Briggs & Stratton VXG6500, Vox 030339, Vox 030340 Operator's Manual
Portable Generator
Operator’s Manual
BRIGGS & STRATTON POWER PRODUCTS GROUP, LLC
JEFFERSON, WISCONSIN, U.S.A.
Manual No. 205156GS Revision A (01/03/2008)
Thank you for purchasing this quality-built Briggs & Stratton generator. We are pleased that you’ve placed your confidence in
the VOX™ brand. When operated and maintained according to the instructions in this manual, your Briggs & Stratton
generator will provide many years of dependable service.
This manual contains safety information to make you aware of the hazards and risks associated with generators and how to
avoid them. This generator is designed and intended only for supplying electrical power for operating compatible electrical
lighting, appliances, tools and motor loads, and is not intended for any other purpose. It is important that you read and
understand these instructions thoroughly before attempting to start or operate this equipment. Save these instructions for
future reference.
This generator requires final assembly before use. Refer to the Assembly section of this manual for instructions on final
assembly procedures. Follow the instructions completely.
Where to Find Us
You never have to look far to find Briggs & Stratton support and service for your generator. Consult your Yellow Pages. There
are over 30,000 Briggs & Stratton authorized service dealers worldwide who provide quality service. You can also contact
Briggs & Stratton Customer Service by phone at (800) 743-4115, or on the Internet at BRIGGSandSTRATTON.COM. For
engine related questions, call American Honda Motor Company, Inc. at (800) 426-7701 or visit www.honda-engines.com for a
dealer locator.
Generator
Model Number
Revision
Serial Number
Date Purchased
Briggs & Stratton Power Products Group, LLC
900 North Parkway
Jefferson, WI 53549
Copyright © 2008 Briggs & Stratton Power Products Group,
LLC. All rights reserved. No part of this material may be
reproduced or transmitted in any form by any means without
the express written permission of Briggs & Stratton Power
Products Group, LLC.
2 BRIGGSandSTRATTON.COM
Table of Contents
Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Equipment Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Unpack Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Shipment Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Install Wheel Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Add Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Add Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
System Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connecting to a Building’s Electrical System. . . . . . . . . . . . . . . . . . . . . . . . 9
Generator Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cord Sets and Receptacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Ground Fault Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Connecting Electrical Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Stopping the Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Operating Automatic Idle Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Charging a Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Don’t Overload Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Generator Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Generator Owner Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Product Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Common Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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3
3
Operator Safety
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.
This generator incorporates GFCI (Ground Fault Circuit
Interrupter) outlet protection and has its neutral bonded to
ground to comply to OSHA inspections on job sites. This
generator will not function when connected to a 2 pole
transfer switch since the home or building main breaker box
also has a neutral bonded to ground. When both the
generator and the home or building breaker box contains a
neutral bonded to ground, the generators GFCI will open and
no outlets will function.
WARNING
Removing the neutral bond could result in death,
bodily injury and/or property damage.
• DO NOT remove the neutral bond.
Safety Rules
This is the safety alert symbol. It is used to alert
you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid
possible injury or death.
The safety alert symbol ( ) is used with a signal word
(DANGER, WARNING, CAUTION), a pictorial and/or a safety
message to alert you to hazards. 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, might result in minor or moderate
injury. NOTICE indicates a situation that could result in
equipment damage. Follow safety messages to avoid or
reduce the risk of injury or death.
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 unsafe.
Hazard Symbols and Meanings
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. See
Don’t Overload Generator in the Operation section.
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 this 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.
A B C
D E
G H
K L
A - Explosion G - Flying Objects
B - Fire H - Explosive Pressure
C - Electric Shock J - Chemical Burn
D - Toxic Fumes K - Moving Parts
E - Kickback L - Read Manual
F - Hot Surface
F
J
4 BRIGGSandSTRATTON.COM
DANGER
Storage batteries give off explosive hydrogen
gas during recharging.
Hydrogen gas stays near battery for a long time
after battery has been charged.
Slightest spark will ignite hydrogen and cause
explosion.
You can be blinded or severely injured.
Battery electrolyte fluid contains acid and is
extremely caustic.
Contact with battery fluid will cause severe
chemical burns.
• DO NOT allow any open flame, spark, heat, or lit cigarette during
and for several minutes after charging a battery.
• Wear protective goggles, rubber apron, and rubber gloves.
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 start or run engine indoors or in an enclosed area,
(even if windows and doors are open), including the generator
compartment of a recreational vehicle (RV).
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
Starter cord kickback (rapid retraction) can result
in bodily injury. 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 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.
Fire or explosion can cause severe burns or
death.
WHEN ADDING OR DRAINING FUEL
• Turn generator 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.
• 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 tip engine or equipment at angle which causes fuel to
spill.
• This generator is not for use in mobile equipment or marine
applications.
WHEN TRANSPORTING OR REPAIRING EQUIPMENT
• Transport/repair with fuel tank EMPTY or with fuel shutoff valve
OFF.
• 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 can ignite fuel vapors.
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.
5
WARNING
Generator produces hazardous voltage.
Failure to isolate generator from power utility
can result in death or injury to electric utility
workers due to backfeed of electrical energy.
• When using generator for backup power, notify utility company.
Use approved transfer equipment to isolate generator from
electric utility.
• 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 or feet are wet.
• DO NOT allow unqualified persons or children to operate or
service generator.
WARNING
Contact with muffler area can result in serious
burns.
Exhaust heat/gases can ignite combustibles,
structures or damage fuel tank causing a fire.
• DO NOT touch hot parts and AVOID hot exhaust gases.
• Allow equipment to cool before touching.
• Keep at least 5 feet (1.5 m) of clearance on all sides of
generator including overhead.
• Code of Federal Regulation (CFR) Title 36 Parks, Forests, and
Public Property require equipment powered by an internal
combustion engine to have a spark arrester, maintained in
effective working order, complying to USDA Forest service
standard 5100-1C or later revision. In the State of California a
spark arrester is required under section 4442 of the California
Public resources code. Other states may have similar laws.
WARNING
Starter and other rotating parts can entangle
hands, hair, clothing, or accessories.
• NEVER operate generator without protective housing or covers.
• DO NOT wear loose clothing, jewelry or anything that may be
caught in the starter or other rotating parts.
• Tie up long hair and remove jewelry.
WARNING
Unintentional sparking can result in fire or
electric shock.
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.
CAUTION
Excessively high operating speeds increase risk of injury
and damage to generator.
Excessively low speeds impose a heavy load.
• DO NOT tamper with governed speed. Generator supplies
correct rated frequency and voltage when running at governed
speed.
• DO NOT modify generator in any way.
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. See
Don’t Overload Generator in the Operation section.
• 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.
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, ask dealer or contact
local service center.
• 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.
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Assembly
Your generator requires some assembly and is ready for use
after it has been properly serviced with the recommended oil
and fuel.
If you have any problems with the assembly of your generator,
please call the generator helpline at (800) 743-4115. If calling
for assistance, please have the model, revision, and serial
number from the data tag available. See Generator Controls
and Features for data tag location.
Unpack Generator
1. Set the carton on a rigid, flat surface.
2. Remove everything from carton except generator.
3. Open carton completely by cutting each corner from
top to bottom.
4. Leave generator on carton to install wheel kit.
Install Wheel Kit
NOTE: Wheel kit is not intended for over-the-road use.
You will need the following tools to install these
components:
• 3/8” and 13 mm wrench
• Socket wrench with a 3/8” and a 13 mm socket
• Pliers
• Safety glasses
Install the wheel kit as follows:
1. Tip generator so that engine end is up.
2. Slide axle (A) through both mounting brackets.
3. Slide a wheel (B) over axle.
NOTE: Be sure to install wheel with raised hub inboard.
4. Place a washer (C) on axle and then place an e-ring (D)
in axle groove.
Shipment Contents
The generator is supplied with:
• Engine oil
• Operator’s manual
• Engine operator’s manual
• Battery charge cables
• Wheel kit
• 120/240 Volt, 30 Amp locking plug
• 120 Volt, 30 Amp locking plug
N
M
K
CAUTION
E-rings can cause eye injury.
E-rings can spring back and become airborne
when installing or removing.
• Always wear eye protection when installing/removing e-rings.
5. Install e-ring with pliers, squeezing from top of e-ring
to bottom of axle.
6. Repeat steps 3 through 5 to secure second wheel.
7. Tip generator so that engine side is down.
8. Attach clamps (E) to brackets (F) on both sides of
generator with 1/4 - 20 hex screws (G).
L
J
H
B
A
F
A
B
C
D
E
G
C
D
7
9. Repeat steps 2 through 5 to secure the third and fourth
FUEL
TANK
wheels.
10. Attach handles (H) to brackets on generator frame as
shown, with 45 mm capscrews (J), flat washers (K),
nylon washers (L), and M8 lock nuts (M).
NOTE: DO NOT overtighten. Handles must be able to move
up and down freely.
11. Return generator to normal operating position (resting
on wheels).
12. To apply brakes, push down firmly on handle of both
clamps until it locks in the down position and engages
the wheels.
IMPORTANT: The generator is designed to be used on level
surfaces.
13. Loop handle pins (N) on generator frame just above
handle brackets.
14. Raise handles and insert handle pins to move
generator.
15. To release brakes, pull up on handle of both clamps
until it locks in the up position.
Add Engine Oil
• Place generator on a level surface.
NOTE: Verify provided oil bottles are the correct viscosity for
current ambient temperature.
• Refer to engine operator’s manual and follow oil
recommendations and instructions.
NOTICE
Any attempt to crank or start the engine before it has been
properly filled with the recommended oil will result in
equipment failure.
• Refer to engine manual for oil information.
• Damage to equipment resulting from failure to follow this
instruction will void warranty.
Add Fuel
NOTE: Refer to engine operator’s manual and follow fuel
recommendations.
WARNING
Fuel and its vapors are extremely flammable and
explosive.
Fire or explosion can cause severe burns or
death.
WHEN ADDING FUEL
• Turn generator OFF and let it cool at least 2 minutes before
removing fuel cap. Loosen cap slowly to relieve pressure in
tank.
• Fill 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.
• DO NOT light a cigarette or smoke.
1. Clean area around fuel fill cap, remove cap.
2. Slowly add unleaded gasoline (A) to fuel tank (B). Be
careful not to fill above the baffle (C). This allows
adequate space for fuel expansion as shown.
C
3. Install fuel cap and let any spilled fuel evaporate before
starting engine.
B
A
NOTE: Check oil often during engine break–in. Refer to
engine operator’s manual for recommendations.
8 BRIGGSandSTRATTON.COM
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