GE 540000, 610000 User Manual

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es

fr

Operator’s Manual Manual del Operario Manuel de l’opérateur

Model 540000		Vanguard	Model 610000		Vanguardt
		Reproduction
		Gaseous	for		Gaseous
		Not

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

English

E 2011 Briggs & Stratton Corporation,		Form No. 279768TRI
Milwaukee, WI, USA. All rights reserved.		Revision: A
Español	Français

en		es		fr

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						for
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				Reproduction
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			D	Reproduction
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General Information

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:

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.

Model: Type: Code:

	Power Rating							WARNING
	The gross power rating for individual gas engine models is labeled in accordance with							Briggs & Stratton does not approve or authorize the use of these engines
	SAE (Society of Automotive Engineers) code J1940 (Small Engine Power & Torque							on 3-wheel All Terrain Vehicles (ATVs), motor bikes, fun/recreational
	Rating Procedure), and rating performance has been obtained and corrected in							go-karts, aircraft products, or vehicles intended for use in competitive
	accordance with SAE J1995 (Revision 2002--05). Torque values are derived at 3060							events. Use of these engines in such applications could result in property
	RPM; horsepower values are derived at 3600 RPM. Net power values are taken with							damage, serious injury (including paralysis), or even death.
	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							NOTICE: This engine was shipped from Briggs & Stratton without oil. Before you start
	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							the engine, make sure you add oil according to the instructions in this manual. If you
	may not develop the rated gross power when used in a given piece of power equipment.							start the engine without oil, it will be damaged beyond repair and will not be covered
	This difference is due to a variety of factors including, but not limited to, the variety of							under warranty.
	engine components (air cleaner, exhaust, charging, cooling, carburetor, fuel pump, etc.),
	application limitations, ambient operating conditions (temperature, humidity, altitude), and
	engine--to--engine variability.				Reproduction
	Due to manufacturing and capacity limitations, Briggs & Stratton may substitute an
	engine of higher rated power for this Series engine.							WARNING
	Operator Safety							Fuel and its vap rs are extremely flammable and explosive.
								Fire or expl s n can cause severe burns or death.
		SAFETY AND CONTROL SYMBOLS						When Adding Fuel
								Fill fuel tank ou doors or in well-ventilated area.
							forChe k f		el lines, tank, cap, and fittings frequently for cracks or leaks.
								Repla	if ne essary.
								When Starting Engine
	Fire	Moving Parts		Oil	Toxic Fumes	Slow		Ens re that spark plug, muffler, and air cleaner (if equipped) are in place and
								secured.
					Not			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
				Explosion	Shock	Fuel		air filter (if equipped) removed.
	Fast	Stop						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
	Choke	On Off		Fuel Shutoff	Kickback	Wear Eye		Store away from furnaces, stoves, water heaters or other appliances that have
						Protection		pilot lights or other ignition sources because they can ignite fuel vapors.
	Hazardous	Read Manual		Hot Surface	Frostbite
	Chemical							WARNING
								Starting engine creates sparking.
								Sparking can ignite nearby flammable gases.
	The safety alert symbol		is used to identify safety information about hazards that can					Explosion and fire could result.
	result in personal injury. A signal word (DANGER, WARNING, or CAUTION) is used with the							If there is natural or LP gas leakage in area, do not start engine.
	alert symbol to indicate the likelihood and the potential severity of injury. In addition, a hazard
								Do not use pressurized starting fluids because vapors are flammable.
	symbol may be used to represent the type of hazard.
	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							WARNING
	serious injury.							Engines give off carbon monoxide, an odorless, colorless, poison gas.
								Breathing carbon monoxide can cause nausea, fainting or death.
	CAUTION indicates a hazard which, if not avoided, could result in minor or							Start and run engine outdoors.
	moderate injury.
								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.

4	VanguardEngines.com

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

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

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
								WARNING
			Running engines produce heat. Engine parts, especially muffler,
								Missing or inoperative “fuel lock-off” valve can cause a fire or
			become extremely hot.
								explosion.
			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.						Do not operate the equ pme t if the “fuel lock-off” valve is missing or inoperative.
	Remove accumulated debris from muffler area and cylinder area.						for
	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 federal
		jurisdictions may have similar laws. Contact the original equipment
		manufacturer, retailer, or dealer to obtain a spark arrester designed f			r the
		exhaust system installed on this engine.
			WARNING
			Unintentional sparking can result in fire or electric shock.
				Not
			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.		Reproduction
	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.

		5
	en

Features and Controls

Compare the illustration 1 with your engine to familiarize yourself with the location of 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

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/ft3 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.

Operation

How To Add Fuel

Oil capacity (see the Specifications section)

Oil Recommendations

WARNING

We recommend the use of Briggs & Stratton Warranty Certified oils for best

Fuel and its vapors are extremely flammable and explosive.

performance. Other high-quality detergent oils are acceptable if classified for service SF,

Fi e or expl si can cause severe burns or death.

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.

When Adding Fuel

Fill fuel tank ou doors or n well-ventilated area.

°F

°C

Che k fuel lines, ank, cap, and fittings frequently for cracks or leaks.

Repla if ne essary.

Not

for

30

For information on refueling natural or LP gas engines, read the operating instructions

supplied by the eq ipment manufacturer.

H

w To Start The Engine - Figure 3

WARNING

SAE

10W30-

Synthetic5W30-

5W-30

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

* Below 40°F (4°C) the use of SAE 30 will result in hard starting.

secured.

Do not crank engine with spark plug removed.

** Above 80°F (27°C) the use of 10W-30 may cause increased oil consumption. Check

oil level more frequently.

Reproduction

How To Check/Add Oil - Figure

2

WARNING

Before adding or checking the oil

Engines give off carbon monoxide, an odorless, colorless, poison gas.

Breathing carbon monoxide can cause nausea, fainting or death.

Place engine level.

Clean the oil fill area of any debris.

Start and run engine outdoors.

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

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

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

NOTICE: This engine was shipped from Briggs & Stratton without oil. Before you start

(B) on the dipstick.

the engine, make sure you add oil according to the instructions in this manual. If you

	4.	If low, add oil slowly into the engine oil fill (C). Do not overfill. After adding oil, wait	start the engine without oil, it will be damaged beyond repair and will not be covered
		one minute and then recheck the oil level.
			under warranty.
	5.	Replace and tighten the dipstick.
			Note: Some engines and equipment have remote controls. See the equipment manual

	Oil Pressure	for location and operation of remote controls.
		1. Check the oil level. See the How To Check/Add Oil section.

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.

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) to the fast position. Operate the engine in the fast

position.

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

6	VanguardEngines.com

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

VanguardEngines.com or call 1-800-999-9333 (in USA).

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.

NOTICE: To extend the life of the starter, use short starting cycles (five seconds
maximum). Wait one minute between starting cycles.			How To Replace The Spark Plug - Figure 4
How To Stop The Engine - Figure 3			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
1. Move the throttle control to the slow position, turn the key switch (C) to the off			Specifications section.
			Note: In some areas, local law requires using a resistor spark plug to suppress ignition
position (Figure 3). Remove the key and keep in a safe place out of the reach of			signals. If this engine was originally equipped with a resistor spark plug, use the same
children.			type for replacement.
2. After the engine stops, turn the fuel shut-off valve (A), if equipped, to the closed
position.			Inspect Muffler And Spark Arrester - Figure 5
Maintenance
						WARNING
We recommend that you see any Briggs & Stratton Authorized Dealer for all
maintenance and service of the engine and engine parts.						Running engines produce heat. Engine parts, especially muffler,
NOTICE: All the components used to build this engine must remain in place for proper
						become extremely hot.
operation.
						Severe thermal burns can occur on contact.
Emissions Control						Combustible debris, such as leaves, grass, brush, etc. can catch fire.
Maintenance, replacement, or repair of the emissions control devices and systems				Allow muffler, engine cylinder and fins to cool before touching.
may be performed by any non-road engine repair establishment or individual.				Remove accumulated debris from muffler area and cylinder area.
However, to obtain “no charge” emissions control service, the work must be performed				It is a violation of California Public Resource Code, Section 4442, to use or
by a factory authorized dealer. See the Emissions Warranty.				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
WARNING				jurisdictions may have similar laws. Contact the original equipment
				manufacturer, retailer, or dealer to obtain a spark arrester designed for the
Unintentional sparking can result in fire or electric shock.				exhaust system installed on this engine.
Unintentional start-up can result in entanglement, traumatic			Remove accumulated debris from muffler area and cylinder area. Inspect the muffler (A,
amputation, or laceration.
Fire hazard			Figu e 5) for cracks, c rr				si , r	ther damage. Remove the spark arrester (B), if
			equipped, and inspect f				r damage	r carbon blockage. If damage is found, install
			replacement par s bef re perating.
Before performing adjustments or repairs:						WARNING: Replacement parts must be of the same design and installed
Disconnect the spark plug wire and keep it away from the spark plug.				in the same position as the original parts. Other parts may not perform as well, may
	for
Disconnect battery at negative terminal (only engines with electric start.)				damage the nit, and may result in injury.

Use only correct tools.

	Do not tamper with governor spring, links or other parts to increase engine				How To Change The Oil - Figure 6
		speed.
	Replacement parts must be of the same design and installed in the same				Used		il is a hazardous waste	and must be disposed of properly. Do not discard
		position as the original parts. Other parts may not perform as well, may damage			with h		usehold waste. Check with your local authorities, service center, or dealer for safe
		the unit, and may result in injury.	Not		disp sal/recycling facilities.
	Do not strike the flywheel with a hammer or hard object because the flywheel
		may later shatter during operation.			Remove Oil
	When testing for spark:			1.		With engine off but still warm, disconnect the spark plug wire (A) and keep it away
	Use approved spark plug tester.
						from the spark plug (Figure 6).
	Do not check for spark with spark plug removed.			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.
	Maintenance Chart				Change The Oil Filter
					All models are equipped with an oil filter. For replacement intervals, see the
					Maintenance chart.
	First 5 Hours
			Reproduction1. Drain the oil from the engine. See Remove Oil section.
		Change oil
				2.		Remove the oil filter (C, Figure 6) and dispose of properly.
	Every 8 Hours or Daily			3.		Before installing the new oil filter, lightly lubricate the oil filter gasket with fresh, clean
	Check engine oil level					oil.
	Clean area around muffler and controls			4.		Install the oil filter by hand until the gasket contacts the oil filter adapter, then tighten
	Every 100 Hours or Annually					the oil filter 1/2 to 3/4 turns.
				5.		Add oil. See Add Oil section.
	Clean or change air filter * Y
				6.		Start and run the engine. As the engine warms up, check for oil leaks.
	Change engine oil and filter
				7.		Stop the engine and check the oil level. It should be at the top of the full indicator (F)
		Replace spark plug
						on the dipstick.
	Check muffler and spark arrester
	Every 250 Hours or Annually				Add Oil
	Check valve clearance. Adjust if necessary.					Place engine level.
	Every 400 Hours or Annually					Clean the oil fill area of any debris.
	Change air filter Y					See the Specifications section for oil capacity.
	Clean air cooling system *			1.		Remove the dipstick (D, Figure 6) and wipe with a clean cloth.
	Clean oil cooler fins *			2.		Pour the oil slowly into the engine oil fill (E). Do not overfill. After adding oil, wait
	Every 600 Hours or Annually					one minute and then check the oil level.
				3.		Install and tighten the dipstick.
	Change safety filter (if equipped)
					4.	Remove the dipstick and check the oil level. It should be at the top of the full indicator
	* In dusty conditions or when airborne debris is present, clean more often.
						(F) on the dipstick.
	Y	Every third air filter change, replace the inner safety filter (if equipped).		5.		Install and tighten the dipstick.

		7
	en

	How To Service The Air Filter - Figure 7		8	How To Clean The Air Cooling System - Figure 9	10
		WARNING		WARNING
				Running engines produce heat. Engine parts, especially muffler,
		Fuel and its vapors are extremely flammable and explosive.		become extremely hot.
		Fire or explosion can cause severe burns or death.		Severe thermal burns can occur on contact.
				Combustible debris, such as leaves, grass, brush, etc. can catch fire.
	Never start or run the engine with the air cleaner assembly (if equipped) or the			Allow muffler, engine cylinder and fins to cool before touching.
		air filter (if equipped) removed.		Remove accumulated debris from muffler area and cylinder area.
				NOTICE: Do not use water to clean the engine. Water could contaminate the fuel
	NOTICE: Do not use pressurized air or solvents to clean the filter. Pressurized air can			system. Use a brush or dry cloth to clean the engine.
	damage the filter and solvents will dissolve the filter.			This is an air cooled engine. Dirt or debris can restrict air flow and cause the engine to
	The air filter system uses either a cyclonic air filter or a low-profile air filter. See the			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,
	Maintenance Chart for service requirements.
				Figure 9). Keep linkage, springs and controls (B) clean. Keep the area around and
	Cyclonic Air Filter System			behind the muffler (C) free of any combustible debris. Make sure that the oil cooler fins
	1. Open the latches (A) and remove the cover (B). See Figure 7.			(D) are free of dirt and debris.
				Clean the area under the panel (E, Figure 10). Loosen the two screws (F) until you hear
	2.	Remove the air filter (C).
				a click. Remove the panel and clean the area of dirt and debris. Make sure the underside
	3. To loosen debris, gently tap the air filter on a hard surface. If the air filter is			of the panel is also clean. Install the panel and tighten the screws until you hear a click.
		excessively dirty, replace with a new air filter.		Note: To remove the panel on engines equipped with the Cyclonic Air Filter System (G,
	4.	The cyclonic air filter system also has a safety filter (D) (if equipped). See the		Figure 10), loosen the fastener (H) and pivot the Cyclonic Air Filter away from the
		Maintenance Chart for service requirements. To remove, carefully pull the safety		engine. It is not necessary to remove the flexible air cleaner hose (J). After cleaning,
		filter away from air cleaner body (E) and discard. Make sure that dirt or debris do not		make sure to reposition the air filter and tighten the fastener.
		enter the engine.		Storage
	5.	Install the new safety filter in the air cleaner body.

6. Install the air filter over the safety filter.

	7.	Install the cover and close the latches.	WARNING
	Low-Profile Air Filter System
			Fuel and its vapors are extremely flammable and explosive.
	1.	Remove the knob (F) and the cover (G). See Figure 8.
			Fi e or expl s can cause severe burns or death.

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

3.Remove the air filter (K).

					When Storing Fuel Or Equ pment With Fuel In Tank
				for
Tune-up Specifications *		ReproductionTune-up Specifications *
4.	Remove the pre-cleaner (L), if equipped, from the air filter.		Not			Store away from furnaces, stoves, water heaters or other appliances that have
5.	To loosen debris, gently tap the air filter on a hard surface. If the air fil er is					pilot lights or o her igni ion sources because they can ignite fuel vapors.
	excessively dirty, replace with a new air filter.
6.	Wash the pre-cleaner in liquid detergent and water. Then allow it to th ughly air				Engine Oil
	dry. Do not oil the pre-cleaner.				While the engine is still warm, change the engine oil.
7.	Assemble the dry pre-cleaner to the air filter.				Troubleshooting
8.	Install the air filter and secure with retainer and nut.
9.	Install the cover and secure with knob.				Need Assistance? Go to VanguardEngines.com or call 1-800-999-9333.

S ecifications

Engine Specifications			Engine Specifications
Model	540000		Model	610000
Displacement	54.68 ci (896 cc)		Displacement	60.60 ci (993 cc)
Bore	3.366 in (85.5 mm)		Bore	3.366 in (85.5 mm)
Stroke	3.071 in (78.0 mm)		Stroke	3.406 in (77.21 mm)
Oil Capacity	78 -- 80 oz (2.3 -- 2.4 L)		Oil Capacity	78 -- 80 oz (2.3 -- 2.4 L)
Model	540000		Model	610000
Spark Plug Gap	0.020 in (0.51 mm)		Spark Plug Gap	0.020 in (0.51 mm)
Spark Plug Torque	180 lb-in (20 Nm)		Spark Plug Torque	180 lb-in (20 Nm)
Armature Air Gap	0.005 - 0.008 in (0.13 - 0.20 mm)		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)		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)		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, Cyclonic	841497
Safety Filter, Cyclonic	821136
Air Filter, Low-Profile	692519
Pre-Cleaner, Low-Profile	692520
Oil -- SAE 30	100028
Oil Filter	842921

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

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

8	VanguardEngines.com