Separating alternator from engine on a small diesel, gasoline or dual and tri-fuel generators.

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  • OVERALL DIFFICULTY INDEX: 6/10
  • IF YOU HAVE NO TOOLS, YOU PAY $75 TO GET THEM FOR THIS JOB
  • IF YOU HAVE NO EXPERIENCE YOU SPEND 4 HOURS TO CARRY OUT THIS JOB
  • RISK OF HAND INJURY, SEE BELOW​
BEFORE YOU START
  • Your engine should be cold for this intervention. Do not attempt to work on a hot engine.
  • Watch out when unscrewing the alternator bolts, they could loosen suddenly sending your hand onto a hard or sharp surface resulting in an injury.
DISCLAIMER:
Our pictorials are of informative nature and do illustrate works carried out by ourselves at our own premises for our own use and satisfaction.
Readers who envisage to carry out similar works inspired by the below method shall do this at their own risks and liability.
Note: the below works are widely compatible with any of the KAMA and KIPOR KDE5000, KDE5500, KDE6000 and KDE6500 generators.

When to separate a small generator's alternator from its engine

This tutorial shows how to separate the alternator of a small diesel generator, from the engine shaft.
It allows to intervene on any of the alternator or the engine, depending on the purpose of your intervention.
Usually, you need to separate the alternator and engine of your small diesel genset in the following cases:
  • Repairing broken parts inside the engine
  • Overhauling the engine
  • Replacing piston rings
  • Rewinding the alternator

How to remove (extract) the alternator from the engine crank on a small generator with any type of fuel or engine.

1- Cut the cable ties that hold the wire bundles to the alternator legs.
2- Unplug all connectors of all wires that come out of the alternator.
3- Unscrew the two bolts that hold the alternator's crown.
4- Take it out and leave it hanging there. Do not disconnect the stator wires.
5- Remove the excitation brushes holder by taking out its screw.
6- Prepare your ratchet handle for loosening the alternator's rotor bolt.
7- Block the engine by inserting long nose pliers in the flywheel fins.   
8- Unscrew the rotor bolt and then the stator bolts (4).
9- Remove the nuts that hold the alternator legs.
10- Lift the alternator upwards and insert a wooden piece to keep it away from the generator's frame (chassis)
11- Place the extractor. Make sure it is well centered then rotate the axle clockwise until the stator comes out.
12- Put the stator aside.
13- Hit the rotor with a 1-2 Kg hammer and a piece of wood in between. Do not hit the rotor directly with the hammer!
14- One short and firm hit will bring it out of its conical coupling with the engine's shaft.
15- Complete the operation by unscrewing and removing the alternator fan housing.
That's it!

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See also our other tips for generator repair: