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Service and Repair Manual 5500 Watt Portable Generator — Model 030430 This generator is rated in accordance with CSA (Canadian Standards Association) standard C22.2 No. 100-04 (motors and generators). Manual No. 279787GS Revision A BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC
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5500 Watt Portable Generator — Model 030430

Dec 18, 2021

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Page 1: 5500 Watt Portable Generator — Model 030430

Service and Repair Manual5500 Watt Portable Generator — Model 030430

This generator is rated in accordance with CSA (Canadian Standards Association) standard C22.2 No. 100-04 (motors and generators).

Manual No. 279787GS Revision A BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC

Page 2: 5500 Watt Portable Generator — Model 030430

2 BRIGGSandSTRATTON.COM

Briggs & Stratton Power Products Group, LLCP.O. Box 702Milwaukee, WI 53201-0702

Copyright © 2010. All rights reserved. No part of this material may be reproduced or transmitted in any form without the express written permission of Briggs & Stratton Power Products Group, LLC.

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Table of Contents

Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . 4

Generator Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Alternator Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Generator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 10

Alternator Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Generator Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Generator Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 20

Generator Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Engine Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Fuel System and Carburetion . . . . . . . . . . . . . . . . . . . . . . . 29

Governor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Cylinder Head and Valves . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Starters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Lubrication Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Cylinders, Covers, and Sumps . . . . . . . . . . . . . . . . . . . . . . 43

Crankshafts and Camshafts . . . . . . . . . . . . . . . . . . . . . . . . 45

Piston, Rings, and Connecting Rod . . . . . . . . . . . . . . . . . . 47

Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Generator Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . 57

Engine Illustrated Parts List . . . . . . . . . . . . . . . . . . . . . . . . 65

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Save These Instructions

The safety alert symbol indicates a potential personal injury hazard. A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to designate a degree or level of hazard seriousness. A safety symbol may be used to represent the type of hazard. The signal word NOTICE is used to address practices not related to personal injury.

DANGER indicates a hazard which, if not avoided, will result in death or serious injury.

WARNING indicates a hazard which, if not avoided, could result in death or serious injury.

CAUTION indicates a hazard which, if not avoided, could result in minor or moderate injury.NOTICE addresses practices not related to personal injury.

Important Safety Instructions

The manufacturer cannot possibly anticipate every possible circumstance that might involve a hazard. The warnings in this manual, and the tags and decals affixed to the unit are, therefore, not all-inclusive. If you use a procedure, work method or operating technique that the manufacturer does not specifically recommend, you must satisfy yourself that it is safe for you and others. You must also make sure that the procedure, work method or operating technique that you choose does not render the generator system unsafe.

Safety Symbols and Meanings

Equipment Description

Read this manual carefully and become familiar

with your generator. Know its applications, its

limitations and any hazards involved.

The generator is an engine-driven, revolving field, alternating current (AC) generator. It was designed to supply electrical power for operating compatible electrical lighting, appliances, tools and motor loads. The generator’s revolving field is driven at about 3,600 rpm by a single-cylinder engine.

NOTICE: Exceeding generator’s wattage/amperage capacity could damage generator and/or electrical devices connected to it.• DO NOT exceed the generator’s wattage/amperage

capacity.

Every effort has been made to ensure that the information in this manual is both accurate and current. However, the manufacturer reserves the right to change, alter, or otherwise improve the generator and the documentation at any time without prior notice.

The Emission Control System for this generator is warranted for standards set by the Environmental Protection Agency and the California Air Resources Board.

Toxic Fumes Kickback Electrical Shock

Fire Explosion Read Manual

Hot SurfaceFlying ObjectsMoving Parts

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WARNING Running engine gives off carbon monoxide, an odorless, colorless, poison gas.Breathing carbon monoxide can cause headache, fatigue, dizziness, vomiting, confusion, seizures, nausea, fainting or death.

Operate generator ONLY outdoors.• Install a battery operated carbon monoxide alarm near • the bedrooms.Keep exhaust gas from entering a confined area through • windows, doors, ventilation intakes, or other openings.DO NOT operate this product inside any building, carport, • porch, mobile equipment, marine applications, or enclosure, even if windows and doors are open.

WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

WARNING Certain components in this product and related accessories contain chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Wash hands after handling.

WARNING This generator does not meet U.S. Coast Guard • Regulation 33CFR-183 and should not be used on marine applications.Failure to use the appropriate U.S. Coast Guard approved • generator could result in death or serious injury and/or property damage.

WARNING Starter cord kickback (rapid retraction) will pull hand and arm toward engine faster than you can let go, which could cause broken bones, fractures, bruises, or sprains resulting in serious injury.

When starting engine, pull cord slowly until resistance is • felt and then pull rapidly to avoid kickback.NEVER start or stop engine with electrical devices • plugged in and turned on.

WARNING Fuel and its vapors are extremely flammable and explosive which could cause burns, fire or explosion resulting in death, serious injury and/or property damage.

WHEN ADDING OR DRAINING FUEL

Turn generator engine OFF and let it cool at least 2 • minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.Fill or drain fuel tank outdoors.• DO NOT overfill tank. Allow space for fuel expansion.• If fuel spills, wait until it evaporates before starting engine.• Keep fuel away from sparks, open flames, pilot lights, • heat, and other ignition sources.Check fuel lines, tank, cap and fittings frequently for • cracks or leaks. Replace if necessary.DO NOT light a cigarette or smoke.•

WHEN STARTING EQUIPMENT

Ensure spark plug, muffler, fuel cap, and air cleaner are in • place.DO NOT crank engine with spark plug removed.•

WHEN OPERATING EQUIPMENT

DO NOT operate this product inside any building, carport, • porch, mobile equipment, marine applications, or enclosure.DO NOT tip engine or equipment at angle which causes • fuel to spill.DO NOT stop engine by moving choke control to “Choke” • position ( ).

WHEN TRANSPORTING, MOVING OR REPAIRING EQUIPMENT

Transport/move/repair with fuel tank EMPTY or with fuel • shutoff valve OFF.DO NOT tip engine or equipment at angle which causes • fuel to spill.Disconnect spark plug wire.•

WHEN STORING FUEL OR EQUIPMENT WITH FUEL IN TANK

Store away from furnaces, stoves, water heaters, clothes • dryers, or other appliances that have pilot light or other ignition source because they could ignite fuel vapors.

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WARNING Generator voltage could cause electrical shock or burn resulting in death or serious injury.

Use approved transfer equipment to prevent backfeed by • isolating generator from electric utility workers.When using generator for backup power, notify utility company.• Use a ground fault circuit interrupter (GFCI) in any damp or • highly conductive area, such as metal decking or steel work.DO NOT touch bare wires or receptacles.• DO NOT use generator with electrical cords which are • worn, frayed, bare or otherwise damaged.DO NOT operate generator in the rain or wet weather.• DO NOT handle generator or electrical cords while standing • in water, while barefoot, or while hands and feet are wet.DO NOT allow unqualified persons or children to operate • or service generator.

WARNING Exhaust heat/gases could ignite combustibles, structures or damage fuel tank causing a fire, resulting in death, serious injury and/or property damage.

Contact with muffler area could cause burns resulting in serious injury.

DO NOT touch hot parts and AVOID hot exhaust gases.• Allow equipment to cool before touching.• Keep at least 5 feet (152 cm) of clearance on all sides of • generator including overhead.It is a violation of California Public Resource Code, • Section 4442, to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the exhaust system is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order. Other states or federal jurisdictions may have similar laws.Contact the original equipment manufacturer, retailer, or dealer to obtain a spark arrester designed for the exhaust system installed on this engine.Replacement parts must be the same and installed in the • same position as the original parts.

WARNING Unintentional sparking could cause fire or electric shock resulting in death or serious injury.

WHEN ADJUSTING OR MAKING REPAIRS TO YOUR GENERATOR

Disconnect the spark plug wire from the spark plug and • place the wire where it cannot contact spark plug.

WHEN TESTING FOR ENGINE SPARK

Use approved spark plug tester.• DO NOT check for spark with spark plug removed.•

WARNING Starter and other rotating parts could entangle hands, hair, clothing, or accessories resulting in serious injury.

NEVER operate generator without protective housing or • covers.DO NOT wear loose clothing, jewelry or anything that • could be caught in the starter or other rotating parts.Tie up long hair and remove jewelry.•

WARNING Excessively high operating speeds could result in minor injury and/or generator damage. Excessively low speeds impose a heavy load.

DO NOT tamper with governor spring, links, or other parts • to increase engine speed. Generator supplies correct rated frequency and voltage when running at governed speed.DO NOT modify generator in any way.•

NOTICE Improper treatment of generator can damage it and shorten its life.

Use generator only for intended uses.• If you have questions about intended use, contact your • authorized dealer.Operate generator only on level surfaces.• DO NOT expose generator to excessive moisture, dust, • dirt, or corrosive vapors.DO NOT insert any objects through cooling slots.• If connected devices overheat, turn them off and • disconnect them from generator.Shut off generator if:• -electrical output is lost; -equipment sparks, smokes, or emits flames; -unit vibrates excessively.

NOTICE Exceeding generators wattage/amperage capacity can damage generator and/or electrical devices connected to it.

DO NOT exceed the generator’s wattage/amperage • capacity.Start generator and let engine stabilize before connecting • electrical loads.Connect electrical loads in OFF position, then turn ON for • operation.Turn electrical loads OFF and disconnect from generator • before stopping generator.

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Generator Components

A - Fuel Tank — Capacity of seven (7) U.S. gallons (26.5 L)B - Fuel Valve — Used to turn fuel supply on and off to

engine.C - Choke Lever — Used when starting a cold engine.D - Air Cleaner — Protects engine by filtering dust and

debris out of intake air.E - Recoil Starter — Used to start the engine.F - Engine Rocker Switch — Set this switch to “ON” before

using recoil starter. Set switch to “OFF” to stop engine.G - Oil Fill Cap — Check and fill engine with oil here.H - Oil Drain Plug — Drain engine oil hereJ - Grounding Fastener — Consult your local agency having

jurisdiction for grounding requirements in your area.

K - Identification Label — Provides model, revision, and serial number of generator. Please have this readily available when calling for assistance.

L - Rocker Switch Circuit Breaker — The receptacles are provided with a rocker switch circuit breaker to protect the generator against electrical overload.

M - 120/240 Volt AC, 30 Amp Locking Receptacle — May be used to supply electrical power for the operation of 120 and/or 240 Volt AC, 30 Amp, single phase, 60 Hz electrical, lighting, appliance, tool, and motor loads.

N - Spark Arrester Muffler — Exhaust muffler lowers engine noise and is equipped with a spark arrester screen.

P - Engine Data Tag — Provides model, type, trim, and date code for the engine.

R - 120 Volt AC, 20 Amp, Duplex Receptacles — May be used to supply electrical power for the operation of 120 Volt AC, 20 Amp, single phase, 60 Hz electrical, lighting, appliance, tool, and motor loads.

A

B

C

D

E

F

G

H

J

K

L

M

N

R

P

Page 8: 5500 Watt Portable Generator — Model 030430

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Alternator Components

A - Alternator Adapter

B - Rotor Assembly

C - Slip Rings

D - Stator

E - Roll Pin

F - Rear Bearing Carrier

G - Taptite

H - Brush Holder / Bridge Rectifier Assembly

J - Hex-Head Cap Screw

G E

C

B

A

E

J

H

F

D

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Brush Holder / Bridge Rectifier Assembly

The brush holder is mounted to the rear bearing carrier. The positive (+) brush contacts the slip ring nearest the rotor bearing.

The bridge rectifier is made up of four diodes and a varistor, shown schematically in Figure 2. The diode (rectifier) permits current flow in one direction only. Stator excitation winding (AC) output leads connect to the two terminals labeled J1 and J2 (C, Figure 1) located on top of the bridge rectifier. Direct current (DC) is taken from the bridge rectifier and applied to the rotor via the brush and slip rings. The varistor is a “variable resistor” which protects the diodes against high voltage surges.

This generator is equipped with a bridge rectifier (A, Figure 1) attached to the brush holder assembly (B).

How it Works

Figure 3 is an operating diagram of a revolving field alternator with a bridge rectifier.

Figure 3

Figure 1

B

C

A

Figure 2

A - RotorB - Magnetic Lines of FluxC - Excitation Winding

B

B

C

E

F

G

NOTICE: The brushes are made of a carbon material and can easily break. Use care when removing and installing the brushes.

D - Bridge RectifierE - Power WindingF - Receptacle G - Slip Ring

The brush rectifi er acts to supply direct current (DC) fl ow to the rotor winding. The increase in current fl ow through the rotor results in a proportional increase in the rotor’s magnetic fi eld strength, which induces alternating currect (AC) in the windings of the stator.

1. The rotor (A) may be considered a permanent magnet since some residual magnetism is always present in the steel laminations.

2. The rotor (A) is rotated at a pre-determined speed. 3. Residual or “stored” magnetism in the rotor winding

creates magnetic lines of flux (B) which cut through stator excitation winding (C) and power winding (E), to induce Electro Motive Force (EMF) into both windings.

4. Winding (C) is the excitation winding. The EMF induced into this winding produces an alternating currect (AC) flow, which is applied to a bridge rectifier (D).

5. The bridge rectifier changes alternating current (AC) into direct current (DC).

6. Direct current (DC) from the bridge rectifier is applied to the rotor windings (A) via the slip rings (G) and brush assembly, to create a magnetic field that is stronger than that created by the residual magnetism of the rotor.

7. This stronger magnetic field induces a greater EMF (and resulting current flow) into both stator windings (C and E).

8. The cycle then repeats itself until a predetermined (AC) output is reached. Any load(s) connected to the receptacle (F) completes circuit.

D

A

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Generator Troubleshooting

Figure 4

Refer to Figure 4 for wire identification and locations when performing the troubleshooting procedures.

LEGEND

WIRE NUMBER WIRE COLOR

0 Green2 Red6 Blue11 Blue22 Red33 Black44 Gray

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Figure 5 is a troubleshooting flowchart for “Direct Excited” (Brush Type) generators.

Test 1:Check AC output

voltage and frequency

Test 2:Flash the Field

Test 3:Isolate Control Panel

Low voltage less than 1

volt or zero ?

Low voltage and frequency

OutputOK? END

See:Check Alternator

Inspect Control Panel

OutputOKat

Harness?

Check and AdjustEngine Governor

YES

NO

NO

YES

Figure 5

OutputOK? YES

NOEND

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In normal generator operation, upon startup there is some “residual” magnetism in the rotor to get the generating process started. Residual magnetism is what is left in the rotor after the unit has shut down. When residual magnetism is lost, the unit will have an output voltage that will remain at zero. This usually occurs if the unit is out of use for a long period of time. If residual magnetism is lost, it can usually be restored by “fl ashing the fi eld” with a simple process involv-ing a (DC) battery. 1. Obtain a 12VDC battery and two jumper leads with

alligator clip ends. 2. Remove the four screws and remove the rear bearing

cover. 3. Locate the brush/bridge rectifier inside the rear bearing

carrier. 4. Remove wires #2 and #6 (red and blue) from the

rectifier terminals J1 and J2.NOTICE: Isolate wires #2 and #6. Do not let the terminals touch or contact ground. 5. Apply 12VDC across terminals J1 and J2, polarity is

not important. Connect battery negative last (Figure 6).

6. Start the engine and allow it to stabilize at running speed.

7. After about 5 seconds, shut the engine down. 8. Disconnect the battery wires from the brushes.

(Disconnect negative (-) battery wire last). 9. Restart the unit and check once again for proper (AC)

output voltage. • If output voltage is within specifications,

troubleshooting is complete. • If output voltage is not within specifications, proceed to

Test 3- Isolate Control Panel.

WARNING Battery posts, terminals and other components in this product and related accessories contain chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. Wash hands after handling.

WARNING Starter and other rotating parts could entangle hands, hair, clothing, or accessories resulting in serious injury.

NEVER operate generator without protective housing or • covers.DO NOT wear loose clothing, jewelry or anything that • could be caught in the starter or other rotating parts.Tie up long hair and remove jewelry.•

TEST 1 - Check Voltage and Frequency Output

1. Disconnect any electrical loads. 2. Check all circuit breakers and verify they are ON. 3. Set meter to measure AC volts. 4. Connect the meter test leads into a 120 VAC generator

receptacle. 5. Connect a frequency meter into a generator receptacle. 6. Start the generator engine, let it stabilize and warm up. 7. Read the “no-load” voltage and frequency, and analyze

the results as follows: • If zero volts or less than 1VAC is indicated proceed to

Test 2 - Flash the Field. • If low voltage is indicated, but readings is above 1VAC

and AC frequency is normal proceed to Test 3 - Isolate the Control Panel.

• If low voltage is indicated, but reading is above 6VAC and AC frequency is low the engine governor may need adjustment. Refer to the appropriate engine manual for further governor troubleshooting.

TEST 2 - Flash the Field

WARNING Generator voltage could cause electrical shock or burn resulting in death or serious injury.

DO NOT touch bare wires or receptacles.• DO NOT allow unqualified persons or children to operate • or service generator.

Figure 6

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TEST 3 - Isolate Control Panel

A “No Output” condition may or may not be related to the alternator windings. To help isolate where the issue is, follow these steps: 1. With the engine OFF, disconnect the power lead

harness from the back of the control panel. 2. Set meter to measure AC volts. 3. Connect the test leads to the stator wires #11 and #22

located in the control panel connector. Polarity does not matter.

4. Start the engine and measure the voltage output. 5. Shut off the engine. • A voltage output of 120VAC indicates the alternator

is functioning, and the no output condition is likely in the control panel. Disassemble the control panel and inspect for any indication of what may cause no output. Refer to the unit wiring diagram to verify connections.

• A low voltage output indicates the alternator needs to be tested. Proceed to Check Alternator.

Check Alternator

Alternator Disassembly

The alternator can be diagnosed without complete disassem-bly. To access the power winding, disconnect the connector from the back of the control panel. The Brush Rectifi er (D) is mounted inside the rear bearing carrier (E, Figure 7). To access the brush rectifi er, remove the four screws (A) and remove the plastic, rear bearing cover (B). Remove the two screws (C) and carefully pull out the brushes. Disconnect wires #2 and #6 (excitation winding).Once removed, the rotor slip rings can be accessed through the area where the brushes were mounted.

NOTICE: The brushes are made of a carbon material and can easily break. Use care when removing and installing the brushes.

Figure 7

A

C

B

D

E

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Measure Winding Resistance

Test Stator AC Power Winding Resistance

1. Set meter to measure Ohms. 2. Connect the test leads to stator wires #11 and #22

located in the harness going to the control panel connector (Figure 8).

3. Measure the resistance and compare it the nominal resistance from the specifications listed in the back of this manual.

4. Connect the test leads to stator wires #33 and #44 located in the control panel connector (Figures 9).

5. Measure the resistance and compare it to the nominal resistance listed in the back of this manual.

• A reading within the specifications listed is acceptable. • A reading of infinity or high resistance indicates an

opening in the power winding. Replace the stator. • A low reading indicates a shorted stator winding.

Replace the stator. 6. Connect one meter test lead to a proper ground on

alternator. Connect the other test lead to the stator power winding.

• A reading of infinity should be measured. If a reading of infinity is measured and the stator resistance is within specifications, the stator is functioning properly.

• A reading other than infinity indicates a stator winding shorted to ground. Replace the stator.

Figure 8

Figure 9

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Test Stator Excitation Winding Resistance

The excitation wires may be colored (red and blue) or numbered (#2 and #6). Colored excitation wires must not be confused with the colored power wires. The excitation wires were disconnect earlier from the brush rectifi er earlier in Measuring Winding Resistance. 1. Set meter to measure Ohms. 2. Connect the test lead to the stator excitation wires

#2 and #6 (Figure 10). These wires were previously disconnected from the brush rectifier.

Figure 10

3. Measure the resistance and compare it to the nominal resistance listed in the back of this manual.

• A reading within the specifications listed is acceptable. • A reading of infinity or high resistance indicates an

opening in the power winding. Replace the stator. • A low reading indicates a shorted winding. Replace the

stator. 4. Connect one test lead to a stator power wire. Connect

the other test lead to one of the stator excitation wires. • A reading of infinity should be measured. If a reading of

infinity is measured and the stator resistance is within specifications, the stator is functioning properly.

• A reading other than infinity indicates a power winding shorted to an excitation winding. Replace the stator.

5. Connect one test lead to an excitation wire. Connect the other test lead to a proper metal ground.

• A reading of infinity should be measured. • A reading other than infinity indicates a winding shorted

to ground. Replace the stator.

Check Rotor Resistance

1. Set meter to measure Ohms. 2. Connect one test lead to each rotor slip ring (Figure 11).

The slip rings can be accessed through the area where the brushes were removed. Polarity does not matter.

Figure 11

NOTICE: Do not connect the test lead terminals. Ensure that each test lead makes a connection to each slip ring. 3. Measure the rotor resistance. Compare it to the nominal

resistance from the specifications listed in the back of this manual.

• A reading of infinity or a very high resistance indicates an open circuit or a partially open condition of the rotor windings.

• A very low resistance indicates a shorted rotor. Replace the rotor.

• If resistance is within specifications, proceed to Step 4. 4. Connect one test lead to a proper metal ground on the

engine or alternator and the other test lead to either slip ring.

• A reading of infinity should be measured. If a reading of infinity is measured and the rotor resistance is within specifications, the rotor is functioning properly.

• A reading other than infinity indicates a rotor winding shorted to the rotor shaft. Replace the rotor.

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Alternator Disassembly

Refer to Figure 12 for part identification and to aid in the diasassembly of the alternator.

Figure 12

A - Plastic End Cover

B - Rotor Through Bolt

C - Mounting Screws (2) for Brush Holder

D - Rear Bearing Carrier

E - Roll Pin

F - Stator

G - Steel Laminations

H - Alternator Adapter

J - Engine Adapter

K - Mounting Screws (4) for Adapters

L - Stator Bolts (4)

A B C D E F G H

L

E

KJ

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17

Remove the Stator

Ensure the engine/alternator assembly is set on a sturdy work surface. Do not set the engine/alternator assembly on the plastic end cover. 1. Remove the plastic end cover (A, Figure 12). 2. Remove the two mounting screws that secure the

brush holder (C) to the rear bearing carrier. Disconnect the brush holder and set aside.

3. Remove the four stator bolts (L) that secure the rear bearing carrier to the alternator.

4. Remove the stator assembly. You may need to tap lightly on the stator assembly with a plastic, dead-blow hammer to loosen it from the alternator adapter (H).

5. Slide the stator out of the alternator adapter and off the rotor.

NOTICE: Use care not to damage the windings. Set the stator on the laminations, not on the coils of the wire.

Remove the Rotor

1. Remove the four screws (D) that secure the alternator adapter to the engine adapter (J).

2. Loosen, but do not remove, the rotor through-bolt (B). The rotor through-bolt will prevent the rotor from falling during disassembly.

3. While supporting and pulling the rotor with one hand, strike the rotor assembly, on the steel laminations with a plastic, dead blow hammer (Figure 13) until it separates from the engine shaft.

Assemble the Alternator

1. Install the rotor and torque to values listed in Specifications.

2. With stator harness and lead wires facing away from the engine, place stator (A, Figure 14) over rotor and into adapter casting (B). Verify roll pin slot (C), in stator, lines up with the roll pin (D) in adapter.

3. Use a plastic, dead blow hammer to evenly seat stator into the adapter casting.

4. Unscrew the through-bolt and carefully slide rotor off the engine crankshaft.

Except for certain engine repairs, there is no need to remove the engine adapter from the engine.

Figure 13

Figure 14

B

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4. Pull wires up through rear bearing carrier (A, Figure 15). Set rear bearing carrier on rotor bearing and stator. Verify second roll pin slot (B) in stator lines up with roll pin (C) in rear bearing carrier.

5. Using a plastic, dead blow hammer, tap rear bearing carrier evenly over rotor bearing and stator until it seats.

NOTICE: Do not use stator bolts to draw assembly together.

Figure 15

9. Once wires are connect, rotate brush set three times to reduce the slack in the wires (A, Figure 17).

6. Insert stator bolts into each hole around the rear bearing carrier. Tighten bolts in a criss-cross pattern until snug, then torque to values listed in Generator Specifications.

7. Rotate engine flywheel by hand slowly to ensure that the alternator is not binding.

8. Hold brush set with brushes down and tab (A, Figure 16) facing you. Attach red #6 wire to negative terminal (B) on the left. Attach blue #2 wire to positive terminal (C) on the right.

10. Set brushes down into slot on rear bearing carrier with tab facing down. Align holes in brush set and rear bearing carrier and insert screws (B). Torque screws to values listed in Generator Specifications.

11. Route wires away from all rotating parts, then install cover.

Figure 17

A

B

Figure 16

AB

C

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No Load Voltage 255-273No Load Frequency (RPM) 62.0 - 62.5 Hertz (3720 - 3750 RPM)Starting Wattage 8,250 wattsWattage* 5,500 wattsAC Load Current

at 120 Volts 45.8 Ampsat 240 Volts 22.9 Amps

Phase Single PhaseRated Frequency 60 HertzDisplacement 18.61 ci (305 cc)Spark Plug Gap 0.030 in. (0.76 mm)Fuel Capacity 7 U.S. gallons (26.5 L)Oil Capacity 28 Ounces (0.83 Liters)

Resistance Values

Winding Resistance 030430-2

Rotor (at the slip rings) 24.3 - 29.1 OhmPower (wires 11-22 & 33-44) 0.19 - 0.24 / 0.19 - 0.24 OhmExcitation (wires 2-6) 1.26 - 1.50 Ohm

Power Ratings: The gross power rating for individual gas engine models is labeled in accordance with SAE (Society ofAutomotive Engineers) code J1940 (Small Engine Power & Torque Rating Procedure), and rating performance has beenobtained and corrected in accordance with SAE J1995 (Revision 2002-05). Torque values are derived at 3060 RPM; horsepowervalues are derived at 3600 RPM. Actual gross engine power will be lower and is affected by, among other things, ambientoperating conditions and engine-to-engine variability. Given both the wide array of products on which engines are placed andthe variety of environmental issues applicable to operating the equipment, the gas engine will not develop the rated gross powerwhen used in a given piece of power equipment (actual "on-site" or net power). This difference is due to a variety of factorsincluding, but not limited to, accessories (air cleaner, exhaust, charging, cooling, carburetor, fuel pump, etc.), applicationlimitations, ambient operating conditions (temperature, humidity, altitude), and engine-to-engine variability. Due tomanufacturing and capacity limitations, Briggs & Stratton may substitute an engine of higher rated power for this Series engine.

* This generator is rated in accordance with CSA (Canadian Standards Association) standard C22.2 No. 100-04 (motors and generators).

Fastener Torque Values

Engine Adapter to Engine 200 lb-in. (23 Nm)Alternator Adapter to Engine Adapter 200 lb-in. (23 Nm)Rotor Bolt to Crankshaft 200 lb-in. (23 Nm)Brushes to Rear Bearing Carrier 50 lb-in. (7 Nm)Stator Bolt 80 lb-in. (9 Nm)

Generator Specifications

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Generator Wiring Diagram

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Generator Schematic

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Notes

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Fuel and Oil Recommendations

Engine Maintenance

Fuel must meet these requirements:Clean, fresh, unleaded gasoline.• A minimum of 87 octane / 87 AKI (90 RON).• Gasoline with up to 10% ethanol (gasahol) or up to 15% • MTBE (methyl tertiary butyl ether) is acceptable.

NOTICE: Do not use unapproved gasoline, such as E85. Do not mix oil in gasoline or modify the engine to run on alter-nate fuels. This will damage the engine components and void the engine warranty.

To protect the fuel system from gum formation, mix a fuel stabilizer into the fuel. All fuel is not the same. If starting or performance problems occur, change fuel providers or change brands. This engine is certifi ed to operate on gasoline. The emissions control system for this engine is EM (Engine Modifi cations).

High Altitude

At altitudes over 5,000 feet (1524 meters), a minimum 85 octane / 85 AKI (89 RON) gasoline is acceptable. To remain emissions compliant, high altitude adjustment is required. Operation without this adjustment will cause decreased per-formance, increased fuel consumption, and increased emis-sions. Operation of the engine at altitudes below 2,500 feet (762 meters) with the high altitude kit is not recommended.

Oil must meet these requirements:Briggs & Stratton warranty certified oils are highly • recommended for best performance.Other high-quality detergent oils are acceptable if classified • for service SF, SG, SH, SJ or higher.Do not use special additives.•

Outdoor temperatures determine the proper oil viscosity for the engine. Use the chart (Figure 15) to select the best viscosity for the outdoor temperature range expected.

Figure 15

Maintenance Chart

First 5 Hours

Change oil• Every 8 Hours or Daily

Check engine oil level• Clean area around muffler and controls• Clean finger guard•

Every 25 Hours or Annually

Clean air filter*• Clean pre-cleaner*•

Every 50 Hours or Annually

Change engine oil• Check muffler and spark arrester•

Annually

Replace air filter• Replace pre-cleaner• Replace spark plug• Replace fuel filter• Clean air cooling system*•

*In dusty conditions or when airborne debris is present, clean more often.

Combustion Chamber

Remove combustion chamber deposits every 500 hours or whenever the cylinder head is removed.With the piston at Top Dead Center (TDC), scrape deposits from top of piston and upper bore with a plastic scraper.Remove the loosened deposits from around the top ring land area using compressed air or a shop vacuum and a soft bristle brush.

NOTICE: Use care to prevent debris from entering push rod or oil return cavities in cylinder. Do not damage bore, top of piston, cylinder head, or cylinder head gasket surfaces.

It is not necessary to remove the discoloration marks on the piston, valves, and/or cylinder head. These marks are normal and will not affect engine operation.

Combustion Chamber

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Air Filter Maintenance

A correctly serviced air fi lter protects internal engine parts from airborne dirt and dust. Poor fi lter maintenance will allow dirt and dust to be drawn into the engine, causing wear to the intake system and contamination of the oil. Dirt in the oil forms an abrasive mixture which wears down moving parts.

NOTE: Do not use pressurized air or solvents to clean the fi lter. Pressurized air can damage the fi lter and solvents will dissolve the fi lter.

1. Loosen screws (A, Figure 16) and remove air cleaner cover (B).

2. Carefully remove cartridge (C) from base (D). 3. Install clean (or new) air cleaner assembly inside cover.

Dispose of old filter properly. 4. Assemble air cleaner cover onto base and tighten

screws.

Figure 16

Spark Plug Maintenance

Spark plugs should be replaced every year.

NOTICE: Spark plugs have different thread “reach” and heat ranges. When changing a spark plug, use only the specifi ed replacement, otherwise engine damage could occur.

NOTE: In some areas, local law requires using resistor spark plugs to suppress radio frequency interference.

1. Disconnect spark plug wire. 2. Remove and inspect spark plug for wear and damage.

Replace spark plug if electrodes are burned away, or the porcelain is cracked.

3. Do not blast clean spark plugs. Clean by scraping or wire brushing, and then washing in a commercial solvent.

4. Using a wire gage, check and set the gap (A, Figure 17). See Engine Specifications.

5. Re-install spark plug and torque to values listed in Specifications.

6. Connect spark plug wire.

Figure 17

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Cooling System Maintenance

Dirt or debris can restrict air fl ow and cause the engine to overheat, resulting in poor performance and reduced engine life. Continued operation with a clogged cooling system can cause severe overheating and possible engine damage. Clean these areas (A, Figure 18) yearly or more often when dust or airborne debris is present.NOTICE: Do not use water to clean the engine. Water could contaminate the fuel system. Use a brush or dry cloth to clean the engine.

Exhaust System Maintenance

WARNING Exhaust heat/gases could ignite combustibles, structures or damage fuel tank causing a fire, resulting in death, serious injury and/or property damage.

Contact with muffler area could cause burns resulting in serious injury.

DO NOT touch hot parts and AVOID hot exhaust gases.• Allow equipment to cool before touching.• Keep at least 5 feet (152 cm) of clearance on all sides of • generator including overhead.It is a violation of California Public Resource Code, • Section 4442, to use or operate the engine on any forest-covered, brush-covered, or grass-covered land unless the exhaust system is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order. Other states or federal jurisdictions may have similar laws.Contact the original equipment manufacturer, retailer, or dealer to obtain a spark arrester designed for the exhaust system installed on this engine.Replacement parts must be the same and installed in the • same position as the original parts.

Inspect Exhaust System

All exhaust system components must be inspected whenever the exhaust system is disassembled. Check muffl er mounting bracket and/or muffl er adapters for cracked welds or break-age. Check muffl er for split seams, loose internal parts, or cracked welds. Replace any damaged parts with new OEM parts.Never reinstall broken or damaged components.

Clean and Inspect the Spark Arrester

1. To remove muffler heat shield (A, Figure 19) from muffler (B), remove four screws that connect guard to muffler bracket.

2. Remove four screws that attach spark arrestor screen (C).

2. Inspect screen and obtain a replacement if torn, perforated or otherwise damaged. DO NOT use a defective screen. If screen is not damaged, clean it with a commercial solvent.

3. Reattach screen and muffler guard.

Figure 18

Figure 19

A

B

C

A

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Oil and Oil Filter Maintenance

Change oil after the fi rst 5 hours of operation. After that, change oil after every 50 hours of operation. Change oil more often if engine is operated in dirty or dusty conditions, under heavy loads, or in high ambient temperatures.

1. Remove oil drain plug from side or bottom of engine and drain oil while the engine is still warm.

2. Install drain plug. 3. Remove oil fi lter, if equipped. 4. Apply light coat of clean engine oil to new filter gasket.

Screw new fi lter on by hand until gasket contacts fi lter mounting adapter. Then tighten an additional 1/2 to 3/4 turn.

5. Fill crankcase with the correct amount of new oil. 6. Start engine and run at idle for a minute or so. Shut

engine off and wait for oil to settle back into the cylinder.

7. Check dipstick. If necessary, add more oil slowly to bring level to FULL mark on dipstick.

NOTICE: Do not overfi ll. Overfi lling can cause seals to fail, smoke from the exhaust, or overheating due to oil foaming.

8. Replace oil fill cap and dipstick. 9. Start and run engine. Check for oil leaks.

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Engine AdjustmentsGovernor Adjustments

A complete governor system adjustment includes a static adjustment, engine warm-up, idle and/or governed idle adjustment, and top no-load adjustment. Be sure to complete all steps.

Static Adjustment

1. Loosen screw holding governor lever to governor crank (A, Figure 20).

2. Rotate throttle linkage from idle position to wide open throttle. Note direction of rotation of the governor arm attached to the throttle linkage.

3. While holding linkage at wide open throttle, use the appropriate tool to rotate the governor shaft until it stops in the direction noted in Step 2.

4. Tighten screw holding governor lever to governor crank per Engine Specifications.

5. Before starting engine, manually actuate throttle linkage to check for binding.

Figure 20

Idle and Top No Load Adjustment

1. Start engine and run until it reaches operating temperature.

2. Place throttle in SLOW position. 3. Hold throttle lever against idle speed screw, and, using

Tachometer #19200 or #19389, adjust screw to obtain 1300 RPM. Release throttle lever.

4. Using Tang Bender #19229 or #19352, bend governed idle spring tang to obtain 1750 RPM (Figure 21).

Figure 21

5. Place throttle in FAST position. 6. Adjust screw to obtain correct Top No Load RPM

(Figure 22).

Figure 22

NOTE: Correct Top No Load RPM for each model-type-trim can be found in the engine replacement data on Briggs & Stratton websites.

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Adjust Valve Clearance

NOTE: Check valve clearance while the engine is cold.

1. Turn crankshaft counterclockwise until piston is at top dead center on the compression stroke. This prevents the compression release from holding the valves open.

2. Insert a narrow screwdriver or rod into the spark plug hole as a gauge, then slowly turn crankshaft counterclockwise until the piston has moved down the bore by 1/4” (6mm).

3. Using a feeler gauge (A, Figure 23), adjust rocker nut to obtain the clearance as listed in Specifications.

4. Hold rocker nut and tighten the rocker ball setscrew (B) to the torque valve shown in Specifications.

5. Check clearance again and re-adjust, if necessary. 6. Repeat for other valve.

NOTE: On some models, the nut and setscrew are positioned above the push rod ends.

Figure 23

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Fuel Systems and Carburetion

NOTE: Replace air cleaner gaskets and mounting gaskets whenever carburetor is removed for service.

NOTE: Do not insert a screw in the end of the fuel hose to stop fuel fl ow. Screw threads will loosen rubber particles which will get into the carburetor.

NOTE: Before servicing the carburetor, turn the fuel shutoff valve to the OFF position.

WARNING Fuel and its vapors are extremely flammable and explosive which could cause burns, fire or explosion resulting in death, serious injury and/or property damage.

WHEN ADDING OR DRAINING FUEL

Turn generator engine OFF and let it cool at least 2 • minutes before removing fuel cap. Loosen cap slowly to relieve pressure in tank.Fill or drain fuel tank outdoors.• DO NOT overfill tank. Allow space for fuel expansion.• If fuel spills, wait until it evaporates before starting engine.• Keep fuel away from sparks, open flames, pilot lights, • heat, and other ignition sources.Check fuel lines, tank, cap and fittings frequently for • cracks or leaks. Replace if necessary.DO NOT light a cigarette or smoke.•

WHEN STARTING EQUIPMENT

Ensure spark plug, muffler, fuel cap, and air cleaner are in • place.DO NOT crank engine with spark plug removed.•

WHEN OPERATING EQUIPMENT

DO NOT operate this product inside any building, carport, • porch, mobile equipment, marine applications, or enclosure.DO NOT tip engine or equipment at angle which causes • fuel to spill.DO NOT stop engine by moving choke control to “Choke” • position ( ).

WHEN TRANSPORTING, MOVING OR REPAIRING EQUIPMENT

Transport/move/repair with fuel tank EMPTY or with fuel • shutoff valve OFF.DO NOT tip engine or equipment at angle which causes • fuel to spill.Disconnect spark plug wire.•

WHEN STORING FUEL OR EQUIPMENT WITH FUEL IN TANK

Store away from furnaces, stoves, water heaters, clothes • dryers, or other appliances that have pilot light or other ignition source because they could ignite fuel vapors.

Removal

1. Close shut-off valve, if equipped. 2. Remove air cleaner assembly. 3. Remove screws (A, Figure 24) and the control panel/

trim plate. 4. Release hose clamp and disconnect fuel hose from

carburetor fitting. 5. Place hose in appropriate container, open shut-off

valve, and allow fuel to completely drain from tank. 6. Remove the mounting screws from tank support.

Carefully slip fuel hose under governor link and allow spark plug wire to slip through hole in support as tank is removed.

7. Remove tank support from tank, if equipped.

Fuel Tanks and Shut-off Valves

Figure 24

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Inspection

1. Clean gummy or dirty fuel tanks with Briggs & Stratton Carburetor Cleaner #100041 or #100042, or equivalent.

2. Inspect fuel tank for: • Corrosion • Leaks • Broken mounting brackets 3. Check fuel cap and filler neck for: • Proper seals • Vents • Functional quantity gauge (if equipped) 4. Check fuel filter for blockage of any kind. 5. Check fuel shut off valve for proper operation.Clean or replace parts as required. Fuel filter replacement is recommended annually or any time the fuel system is serviced.

Installation

1. Install tank support to tank. Slip fuel hose under governor link and spark plug wire through hole in support as tank is installed. Torque screws to values listed in Engine Specifications.

2. Assemble shut-off valve and fuel filter, if equipped, to fuel hose.

3. Install hose assembly to tank fitting and carburetor fitting with new clamps.

4. Install control panel/trim plate. Torque screws to values listed in Engine Specifications.

5. Add small amount of fuel to tank, open shut off valve, and check for leaks. Repair as necessary.

6. Install air cleaner assembly. 7. Start engine and check for leaks. Repair as necessary.

Carburetor Service

LMT Carburetor

Two versions of this carburetor have been used (Figures 25 and 26). These carburetors have a fi xed high speed main jet with a screw for idle mixture and idle speed adjustment. The letters LMT are cast into the body of the carburetor while the iden-tifi cation numbers are stamped into the carburetor mounting fl ange next to the idle mixture screw or above the fuel inlet.

Figure 25

Figure 26

WARNING Before servicing the carburetor or other fuel system components, drain all fuel from the tank and turn OFF the fuel valve (if equipped). DO NOT attempt to stop the fuel flow by plugging the fuel hose.

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Remove Carburetor

1. Remove air cleaner assembly. Discard the gasket. 2. Move clamp and disconnect hose from carburetor. 3. Remove two carburetor screws or nuts while holding

carburetor. 4. Carefully rotate carburetor to disconnect throttle (A,

Figure 27) and spring (B) and the choke link during removal.

Figure 27

Disassemble Carburetor

1. Remove solenoid and solenoid washer. Discard washer. Remove float bowl and float bowl gasket from carburetor. Discard gasket.

2. Using Carburetor Nozzle Screwdriver #19280, remove the main carburetor emulsion tube (A, Figure 28).

Figure 28

3. Remove float hinge pin, float, and inlet needle. Discard the hinge pin and inlet needle.

4. Screw a 1/4-20 tap into fuel inlet seat 3-4 turns and remove.

5. Place a hex nut (A, Figure 29) and washer (B) on a 1/4-20 screw. Place 1/4” drive 3/8” socket (C) over fuel inlet seat.

6. Thread screw into tapped inlet seat until screw bottoms. Thread nut down to washer and continue turning nut until inlet seat is free from carburetor body.

Figure 29

7. Remove idle mixture limiter cap, when used, then remove idle mixture screw with spring and idle speed screw with spring.

8. Rotate throttle shaft to closed position and remove throttle valve screws and throttle valve.

9. Remove throttle shaft, foam seal, and throttle shaft seal from carburetor body. Discard seals.

10. If carburetor is equipped with a plastic choke shaft, rotate choke shaft to wide open position, then pull choke valve out of choke shaft. Remove choke shaft, return spring (when used), and foam seal. Discard seal.

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Figure 30

- OR -

If carburetor is equipped with a metal choke shaft, rotate choke shaft to closed position. Remove two choke valve screws and choke valve. Remove choke shaft, return spring and foam seal. Discard seal. 11. With a modified pin punch (A, Figure 30) remove welch

plug (B) from carburetor body.

NOTE: Do not attempt to remove the pilot jets, which are pressed in and not serviceable.

Inspect and Clean Carburetor

1. Inspect openings in the carburetor body for evidence of wear or damage. If found, replace the entire carburetor assembly.

2. Inspect the choke shaft, choke valve, throttle shaft, and throttle valve for evidence of wear or damage. Replace parts as necessary.

3. Using Carb/Choke Cleaner #100041 or #100042, thoroughly clean the following components, then follow with compressed air to dry:

• Passages in the fixed main jet (bowl nut) or emulsion tube

• Inside and outside of the fuel bowl • Float • Choke shaft and choke valve • Throttle shaft and throttle valve • All passages, openings, and the inside and outside of

the carburetor bodyNOTE: Do not soak non-metallic components, such as fl oats, o-rings, seals, or diaphragms, in carb/choke cleaner or they will be damaged. 4. If any passages remain plugged after cleaning, replace

the component or the entire carburetor assembly.

Assemble Carburetor

Consult the Illustrated Parts List to obtain the appropriate carburetor overhaul kit before reassembling the carburetor. 1. Install new welch plug (A, Figure 31) with pin punch

(B) of slightly smaller diameter than the plug. Press against the plug until it is flat in the carburetor opening. Do not cave in plug. Seal the edge of the plug with non-hardening sealant.

2. If carburetor is equipped with a metal choke shaft,

• Install new foam seal and return spring (C, Figure 32) on choke shaft, hooking small hook (A) in notch on choke lever (D).

• Insert choke shaft assembly into carburetor body and engage large end of return spring (E) on boss. If carburetor has detent spring, guide spring into slot in choke shaft lever (B).

• Place choke valve (F) on shaft and install screws, then actuate the choke shaft to check for proper movement.

Figure 31

Figure 32

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- OR -

3. If carburetor is equipped with a plastic choke shaft, • Install new foam seal and return spring on choke shaft

(C, Figure 33) with straight end of spring against choke shaft lever (B).

• Insert choke shaft assembly into carburetor body and engage large end of return spring on anchor pin or boss (A). Lift choke slightly and turn counterclockwise until stop on lever clears anchor pin or boss, then push shaft down.

Figure 33

• Insert choke valve (D) into choke shaft with dimples (E) toward fuel inlet side of carburetor. Actuate the choke shaft to check for proper movement.

4. Install new throttle shaft seal (C, Figure 34) with sealing lip down in carburetor body until top of seal is flush with top of carburetor (D). Install new foam seal (B) on throttle shaft, then slide shaft into carburetor body. Rotate shaft until flat is facing out. Position throttle valve (E) on flat with numbers facing out, then install screws. Actuate the throttle shaft to check for proper movement.

Figure 34

5. Install idle speed screw and spring, then install idle mixture screw with spring and turn until head of screw touches spring.

6. Using Knockout Pin #19135, press new fuel inlet seat (A, Figure 35) until flush with fuel inlet boss (B).

Figure 35 7. Insert new inlet needle in slot on float, then position

float in carburetor body. Secure with new hinge pin and center the pin between the float bosses.

8. Install emulsion tube using Carburetor Screwdriver #19280 until tube seats (A, Figure 36).

9. Place new bowl gasket on carburetor body and install fuel bowl. Place new washer on solenoid and install.

10. After installing emulsion tube, use compressed air to blow out any chips or debris that may have been loosened while installing tube.

Figure 36

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Install Carburetor

NOTE: Always replace air cleaner gaskets and carburetor mounting gaskets any time the carburetor has been removed for service.

1. Position new gasket on studs with long edge of gasket opposite fuel inlet of carburetor.

2. Hook governor spring (B, Figure 37) in throttle lever hole without grommet. Hook governor link (A) in throttle lever hole with grommet.

Figure 37

3. Hook choke link into outer hole of choke shaft from underneath. Slide other end of choke link into slot in governor control bracket.

4. Position carburetor on engine. Install screws or nuts and torque to values listed in Engine Specifications.

5. Connect fuel hose to carburetor and secure with hose clamp.

6. Using new gasket, install air cleaner assembly to carburetor.

7. After final carburetor adjustment (last step below), use Knockout Pin #19135 (A, Figure 38) to install new limiter cap (B) with flat side facing up.

Figure 38

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Governor SystemsLinkage and Spring Orientation

NOTE: Be sure to note hole position of linkage before removing.

Figure 39

Governed RPM Limits

To comply with specifi ed top governed speed limits, Briggs & Stratton supplies engines with an adjustable top speed limit, which the equipment manufacturers set to their own specifi -cations. Top governed speed should be checked with a tachometer when the engine is operating on a completely assembled unit. The equipment should be operated under no load when mak-ing these checks. If a governor spring must be replaced, consult the appropri-ate Illustrated Parts List for the correct part number.After a new governor spring is installed, check the engine top governed speed with an accurate tachometer, as noted above, and adjust as required.

The mechanical governor is part of the crankcase cover. The governor gear (A, Figure 40) is driven by the crankshaft timing gear (B) through an idler gear (C). The governor crank (D) is mounted in the cylinder assembly.NOTE: Stamped side of idler gear faces out.

Disassemble

1. Drain oil from engine. Remove burrs and clean crankshaft, then remove crankcase cover. Set aside.

2. Loosen governor lever nut (A, Figure 41). 3. Slide lever off governor crank (B) and disconnect from

governor link (C). 4. Remove push nut and washer (D) from governor crank.

Remove any burrs from governor crank, and then remove crank from inside cylinder.

Governor Service

Figure 40

Figure 41

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Inspect Governor

1. Check governor gear assembly for worn weight pins, worn or damaged governor cup, and chipped or damaged teeth.

2. If wear or damage is found, remove the governor gear by carefully prying it off the spindle with two flat-bladed screw drivers (A, Figure 42). Discard the washer at the base of the spindle.

3. Install new washer on spindle, then carefully press new governor gear assembly on spindle until fully seated.

4. Check idler gear for wear or damage. If found, remove retainer clip and gear, then install new gear.

5. Check governor crank for wear or damage. Replace if necessary.

Figure 42

Assemble

1. Install governor crank from inside cylinder. Slide washer (when used) on crank and install new push nut.

2. Slide the governor lever on crank and finger-tighten bolt and nut until crank turns with a slight resistance.

3. Rotate crank until paddle is aligned with cup on governor gear assembly.

4. Install new crankcase cover gasket(s) of same thickness as originally removed from cylinder.

5. Place seal protector in oil seal and slide cover over crankshaft until it seats.

NOTE: It may be necessary to rotate crankshaft to engage idler gear with timing gear. 6. Install cover or sump screws in order shown in Figure

43. Torque to values listed in Engine Specifications. 7. Adjust governor system.

Figure 43

12

3

4

5

6

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Cylinder Head and ValvesBefore the cylinder head can be removed, other external parts must be removed, such as the air cleaner, fuel tank, oil fi ll tube, blower housing, muffl er, carburetor, control bracket assembly, and intake manifold.

1. Remove four screws from rocker cover, then remove cover and gasket (A, Figure 44).

Remove Cylinder Head

Figure 44 2. Remove cylinder head screws, then remove head and

gasket from cylinder. 3. Remove push rods one at a time, marking the location

and orientation of each for proper installation later.

NOTE: On model 210000 the intake push rod (lower, alumi-num) is hollow and the exhaust push rod (upper, steel) has a red band of paint for identifi cation.

4. Using a plastic scraping tool, carefully clean all traces of head gasket from the head and cylinder mating surfaces.

Disassemble Cylinder Head

1. Loosen rocker arm screws and/or lock nuts, and remove from rocker arm studs. Remove rocker arms and rocker balls from studs (A, Figure 45).

Figure 45

2. Remove the rocker arm studs. 3. Using thumbs, press down on each valve spring

retainer and disengage retainer (A, Figure 46) from valve stem (B). Remove retainers, springs, valves, and intake valve stem seal/washer, if equipped.

Figure 46

4. Remove push rod cylinder head plate and plate gasket. Remove and discard the plastic push rod guides from the head plate.

Inspection

1. Visually inspect head for cracks, excessive heat discoloration, warping of the cylinder or rocker cover mating surfaces, and burned or damaged valve seats. Replace head, if any of these problems are found.

2. If head passes visual inspection, use Plug Gauge #19122 to check valve guides for wear. If gauge enters the guide 1/4” (6.4 mm) or more, replace the entire head. If plug gauge is not available, see Engine Specifications for the valve guide reject dimension.

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Assemble Cylinder Head

1. Install new plastic push rod guides (A, Figure 47) into the cylinder head plate.

Install Cylinder Head

1. Coat threads of all cylinder head screws with Valve Guide Lubricant #93963.

2. Using a new head gasket, install cylinder head on cylinder and start screws by hand. Step-torque screws in sequence shown in Figures 49, until final torque value is achieved. Torque screws to value listed in Engine Specifications

Figure 47 2. Using new plate gasket, install the cylinder head plate.

Torque screws to values listed in Engine Specifications. 3. Lightly coat valve stems with Valve Guide Lubricant

#93963. Then insert valves into cylinder head. Do not get lubricant on valve face, valve seat, or exposed end of valve stem.

Figure 48

Figure 49

3. If guides are replaced, or the original guides still meet specifications, use Finish Reamer #19066 and Reamer Guide #19191 to ensure proper sizing and to clean out the guides. Thoroughly clean all reaming debris from cylinder head.

4. Inspect valves for wear or damage. Replace if necessary.

NOTE: Valve faces can be resurfaced on a commercially available valve grinder. However, Briggs & Stratton does not recommend this practice because the quality of the resurfac-ing may be insuffi cient. Instead, valve replacement is recom-mended.

5. Oil the intake valve guide and intake valve stem, then insert valve into head.

6. Using Valve Lapping Tool #19258 and Lapping Compound #94150, lap valve and seat together to assure a good sealing surface. Remove valve, the repeat procedure for the exhaust valve.

7. Thoroughly clean both valves and cylinder head of all lapping compound residue.

4. Oil inside diameter of new stem seal/washer and install on intake valve stem. Slide seal down against head plate or cylinder head.

5. Support valve side of cylinder head on clean shop rags. Place valve springs and valve spring retainers over valve stems. Using thumbs, press against each retainer until it securely locks into groove in valve stem (A, Figure 48).

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NOTE: Do not torque each screw in one step as it may result in a warped cylinder head. Step-torque all screws to approxi-mately 1/3 of fi nal torque value, then to 2/3 fi nal torque value, then fi nish at fi nal torque values. 3. Install rocker arm studs. Torque to values listed in

Engine Specifications. 4. Install push rods through guides and into same

positions as removed. Ensure rods are seated in valve tappets. Place valve stem caps (if used) on valve stems (Figure 50).

5. Place rocker arms and rocker balls on rocker arm studs. Install rocker arm screws and/or lock nuts on studs and tighten until there is zero clearance between the valve stem caps and the rocker arms.

6. Rotate crankshaft at least twice to ensure proper movement of the push rods and rocker arms.

7. Adjust valve clearance , then install a new rocker cover gasket and the rocker cover. Torque screws to values listed in Engine Specifications.

Figure 50

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StartersOn some engines, the rewind starters are attached to the blower housing with screws and can be quickly removed.

Other starters are riveted or spot welded to the blower hous-ing and must be drilled to remove, following the procedures below. For installation, screws and nuts are available sepa-rately from the Illustrated Parts List and are included with complete replacement starters.

Remove Blower Housing / Rewind Starter

1. Drain fuel tank or close fuel shut-off valve. Disconnect spark plug wire.

2. Remove the entire air cleaner assembly. 3. Remove the screws (A, Figure 51) and the control panel

trim.

Figure 51

4. Remove the screws (B, Figure 52) and blower housing.

Figure 52

5. Carefully drill through all rivet heads and remove rewind starter. Do not allow drill bit to cut into the holes in the starter housing.

NOTE: Do not attempt to drill out the rivets while the blower is still on the engine. The rivets are made of steel and the shavings will collect on the fl ywheel magnets.

Disassemble Rewind Starter

1. Pull out rope from rewind starter as far as it will go. Then allow rope to retract slightly until the hole in the pulley and the eyelet in the housing are lined up. Securely clamp the pulley and housing together to prevent the pulley from spinning.

2. Pull the rope knot out of the pulley. Untie the knot and then slip rope out of rewind starter. Remove insert from rope handle. Untie knot and slip insert and handle from rope.

3. Carefully release the clamp on the starter and allow the pulley to SLOWLY unwind until it stops.

4. Remove shoulder screw and retainer plate from pulley. Lift out the pawls and pawl springs (if used).

5. Rotate pulley until rewind spring is disengaged from anchor tab in the starter housing. Carefully lift out pulley with spring. DO NOT remove the spring from the pulley.

Rewind Starter Service

WARNING The starter spring remains under tension even if the rope has been removed and the pulley has unwound. Wear safety glasses to prevent eye injury when removing or installing the pulley/spring assembly.

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8. Carefully release the clamp on the starter and allow the pulley to SLOWLY unwind until the rope is retracted. Smoothly pull the rope handle several times to ensure proper operation of the starter assembly.

Install Blower Housing / Rewind Starter

Some starters are riveted or spot welded to the blower hous-ing and must be drilled to remove. For installation, screws and nuts are available separately from the Illustrated Parts List and are included with complete replacement starters. 1. Install the blower housing and torque the screws to

values listed in Engine Specifications. 2. Install the screws (A, Figure 53) and the control panel

trim torquing the screws to values listed in Engine Specifications.

3. Install the air cleaner assembly. 4. Fill fuel tank or open fuel shut-off valve. Connect the

spark plug wire.

Figure 53

Inspect Rewind Starter Parts

NOTE: Do not remove the spring from the pulley. Both parts are serviced only as an assembly. 1. Inspect the pulley for wear, cracks, rough edges, or

burrs in the rope groove and look for wear in the center hole. If wear or damage is found, replace the pulley and spring assembly.

2. Inspect the spring for broken ends, kinks, or burrs. If damage is found, replace the pulley and spring assembly.

3. Inspect the starter housing for wear or burrs at the rope eyelet, the center pivot post, and the anchor tab. If damage is found, replace the housing.

4. Inspect the drive pawls for wear at the tips or pivot points. Replace pawls if worn.

5. Inspect the rope for broken or frayed areas. Replace rope if necessary.

Assemble Rewind Starter

1. Install pulley and spring assembly into starter housing. Rotate pulley clockwise until slight resistance is felt, which indicates that the spring has engaged in the anchor tab.

2. Install pawl springs (if used) and pawls. Position retainer plate on pulley. Ensure that the slots in the retainer fit over the tabs in the pulley, then install shoulder screw. Torque screw to value shown in Engine Specifications.

3. While holding retainer, rotate the pulley to extend and retract the pawls. If they do not move properly, remove and reinstall the retainer plate.

4. Turn pulley clockwise until the spring is wound tight. Then allow pulley to unwind slightly until the hole in the pulley and the eyelet in the housing are lined up. Securely clamp the pulley and housing together to prevent the pulley from spinning.

NOTE: Before proceeding, consult the Illustrated Parts List or Specifi cations to ensure correct diameter and length of rope is being installed.

5. Insert one end of starter rope through eyelet and then through hole in pulley. Tie an overhand knot in end of rope, then pull rope until knot is seated in pulley. Trim excess rope if necessary.

6. Slip other end of rope through handle and insert. Tie a knot in end of rope, then pull rope until knot is seated in the insert. Trim excess rope if necessary.

7. Quickly burn each end of the rope with an open flame to prevent swelling and fraying of the weave. Then press the handle insert into the rope handle.

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Lubrication SystemsExtended Oil Fill and Dipstick

These models use a plastic extended oil fi ll tube and a quarter-turn dipstick. The oil fi ll tube screws into the crank-case cover.

Breathers

Briggs & Stratton engines utilize a breather valve to control and maintain crankcase vacuum. The breather valve is a fi ber disc or reed which closes on the piston up stroke and opens on the piston down stroke. The breather is located on the cylinder or inside the rocker cover, depending on engine model.

Remove Breather

1. Disconnect breather hose (B, Figure 54) from air cleaner.

2. Remove rocker cover with breather hose (A) and gasket. Discard gasket.

Check Breather

1. Gently blow air into the breather tube. There should be no air flow out the valve.

2. Apply vacuum to the breather tube. Air should flow freely into the valve.

3. If air flow is restricted under vacuum at the tube, or has no resistance when blowing on the tube, replace the valve cover.

Install Breather

1. Securely insert breather hose into hole in air cleaner base.

2. Place new gasket and valve cover on cylinder head. 3. Install four screws and torque to values listed in Engine

Specifications.

NOTE: Install three long screws on the sides and bottom edges of valve cover. Install short screw on top of valve cover.Securely insert other end of breather hose into hole in rocker cover.

Figure 54

Oil Dipper Lubrication

Two types of dippers are used on horizontal shaft engines. One is integral to the rod cap, the other is a separate part (A, Figure 55) attached to the rod cap with a connecting rod screw.Inspect the dipper for evidence of bending, cracking, or looseness. Replace if necessary following instructions listed under Pistons, Rings, and Connecting Rods.

Figure 55

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Cylinders, Covers and SumpsInspect Cylinder

1. Visually check cylinder for cracks, stripped threads, and bore damage.

• If cracks are found, replace the cylinder. • Stripped threads can sometimes be repaired using

a helicoil, but if multiple holes have thread damage, replace the cylinder.

• Bore damage, if not severe, may be corrected by reconditioning or resizing (see below).

Check cylinder head mounting surface for distortion with a straight edge (Figure 56). If mounting surfaces are distorted more than 0.004 in. (0.1 mm), the cylinder must be replaced.

Figure 56

2. Check cylinder bore for war using Telescoping Gauge #19485 and Dial Caliper #19199.

Figure 57

Measure twice (90° apart) at the top, center, and bottom of the piston ring travel (Figure 57).

Compare measurements to the standard cylinder bore sizes provided in Engine Specifi cations.If the cylinder bore is more than 0.003 in. (0.08 mm) oversize, or 0.0015 in. (0.04 mm) out of round, it must be resized.

Reconditioning Bore

If cylinder bore is within specifi cations and shows no signs of scoring or other damage, it can be reconditioned us-ing a rigid hone with fi nishing stones to restore the proper crosshatch angle. The correct crosshatch of approximately 45° (Figure 58) ensures proper lubrication and piston ring break-in.

Figure 58

NOTICE: IT IS MOST IMPORTANT THAT THE ENTIRE CYLINDER BE THOROUGHLY CLEANED AFTER HONING.

Resizing Bore

Always resize to exactly 0.020 in. (0.51 mm) larger than standard bore size. Done accurately, the service oversize rings and pistons will fi t perfectly with proper clearances.Cylinder can be quickly resized with Hone #19205 or #19201. Use the stones and lubrication recommended by the hone manufacturer to reproduce the sizing and fi nish.

45°

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1. Wash the cylinder thoroughly in a solvent such as kerosene or other commercial solvent.

2. Wash cylinder again using a stiff brush with soap and hot water.

3. Rinse cylinder thoroughly with hot running water. 4. Repeat washing and rinsing until all traces of honing

grit are gone.

NOTE: Honing grit is highly abrasive and will cause rapid wear to all of the internal components of the engine. When cylinder and crankcase have been thoroughly cleaned, use a clean white rage to wipe the cylinder bore. If honing grit is present, it will appear as a grey residue on the rag. Re-wash and rinse entire cylinder then check again. When there is no trace of honing grit on the rag, the cylinder is properly cleaned. Oil the cylinder bore to prevent rusting.

Cleaning Cylinder

Main Bearings

Check Bearings

Main bearings should be replaced if scored or if a plug gauge (A, Figure 59) will enter bearing. Try gauge at several locations in bearing.

Figure 59

Covers and Sumps

Installation

1. Place seal protector on oil seal. 2. Make sure mechanical governor fear and oil pump

(when used) is engaged with cam gear. Do not for force cover or sump.

3. Install screws and tighten in sequence shown (Figure 60).

4. Torque screws to values listed in Engine Specifications.

Figure 60

2 1

3

4

5

6

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Crankshafts and CamshaftsRemove Crankshaft and Camshaft

1. Drain oil from engine and all fuel from fuel tank. 2. Remove blower housing/rewind assembly and flywheel/

fan assembly. 3. Remove burrs and clean crankshaft, then remove

crankcase cover or sump. Set aside.NOTE: If crankcase cover or sump sticks, tap lightly with a soft hammer on alternate sides near dowel pins (A, Figure 61). It is not necessary to remove dowel pins.

Figure 61

4. Carefully tip engine with PTO-end facing up. 5. Rotate crankshaft until timing marks (A, Figure 62)

are aligned. With camshaft in this position, the valve tappets will remain clear of cam lobes. Lift out camshaft (B).

Figure 62

6. Rotate crankshaft to place piston at Top Dead Center. 7. Remove connecting rod cap, then slide out crankshaft.

Check Crankshaft

1. Inspect crankshaft for scoring on mag journal (A, Figure 63), crankpin journal (B), and PTO journal (C). Replace crankshaft if scoring is found or if crankshaft is bent. DO NOT attempt to straighten bent crankshafts.

Figure 63

2. Using a dial caliper, measure the journal diameters. Compare results to values listed in Engine Specifications. If wear exceeds the reject dimensions, replace the crankshaft.

Check Camshaft

1. Check gear (A, Figure 64) for worn or damaged teeth. Check lobes (D) and journals (B, C) for scratching or scoring. Check compression release mechanism (A, Figure 65) for wear, burrs, or sticking. Replace camshaft if any of these conditions are found.

Figure 64

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Figure 65

2. Using a dial caliper, measure the journal diameters and cam lobes. Compare results to values listed in Specifications. If wear exceeds the reject dimensions, replace the camshaft.

Install Crankshaft and Camshaft

1. Lubricate the cylinder bearing/oil seal with engine oil. 2. Install intake and exhaust valve tappets. 3. Support both ends of the crankshaft, and carefully

install into the cylinder. 4. Assemble connecting rod assembly to crankshaft. 5. Install the timing gear to the crankshaft with timing

mark out. 6. Install camshaft, making sure tappets clear cam lobes.

Timing marks (A, Figure 66) must align. 7. Make sure the paddle on the governor shaft (B)

is rotated in line with the governor cup inside the crankcase cover.

Figure 66

Install Crankcase Cover or Sump

1. Using a new gasket, install crankcase cover or sump using seal protectors. Do not force cover or sump on cylinder.

NOTE: It may be necessary to rotate idler gear to mesh with timing gear when installing cover. 2. Install screws in sequence shown (Figure 67).NOTE: The screw in position 4 was coated with sealant. If sealant is missing, coat with a non-hardening sealant such as Permatex® 2 or equivalent.

Figure 67Check and Adjust Crankshaft End Play

When the crankcase cover or sump is installed with a standard gasket, end play should match values listed in Engine Specifications.If end play is less than specified, remove cover or sump and install an additional gasket. Do not use more than two gaskets.If end play is more than specified, remove cover or sump and install a shim per the Illustrated Parts List, or replace the cover or sump.NOTE: If using shims, install shim on PTO-end of crankshaft (A, Figure 68).

Figure 68

2 1

3

4

5

6

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Pistons, Rings, and Connecting RodsRemove Piston and Connecting Rod

1. Carefully remove any carbon or ridge at top of cylinder bore to prevent ring breakage.

2. Remove rod bolts and connecting rod cap (A, Figure 69).

3. Push piston and rod assembly out through top of cylinder.

Figure 69

Disassemble

1. Rotate pin retainer until one end is exposed in notch in pin bore.

2. Remove the two retainer pins (A, Figure 70) with needle nose pliers.

3. Slide out pin (B) from opposite side and remove connecting rod from piston.

Figure 70

4. Using Piston Ring Expander #19340 (Figure 71), remove rings one at a time. Not the order and orientation of the rings before removal.

Figure 71

NOTE: Some oil control rings consist of two thin steel rails and a spring expander. These must be removed by hand as follows: • Grasp one end of the upper steel rail and wind the rail

from the oil ring groove into the center ring groove. Repeat into the top ring groove and then off the piston.

• Remove the spring expander, then remove the lower steel rail.

Inspect Piston and Pin

1. Inspect piston for scoring, galling, or other damage. Replace piston if necessary.

2. Using a dial caliper or plug gauge, measure the pin bore diameter. Compare with reject dimensions listed in Engine Specifications. If pin bore exceeds reject dimensions, replace the piston.

3. Measure outside diameter of pin and compare to the reject dimension listed in Engine Specifications. If pin is smaller than the reject dimension, replace the pin.

4. Clean carbon from top ring groove. 5. Place NEW ring groove (Figure 72) and, using a feeler

gauge, measure space between ring and ring land. Compare with reject dimensions listed in Engine Specifications. If clearance is greater than shown, the piston must be replace.

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Figure 72

Check Ring End Gap

It is recommended that the entire ring set be replaced when servicing the piston and/or cylinder bore. However, the original rings can be re-used if they are not damaged and are checked as follows: 1. Clean all carbon from the rings and the cylinder bore. 2. Insert an original ring (A, Figure 73) approximately one

inch down into the cylinder bore. 3. Check end gap with feeler gauge. Compare with reject

dimensions listed in Engine Specifications. If gap of any of the rings exceeds the reject dimension, all rings should be replaced.

Figure 73

Check Connecting Rod

If the crankpin bearing (A, Figure 74) or the piston pin bearing (B) is scored, the rod must be replaced. 1. Reinstall rod cap and bolts on rod. 2. Using a dial caliper or plug gauge, measure the two

bearing diameters. Compare with reject dimensions listed in Engine Specifications. If either bearing exceeds the reject dimensions, the rod must be replaced.

3. Remove rod bolts and rod cap. Set aside.

Figure 74

Assemble

1. Install a pin retainer into one groove in piston bore. 2. Oil the piston pin bore, connecting rod pin bore, and

the pin. Insert rod into piston, then slip pin through piston and rod bores until it seats against the retainer or shoulder stop.

NOTE: The notch or arrow (A, Figure 75) on the piston and “MAG” on the rod (B) must face the same direction. When installed in the engine, the notch will face the flywheel.

Figure 75

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3. Install a pin retainer into groove on open side of piston pin bore. Ensure retainers are firmly seated in grooves.

4. Using Piston Ring Expander #19340, install oil ring and spring expander, then the center ring, then the top ring. Follow the orientation noted at the time of disassembly, or use the instructions provided if installing a new ring set.

NOTE: If oil ring consists of two steel rails and a spring expander, they must be installed by hand as follows: • Grasp one end of lower steel rail and wind it over the

top ring groove, then into the center ring groove, and finally into the oil ring groove.

• Install the spring expander on top of the lower rail, then install the upper steel rail.

Install Piston and Connecting Rod

1. Thoroughly clean and oil cylinder bore and crankpin journal.

2. Rotate crankshaft until crankpin journal is a bottom of stroke.

3. Using Ring Compressor Tool #19070 or #19230, install piston with notch or arrow (A, Figure 76) toward flywheel side of engine, taking care not to damage crankpin journal or connecting rod bearing.

Figure 76

4. Fit connecting rod bearing on crankpin journal, then install rod cap with match marks aligned.

5. Cap should snap into position when assembled correctly. Install rod screws and dipper.

6. Tighten screw closest to piston (A, Figure 77) first, then screw farthest from piston (B) second. Torque screws to values listed in Engine Specifications.

Figure 77

NOTE: Failure to use a torque wrench can result in loose rods causing breakage, or over-tightened rods causing scoring. 7. Rotate crankshaft two revolutions to ensure crankpin

and rod do not bind. 8. Move connecting rod sideways to ensure rod has

clearance on crankpin side.

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Engine Specifications - Model 200000 Horizontal Series

ENGINE SPECIFICATIONS

Armature Air Gap 0.010 - 0.014 in. (0.25 - 0.36 mm)Crankshaft End Play 0.002 - 0.028 in. (0.05 - 0.71 mm)Spark Plug Gap 0.030 in. (0.76 mm)Valve Clearance - Intake 0.004 - 0.006 in. (0.10 - 0.15 mm)Valve Clearance - Exhaust 0.004 - 0.006 in. (0.10 - 0.15 mm)

FASTENER TORQUE SPECIFICATIONS TORQUE

Air Cleaner Base / Backplate 90 lb-in. (10 Nm)Armature 30 lb-in. (3 Nm) Blower Housing 90 lb-in. (10 Nm) Carburetor Bowl Screw / Solenoid 90 lb-in. (10 Nm) Carburetor to Cylinder Head 85 lb-in. (10 Nm)Connecting Rod 100 lb-in. (11 Nm)Control Bracket 100 lb-in. (11 Nm)Control Panel Trim 40 lb-in. (5 Nm)Crankcase Cover 100 lb-in. (11 Nm)Cylinder Head 220 lb-in. (25 Nm)Cylinder Shield 30 lb-in. (3 Nm)Exhaust Manifold / Adapter 180 lb-in. (20 Nm)Flywheel Nut 120 lb-ft. (160 Nm) Flywheel Fan 140 lb-in. (16 Nm)Flywheel Guard 30 lb-in. (3 Nm)Fuel Tank 90 lb-in. (10 Nm)Governor Lever Nut 40 lb-in. (5 Nm)Muffl er 180 lb-in. (20 Nm)Muffl er Support Bracket 125 lb-in. (14 Nm)Oil Drain Plug 100 lb-in. (11 Nm)Oil Fill Tube 30 lb-in. (3 Nm)Rewind Starter 30 lb-in. (3 Nm)Rocker Arm Stud 100 lb-in. (11 Nm)Rocker Ball Set Screw or Nut 45 lb-in. (5 Nm)Spark Plug 180 lb-in. (20 Nm)Starter Cover 20 lb-in. (2 Nm)Starter Motor 140 lb-in. (16 Nm)Rocker Cover 75 lb-in. (8 Nm)

Engine Specifications

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REJECT DIMENSIONS STANDARD SIZE REJECT SIZE

CYLINDER

Main Bearing 0.876 in. (22.25 mm) 0.878 in. (22.30 mm)Camshaft Bearing 0.5011 in. (15.88 mm) 0.504 in. (12.80 mm)Bore Diameter 2.688 in. (65.10 mm) 2.691 in. (68.33 mm)Bore Out-of-Round N/A 0.0015 in. (0.04 mm)CYLINDER HEAD

Valve Guide 0.249 in. (6.32 mm) 0.267 in. (6.78 mm)Intake Valve Stem Diameter 0.247 in. (6.28 mm) 0.244 in. (6.20 mm)Exhaust Valve Stem Diameter 0.247 in. (6.28 mm) 0.244 in. (6.20 mm)CYLINDER COVER

Main Bearing 1.063 in. (27.00 mm) 1.065 in. (27.05 mm)Camshaft Bearing 0.501 in. (12.72 mm) 0.504 in. (12.80 mm)CRANKSHAFT

Crankpin Journal 1.098 in. (27.89 mm) 1.097 in. (27.86 mm)Mag-Side Journal 0.874 in. (22.19 mm) 0.873 in. (22.17 mm)PTO-Side Journal 1.0615 in. (26.96 mm) 1.060 in. (26.92 mm)CAMSHAFT

Mag-Side Journal 0.499 in. (12.67 mm) 0.498 in. (12.65 mm)PTO-Side Journal 0.499 in. (12.67 mm) 0.798 in. (12.65 mm)Intake Lobes 1.112 in. (28.24 mm) 1.098 in. (27.89 mm)Exhaust Lobes 1.112 in. (28.24 mm) 1.098 in. (27.89 mm)CONNECTING ROD

Crank Pin Bearing 1.100 in. (37.06 mm) 1.102 in. (27.99 mm)Piston Pin Bearing 0.6258 in. (15.89 mm) 0.6268 in. (15.92 mm)PISTON

Piston Pin 0.6247 in. (15.86 mm) 0.6291 in. (15.98 mm)Piston Pin Beating 0.6258 in. (15.89 mm) 0.6311 in. (16.03 mm)Ring End Gap (Top) 0.006-0.010 in. (0.15-0.25 mm) 0.020 in. (0.51 mm)Ring End Gap (Middle) 0.012-0.025 in. (0.30-0.51 mm) 0.020 in. (0.51 mm)Ring End Gap (Oil Control) 0.020-0.016 in. (0.51-0.63 mm) 0.035 in. (0.89 mm)Ring Land Clearance (Top) 0.002-0.003 in. (0.05-0.08 mm) 0.004 in. (0.10 mm)Ring Land Clearance (Middle) 0.002-0.003 in. (0.05-0.08 mm) 0.004 in. (0.10 mm)Ring Land Clearance (Oil Control) 0.002-0.004 in. (0.05-0.10 mm) 0.005 in. (0.12 mm)

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Engine Specifications - Model 210000 Horizontal Series

ENGINE SPECIFICATIONS

Armature Air Gap 0.010 - 0.014 in. (0.25 - 0.36 mm)Crankshaft End Play 0.002 - 0.028 in. (0.05 - 0.71 mm)Spark Plug Gap 0.030 in. (0.76 mm)Valve Clearance - Intake 0.004 - 0.006 in. (0.10 - 0.15 mm)Valve Clearance - Exhaust 0.004 - 0.006 in. (0.10 - 0.15 mm)

FASTENER TORQUE SPECIFICATIONS TORQUE

Air Cleaner Base / Backplate 90 lb-in. (10 Nm)Armature 30 lb-in. (3 Nm) Blower Housing 90 lb-in. (10 Nm) Carburetor Bowl Screw / Solenoid 90 lb-in. (10 Nm) Carburetor to Cylinder Head 85 lb-in. (10 Nm)Connecting Rod 100 lb-in. (11 Nm)Control Bracket 100 lb-in. (11 Nm)Control Panel Trim 40 lb-in. (5 Nm)Crankcase Cover 100 lb-in. (11 Nm)Cylinder Head 220 lb-in. (25 Nm)Cylinder Shield 30 lb-in. (3 Nm)Exhaust Manifold / Adapter 180 lb-in. (20 Nm)Flywheel Nut 120 lb-ft. (160 Nm) Flywheel Fan 140 lb-in. (16 Nm)Flywheel Guard 30 lb-in. (3 Nm)Fuel Tank 90 lb-in. (10 Nm)Governor Lever Nut 40 lb-in. (5 Nm)Muffl er 180 lb-in. (20 Nm)Muffl er Support Bracket 125 lb-in. (14 Nm)Oil Drain Plug 100 lb-in. (11 Nm)Oil Fill Tube 30 lb-in. (3 Nm)Rewind Starter 30 lb-in. (3 Nm)Rocker Arm Stud 100 lb-in. (11 Nm)Rocker Ball Set Screw or Nut 45 lb-in. (5 Nm)Spark Plug 180 lb-in. (20 Nm)Starter Cover 20 lb-in. (2 Nm)Starter Motor 140 lb-in. (16 Nm)Rocker Cover 75 lb-in. (8 Nm)

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REJECT DIMENSIONS STANDARD SIZE REJECT SIZE

CYLINDER

Main Bearing 1.1825 in. (30.03 mm) 1.184 in. (30.07 mm)Camshaft Bearing 0.5011 in. (15.88 mm) 0.504 in. (12.80 mm)Bore Diameter 3.300 in. (83.82 mm) 3.304 in. (83.92 mm)Bore Out-of-Round N/A 0.0015 in. (0.04 mm)CYLINDER HEAD

Valve Guide 0.236 in. (5.99 mm) 0.240 in. (6.10 mm)Intake Valve Stem Diameter 0.234 in. (5.93 mm) 0.233 in. (5.92 mm)Exhaust Valve Stem Diameter 0.234 in. (5.93 mm) 0.233 in. (5.92 mm)CYLINDER COVER

Main Bearing 1.1825 in. (30.03 mm) 1.184 in. (30.07 mm)Camshaft Bearing 0.501 in. (12.72 mm) 0.504 in. (12.80 mm)CRANKSHAFT

Crankpin Journal 1.2485 in. (31.71 mm) 1.2475 in. (31.68 mm)Mag-Side Journal 1.1795 in. (29.95 mm) 1.178 in. (29.92 mm)PTO-Side Journal 1.1795 in. (29.95 mm) 1.178 in. (29.92 mm)CAMSHAFT

Mag-Side Journal 0.499 in. (12.67 mm) 0.498 in. (12.65 mm)PTO-Side Journal 0.499 in. (12.67 mm) 0.798 in. (12.65 mm)Intake Lobes 1.216 in. (30.88 mm) 1.212 in. (30.77 mm)Exhaust Lobes 1.216 in. (30.88 mm) 1.212 in. (30.77 mm)CONNECTING ROD

Crank Pin Bearing 1.250 in. (31.75 mm) 1.252 in. (31.80 mm)Piston Pin Bearing 0.6728 in. (17.09 mm) 0.6742 in. (17.12 mm)PISTON

Piston Pin 0.6722 in. (17.07 mm) 0.6717 in. (17.06 mm)Piston Pin Beating 0.6728 in. (17.09 mm) 0.6742 in. (17.12 mm)Ring End Gap (Top) 0.008-0.016 in. (0.15-0.25 mm) 0.030 in. (0.76 mm)Ring End Gap (Middle) 0.008-0.016 in. (0.30-0.51 mm) 0.030 in. (0.76 mm)Ring End Gap (Oil Control) 0.020-0.016 in. (0.51-0.63 mm) 0.030 in. (0.76 mm)Ring Land Clearance (Top) 0.002-0.003 in. (0.05-0.08 mm) 0.004 in. (0.10 mm)Ring Land Clearance (Middle) 0.002-0.003 in. (0.05-0.08 mm) 0.004 in. (0.10 mm)Ring Land Clearance (Oil Control) 0.002-0.004 in. (0.05-0.10 mm) 0.005 in. (0.12 mm)

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Engine Specifications - Model 210000 Vertical Series

ENGINE SPECIFICATIONS

Armature Air Gap 0.010 - 0.014 in. (0.25 - 0.36 mm)Crankshaft End Play 0.002 - 0.034 in. (0.05 - 0.86 mm)Spark Plug Gap 0.030 in. (0.76 mm)Valve Clearance - Intake 0.004 - 0.006 in. (0.10 - 0.15 mm)Valve Clearance - Exhaust 0.005 - 0.007 in. (0.13 - 0.18 mm)

FASTENER TORQUE SPECIFICATIONS TORQUE

Air Cleaner Base / Backplate 90 lb-in. (10 Nm)Armature 30 lb-in. (3 Nm) Blower Housing 90 lb-in. (10 Nm) Carburetor Bowl Screw / Solenoid 90 lb-in. (10 Nm) Carburetor to Cylinder Head 85 lb-in. (10 Nm)Connecting Rod 100 lb-in. (11 Nm)Control Bracket 100 lb-in. (11 Nm)Control Panel Trim 40 lb-in. (5 Nm)Crankcase Cover 100 lb-in. (11 Nm)Cylinder Head 220 lb-in. (25 Nm)Cylinder Shield 30 lb-in. (3 Nm)Exhaust Manifold / Adapter 180 lb-in. (20 Nm)Flywheel Nut 120 lb-ft. (160 Nm) Flywheel Fan 140 lb-in. (16 Nm)Flywheel Guard 30 lb-in. (3 Nm)Fuel Tank 90 lb-in. (10 Nm)Governor Lever Nut 40 lb-in. (5 Nm)Muffl er 180 lb-in. (20 Nm)Muffl er Support Bracket 125 lb-in. (14 Nm)Oil Drain Plug 100 lb-in. (11 Nm)Oil Fill Tube 30 lb-in. (3 Nm)Rewind Starter 30 lb-in. (3 Nm)Rocker Arm Stud 100 lb-in. (11 Nm)Rocker Ball Set Screw or Nut 45 lb-in. (5 Nm)Spark Plug 180 lb-in. (20 Nm)Starter Cover 20 lb-in. (2 Nm)Starter Motor 140 lb-in. (16 Nm)Rocker Cover 75 lb-in. (8 Nm)

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REJECT DIMENSIONS STANDARD SIZE REJECT SIZE

CYLINDER

Main Bearing 1.3795 in. (35.04 mm) 1.383 in. (35.13 mm)Camshaft Bearing 0.5011 in. (15.88 mm) 0.504 in. (12.80 mm)Bore Diameter 3.437 in. (87.30 mm) 3.441 in. (87.40 mm)Bore Out-of-Round N/A 0.0015 in. (0.04 mm)CYLINDER HEAD

Valve Guide 0.237 in. (6.02 mm) 0.240 in. (6.10 mm)Intake Valve Stem Diameter 0.235 in. (5.97 mm) 0.233 in. (5.92 mm)Exhaust Valve Stem Diameter 0.235 in. (5.97 mm) 0.233 in. (5.92 mm)CYLINDER COVER

Main Bearing 1.625 in. (41.31 mm) 1.629 in. (27.05 mm)Camshaft Bearing 0.501 in. (12.72 mm) 0.504 in. (12.80 mm)CRANKSHAFT

Crankpin Journal 1.498 in. (38.06 mm) 1.497 in. (38.02 mm)Mag-Side Journal 1.377 in. (34.99 mm) 1.376 in. (34.95 mm)PTO-Side Journal 1.624 in. (41.26 mm) 1.623 in. (41.22 mm)CAMSHAFT

Mag-Side Journal 0.499 in. (12.67 mm) 0.498 in. (12.65 mm)PTO-Side Journal 0.499 in. (12.67 mm) 0.798 in. (12.65 mm)Intake Lobes 1.112 in. (28.24 mm) 1.098 in. (27.89 mm)Exhaust Lobes 1.112 in. (28.24 mm) 1.098 in. (27.89 mm)CONNECTING ROD

Crank Pin Bearing 1.500 in. (38.10 mm) 1.502 in. (27.99 mm)Piston Pin Bearing 0.8006 in. (20.33 mm) 0.802 in. (20.37 mm)PISTON

Piston Pin 0.7998 in. (20.31 mm) 0.799 in. (20.29 mm)Piston Pin Beating 0.8006 in. (20.33 mm) 0.802 in. (20.37 mm)Ring End Gap (Top) 0.006-0.009 in. (0.15-0.23 mm) 0.030 in. (0.76 mm)Ring End Gap (Middle) 0.014-0.018 in. (0.35-0.45 mm) 0.030 in. (0.76 mm)Ring End Gap (Oil Control) 0.020-0.016 in. (0.51-0.63 mm) 0.030 in. (0.76 mm)Ring Land Clearance (Top) 0.002-0.003 in. (0.05-0.08 mm) 0.007 in. (0.18 mm)Ring Land Clearance (Middle) 0.002-0.003 in. (0.05-0.08 mm) 0.007 in. (0.18 mm)Ring Land Clearance (Oil Control) 0.002-0.004 in. (0.05-0.10 mm) 0.007 in. (0.18 mm)

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Generator Illustrated Parts List

ALTERNATOR IDENTIFICATION:

The identification label/data tag provides model, revision, and serial number of generator. It is necessary to know the model number as well as the revision number when determining the type of alternator used on your generator.

Generator Model Number

Generator Revision Number

Identification Label / Data Tag

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Item Part # Description

1 186059GS ADAPTER, Mounting, Alternator2 204105GS ASSY., Rotor (Includes Item 8)3 208368GS STATOR 4 186060GS RBC, with O-Ring (p/n 189197GS)5 86308CGS HHCS, M6 - 1.0 x 130 SEMS6 91825GS ASSY., Holder, Rectifier/Brush7 66849GS TAPTITE, M5 - 0.8 x 168 65791GS BEARING9 81917GS PIN, Roll, 4mm x 10

Alternator

NOTICE: Alternator Identification. Use this exploded view on Model 030430 Generators that have a Revision Number of 02.See data tag for revision number.

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Main Unit

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Parts List - Main Unit Item Part # Description 1 209877BUGS CRADLE (Includes Items 20 & 31) 2 209287BUGS HANDLE 3 67989GS NUT 4 190220GS ADAPTER-ENGINE 5 NSP ALTERNATOR 6 * NUT-HEX M8 - 1.25 7 195398GS SCREW 8 96796GS WASHER 9 * WASHER-5/16-M8 LOCK 10 190274BGS SCREW 11 187365FGS SCREW 12 194150GS MOUNT-VIBRATION 13 * HHCS-M8-1.25 x 25 14 189009GS BRACKET 15 695398 GASKET 16 * HHCS-M6-1.0 x 12 17 189008GS MUFFLER 18 204885GS SCREW 19 83083GS ARRESTOR-SPARK 20 B4986GS DECAL 21 194153GS MOUNT-VIBRATION 22 87680GS NUT 23 * HHCS-M6-1.0 x 40 24 194390GS HEATSHIELD 25 191190GS CAP 26 74908GS TAPTITE 27 207525GS PIN 28 206887GS DECAL 29 206888GS DECAL 30 207889GS DECAL 31 196830GS DECAL

Item Part # Description

32 200658GS DECAL 34 195422GS COVER-REAR BEARING 35 791745 HOSE-FUEL (cut to fit) 36 192376GS SCREW 37 56893GS CRIMPTITE 38 B2153GS SCREW 40 199256GS BOLT 41 192980GS KIT-FUEL VALVE 44 194217GS TANK-FUEL (Includes Items 41, 50, 51, 52, 53 & 55) 45 B4363GS CAP-FUEL GAUGE 48 14353621GS WIRE 50 188333GS DECAL 51 194799GS DECAL 52 189235GS DECAL 53 202997GS DECAL 55 197798GS DECAL 58 310763GS PANEL-CONTROL 59 189164GS PALNUT-3/16 60 208183GS HEAT SHIELD 900 § ENGINE

Parts Not Illustrated

206883GS MANUAL-OPERATOR 206775GS CORDSET 189208GS STABILIZER-FUEL

* - Items without part numbers are common fasteners and are available at local hardware stores.§ - Contact Engine Manufacturer

Main Unit

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Item Part # Description

1 201571GS PANEL-CONTROL 2 197472GS COVER-OUTLET 3 201572GS BOX-CONTROL PANEL 4 197731GS OUTLET-120V 20A 5 189164GS PALNUT-3/16 6 202951GS LAMP-LED 7 * SCREW-3 x 6, TAPPING 8 209676GS BREAKER-CIRCUIT 23A 191481GS BOOT (not shown) 9 43437GS OUTLET-120/240V TL30A 10 201678GS CONNECTOR-6 PIN 11 * PPPHS-M3-0.5 x 12

* - Items without part numbers are common fasteners and are available at local hardware stores.

Control Panel

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Item Part # Description

1 207175GS WHEEL 2 * WASHER-5/8 3 208101GS AXLE 4 191265GS E-RING 5 * HHCS-M8 1.25 x 20 6 67989GS NUT 7 189522ZGS SUPPORT-LEG Parts Not Illustrated

196157GS KIT-HARDWARE

* - Items without part numbers are common fasteners and are available at local hardware stores.

Wheel Kit

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Engine Illustrated Parts List

ENGINE IDENTIFICATION:

The engine model, type, trim, and date code are located on the valve cover. It is necessary to know the code as well as the model and type number when performing adjustments, repairs, or ordering replacement parts.

2163XX – XXXX–XX – XXXXXXXX MODEL TYPE CODE

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216300

1330 REPAIR MANUAL1058 OPERATOR’S MANUAL 1319 WARNING LABEL

REQUIRED when replacing partswith warning labels affixed.

3

552718

718A

2117

20

1221

1194

27

27

30

32

46

741

146

24

742

746

220

22

18

19

1

16

415

219

29

28

2526

2307A

306A

524

287 842

847 523

525

15

529

170

522

Engine

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216300

35

868

7

451026

383

337

1022

91413

1100 798

1022

36

635

51

51A

34

33 42

192

1029

1023

5

42

7

1095 VALVE GASKET SET

1022

868

51

51A

358 ENGINE GASKET SET

51

51A

7

1022

868

163

20

12

3

883A

883A

1171

Engine

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216300

135

369

104A105A

137A

1127A

975A

133A

51

51A122

1127A

975 137

130A

135

117

127A

104A

105A

98A

125

133A

95A 118

632A

633B

97A

51

51A

121A CARBURETOR OVERHAUL KIT

105A

104A 137A

127A

633B51

51A163

98A

121 CARBURETOR OVERHAUL KIT

105A

104A

127A

633B51

51A 163

98A

137

633B

951

633B

109D

108A

633B

109E

633B

109D141

108A

141C

633B

109E

108A

Engine

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216300

832B

613B

836B

NOTE: This muffler is intended for replacementpurposes only and is not to be usedfor retrofitting to engines with differentexhaust systems.

883C

832C

836C300C

863C

740

740A

819

355

436C

437

1177

300E

883A

613676C

677A

53

161

445

967

163

11C

425

968A

161B

185

425A968

Engine

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216300

3778

1036 EMISSIONS LABEL

305

732

332

455

1070

1005

23

727A

304

725A

1298

622

695

363

1212

55

1211

1210

59

58

459689

456

597

608

60

65

37A

78A

Engine

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216300

972A957A

957

211

209

632

621

410

188668

773

1138

505

562

564

227

504

222

271A

1230

1404

604A

222B

278

190

958

601

601

187 187A

663

281

615

616

614

404

267

265

270

268

269271

Engine

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216300

493A

503

361A

347B

920

579

577A

813

627A

578A

990A

892A

500A

356J

356A

356D

356C

356B

356

356L

356K

356H

851

334

333

1054

1052A

799

286

364A

500664

990

892

1051

801

310503

802

697

783

513

510309

1090

579

789

835

356M

347

501

526578

NOTE: All stators use a No. 1119 mounting screw.

NOTE: The proper flywheel part number and/or the alternator magnet size willdetermine the alternator type or output. See repair instruction manualfor additional information.

1119

474D

10--16 AMP

Engine

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1 794850 Cylinder Assembly2 698340 Kit--Bushing/Seal

(Magneto Side)3 391086S Seal--Oil

(Magneto Side)5 794870 Head--Cylinder7 697690 Gasket--Cylinder Head

11C 696796 Tube--Breather12 694953 Gasket--Crankcase13 794829 Screw15 691686 Plug--Oil Drain16 794716 Crankshaft

Used on Type No(s).0112, 0113, 0116,0541.-- -- -- -- -- -- -- Note ---- -- -- --794717 CrankshaftUsed on Type No(s).0036, 0118.794718 CrankshaftUsed on Type No(s).0110, 0111, 0114,0115, 0117, 0570.

17 695434 Bearing--Ball18 791965 Cover--Crankcase

-- -- -- -- -- -- -- Note ---- -- -- --791412 Cover--CrankcaseUsed on Type No(s).0036, 0541.

19 698340 Kit--Bushing/Seal(PTO Side)

20 391086S Seal--Oil(PTO Side)

21 281658S Cap--Oil Fill22 794825 Screw

(CrankcaseCover/Sump)

23 794814 FlywheelUsed on Type No(s).0036, 0110, 0113,0117, 0118, 0570.-- -- -- -- -- -- -- Note ---- -- -- --794812 FlywheelUsed on Type No(s).0111, 0112, 0114,0115, 0116, 0541.

24 222698S Key--Flywheel25 793318 Piston Assembly

(Standard)(Used After Code Date08032300).-- -- -- -- -- -- -- Note ---- -- -- --793794 PistonAssembly(Standard)(Used Before CodeDate 08032400).793325 PistonAssembly(.020” Oversize)(Used After Code Date08032300).793797 PistonAssembly(.020” Oversize)(Used Before CodeDate 08032400).(.020” Oversize)793318 PistonAssembly(Standard)Used on Type No(s).0110, 0111, 0114,0115, 0117, 0570.793325 PistonAssembly(.020” Oversize)Used on Type No(s).0110, 0111, 0114,0115, 0117, 0570.

26 793319 Ring Set(Standard)-- -- -- -- -- -- -- Note ---- -- -- --793324 Ring Set(.020” Oversize)697692 Ring Set(Standard)Used on Type No(s).0110, 0111, 0114,0115, 0117, 0570.697698 Ring Set(.020” Oversize)Used on Type No(s).0110, 0111, 0114,0115, 0117, 0570.

27 690975 Lock--Piston Pin28 696581 Pin--Piston29 694691 Rod--Connecting30 694692 Dipper--Connecting

Rod32 690976 Screw

(Connecting Rod)33 697576 Valve--Exhaust34 792200 Valve--Intake35 694865 Spring--Valve

(Intake)36 694865 Spring--Valve

(Exhaust)37 790730 Guard--Flywheel

37A 699047 Guard--Flywheel42 499586 Keeper--Valve45 690977 Tappet--Valve46 795697 Camshaft51 694874 Gasket--Intake

51A 694875 Gasket--Intake53 794830 Stud

(Carburetor)55 695288 Housing--Rewind

Starter58 693389 Rope--Starter

(Cut to RequiredLength)

59 805957 Insert--Grip60 490652 Grip--Starter Rope65 699228 Screw

(Rewind Starter)78 795026 Screw

(Cover FlywheelGuard)

78A 699205 Screw(Flywheel Guard)

95A 690718 Screw(Throttle Valve)

TRAP.FERTRAP.FERTRAP.FERNO. NO. DESCRIPTION NO. NO. DESCRIPTION NO. NO. DESCRIPTION

Engine

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216300

97A 796334 Shaft--Throttle(Used After Code Date08071700).-- -- -- -- -- -- -- Note ---- -- -- --696387 Shaft--Throttle(Used Before CodeDate 08071800).796334 Shaft--Throttle(Used After Code Date09020800).Used on Type No(s).0110, 0111, 0114,0115, 0570.696387 Shaft--Throttle(Used Before CodeDate 09020900).Used on Type No(s).0110, 0111, 0114,0115, 0570.796334 Shaft--ThrottleUsed on Type No(s).0117.

98A 695408 Kit--Idle Speed104A 694918 Pin--Float Hinge105A 696136 Valve--Float Needle108A 696143 Valve--Choke109D 790149 Shaft--Choke109E 696735 Shaft--Choke

117 796332 Jet--Main(Standard)(Used After Code Date08071700).-- -- -- -- -- -- -- Note ---- -- -- --696134 Jet--Main(Standard)(Used Before CodeDate 08071800).796332 Jet--Main(Standard)(Used After Code Date09020800).Used on Type No(s).0110, 0111, 0114,0115, 0570.696134 Jet--Main(Standard)(Used Before CodeDate 09020900).Used on Type No(s).0110, 0111, 0114,0115, 0570.796332 Jet--Main(Standard)Used on Type No(s).0117.

118 796333 Jet--Main(High Altitude)(Used After Code Date08071700).-- -- -- -- -- -- -- Note ---- -- -- --696135 Jet--Main(High Altitude)(Used Before CodeDate 08071800).796333 Jet--Main(High Altitude)(Used After Code Date09020800).Used on Type No(s).0110, 0111, 0114,0115, 0570.696135 Jet--Main(High Altitude)(Used Before CodeDate 09020900).Used on Type No(s).0110, 0111, 0114,0115, 0570.796333 Jet--Main(High Altitude)Used on Type No(s).0117.

121 796137 Kit--CarburetorOverhaul(Used After Code Date08071700).-- -- -- -- -- -- -- Note ---- -- -- --796137 Kit--CarburetorOverhaul(Used After Code Date09020800).Used on Type No(s).0110, 0111, 0114,0115, 0570.796137 Kit--CarburetorOverhaulUsed on Type No(s).0117.

121A 696146 Kit--CarburetorOverhaul(Used Before CodeDate 08071800).-- -- -- -- -- -- -- Note ---- -- -- --696146 Kit--CarburetorOverhaul(Used Before CodeDate 09020900).Used on Type No(s).0110, 0111, 0114,0115, 0570.

122 694876 Spacer--Carburetor(Black)

125 796321 Carburetor127A 690727 Plug--Welch130A 696139 Valve--Throttle133A 694914 Float--Carburetor

135 698780 Tube--Fuel Transfer(Used After Code Date08071700).-- -- -- -- -- -- -- Note ---- -- -- --696142 Tube--FuelTransfer(Used Before CodeDate 08071800).698780 Tube--FuelTransfer(Used After Code Date09020800).Used on Type No(s).0110, 0111, 0114,0115, 0570.698780 Tube--FuelTransfer696142 Tube--FuelTransfer(Used Before CodeDate 09020900).Used on Type No(s).0110, 0111, 0114,0115, 0570.698780 Tube--FuelTransferUsed on Type No(s).0117.

TRAP.FERTRAP.FERTRAP.FERNO. NO. DESCRIPTION NO. NO. DESCRIPTION NO. NO. DESCRIPTION

Engine

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137 698781 Gasket--Float Bowl(Used After Code Date08071700).-- -- -- -- -- -- -- Note ---- -- -- --698781 Gasket--FloatBowl(Used After Code Date09020800).Used on Type No(s).0110, 0111, 0114,0115, 0570.698781 Gasket--FloatBowlUsed on Type No(s).0117.

137A 695426 Gasket--Float Bowl(Used Before CodeDate 08071800).-- -- -- -- -- -- -- Note ---- -- -- --695426 Gasket--FloatBowl(Used Before CodeDate 09020900).Used on Type No(s).0110, 0111, 0114,0115, 0570.

141 696145 Kit--Choke Shaft141C 699979 Shaft--Choke

146 690979 Key--Timing161 794768 Base--Air Cleaner

161B 794767 Base--Air Cleaner163 692277 Gasket--Air Cleaner170 794833 Stud

(Crankcase Cover/Sump)

185 794838 Nut(Air Cleaner Base)

187 791766 Line--Fuel(15 Inches Long)(Cut To RequiredLength)

187A 791869 Line--Fuel188 699479 Screw

(Control Bracket)190 699220 Screw

(Fuel Tank)192 690083 Adjuster--Rocker Arm209 694867 Spring--Governor211 695307 Spring--Governor Idle219 693578 Gear--Governor220 691724 Washer

(Governor Gear)

222 794799 Bracket--ControlUsed on Type No(s).0036, 0112, 0113,0116, 0118, 0541.

222B 794804 Bracket--ControlUsed on Type No(s).0110, 0111, 0114,0115, 0117, 0570.

227 694864 Lever--GovernorControl

265 691024 Clamp--Casing267 699492 Screw

(Casing Clamp)268 691025 Casing--Control Wire

(Cut to RequiredLength)

269 691026 Wire--Control(Cut to RequiredLength)

270 691027 Nut(Control Wire Casing)

271 691028 Lever--Control271A 695381 Lever--Control

278 798196 Washer(Governor ControlLever)(Used After Code Date09101800).-- -- -- -- -- -- -- Note ---- -- -- --792008 Washer(Governor ControlLever)(Used Before CodeDate 09101900).

281 697268 Panel--Control286 793696 Module--Oil Sensor287 699629 Screw

(Dipstick Tube)300C 793701 Muffler

(This muffler isintended forreplacement purposesonly and is not to beused for retrofitting toengines with differentexhaust systems)

300E 794949 Muffler304 795699 Housing--Blower305 699481 Screw

(Blower Housing)

306A 697240 Shield--Cylinder307A 794822 Screw

(Cylinder Shield)309 695479 Motor--Starter

-- -- -- -- -- -- -- Note ---- -- -- --794498 Motor--StarterUsed on Type No(s).0111, 0115.

310 690323 Bolt(Starter Motor)

332 794824 Nut(Flywheel)

333 798853 Armature--Magneto334 699477 Screw

(Magneto Armature)337 491055S Plug--Spark

-- -- -- -- -- -- -- Note ---- -- -- --792015 Plug--SparkUsed on Type No(s).0117.

347 697854 Switch--RockerUsed on Type No(s).0570.-- -- -- -- -- -- -- Note ---- -- -- --795333 Switch--RockerUsed on Type No(s).0110, 0111, 0113,0114, 0115, 0117,0118.

347B 790949 Switch--RockerUsed on Type No(s).0112, 0541.

355 794842 Washer(Muffler Bracket)

356 692603 Wire--Stop356A 692390 Wire--Stop356B 695815 Wire--Stop356C 695295 Wire--Stop356D 695366 Wire--Stop356H 696482 Wire--Stop356J 699994 Wire--Stop356K 697397 Wire--Stop356L 792609 Wire--Stop356M 794290 Wire--Stop

358 695438 Gasket Set--Engine361A 691693 Screw

(Starting Switch)363 19203 Puller--Flywheel

364A 699947 Terminal--Oil Plug

TRAP.FERTRAP.FERTRAP.FERNO. NO. DESCRIPTION NO. NO. DESCRIPTION NO. NO. DESCRIPTION

Engine

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216300

369 695422 Spring--Float Bowl(Used Before CodeDate 08071800).-- -- -- -- -- -- -- Note ---- -- -- --695422 Spring--FloatBowl(Used Before CodeDate 09020900).Used on Type No(s).0110, 0111, 0114,0115, 0570.

383 19576S Wrench--Spark Plug404 795759 Washer

(Governor Crank)410 695382 Link--Control415 691363 Plug425 794836 Screw

(Air Cleaner Cover)425A 794835 Screw

(Air Cleaner Cover)436C 792374 Manifold--Exhaust

437 794844 Screw(Exhaust Manifold)

445 491588S Filter--Air CleanerCartridge

455 794867 Cup--Flywheel456 692299 Plate--Pawl Friction459 281505S Pawl--Rachet

474D 695466 AlternatorUsed on Type No(s).0112, 0116, 0541.

493A 691177 Bracket--MountingUsed on Type No(s).0112, 0115, 0116,0541.

500 691086 Washer(Key Switch)Used on Type No(s).0116.

500A 792613 Washer(Key Switch)

501 797375 RegulatorUsed on Type No(s).0112, 0116, 0541.

503 691532 Strap--Starter504 695383 Washer Set--Friction

505 793515 Nut(Governor ControlLever)(Used After Code Date09101800).-- -- -- -- -- -- -- Note ---- -- -- --691251 Nut(Governor ControlLever)(Used Before CodeDate 09101900).

510 693699 Drive Starter513 692024 Clutch--Drive522 697689 Plug--Dipstick/Fill523 695344 Dipstick524 691876 Seal--Dipstick Tube525 695343 Tube--Dipstick526 690297 Screw

(Regulator)529 791822 Grommet552 694674 Bushing--Governor

Crank562 798197 Bolt

(Governor ControlLever)(Used After Code Date09101800).-- -- -- -- -- -- -- Note ---- -- -- --793216 Bolt(Governor ControlLever)(Used Before CodeDate 09101900).

564 699492 Screw(Control Cover)

577A 690795 Cable Starter578 692306 Wire Assembly

578A 790948 Wire Assembly579 691029 Nut

(Starter Cable)597 691696 Screw

(Pawl Friction Plate)601 791850 Clamp--Hose

604A 791752 Cover--Control608 695287 Starter--Rewind

613 794846 Screw(Muffler)

613B 794844 Screw(Muffler)

614 691620 Pin--Cotter(Governor Crank)

615 694676 Retainer--GovernorShaft(Governor Gear)(Used Before CodeDate 08021500).

616 795758 Crank--Governor621 692310 Switch--Stop622 794839 Washer

(Heat Shield)627A 792608 Panel

632 695917 Link--Throttle(Used Before CodeDate 08071800).-- -- -- -- -- -- -- Note ---- -- -- --695917 Link--Throttle(Used Before CodeDate 09020900).Used on Type No(s).0110, 0111, 0114,0115, 0570.

632A 796324 Link--Throttle(Used After Code Date08071700).-- -- -- -- -- -- -- Note ---- -- -- --796324 Link--Throttle(Used After Code Date09020800).Used on Type No(s).0110, 0111, 0114,0115, 0570.796324 Link--ThrottleUsed on Type No(s).0117.

633B 690998 Seal--Choke/ThrottleShaft

635 691909 Boot--Spark Plug654 794838 Nut

(Carburetor)663 699492 Screw

(Control Panel)

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664 691087 Nut(Key Switch)Used on Type No(s).0116.

668 694257 Spacer(Control Bracket)

676C 697816 Deflector--Muffler(Side Out)

677A 699776 Screw(Muffler Deflector)

689 691855 Spring--Friction695 698807 Screw

(Ring Gear)697 795026 Screw

(Drive Cap)718 690959 Pin--Locating

718A 695178 Pin--Locating725A 792995 Heat Shield

Used on Type No(s).0110, 0111, 0114,0115, 0117, 0570.

727A 697465 Cover--Starter Drive732 699200 Screw

(Starter Drive Cover)740 710090 Nut

(Muffler Bracket)740A 794843 Nut

(Muffler Bracket)741 691288 Gear--Timing742 692564 Retainer--E Ring746 694679 Gear--Idler773 694258 Retainer783 693713 Gear--Pinion789 797457 Harness--Wiring

Used on Type No(s).0116.

798 697890 Screw(Rocker Arm)

799 794937 Screw(Oil Sensor)(Shoulder Screw)-- -- -- -- -- -- -- Note ---- -- -- --699233 Screw(Oil Sensor)

801 694482 Cap--Drive802 691286 Cap--End813 690635 Clamp819 794832 Screw

(Muffler Bracket)832B 793903 Guard--Muffler832C 792380 Guard--Muffler

835 797458 Bracket--Wire HarnessUsed on Type No(s).0116.

836B 699234 Screw(Muffler Guard)

836C 710023 Screw(Muffler Guard)

842 691031 Seal--O Ring(Dipstick Tube)

847 695342 Dipstick/TubeAssembly

851 692424 Terminal--Spark Plug863C 793700 Bracket--Muffler

868 690968 Seal--Valve883A 794818 Gasket--Exhaust883C 710250 Gasket--Exhaust

892 692318 Switch--KeyUsed on Type No(s).0116.

892A 791944 Switch--Key914 794827 Screw

(Rocker Cover)920 691656 Solenoid--Starter951 699961 Lever--Choke957 795027 Cap--Fuel Tank

(Plastic)957A 792647 Cap--Fuel Tank

(Plastic)(Fresh Start)

958 698180 Valve--Fuel Shut Off(Plastic)

967 491435S Filter--Pre Cleaner968 794785 Cover--Air Cleaner

968A 794784 Cover--Air Cleaner972A 694260 Tank--Fuel

(Plastic)

975 698783 Bowl--Float(Used After Code Date08071700).-- -- -- -- -- -- -- Note ---- -- -- --698783 Bowl--Float(Used After Code Date09020800).Used on Type No(s).0110, 0111, 0114,0115, 0570.698783 Bowl--FloatUsed on Type No(s).0117.

975A 696138 Bowl--Float(Used Before CodeDate 08071800).-- -- -- -- -- -- -- Note ---- -- -- --696138 Bowl--Float(Used Before CodeDate 09020900).Used on Type No(s).0110, 0111, 0114,0115, 0570.

990 691959 Key SetUsed on Type No(s).0116.

990A 794696 Key Set1005 794815 Fan--Flywheel1022 690971 Gasket--Rocker Cover1023 697691 Cover--Rocker Arm1026 695177 Rod--Push1029 690972 Arm--Rocker1036 Label--Emissions

(Available From ABriggs & StrattonAuthorized Dealer)

1051 691265 Ring--Retaining1052A 794805 Sensor Oil

1054 280275 Tie--Cable1058 277040 Operator’s Manual1070 794821 Screw

(Flywheel Fan)

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1090 691293 Retainer--Brush1095 695440 Gasket Set--Valve1100 791959 Pivot--Rocker Arm1119 699772 Screw

(Alternator)1127A 695407 Screw--Float Bowl

1138 694255 Nut(Control Bracket)

1171 794828 Stud(Rocker Cover)

1177 710090 Nut(Muffler)

1194 691876 Seal--O Ring(Plug)

1210 498144 Pulley/SpringAssembly(Pulley)

1211 498144 Pulley/SpringAssembly(Spring)

1212 794841 Stud(Blower Housing)

1230 794840 Stud(Control Bracket)

1298 794838 Nut(Heat Shield)

1319 794467 Label--Warning1330 276781 Repair Manual1404 794838 Nut

(Control Cover)

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