Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ installation manual Removing Anticorrosion Zinc

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Anticorrosion Zinc

An anticorrosion zinc anode is installed in the heat exchanger to prevent electrolytic corrosion by seawater. When different metals, such as iron and copper, are placed in a highly conductive liquid (seawater), the iron gradually rusts. The zinc has chemical properties which cause the seawater to react to it rather than the engine components.

The anticorrosion zinc anode should be checked every 100 hours or three months and replaced every 200 hours or yearly. Depending upon operating conditions and seawater properties, the anticorrosion zinc anode may have to be replaced more frequently. See Figure 3-17 and use the following procedure.

INPUTSTOP START
10A
FUSE
00 0 0 0	1/10
TOTAL HOURS
BATT.
CHRG.
	2	1
		258000-D

1. Heat Exchanger

2. Anticorrosion Zinc

Figure 3-17. Removing Anticorrosion Zinc

1.With generator set cooled, drain the cooling seawater system. Close seacock, remove anticorrosion zinc anode from heat exchanger.

2.Use a wire brush to remove the loose corrosion on the anticorrosion zinc anode. Replace the anode when less than 50% of the 11/32 in. (9 mm) dia. by 9/16 in. (14 mm) long portion of zinc remains.

3.Clean threaded hole of heat exchanger and coat threads of anticorrosion zinc anode with pipe sealant (suitable for marine applications). Install anticorrosion zinc anode into heat exchanger.

4.Open seacock. Start generator set and check for leaks at the anticorrosion zinc anode location. Check for seawater flow by observing water discharge from exhaust outlet.

3-16 Scheduled Maintenance

TP-5695 12/93

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Contents Marine Generator Sets Models5CFZ 5CZCalifornia Proposition Table of Contents Safety Precautions and Instructions Carbon monoxide Can cause severe nausea, fainting, or death Carbon monoxide can cause severe nauseaSulfuric acid in batteries Can cause severe injury or death Sulfuric acid in batteries can cause severe injury orExplosive fuel vapors Can cause severe injury or death Explosive fuel vapors can cause severe injury orAccidental starting Can cause severe injury or death Accidental starting can cause severe injury orRotating parts Can cause severe injury or death Flying projectiles can cause severe injury or deathFire Can cause severe injury or death Sudden backfire can cause severe injury or deathSudden flash fire can cause severe injury or death Hazardous noise Can cause loss of hearing246242 Reference Material Pleasure CraftCommercial Vessels Additional ReferencesRoutine Service Parts Part Description Kohler Part NoGlossary of Abbreviations Abbreviation DescriptionNEC Specifications SpecificationsGeneral Specifications IntroductionGenerator 5CFZ/4CZ 5CFZ/6.5CZEngine GX360EVBPR4HS NGK Accessories Service Views Service Views typicalOperation Prestart ChecksController ControllerStarting StoppingEngine Safety Shutdown Switches Circuit ProtectionHigh Water Temperature Shutdown Switch Remote Panel Features Remote Panels OptionalRemote Start and Four-Meter Features Remote Start and Four-Meter Panel KitScheduled Maintenance Service Schedule Or 2 YearsGenerator Specifications Lubrication SystemAdding Oil Oil Change/Oil Filter ChangeFuel System Removing Oil FilterFuel Pump Screen Fuel Pump ScreenCarburetor Adjustments Carburetor/Choke LubricationSpark Plugs Ignition System ServiceIgnition System Problem Means of Identification Possible Cause Normal Gap bridgedOil fouled Carbon fouled12. Checking Spark Plug Gap Hot coolant and steam Can cause severe injury or death Cooling Systems- Closed/Heat ExchangerFilling and Checking 14. Air-Bleed Screw Flushing and Cleaning TP-5695 12/93 Scheduled Maintenance Anticorrosion Zinc 17. Removing Anticorrosion ZincAir Cleaner Mixing Elbow Servicing Air CleanerPressure Cap Servicing Mixing ElbowBattery CleaningChecking Electrolyte Level Checking Specific Gravity21. Specific Gravity Temperature Correction ChargingValve Adjustment 22. Determining Top Dead Center Lubrication Governor AdjustmentGovernor General Generator ServiceWattage Requirements Storage Procedure Troubleshooting EngineUnit cranks but will Not startOperates erratically Problem Possible Cause Corrective Action Stops suddenlyLacks power Electrical System Generator Wiring Diagrams Schematic Wiring Diagram--3.5CFZ, 4CZ, 5CFZ, and 6.5CZDiagrams 4CZTo Load Wire Generator SetsTo Generator To Shore Set Power LO Neutral Ground Load SideLine Side 60 HzL1--L3 Without Jumper LeadPage Motor Loads InstallationGenerator Selection and Wattage Requirements Appliance Loads Kilowatt DeratingTypical Location and Mounting LocationVentilation SpaceMounting Air Requirements CFM L/min Model Combustion CoolingFuel Systems Fuel SupplyAnti-Siphon Provisions Fuel LinesFuel Pump Lift Capabilities Fuel Consumption Max. Lift ft. m In. mmCooling Systems 11. Intake StrainerClosed/Heat Exchanger 13. Seawater StrainerExhaust Systems 15. Closed/Heat Exchanger Cooling System17. Typical Above Waterline Installation Carbon monoxideAbove Waterline Mid/Below WaterlineAC Voltage Connections Installation in Steel or Aluminum VesselsElectrical Systems Battery WiringRemote Start Switch Connection Lead Designations Pin FunctionDimension Drawing--3.5CFZ, 4CZ, 5CFZ, and 6.5CZ SectionSound Shield--Optional on 3.5CFZ and 4CZ Standard on 5CFZ and 6.5CZFor Sales & Service in U.S.A. & Canada Phone Parts Ordering InstructionsOperating Hour Service Log Kohler CO. KOHLER, Wisconsin 53044 Phone