 Generator Model 2 Generator Serial Number Power Box The power box nameplate is installed on the side of the power box PRODUCT No M FG No KANZAKI KOKYUKOKI MFG CO LTD MADE IN JAPAN 2 1 0004613 Figure 8 1 Power Box Model Number 2 Power Box Serial Number PRODUCT OVERVIEW KMG65E Operation Manual 19 ...

Page 24: ...uminates 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 GeneratorTemperatureWarningIndicator Figure 9 4 AredLEDthatilluminateswhen 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 re...

Page 25: ...zed 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 Output Voltage 230V Output Frequency 50Hz Maximum Input Speed 3500 min 1 rpm PRODUCT OVERVIEW KMG65E Operation Manual 21 ...

Page 26: ...This Page Intentionally Left Blank PRODUCT OVERVIEW 22 KMG65E Operation Manual ...

Page 27: ... 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 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 ...

Page 28: ...ondition Make sure you check the following items and have any repairs completed before you operate the marine generating system Before operating check all wiring connections Ensure the connections are tight and there is no wear or damage to the wiring harnesses or connectors Ensure no warning LEDs are illuminated when the marine generator is running Ensure no abnormal noise is heard while the mari...

Page 29: ...sary starting current required is greater than the rated load Set the engine speed at 2200 to 2500 rpm to handle the larger draw 3 Turn the power box ON OFF switch to ON Ensure the Power Box is Running indicator illuminates Figure 1 When lit 230V are available and the system is ready for use 0004615 InvTemp MORESPEED OVERLOAD OFF ON GenTemp Figure 1 Note When restarting tools or appliances that ha...

Page 30: ...Insufficient Engine Speed Warning Indicator and Generator Temperature Warning Indicator Overload The timer starts and the system will stop automatically according to the load level InvTemp MORESPEED OVERLOAD OFF ON GenTemp 0004619 Generator Temperature Warning Indicator Generator temperature is too high The system stops automatically Correct the problem and reset the system InvTemp MORESPEED OVERL...

Page 31: ...e without turning all tools or appliances to OFF Restarting the system with tools or appliances ON may cause unexpected movement of the tools or appliances 2 Before shutting down the marine generator let the system run at low speed for approximately 5 minutes to allow the system to cool down Note Failure to properly cool down the system may cause a warning indicator to light when you restart the s...

Page 32: ...This Page Intentionally Left Blank OPERATION 28 KMG65E Operation Manual ...

Page 33: ...the battery electrolyte is frozen slowly warm the battery before you recharge it ALWAYSdisconnecttheexternalpowerline from the boat and shut off all the power box output breakers before servicing the system Crush Hazard ALWAYS use lifting equipment with sufficient capacity to lift marine generator NEVER support marine generator with equipment not designed to support the weight of the marine genera...

Page 34: ... turn Entanglement Hazard NEVER leave the key in the key switch when you are servicing the engine or marine generator Someone may accidentally start the engine and not realize you are servicing it Avoid unexpected equipment movement Shift the marine gear into the NEUTRAL position any time the engine is at idle Electrical Shock Hazard Avoid serious personal injury or equipment damage ALWAYS turn of...

Page 35: ...nd performance characteristics and shorten the marine generator s life Any alterations to this marine generator may affect the warranty coverage of your marine generator If you remove the battery from the marine generator system insulate the terminal on the end of the red positive battery cable Sparks may cause damage of the electronic circuits When you install a battery ALWAYS use correct polarit...

Page 36: ...6x1 0 M8x1 25 M10x1 5 M12x1 75 Tightening Torque Aluminum 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 Cast Iron or Steel 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 0 MAINTENANCE 32 KMG65E Operation Manual ...

Page 37: ... the same 1 0004649 1 0004650 1 Disconnect battery cables beginning with negative cable first or turn battery master switch if equipped to OFF 2 Turn the cap of the fuse holder with a screwdriver 3 Remove the fuse 4 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 MAINTENANCE KMG65E Operation Man...

Page 38: ...nnect the appropriate control panel harness from the LED 0004651 3 Pull the LED while pushing the upper and lower tabs 4 Align the tabs of the new LED and install 5 Connect the panel harness 6 Connect the battery cables beginning with negative cable first or turn the battery master switch if equipped to ON MAINTENANCE 34 KMG65E Operation Manual ...

Page 39: ...hese cables are disconnected or the thermal switch is damaged the system will not run If the thermal switch is damaged see your authorized Yanmar marine dealer or distributor 4 Faulty switch Check the switch If the switch is faulty replace the switch See your authorized Yanmar marine dealer or distributor 5 Fuse blows out Check the fuse on the panel Replace if necessary If the fuse continues to bl...

Page 40: ...e Warning indicator is illuminated and system has stopped running Temperature of generator is too high Investigate and repair the cause When the generator cools the system can be restarted 13 Power Box Temperature Warning indicator is illuminated and the system has stopped running Temperature of power box is too high Investigate and repair the cause When the power box cools the system can be resta...

Page 41: ...D OFF ON GenTemp The lighting time varies according 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 Insufficient engine speed PANEL a few seconds a few seconds 0004621 OVERLOAD OVERLOAD OVERLOAD OVERLOAD Figure 1 TROUBLESHOOTING KMG65E Operation Manual 3...

Page 42: ...This Page Intentionally Left Blank TROUBLESHOOTING 38 KMG65E Operation Manual ...

Page 43: ...45 2 lb without fan Power Box 13 kg 28 6 lb Dimension of Main Components 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 the Power Box 3A 12V DC Applicable Marine Gear or Sail Drive Model SD50 KM35A 2 KM35P Applicable Engine Model 3JH4E 4JH4E Not applicable to other Yanmar engines Permissible Input Speed of Generator 3500 rpm Applicable Standard EMC ...

Page 44: ...ee Figure 1 Insufficient 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 Output A 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 Output kVA Maximum 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 Ou...

Page 45: ...EM DIAGRAMS Power Box and Control Panel 320 14 17 320 12 60 220 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 2 Unit mm inch SPECIFICATIONS KMG65E Operation Manual 41 ...

Page 46: ...ING CONTROL PANEL POWER HARNESS BATTERY HARNESS GENERATOR HARNESS 0004624 YELLOW ORANGE 6 5 4 3 2 1 1 OUTPUT CABLE MAX 10M SIZE AWG 14 1 MARK CUSTOMER S PREPARATION PARTS B B ATT R 12VDC GENERATOR R POWER BOX INPUT L POWER BOX INPUT W POWER BOX INPUT Y THERMAL SWITCH Y THERMAL SWITCH R POWER BOX INPUT L POWER BOX INPUT W POWER BOX INPUT Y THERMAL SWITCH Y THERMAL SWITCH ON LY KMG65E S6 K6 4 MORE S...

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