CORROSION PROTECTION

Transcription

1 SERVICE MANUAL NUMBER 11 Tle of Contents CORROSION PROTECTION Setion 7A - All Models CORROSION PROTECTION - ALL MODELS Speifitions A-2 Speil Tools A-2 Lurints/Selers/Adhesives A-2 Continuity Ciruit A-2 Anodi Blok A-5 Trim Cylinder Anodes A-8 Anodi Trim T or Plte A-9 Brvo One Drive Units A-9 Brvo Two Drive Units A-11 Brvo Three Drive Units A-11 Integrl MerCthode System A-12 Removing Eletrode Assemly A-12 Instlling Eletrode Assemly A-13 Connet Eletril Leds to Controller Assemly A-15 Wiring Digrms A-16 MerCthode Monitor A-16 MerCthode Controller A-17 Quiksilver Isoltor A-18 Corrosion Protetion Testing nd Trouleshooting A-18 Test Equipment Set-Up A-21 Low Redings A-22 High Reding A-24 Norml Reding But Corrosion is Evident A-25 7 A MARCH 1998 Pge 7A-1

2 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 11 Speifitions Speil Tools DESCRIPTION MerCthode Referene Eletrode Test PART NUMBER 76675A1 Quiksilver VOA Meter* A1 *If you do not lredy hve this meter, use digitl multi-meter (suh s Rdio Shk ). DO NOT use stndrd nlog (Needle-Type) Meter s inurte redings will result. IMPORTANT: Quiksilver Volt/Ohm Meter nd Multi-Meter DVA/Tester re no longer reommended for testing orrosion protetion. Lurints/Selers/Adhesives Continuity Ciruit DESCRIPTION PART NUMBER Quiksilver Liquid Neoprene Trnsom ssemly nd sterndrive unit re equipped with ground iruit wires to ensure good eletril ontinuity etween engine, trnsom ssemly, nd sterndrive omponents. Good ontinuity is essentil for the zin trim t nd MerCthode System to funtion most effetively. Inspet the following ground iruit omponents, t intervls (Setion 1B), for loose onnetions, roken or frying wires. - Steering Lever Ground Wire Pge 7A MARCH 1998

3 SERVICE MANUAL NUMBER 11 CORROSION PROTECTION - ALL MODELS Inner Trnsom Plte to Giml Housing Ground Wire - Driveshft Housing to Ger Housing Ground Plte (Inside Trim T Cvity) - Giml Housing to Giml Ring Ground Wire Gsoline Models Diesel Models - Flywheel Housing Grounding Stud - Ground Wire - Inner Trnsom Plte Grounding Srew - DO NOT Ground ANY Aessory t this onnetion MARCH 1998 Pge 7A-3

4 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 11 d d - Giml Ring to Bell Housing Ground Wire e - Drive Unit to Bell Housing Ground Plte f e f - Driveshft Housing to Ger Housing Anodi Plte g - Hydruli Connetor Blok to Giml Housing Ground Wsher g h h h - Anodi Blok to Hydruli Mnifold nd Ground Wshers (Beneth Srews). i j i - U-joint Bellows Ground Clip j - Exhust Bellows Ground Clips Pge 7A MARCH 1998

5 SERVICE MANUAL NUMBER 11 Anodi Blok CORROSION PROTECTION - ALL MODELS CAUTION DO NOT pint new nodi lok s this will render it ineffetive s glvni orrosion inhiitor. 1. Remove srews, ground wshers nd gsket from nodi lok. Remove nodi lok to hydruli mnifold gsket nd disrd. e d Erlier Style Anodi Blok - Anodi Blok - Srews - Continuity Wshers d - Gsket e - Sel e d Lter Style Anodi Blok - Anodi Blok - Srew - Continuity Wsher d - Gsket e - Sel MARCH 1998 Pge 7A-5

6 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER Chek ondition of hydruli mnifold nd len ny deris from threded holes. - Srew Holes - Hydruli Mnifold Exmine ruer sel inside of hydruli mnifold lok for signs of lekge or wer. Reple if neessry Hydruli Mnifold - Ruer Sel If ruer sel needs replement, push old sel out of hydruli mnifold nd instll new sel s shown Hydruli Mnifold - Ruer Sel Pge 7A MARCH 1998

7 SERVICE MANUAL NUMBER Instll srews nd wshers into lok s shown. CORROSION PROTECTION - ALL MODELS - Srews (2) - Anodi Blok - Continuity Wshers (2) CAUTION To e effetive, new nodi lok MUST mke good ontinuity ontt with giml housing. 6. Be sure new gsket is in proper position etween nodi lok nd hydruli mnifold. Apply Quiksilver Perfet Sel (P/N ) to threds of srew one they re through lok Srews (2) - Anodi Blok - Gsket 7. Snug oth srews evenly into hydruli mnifold, then torque to l. in. (9-14 N m) Srews nd Wshers - Anodi Blok MARCH 1998 Pge 7A-7

8 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 11 Trim Cylinder Anodes CAUTION DO NOT pint new trim ylinder nodes, s this will render them ineffetive s glvni orrosion inhiitor. 1. Remove srews tht seure nodes to trim ylinders. Remove nodes. - Srews - Trim Cylinder Anodes Srpe mounting surfe on ylinder end-p down to re metl. 3. Instll new nodes nd tighten seurely. Pge 7A MARCH 1998

9 SERVICE MANUAL NUMBER 11 Anodi Trim T or Plte CORROSION PROTECTION - ALL MODELS NOTE: Lter models re equipped with n nodi plte insted of trim t. Replement proedure is the sme. - Trim T - Anodi Plte Brvo One Drive Units CAUTION DO NOT pint new trim t (or nodi plte), s this will render it ineffetive s glvni orrosion inhiitor. 1. Remove plug from driveshft housing to gin ess to tthing srew Plug 2. Use 1/2 in. stndrd soket nd extension, loosen srew, nd remove trim t (or nodi plte). d e - Trim T (Or Anodi Plte, Depending Upon Model) - Plug - (Removed) - 1/2 in. Soket d - Extension e - Srew MARCH 1998 Pge 7A-9

10 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 11 CAUTION To e effetive, new trim t (or nodi plte) MUST mke good eletril ontt with ger housing. 3. Srpe trim t (or nodi plte) mounting surfe on ger housing down to re metl. 4. Instll trim t nd lign stright k. Torque srew to l. ft. (34-47 N m). d e - Trim T (Or Anodi Plte, Depending Upon Model) - Plug - (Removed) - 1/2 in. Soket d - Extension e - Srew Reinstll plug in driveshft housing Plug Pge 7A MARCH 1998

11 SERVICE MANUAL NUMBER 11 Brvo Two Drive Units CORROSION PROTECTION - ALL MODELS 1. Use 1/2 in. stndrd soket to loosen srew nd remove trim t. 2. Srpe trim t mounting surfe down to re metl to insure ontinuity. 3. Instll trim t nd lign stright k. Torque srew to l. ft. (34-47 N m). Brvo Three Drive Units - Srew [Torque to l. ft. (34-47 N m)] - Trim T (Position Stright Bk) NOTE: Erlier Brvo Three drive units were equipped with two nodi pltes. The rer node is tthed with olt from the ottom side of the splsh plte. - Anodi Pltes - Srew (Atthes From Bottom Side) 1. Remove plsti p to gin ess to the node (front) tthing olt Plsti Cp (Removed) - Bolt Srpe the mounting surfe on ger housing down to re metl to insure ontinuity. 3. Instll new node(s). Torque to 23 l. ft. (32 N m). 4. Reinstll plsti p MARCH 1998 Pge 7A-11

12 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 11 Integrl MerCthode System Removing Eletrode Assemly 1. Disonnet eletrode ssemly wires from MerCthode Controller. e - Eletrode Assemly Wire (Ornge) - Eletrode Assemly Wire (Brown) - Erlier Models - Trim Position Sender Wire (Blk) d - Erlier Models - Trim Position Sender Wire (Blk) e - Erlier Models - Wire to Trim Position Guge (Brown/White) d Remove two srews, flt wshers nd lok wshers; then remove eletrode ssemly. e d Eletrode Assemly - Srew (2) - Flt Wsher (2) d - Lok Wsher (2) e - Hydruli Connetor Blok Pge 7A MARCH 1998

13 SERVICE MANUAL NUMBER 11 Instlling Eletrode Assemly CORROSION PROTECTION - ALL MODELS CAUTION O-ring MUST BE properly seted in groove of eletrode ssemly or wter lekge into ot will result. 1. Erlier Model Eletrodes: Instll the O-ring over the ornge nd rown wires from the eletrode ssemly. Set the O-ring in the groove. DO NOT use ny type of seler on the O-ring. - O-ring Groove - O-ring Lter Model Eletrodes: Lter model eletrodes hve ftory instlled ruer grommet nd DO NOT require n O-ring. - Eletrode - Ruer Grommet MARCH 1998 Pge 7A-13

14 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER Form 2 ft. (610mm) long piee of pproximtely.032 in. dimeter wire to the dimensions shown. d - 2 ft. (610mm) OF APPROXIMATELY.032 in. (.8mm) DIA. WIRE - 5 in. (123 mm) -45 Angle d - 1/2 in. (13 mm) Insert 45 ngle end of wire through enter hole in hydruli onnetor lok. 5. Guide wire through hole until wire protrudes through vity on the ottom of exhust pipe Wire 6. Seure ring terminls to trer wire. 7. Guide leds through enter hole in onnetor lok. IMPORTANT: Ornge led is pproximtely 6 in. (150mm) longer thn the rown led. Pge 7A MARCH 1998

15 SERVICE MANUAL NUMBER Pull leds ALL the wy into the ot. CORROSION PROTECTION - ALL MODELS Wire - Leds CAUTION DO NOT pint srifiil nodes or MerCthode System eletrode ssemly, s this will render them ineffetive s glvni orrosion inhiitors. 9. Position nd seure eletrode ssemly to giml housing using two 1-3/8 in. (35mm) long srews, flt wshers nd lokwshers. Torque to l. in. ( N m). DO NOT OVERTIGHTEN. e d Eletrode Assemly - Srew (2) - Flt Wsher (2) d - Lok Wsher (2) e - Hydruli Connetor Blok Connet Eletril Leds to Controller Assemly NOTE: If lk (ground) wire is not ville t terminl lok or from wire hrness, instll seprte led etween ontroller negtive ( ) terminl nd negtive ( ) ttery le tthing point on engine. 1. Connet eletril leds to ontroller ssemly, seurely. (See pplile Wiring Digrms, following.) 2. Apply thin ot of Quiksilver Liquid Neoprene ( ) to ALL eletril onnetions MARCH 1998 Pge 7A-15

16 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 11 Wiring Digrms MerCthode Monitor e d - Ground to Suitle Ground on the Instrument Pnel - Srew, Nut nd Sleeve - Eletrode d - 20 Amp Fuse e - Controller Pge 7A MARCH 1998

17 SERVICE MANUAL NUMBER 11 MerCthode Controller CORROSION PROTECTION - ALL MODELS Controller - 20 Amp Fuse - Eletrode MARCH 1998 Pge 7A-17

18 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 11 Quiksilver Isoltor Bots, whih re onneted to A.C. shore power require dditionl protetion, to prevent destrutive low voltge glvni urrents from pssing thru the shore power ground wire. A Quiksilver Isoltor (7664A3) n e instlled to lok the pssge of these urrents, while still providing pth to ground for dngerous fult (shok) urrents. CAUTION If A.C. shore power is not isolted from ot ground, the MerCthode System nd srifiil nodes my e unle to hndle the inresed glvni orrosion potentil. - Quiksilver Isoltor Corrosion Protetion Testing nd Trouleshooting NOTE: The following orrosion protetion test supersedes ll previously issued tests. This test n e used on pplitions with or without MerCthode System. Use the following test to determine if drive unit is eing fforded dequte orrosion protetion, or if dditionl orrosion protetion is required. If the unit is equipped with MerCthode System, it is reommended tht this test e performed t lest one eh yer, where the ot is moored, to ensure tht the system is funtioning properly. Test requires the us of MerCthode Referene Eletrode Test 76675A1, nd Quiksilver VOA meter A1. This meter is no longer ville from Merury Mrine. If you do not lredy hve this meter, digitl multi-meter (suh s Rdio Shk ) must e used. A STANDARD ANALOG (Needle-Type) METER CANNOT BE USED, AS AN INAC- CURATE READING WILL RESULT. IMPORTANT: Quiksilver Volt/Ohm Meter , nd Multi-Meter DVA/Tester , re no longer reommended for testing orrosion protetion. Pge 7A MARCH 1998

19 SERVICE MANUAL NUMBER 11 CORROSION PROTECTION - ALL MODELS The MerCthode Referene Eletrode Tester 76675A1 is equipped with speil jk (ontining resistor to provide the proper sle reding when used with Quiksilver VOA Meter A1. Previously, we stted tht this plug ould e removed to llow tester to e used with other nlog type meters. Further testing hs reveled tht this ould result in inurte redings nd, therefore, we no longer reommend the removl of this plug, nd the use of other nlog meters. Resistor jk n e left in ple when using digitl meters Quiksilver VOA Meter A1 nd MerCthode Referene Tester 76675A1 - Speil Resistor Jk NOTE: Set-up test equipment s shown on pge 7A-21. IMPORTANT: Be sure to oserve the following when performing test: If equipped with MerCthode System, ensure ttery is fully hrged (12.6 Volts or ove). New ots just pled in servie usully will produe reding higher thn norml. This is due to the drive unit eing proteted y good finish nd new srifiil nodes. To otin n urte dignosis, the test should e performed fter the ot hs een in servie t lest one or two weeks. This will give the pint hne to sok nd Minor rsions nd srthes will hve ppered, whih will result in l more urte reding. Bots should e moored, without eing operted, for t lest 8 hours efore performing tests. This is neessry to llow the MerCthode System nd/or srifiil nodes to polrize the surrounding wter. Be reful not to rok the ot exessively while ording to perform test s this will lter the test reding. 1. Plug negtive meter led into negtive ( ) reeptle of meter. Connet other end of led to negtive ( ) ttery terminl or other onvenient engine ground. 2. Plug Referene Eletrode Tester led into positive (+) reeptle of meter. 3. If using Quiksilver VOA Meter A1, set meter on AUX TEST position. If using digitl meter, set meter on sle required to red millivolts (0-2 volts) MARCH 1998 Pge 7A-19

20 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER Immerse Eletrode Tester in the wter within 6 in. (150mm) of ft end of drive unit. IMPORTANT: There will e different voltge redings depending on the type of Mer- Cthode System you re testing. Eletrode Mounted on Bottom of Trnsom Assemly Eletrodes Mounted on Bot Trnsom 5. The following redings indite tht sterndrive is dequtely proteted:. MODELS WITH ELECTRODES MOUNTED ON BOAT TRANSOM Fresh Wter Ares millivolts with Quiksilver VOA Meter Millivolts with Digitl Meter Slt, Polluted or Minerl Lden Wter Ares: millivolts with Quiksilver VOA Meter Millivolts with Digitl Meter. MODELS WITH ELECTRODE MOUNTED ON BOTTOM OF TRANSOM ASSEMBLY Fresh Wter Ares Millivolts with Quiksilver VOA Meter Millivolts with Digitl Meter Slt, Polluted or Minerl Lden Wter Ares: Millivolts with Quiksilver VOA Meter Millivolts with Digitl Meter 6. If the reding is not within speified limits, or if reding is within speifitions, ut there is evidene of orrosion on sterndrive, refer to the pproprite trouleshooting hrt, following to id in dignosis. Pge 7A MARCH 1998

21 SERVICE MANUAL NUMBER 11 Test Equipment Set-Up CORROSION PROTECTION - ALL MODELS 6 IN. (915 MM) (MAX.) MARCH 1998 Pge 7A-21

22 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 11 Low Redings Cuse 1. Loss of ontinuity etween drive unit omponents nd negtive (-) ttery terminl. 2. Shore power green sfety grounding led not isolted from the power pkge ground (on ots equipped with shore power). 3. Underwter metl prts on the drive unit nd/or ot re unpinted or the pint is in poor ondition. The ot hs more exposed metl thn the nodes nd/or MerCthode system n protet. 4. Anodes pinted. 5. The nodes re improperly grounded or intive. 6. Anodes onsumed (no longer protet). 7. Drive unit nd/or ot ottom pinted with nti-fouling pnt ontining opper or tin. 8. MerCthode referene eletrode or node pinted. 9. Anodi heds used insted of plsti ps. 10. No power to MerCthode ontroller. 11. Poor onnetion etween referene eletrode led (rown) or node led (ornge) nd MerCthode ontroller. 1. Ensure tht ontinuity devies re not missing or dmged nd tht onnetions re len nd tight. 2. Disonnet shore power nd notie if reding inreses. If so, instll Quiksilver Isoltor 76664A3 or n isoltion trnsformer. 3. Prime nd pint underwter metl prts. This will redue the lod on the nodes nd/or MerCthode system. 4. Remove pint or reple nodes. 5. Clen node mounting surfe or reple nodes if they hve oxidized. 6. Reple nodes if eroded 50% or more. 7. Avoid ny eletril interonnetion etween the MerCruiser produt, Anodi Bloks, or MerCthode system nd the pint y llowing minimum of 1-1/2 in. (40 mm) of UNPAINTED re round these items on the trnsom of the ot. 8. Remove pint. 9. Reinstll the plsti ps. 10. Connet the positive (+) volt meter led (set on 0-20 volt sle) to the positive (+) ontroller terminl nd the negtive ( ) volt meter led to the negtive ( ) terminl. The meter should indite ttery voltge. Chek for lown fuse (if so equipped) on the strord MerCthode system. Clen the onnetion or repir wiring s required. 11. Clen nd/or tighten the onnetion. Repir the wiring. Pge 7A MARCH 1998

23 SERVICE MANUAL NUMBER 11 Low Redings (ontinued) Cuse 12. Fulty MerCthode referene eletrode. 13. Fulty MerCthode Controller. 14. Additionl orrosion protetion required. Bots whih re equipped with sizle mount of underwter metl (stinless steel prop, fter plnes, et.), or tht re moored in n re with wrm or rpid flowing wter, my require dditionl protetion. CORROSION PROTECTION - ALL MODELS 12. Disonnet the referene eletrode led(rown) from the ontroller R terminl. Connet the led to the positive (+) terminl of digitl multimeter (set on millivolt sle). Connet the negtive ( ) meter led to the negtive ( ) ttery terminl. Note the meter reding; then repet the test using MerCthode Referene Eletrode Tester 76675A1. You should otin the sme reding in oth ses. If not, reple the referene eletrode. 13. With node nd referene eletrode leds onneted to the ontroller, onnet the jumper wire etween R nd negtive (-) terminls on the ontroller. Connet the positive (+) led of the volt meter (set on 0-20 sle) to A terminl on the ontroller. Connet the negtive (-) meter led to the negtive (-) ontroller terminl. Reding should e s follows: Freshwter Ares - Eletrodes Mounted on ot trnsom: Millivolts Eletrode mounted on ottom trnsom ssemly: Millivolts Sltwter Ares - Eletrodes mounted on ot trnsom: Millivolts Eletrode mounted on ottom of trnsom ssemly: Millivolts If the reding is low, reple the ontroller. 14. Instll dditionl nodes or MerCthode system 88334A2. If the unit is lredy equipped with MerCthode system, seond system my e required MARCH 1998 Pge 7A-23

24 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 11 High Reding Cuse 1. Stry urrent orrosion. If n eletril urrent flowing long metl ondutor leves the metl for wter pth, it will use ioniztion of the metl, nd n re of rpid orrosion. 2. Poor onnetion etween MerCthode referene eletrode led (rown) nd R terminl on ontroller. 3. Fulty MerCthode referene eletrode. 4. Fulty MerCthode ontroller. 1. Oserve the reding while disonneting the eletril omponents one t time until you eliminte the high reding. Corret the ourse of stry urrent. 2. Clen nd /or tighten onnetion. Repir wiring s required. 3. Disonnet the referene eletrode led (rown) from R terminl on the ontroller. Connet the led to the positive (+) terminl of digitl multi-meter (set on millivolt sle). Connet the negtive ( ) meter led to the negtive ( ) ttery terminl. Note the meter reding; then, repet the test using MerCthode Referene Eletrode Tester 76675A1. Both tools should produe the sme reding. If not, reple the referene eletrode. 4. Reple the ontroller. Pge 7A MARCH 1998

25 SERVICE MANUAL NUMBER 11 Norml Reding But Corrosion is Evident CORROSION PROTECTION - ALL MODELS CORROSION ON THE ENTIRE DRIVE UNIT Cuse The drive unit is rised so fre tht the srifiil nodi trim t is out of the wter. Leve the drive unit in the In / Down position when the ot is moored to ensure the trim t is in the wter, providing protetion. CORROSION PROBLEM DEVELOPED AFTER REFINISHING THE DRIVE UNIT Cuse A steel wire rush ws used to len the luminum sting. Steel prtiles eme en-trpped nd set up smll glvni ell. Use only nylon or ristle rush. PAINT BLISTERING ON DRIVE UNIT Cuse Bttery hrger, whih uses 110 volt shore power, improperly onneted to the ttery. Ensure the hrger is onneted orretly. TRIM CYLINDER CORRODING Cuse Continuity lost etween trim ylinder nd drive unit. Instll proper ontinuity devies. ONLY ONE OR TWO COMPONENTS CORRODING (BELL HOUSING, GIMBAL RING, ETC.) Cuse Continuity lost etween drive unit nd omponents. If not lredy done, instll Continuity Ciruit Kit 99940A1. CORROSION IN THE EXHAUST OUTLET AREA Cuse Exhust gs deposits umulting on the drive exterior n result in pint listering nd orrosion. Remove deposits with mrine or utomotive wx. CORROSION OCCURS AFTER THE UNIT IS REMOVED FROM THE WATER Cuse Slt rystls remining on the surfe of the drive omponents omine with high humidity to use eletrolyte formtion, whih results in orrosion. Wsh drive exterior nd flush drive interior with fresh wter MARCH 1998 Pge 7A-25

26 CORROSION PROTECTION - ALL MODELS SERVICE MANUAL NUMBER 11 CORROSION BETWEEN SURFACES Cuse Slt uildup etween surfes. Protet mting prts with Quiksilver Speil Lurint 101 ( A1), Quiksilver 2-4-C Mrine Lurint ( A2), or Perfet Sel ( ). ALUMINUM CORRODING IN LUBRICATED AREAS Cuse Grphite in the lurint. Never use lurints ontining grphite, euse they elerte orrosion. Use speilly formulted Quiksilver mrine lurints. STAINLESS STEEL COMPONENTS CORRODING Cuse Foreign mtter (fishing line, mrine growth, et.) overing the steel nd strving it of oxygen. This uses rekdown of the protetive oxide film nd susequent orrosion (known s oxygen strvtion orrosion). Burying stinless steel in snd or silt n lso use this prolem. Remove foreign mtter nd prevent surfes from eing overed y snd or silt. STAINLESS STEEL PROPELLER CORRODING Cuse Continuity lost etween propeller nd propeller shft. Clen the mting surfes on the propeller, propeller shft, nd tthing prts. If pplile, instll ontinuity wsher. PAINT BLISTERING - THE METAL UNDER THE BLISTERED PAINT IS NOT PITTED Cuse The surfe ws not properly prepred efore pint ws pplied. Snd the surfe down to re metl, prime nd repint with Quiksilver Spry Pint. Pge 7A MARCH 1998