Impeller of Kohler 5E generator in 280DA won't spin

Gunn

Gunn

Well-Known Member
TECHNICAL Contributor
Oct 4, 2006
2,335
Potomac River - MD
Boat Info
2003 280DA and 1995 Sea Ray 175
Engines
Twin 4.3l and 3.0l, all w/ AlphaI GenII drives
Hello all,

So I started the generator yesterday and it was not sucking water and there was no water coming out of the exhaust. I had replaced the impeller two years ago after it disintegrated and it basically has less than 1 hour of runtime on it since then. So I took off the impeller cover and as I suspected, the impeller looks fine...all blades are there and intact. So then I bumped over the starter, even starting it for a second or two. The impeller did not move.

After a bit of research, it looks like my coupler has broken. In looking at the parts list on page 20 is looks to be item # 20, Part # 359448.

Does this all make sense, and am I on the right track?

upload_2022-5-28_16-10-56.png


upload_2022-5-28_16-11-25.png


Now my big question is: How the heck do I get access to this coupler, with the generator in this boat?!! Here is a photo I just took of the assembly:

Kohler5E-Impeller-280DA.jpg


Looks pretty nasty. This is taken looking forward on the starboard side of the generator and boat. To the right is the holding tank. Note that there is only enough clearance to remove 1 of the 4 bolts.

With the 4 bolts loosened on the housing, should I be able to remove the impeller and then remove this assembly? It looks like I'm seeing two parts there. A brass piece covered in a green patina, and a steel piece behind it that is all rust. Where is the coupler? Will I need to remove this steel piece too? There looks to be 2 allen-head bolts holding it in place; 1 I can see, the other I can only feel. I'm worried of their condition too, to be able to loosen them.

Has anyone done this before, in this boat with the minimal clearance? It's crazy how when they installed everything, they didn't leave enough room for the bolts to be removed, arghhhh.

Thanks,

Tom
 
Tom,
It sounds like your coupler has broken. They say it's a common part to break but I've had three boats with the Kohler 5E and never experienced it breaking. That said, after a few friends had theirs go last year I now carry a spare on board.

I'm not familiar with the 280s layout, can you move what the bolts are hitting?

If you remove the impeller and it's housing, I believe the coupler / sleeve is right behind it.
 
Thanks guys, you all are quick. I just came from messing with it and I was able to remove the housing; it wasn't too bad. And those two rusty allen-head bolts came out pretty easily too considering (using a 1/4" allen-head wrench). I made sure to tap in the wrench to get a good bit and they broke free no problem. And sure enough, there was no coupler attached to the shaft.

20220528_170000.jpg


From what I've found elsewhere on this forum, specifically in a post from 2013 (help with kohler 5k genny), the side cover plate should come off, at which point I'll find the broken coupler laying in the bottom. However, I can't get this plate off for the life of me! Only 2 bolts seem to hold it on, which I easily removed (using a 7/16" socket on a 3/8" ratchet). Here is the cover plate, the bolts I removed are circled.
Inked20220528_170915_LI.jpg


I would expect a little prying on the hole would set it free. But no luck. I even put the steel housing back in place with the allen-head bolts and whacked it a couple of times with a soft-blow mallet, as best I could. Nothing. I tried pry bars on the hole, etc. Nothing worked. I thought about making up some kind of puller where I could slip something in the hole, attach a bolt and tighten it, but I don't think I can get something in the hole and not drop it too! I don't want to overthink it though.

This cover should come off now, right? At this point, I may mess with it a little bit more, but I'm about to just add the coupler to the housing shaft and install it and call it a day. The old coupler will just have to lay in the bottom forever. I don't think there's anything moving down there, so it shouldn't cause any harm. But I'd really like to finish the job properly.

Any more tips on this cover removal would be appreciated!

Tom
 
Last edited:
Gunn said:
Thanks guys, you all are quick. I just came from messing with it and I was able to remove the housing; it wasn't too bad. And those two rusty allen-head bolts came out pretty easily too considering. I made sure to tap in the wrench to get a good bit and they broke free no problem. And sure enough, there was no coupler attached to the shaft.

View attachment 127560

From what I've found elsewhere on this forum, specifically in a post from 2013 (help with kohler 5k genny), the side cover plate should come off, at which point I'll find the broken coupler laying in the bottom. However, I can't get this plate off for the life of me! Only 2 bolts seem to hold it on, which I easily removed. Here is the cover plate, the bolts I removed are circled.
View attachment 127561

I would expect a little prying on the hole would set it free. But no luck. I even put the steel housing back in place with the allen-head bolts and whacked it a couple of times with a soft-blow mallet, as best I could. Nothing. I tried pry bars on the hole, etc. Nothing worked. I thought about making up some kind of puller where I could slip something in the hole, attach a bolt and tighten it, but I don't think I can get something in the hole and not drop it too! I don't want to overthink it though.

This cover should come off now, right? At this point, I may mess with it a little bit more, but I'm about to just add the coupler to the housing shaft and install it and call it a day. The old coupler will just have to lay in the bottom forever. I don't think there's anything moving down there, so it shouldn't cause any harm. But I'd really like to finish the job properly.

Any more tips on this cover removal would be appreciated!

Tom
Click to expand...

See my post
Kohler 5e impeller freewheeling
from last August 22, 2021.
Kohler 5e impeller freewheeling
 
I have never tried to remove that cover. I have had to replace the coupler before.
upload_2022-5-28_19-38-28.jpeg
upload_2022-5-28_19-38-28.jpeg
 
Years ago on a gas 260DA, the yellow coupling was laying the bottom pan in 2 pc. Buy 2 and have a spare. Takes 15 min to change.

Bennett
 
bbwhitejr said:
Years ago on a gas 260DA, the yellow coupling was laying the bottom pan in 2 pc. Buy 2 and have a spare. Takes 15 min to change.

Bennett
Click to expand...
Yep, the guys on the dock with Kohler gennys have all had the coupler break, so they all Cary an extra now
 
I am learning from your experience. I have a 2001 280DA with a Kohler 5e.

Please give a link or a part number to the coupler I should carry as a spare….
 
Yep, that is the right part number, Kohler P/N 359448 that I posted in my original post above. I found one on Ebay and saved a couple $$, but the www.partsfortechs.com link was the 2nd best price I could find.

I couldn't get that large circular cover off. From what I've seen, once you remove those two bolts (with a 7/16" socket), it should come right off. Mine must be a bit rusted on or something. But in any case, I was able to reach my index finger down in there and feel the old coupler. Was able to hook it around my finger and bring it up and out of the hole after a few tries. Then I found all of the other pieces. In total, mine shattered into 4 pieces.

20220528_183910.jpg


I've wire brushed the brass part and brushed and painted the steel part with some Eastwood rust-preventative paint. I even back-flushed the heat exchanger, just in case (got a few oyster shell pieces out). All ready to go back together as soon as the parts arrive.

Thanks everyone for the super quick help!

Tom
 
Gunn said:
Yep, that is the right part number, Kohler P/N 359448 that I posted in my original post above. I found one on Ebay and saved a couple $$, but the www.partsfortechs.com link was the 2nd best price I could find.

I couldn't get that large circular cover off. From what I've seen, once you remove those two bolts (with a 7/16" socket), it should come right off. Mine must be a bit rusted on or something. But in any case, I was able to reach my index finger down in there and feel the old coupler. Was able to hook it around my finger and bring it up and out of the hole after a few tries. Then I found all of the other pieces. In total, mine shattered into 4 pieces.

View attachment 127630

I've wire brushed the brass part and brushed and painted the steel part with some Eastwood rust-preventative paint. I even back-flushed the heat exchanger, just in case (got a few oyster shell pieces out). All ready to go back together as soon as the parts arrive.

Thanks everyone for the super quick help!

Tom
Click to expand...
Just for reference, how many hours/years did you have on your original coupler?
 
I’m just asking, since you have gone thru all this why not replace the impeller as well? I’m looking at the center shaft of the impeller with the photo blown up…that’s why I ask
 
DWABoat said:
Just for reference, how many hours/years did you have on your original coupler?
Click to expand...

Well I've owned the boat since 2010 and I never replaced the coupler. There are 770 hours on the generator. But it has sat for the last 2 years without being run (long story). Maybe that had something to do with it...

dwna1a said:
I’m just asking, since you have gone thru all this why not replace the impeller as well? I’m looking at the center shaft of the impeller with the photo blown up…that’s why I ask
Click to expand...

In my original post I mentioned that the impeller had less than ONE hour of use on it. When I removed the impeller it was perfectly fine, nice and pliable and smooth. So I'm going to keep using it. However, I did order another impeller and O-ring (it just arrived today), for next time!

Tom
 
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