Briggs & Stratton 40305B User Manual

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Operator’s Manual

Manual del Operario

Manuel de l’opérateur

Model 540000

Vanguardt

Gaseous

Model 610000

Vanguardt

Gaseous

English

Form No. 279774TRI

Revision: F

Español Français

es fr

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Reproduction

VanguardEngines.com

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General Information

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This manual contains safety information to make you aware of the hazards and risks associated with engines and how to avoid them. It also contains instructions for the proper use and care of the engine. Because Briggs & Stratton Corporation does not necessarily know what equipment this engine will power, it is important that you read and understand these instructions and the instructions for the equipment. Save these

original instructions for future reference.

For replacement parts or technical assistance, record below the engine model, type, and code numbers along with the date of purchase. These numbers are located on your engine (see the Features and Controls page).

Date of purchase:

MM/DD/YYYY

Engine model:

Model: Code:Type:

Look for the 2D barcode located on some engines. When viewed with a 2D--capable device, the code will bring up our website where you can access support information for this product. Data rates apply. Some countries may not have online support information available.

Operator Safety

SAFETY AND CONTROL SYMBOLS

WARNING

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

Fire

Fast

Choke

Hazardous

Chemical

The safety alert symbol is used to identify safety information about hazards that can result in personal injury. A signal word (DANGER, WARNING, or CAUTION) is used with the alert symbol to indicate the likelihood and the potential severity of injury. In addition, a hazard symbol may be used to represent the type of hazard.

Moving Parts

Stop

On Off

Read Manual

Oil

Explosion

Fuel Shutoff

Hot Surface

Toxic Fumes

Shock

Kickback

Frostbite

Slow

Fuel

Wear Eye

Protection

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 indicates a situation that could result in damage to the product.

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

Briggs & Stratton Engines are not designed for and are not to be used to power: fun-karts; go-karts; children’s, recreational, or sport all-terrain vehicles (ATVs); motorbikes; hovercraft; aircraft products; or vehicles used in competitive events not sanctioned by Briggs & Stratton. For information about competitive racing products, see www.briggsracing.com. For use with utility and side-by-side ATVs, please contact Briggs & Stratton Engine Application Center, 1-866-927-3349. Improper engine application may result in serious injury or death.

NOTICE: This engine was shipped from Briggs & Stratton without oil. Before you start the engine, make sure you add oil according to the instructions in this manual. If you start the engine without oil, it will be damaged beyond repair and will not be covered under warranty.

WARNING

Fuel and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death.

When Adding Fuel

 Fill fuel tank outdoors or in well-ventilated area.  Check fuel lines, tank, cap, and fittings frequently for cracks or leaks.

Replace if necessary.

When Starting Engine

 Ensure that spark plug, muffler, and air cleaner (if equipped) are in place and

secured.

 Do not crank engine with spark plug removed.

When Operating Equipment

 Never start or run the engine with the air cleaner assembly (if equipped) or the

air filter (if equipped) removed.

When Transporting Equipment

 On Natural/Liquid Petroleum (LP) Gas engines, transport with fuel cylinder

empty or valve closed, or fuel tank disconnected.

When Storing Fuel Or Equipment With Fuel In Tank

 Store away from furnaces, stoves, water heaters or other appliances that have

pilot lights or other ignition sources because they can ignite fuel vapors.

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WARNING

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Starting engine creates sparking. Sparking can ignite nearby flammable gases. Explosion and fire could result.

 If there is natural or LP gas leakage in area, do not start engine.  Do not use pressurized starting fluids because vapors are flammable.

WARNING

POISONOUS GAS HAZARD. Engine exhaust contains carbon monoxide, a poisonous gas that could kill you in minutes. You CANNOT see it, smell it, or taste it. Even if you do not smell exhaust fumes, you could still be exposed to carbon monoxide gas. If you start to feel sick, dizzy, or weak while using this product, shut it off and get to fresh air RIGHT AWAY. See a doctor. You may have carbon monoxide poisoning.

 Operate this product ONLY outside far away from windows, doors and vents to

reduce the risk of carbon monoxide gas from accumulating and potentially being drawn towards occupied spaces.

 Install battery--operated carbon monoxide alarms or plug--in carbon monoxide

alarms with battery back-up according to the manufacturer’s instructions. Smoke alarms cannot detect carbon monoxide gas.

 DO NOT run this product inside homes, garages, basements, crawlspaces,

sheds, or other partially-enclosed spaces even if using fans or opening doors and windows for ventilation. Carbon monoxide can quickly build up in these spaces and can linger for hours, even after this product has shut off.

 ALWAYS place this product downwind and point the engine exhaust away from

occupied spaces.

WARNING

Rapid retraction of starter cord (kickback) will pull hand and arm toward engine faster than you can let go.

Broken bones, fractures, bruises or sprains could result.

 When starting engine, pull the starter cord slowly until resistance is felt and then

pull rapidly to avoid kickback.

 Remove all external equipment/engine loads before starting engine.  Direct-coupled equipment components such as, but not limited to, blades,

impellers, pulleys, sprockets, etc., must be securely attached.

WARNING

Running engines produce heat. Engine parts, especially muffler, become extremely hot.

Severe thermal burns can occur on contact. Combustible debris, such as leaves, grass, brush, etc. can catch fire.

 Allow muffler, engine cylinder and fins to cool before touching.  Remove accumulated debris from muffler area and cylinder area.  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.

WARNING

Unintentional sparking can result in fire or electric shock. Unintentional start-up can result in entanglement, traumatic

amputation, or laceration. Fire hazard

Before performing adjustments or repairs:

 Disconnect the spark plug wire and keep it away from the spark plug.  Disconnect battery at negative terminal (only engines with electric start.)  Use only correct tools.  Do not tamper with governor spring, links or other parts to increase engine

speed.

 Replacement parts must be of the same design and installed in the same

position as the original parts. Other parts may not perform as well, may damage the unit, and may result in injury.

 Do not strike the flywheel with a hammer or hard object because the flywheel

may later shatter during operation.

When testing for spark:

 Use approved spark plug tester.  Do not check for spark with spark plug removed.

WARNING

Missing or inoperative “fuel lock-off” valve can cause a fire or explosion.

 Do not operate the equipment if the “fuel lock-off” valve is missing or inoperative.

WARNING

Rotating parts can contact or entangle hands, feet, hair, clothing, or accessories.

Traumatic amputation or severe laceration can result.

 Operate equipment with guards in place.  Keep hands and feet away from rotating parts.  Tie up long hair and remove jewelry.  Do not wear loose-fitting clothing, dangling drawstrings or items that could

become caught.

WARNING

Gaseous fuels are extremely flammable and readily form explosive air-vapor mixtures at ambient temperatures.

If you smell gas,

 Do not start the engine.  Do not actuate any electrical switches.  Do not use a phone in the vicinity.  Evacuate the area.  Contact the gas supplier or fire department.

WARNING

Wear eye protection when doing repair work. Frostbite can result from skin/eye contact with leaking LP liquid.

 Installation, adjustment and repair work should be done by a qualified

technician.

 Regularly check flexible supply line. Make sure they are in good condition.

Replace damaged or leaking components.

Features and Controls

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Compare the illustration various features and controls.

A. Engine Identification

Model Type Code

B. Spark Plug

C. Air Cleaner, Low Profile

D. Dipstick

E. Oil Fill

F. Oil Filter

G. Oil Drain Plug

H. Oil Pressure Sensor

I. Finger Guard / Rotating Screen

J. Electric Starter

K. Starter Solenoid

L. Regulator/Rectifier

M. LPG/NG Mixer

N. Oil Cooler

O. Muffler

with your engine to familiarize yourself with the location of

Operation

Oil capacity (see the Specifications section)

Low Oil Protection System (if equipped)

Some engines are equipped with a low oil sensor. If the oil is low, the sensor will either activate a warning light or stop the engine. Stop the engine and follow these steps before restarting the engine.

 Make sure the engine is level.  Check the oil level. See the How To Check/Add Oil section.  If the oil level is low, add the proper amount of oil. Start the engine and make sure

the warning light (if equipped) is not activated.

 If the oil level is not low, do not start the engine. Contact an Authorized Briggs &

Stratton Dealer to have the the oil problem corrected.

Fuel Recommendations

WARNING

Missing or inoperative “fuel lock-off” valve can cause a fire or explosion.

 Do not operate the equipment if the “fuel lock-off” valve is missing or inoperative.

Fuel must meet these requirements:

 Use clean, dry fuel, free of moisture or any particulate material. Using fuels outside

the following recommended values may cause performance problems.

 In engines set up to run on LPG, commercial grade HD5 LPG is recommended.

Recommended fuel composition is fuel with a minimum fuel energy of 2500 BTU’s/ft with maximum propylene content of 5% and butane and heavier gas content of 2.5% and minimum propane content of 90%.

NG or LPG engines are certified to operate on natural or liquid propane gas. The emissions control system for this engine is EM (Engine Modifications).

WARNING: The equipment on which this engine is mounted is equipped

Oil Recommendations

We recommend the use of Briggs & Stratton Warranty Certified oils 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 to select the best viscosity for the outdoor temperature range expected.

°F °C

with an automatic safety gas “fuel lock-off” valve. Do not operate the equipment if the “fuel lock-off” valve is missing or inoperative.

How To Add Fuel

WARNING

SAE 30

10W-30

Synthetic 5W-30

* Below 40°F(4°C) the use of SAE 30 will result in hard starting. ** Above 80°F(27°C) the use of 10W-30 may cause increased oil consumption. Check

oil level more frequently.

How To Check/Add Oil - Figure

Before adding or checking the oil

 Place engine level.  Clean the oil fill area of any debris.

1. Remove the dipstick (A) and wipe with a clean cloth (Figure 2).

2. Insert and tighten the dipstick.

3. Remove the dipstick and check the oil level. It should be at the top of the full indicator (B) on the dipstick.

4. If low, add oil slowly into the engine oil fill (C). Do not overfill. After adding oil, wait one minute and then recheck the oil level.

5. Replace and tighten the dipstick.

5W-30

For information on refueling natural or LP gas engines, read the operating instructions supplied by the equipment manufacturer.

How To Start And Stop The Engine

Fuel and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death.

When Adding Fuel

 Fill fuel tank outdoors or in well-ventilated area.  Check fuel lines, tank, cap, and fittings frequently for cracks or leaks.

Replace if necessary.

WARNING

Fuel and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death.

When Starting Engine

 Ensure that spark plug, muffler, and air cleaner (if equipped) are in place and

secured.

 Do not crank engine with spark plug removed.

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WARNING

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Reproduction

 Operate this product ONLY outside far away from windows, doors and vents to

reduce the risk of carbon monoxide gas from accumulating and potentially being drawn towards occupied spaces.

 Install battery--operated carbon monoxide alarms or plug--in carbon monoxide

alarms with battery back-up according to the manufacturer’s instructions. Smoke alarms cannot detect carbon monoxide gas.

 DO NOT run this product inside homes, garages, basements, crawlspaces,

 ALWAYS place this product downwind and point the engine exhaust away from

occupied spaces.

For information on starting and stopping the engine, read the operating instructions supplied by the equipment manufacturer.

Maintenance

We recommend that you see any Briggs & Stratton Authorized Dealer for all maintenance and service of the engine and engine parts.

NOTICE: All the components used to build this engine must remain in place for proper operation.

Emissions Control

Maintenance, replacement, or repair of the emissions control devices and systems may be performed by any non-road engine repair establishment or individual.

However, to obtain “no charge” emissions control service, the work must be performed by a factory authorized dealer. See the Emissions Warranty.

WARNING

Unintentional sparking can result in fire or electric shock. Unintentional start-up can result in entanglement, traumatic

amputation, or laceration. Fire hazard

Every8HoursorDaily

 Check engine oil level  Clean area around muffler and controls

Every 100 Hours or Annually

 Clean or change air filter *  Change engine oil and filter  Replace spark plug  Check muffler and spark arrester

Every 250 Hours or Annually

 Check valve clearance. Adjust if necessary.

Every 400 Hours or Annually

 Change air filter  Clean air cooling system *  Clean oil cooler fins *

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

How To Replace The Spark Plug - Figure

Check the gap (A, Figure 3) with a wire gauge (B). If necessary, reset the gap. Install and tighten the spark plug to the recommended torque. For gap setting or torque, see the Specifications section.

Note: In some areas, local law requires using a resistor spark plug to suppress ignition signals. If this engine was originally equipped with a resistor spark plug, use the same type for replacement.

Inspect Muffler And Spark Arrester - Figure

WARNING

Running engines produce heat. Engine parts, especially muffler, become extremely hot.

Severe thermal burns can occur on contact. Combustible debris, such as leaves, grass, brush, etc. can catch fire.

Remove accumulated debris from muffler area and cylinder area. Inspect the muffler (A, Figure 4) for cracks, corrosion, or other damage. Remove the spark arrester (B), if equipped, and inspect for damage or carbon blockage. If damage is found, install replacement parts before operating.

WARNING: Replacement parts must be of the same design and installed

in the same position as the original parts. Other parts may not perform as well, may damage the unit, and may result in injury.

Before performing adjustments or repairs:

speed.

 Replacement parts must be of the same design and installed in the same

position as the original parts. Other parts may not perform as well, may damage the unit, and may result in injury.

 Do not strike the flywheel with a hammer or hard object because the flywheel

may later shatter during operation.

When testing for spark:

 Use approved spark plug tester.  Do not check for spark with spark plug removed.

Maintenance Chart

First 5 Hours

 Change oil

How To Change The Oil - Figure

Used oil is a hazardous waste product and must be disposed of properly. Do not discard with household waste. Check with your local author ities, service center, or dealer for safe disposal/recycling facilities.

Remove Oil

1. With engine off but still warm, disconnect the spark plug wire (A) and keep it away from the spark plug (Figure 5).

2. Remove the oil drain plug (B). Drain the oil into an approved container.

3. After the oil has drained, install and tighten the oil drain plug.

Change The Oil Filter

All models are equipped with an oil filter. For replacement intervals, see the Maintenance chart.

1. Drain the oil from the engine. See Remove Oil section.

2. Remove the oil filter (C, Figure 5) and dispose of properly.

3. Before you install the new oil filter, lightly lubricate the oil filter gasket with fresh, clean oil.

4. Install the oil filter by hand until the gasket contacts the oil filter adapter, then tighten theoilfilter1/2to3/4turns.

5. Add oil. See Add Oil section.

6. Start and run the engine. As the engine warms up, check for oil leaks.

7. Stop the engine and check the oil level. It should be at the top of the full indicator (F) on the dipstick.

Add Oil

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 Place engine level.  Clean the oil fill area of any debris.  See the Specifications section for oil capacity.

1. Remove the dipstick (D, Figure 5) and wipe with a clean cloth.

2. Pour the oil slowly into the engine oil fill (E). Do not overfill. After adding oil, wait one minute and then check the oil level.

3. Install and tighten the dipstick.

4. Remove the dipstick and check the oil level. It should be at the top of the full indicator (F) on the dipstick.

5. Install and tighten the dipstick.

How To Clean The Air Cooling System - Figure

WARNING

Running engines produce heat. Engine parts, especially muffler, become extremely hot.

Severe thermal burns can occur on contact. Combustible debris, such as leaves, grass, brush, etc. can catch fire.

 Allow muffler, engine cylinder and fins to cool before touching.  Remove accumulated debris from muffler area and cylinder area.

How To Service The Air Filter - Figure

WARNING

Fuel and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death.

 Never start or run the engine with the air cleaner assembly (if equipped) or the

air filter (if equipped) removed.

NOTICE: Do not use pressurized air or solvents to clean the filter. Pressurized air can damage the filter and solvents will dissolve the filter.

Low-Profile Air Filter System (Figure 6)

1. Remove the knob (F) and the cover (G).SeeFigure6.

2. Remove the nut (H) and the retainer (J).

3. Remove the air filter (K).

4. Remove the pre-cleaner (L), if equipped, from the air filter.

5. To loosen debris, gently tap the air filter on a hard surface. If the air filter is excessively dirty, replace with a new air filter.

6. Wash the pre-cleaner in liquid detergent and water. Then allow it to thoroughly air dry. Do not oil the pre-cleaner.

7. Assemble the dry pre-cleaner to the air filter.

8. Install the air filter and secure with retainer and nut.

9. Install the cover and secure with knob.

Specifications

Engine Specifications

Model 540000 Displacement 54.68 ci (896 cc) Bore 3.366 in (85.5 mm) Stroke 3.071 in (78.0 mm) Oil Capacity 78 -- 80 oz (2.3 -- 2.4 L)

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.

This is an air cooled engine. Dirt or debris can restrict air flow and cause the engine to overheat, resulting in poor performance and reduced engine life.

Use a brush or dry cloth to remove debris from the finger guard/rotating screen (A, Figure 7). Keep linkage, springs and controls clean. Keep the area around and behind the muffler (C) free of any combustible debris. Make sure that the oil cooler fins (D)are free of dirt and debris.

Storage

WARNING

Fuel and its vapors are extremely flammable and explosive. Fire or explosion can cause severe burns or death.

When Storing Fuel Or Equipment With Fuel In Tank

 Store away from furnaces, stoves, water heaters or other appliances that have

pilot lights or other ignition sources because they can ignite fuel vapors.

Engine Oil

While the engine is still warm, change the engine oil.

Troubleshooting

Need Assistance? Go to VanguardEngines.com or call (800) 999-9333 (in USA).

Engine Specifications

Model 610000 Displacement 60.60 ci (993 cc) Bore 3.366 in (85.5 mm) Stroke 3.406 in (86.5 mm) Oil Capacity 78 -- 80 oz (2.3 -- 2.4 L)

Tune-up Specifications *

Model 540000 Spark Plug Gap 0.020 in (0.51 mm) Spark Plug Torque 180 lb-in (20 Nm) Armature Air Gap 0.005 - 0.008 in (0.13 - 0.20 mm) Intake Valve Clearance 0.004 - 0.006 in (0.10 - 0.15 mm) Exhaust Valve Clearance 0.004 - 0.006 in (0.10 - 0.15 mm)

* Engine power will decrease 3.5% for each 1,000 feet (300 meters) above sea level and 1% for each 10 F(5.6 C) above 77 F(25 C). The engine will operate satisfactorily at an angle up to 15. Refer to the equipment operator’s manual for safe allowable operating limits on slopes.

Common Service Parts n

Service Part Part Number

Air Filter, Low-Profile - Generator UL Pre-Cleaner, Low-Profile 692520 Oil -- SAE 30 100028 Oil Filter 842921

n We recommend that you see any Briggs & Stratton Authorized Dealer for all maintenance and service of the engine and engine parts.

841856

Tune-up Specifications *

Model 610000 Spark Plug Gap 0.020 in (0.51 mm) Spark Plug Torque 180 lb-in (20 Nm) Armature Air Gap 0.005 - 0.008 in (0.13 - 0.20 mm) Intake Valve Clearance 0.004 - 0.006 in (0.10 - 0.15 mm) Exhaust Valve Clearance 0.004 - 0.006 in (0.10 - 0.15 mm)

Service Part Part Number

Resistor Spark Plug 491055 Long Life Platinum Spark Plug 5066 Spark Plug Wrench 19374 Spark Tester 19368

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