GE 540000, 610000 User Manual

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Reproduction

Operator’s Manual

Manual del Operario

Manuel de l’opérateur

Model 540000

Vanguardt

Gaseous

Model 610000

Vanguardt

Gaseous

Briggs & Stratton is a registered trademark of Briggs & Stratton Corporation

English

Español Français

es fr

Form No. 279768TRI

Revision: A

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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:

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.

WARNING

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

Power Rating

The gross power rating for individual gas engine models is labeled in accordance with SAE (Society of Automotive Engineers) code J1940 (Small Engine Power & Torque Rating Procedure), and rating performance has been obtained and corrected in accordance with SAE J1995 (Revision 2002--05). Torque values are derived at 3060 RPM; horsepower values are derived at 3600 RPM. Net power values are taken with exhaust and air cleaner installed whereas gross power values are collected without these attachments. Actual gross engine power will be higher than net engine power and is affected by, among other things, ambient operating conditions and engine--to--engine variability. Given the wide array of products on which engines are placed, the gas engine may not develop the rated gross power when used in a given piece of power equipment. This difference is due to a variety of factors including, but not limited to, the variety of engine components (air cleaner, exhaust, charging, cooling, carburetor, fuel pump, etc.), application limitations, ambient operating conditions (temperature, humidity, altitude), and engine--to--engine variability. Due to manufacturing and capacity limitations, Briggs & Stratton may substitute an engine of higher rated power for this Series engine.

Operator Safety

SAFETY AND CONTROL SYMBOLS

Fire

Fast

Choke

Moving Parts

Stop

On Off

Oil

Explosion

Fuel Shutoff

Toxic Fumes

Shock

Kickback

Slow

Fuel

Wear Eye

Protection

WARNING

Briggs & Stratton does not approve or authorize the use of these engines on 3-wheel All Terrain Vehicles (ATVs), motor bikes, fun/recreational go-karts, aircraft products, or vehicles intended for use in competitive events. Use of these engines in such applications could result in property damage, serious injury (including paralysis), or even 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.

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.

Read Manual

Hot Surface

Frostbite

WARNING

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.

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.

WARNING

Engines give off carbon monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide can cause nausea, fainting or death.

 Start and run engine outdoors.  Do not start or run engine in enclosed area, even if doors or windows are open.

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

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WARNING

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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

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

 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

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

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

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.

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.

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.

Features and Controls

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Fuel Recommendations

Compare the illustration various features and controls.

A. Engine Identification

Model Type Code

B. Spark Plug C. Air Cleaner, Cyclonic D. Air Cleaner, Low Profile E. Dipstick F. Oil Fill G. Oil Filter H. Oil Drain Plug I. Oil Pressure Sensor J. Finger Guard / Rotating Screen K. Electric Starter L. Starter Solenoid M. Regulator/Rectifier N. LPG/NG Mixer O. Oil Cooler

with your engine to familiarize yourself with the location of

Operation

Oil capacity (see the Specifications section)

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

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

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

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.

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

SAE 30

10W-30

How To Start The Engine - Figure

WARNING

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.

Oil Pressure

If the oil pressure is too low, a pressure switch (if equipped) will either stop the engine or activate a warning device on the equipment. If this occurs, stop the engine and check the oil level with the dipstick.

If the oil level is below the ADD mark, add oil until it reaches the FULL mark. Start the engine and check for proper pressure before continuing to operate.

If the oil level is between the ADD and FULL marks, do not start the engine. Contact an Authorized Briggs & Stratton Dealer to have the oil pressure problem corrected.

5W-30

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.

Note: Some engines and equipment have remote controls. See the equipment manual for location and operation of remote controls.

1. Check the oil level. See the How To Check/Add Oil section.

2. Make sure equipment drive controls, if equipped, are disengaged.

3. Turn the fuel shut-off valve (A), if equipped, to the on position (Figure 3).

4. Move the throttle control (B)tothefast

5. Turn the electric start switch (C) to the on/start position (Figure 3).

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.

WARNING

Engines give off carbon monoxide, an odorless, colorless, poison gas. Breathing carbon monoxide can cause nausea, fainting or death.

 Start and run engine outdoors.  Do not start or run engine in enclosed area, even if doors or windows are open.

position. Operate the engine in the fast

position.

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Note: If the engine does not start after repeated attempts, go to

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VanguardEngines.com or call 1-800-999-9333 (in USA). NOTICE: To extend the life of the starter, use short starting cycles (five seconds

maximum). Wait one minute between starting cycles.

How To Stop The Engine - Figure

1. Move the throttle control to the slow position, turn the key switch (C) to the off position (Figure 3). Remove the key and keep in a safe place out of the reach of children.

2. After t he engine stops, turn the fuel shut-off valve (A), if equipped, to the closed position.

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

NOTICE: The manufacturer of the equipment on which this engine is installed specifies the top speed at which the engine will be operated. Do not exceed this speed.

How To Replace The Spark Plug - Figure

Check the gap (A, Figure 4) 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 5) 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.

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

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 *

Every 600 Hours or Annually

 Change safety filter (if equipped)

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

Every third air filter change, replace the inner safety filter (if equipped).

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.

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 authorities, 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 6).

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 6) and dispose of properly.

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

4. Install t he 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 t he 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

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

1. Remove the dipstick (D, Figure 6) 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 Service The Air Filter - Figure

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7 8

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.

The air filter system uses either a cyclonic air filter or a low-profile air filter. See the Maintenance Chart for service requirements.

Cyclonic Air Filter System

1. Open the latches (A) and remove the cover (B).SeeFigure7.

2. Remove the air filter (C).

3. 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.

4. The cyclonic air filter system also has a safety filter (D) (if equipped). See the Maintenance Chart for service requirements. To remove, carefully pull the safety filter away from air cleaner body (E) and discard. Make sure that dirt or debris do not enter the engine.

5. Install t he new safety filter in the air cleaner body.

6. Install t he air filter over the safety filter.

7. Install the cover and close the latches.

Low-Profile Air Filter System

1. Remove the knob (F) and the cover (G).SeeFigure8.

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 t he cover and secure with knob.

How To Clean The Air Cooling System - Figure

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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.

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 9). Keep linkage, springs and controls (B) 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.

Clean the area under the panel (E, Figure 10). Loosen the two screws (F) until you hear a click. Remove the panel and clean the area of dirt and debris. Make sure the underside of the panel is also clean. Install the panel and tighten the screws until you hear a click.

Note: To remove the panel on engines equipped with the Cyclonic Air Filter System (G, Figure 10), loosen the fastener (H) and pivot the Cyclonic Air Filter away from the engine. It is not necessary to remove the flexible air cleaner hose (J). After cleaning, make sure to reposition the air filter and tighten the fastener.

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 1-800-999-9333.

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)

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 s afe allowable operating limits on slopes.

Common Service Parts n

Service Part Part Number

Air Filter, Cyclonic 841497 Safety Filter, Cyclonic 821136 Air Filter, Low-Profile 692519 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.

Engine Specifications

Model 610000 Displacement 60.60 ci (993 cc) Bore 3.366 in (85.5 mm) Stroke 3.406 in (77.21 mm) Oil Capacity 78 -- 80 oz (2.3 -- 2.4 L)

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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