Broken Zinc Rod Stuck In Kohler 5K Generator

[Ralph vaughn]

I went to change the Zinc rod in my Kohler 5K generator. When I unscrewed the bolt the Zinc rod had broken off right above the screwed in bolt. I tried to move the Zinc but it is wedged in tight. It is impossible to apply any pressure to the stuck Zinc rod without taking off the complete heat exchanger.

Questions:
1. Can I just leave the broken Zinc Anode in the generator and let it deteriorate and check frequently?
2. How hard is it to remove the heat exchanger? Then any suggestions for getting out the wedged Zinc Anode.

Thanks again for everyone's help.

You guys have saved me a lot of money in professional boat repairs.

Ralph

 

[Todd320]

I currently have a broken zinc in mine as well, was advised to leave it in, I cut a brand new one to only 1/4” of zinc left and installed, now I need to go check and replace with full since it should be fully dissolved by now, hopefully.

 

[BlueYonder]

Run Barnacle Buster, or something like it, through the heat exchanger, the acid will dissolve the broken piece of zinc.

 

[dtfeld]

Can you push it in? If so you can push it in, and possibly install a new one.

To get the old one out like previously mentioned, Barnacle Buster through the heat exchanger, or on some models, you can pull the cap off and remove any accumulated debris.

 

[Little Ducky]

I have a 4kW and mine did the same thing. I just pushed it in and installed a new one.

The 4kW heat exchanger does not have removable end caps. Does the 5kW?

I even removed the entire exchanger to try to fish it out w/o any luck.

 

[Mark.60]

Just be careful with the barnacle buster I have seen it turn zinc into a paste like substance

 

[bbwhitejr]

We had a Kohler 5ECD some years ago and same thing happened. Pushed it on in and installed the new one behind it and never an issue....

Bennett

 

[Ralph vaughn]

Thanks everyone for the great information

Ralph

 

[Carpediem44DB]

Bad idea to leave the pencil zinc in. Better to remove the exchanger end cap and get the old remains out. This is what I found in my heat exchanger last winter and found similar in my heat exchanger on the genny as well. They don't dissolve once they are calcified. I will never leave the remains of a broken pencil zinc to calcify in the exchanger. I had effectively over 50% blockage.
Carpe Diem

 

[juggernaut1]

I just pushed mine in too as can't take the end caps of the Kohler generator heat exchanger.

Never had an issue in the last circa 6 years.

 

[Ralph vaughn]

Thanks so much. I was going to leave the pencil zinc in till I had a little more time. But now I will remove it. Is it a good idea to carefully try and drill out the pencil zinc if I can't tap it out.

Thanks

Ralph

 

[douglee25]

I rebuilt my generator in the shop two years ago and during the rebuild I had broken my zinc off in the exchanger. What I did was pour some muriatic acid in a cup and use a small paint brush to put acid on the zinc. I did this for about 10 mins and the zinc slowly dissolved away. A combination of this plus some small picks and I got the entire area freed up for a new zinc.