Dayton 2ZRP9, 2ZRP8 User Manual
Operating Instructions & Parts Manual 2ZRP8, 2ZRP9
Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described.
Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or
property damage! Retain instructions for future reference.
Dayton® Generator
Description
This Dayton generator was constructed with the highest level of precision and
accuracy. Each component has been rigorously tested by technicians to ensure the
quality, endurance and performance of this generator.
Unpacking
When unpacking the unit, carefully
inspect for signs of obvious or concealed
freight damage. If damage does exist,
file a claim with the transportation company immediately. Be sure that all damaged parts are replaced and that the
mechanical and electrical problems are
corrected prior to operation of the unit.
Tools Required: Philips #2 screwdriver
Specifications
Model ................................2ZRP8 ..........2ZRP9
Engine...............................Honda .........Honda
Watts (AC) Rated ................5000 ............6500
Watts (AC) Max. .................6000 ............7500
Rated Voltage (AC) .... 120V/240 ....120V/240
Max. Amperage ...........35.0/25.0 .....62.5/31.3
Cont. Amperage ..........41.7/20.8 .....54.2/27.1
Frequency ............................60Hz ........... 60Hz
Fuel Tank Capacity .........7.3 gal. ........7.3 gal.
Run Time .........................8.0 hrs .........6.9 hrs
Dimensions (in) ............. 29L x 24.4W x 22.5H
Form 5S6238
General Safety Information
READ OPERATING INSTRUCTIONS
Always become familiar with all the
instructions and warnings before
operating any generator
IMPORTANT SAFETY INSTRUCTIONS
To reduce the risk
of injury, read this
operator’s manual completely before
using. When using this product, the
following basic precautions should
always be followed:
1. Read all the instructions before using
the product.
2. Do not allow children or untrained
persons to operate the generator.
3. Do not operate the generator when
fatigued or under the influence of
drugs or chemicals. Stay alert. Watch
what you are doing.
4. Follow the maintenance instructions
Printed in U.S.A.
06272
0908/433/VCPVP
specified in this manual.
5. When starting the generator, using
recoil starter grip, be sure that
nothing is in a position to be hit by
the operator’s hand or arm.
6. Be sure the switch on electric power
tools is in the “OFF” position before
plugging them into the generator.
7. Keep the immediate area free of all
bystanders.
8. Be sure each person who operates
this generator is properly instructed
in its safe operation.
9. Do not operate the generator or any
electrical tool in any area where
water or similar materials constitute
an electrical hazard to the operator.
Do not operate on wet surfaces, in
rain or in snow.
10. Always be sure that the generator is
on secure footing so that it cannot
slide or shift around, endangering
workers.
11. Avoid contacting the hot exhaust
manifold, muffler or cylinder(s).
Keep clear of all rotating parts.
12. Unless the tool or appliance
is double insulated, it must be
grounded through a properly
grounded receptacle. (See
Preparing the Generator, Grounding
Instructions). Tools and appliances
37-1023 091208
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Dayton Operating Instructions and Parts Manual
Dayton® Generator
2ZRP8, 2ZRP9
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which have 3 prong plugs must be
plugged into extension cords and
electrical receptacles with 3 holes.
Before operating any electrical item,
be sure it is in good repair.
13. Follow instructions in this manual
when testing Ground Fault Circuit
Interrupter to insure reliable
operation.
14. Beware of using this equipment
in confined spaces. Confined
spaces, without sufficient fresh air
ventilation,can contain dangerous
gases. Running gasoline engines in
such environments can lead to deadly
explosions and/or asphyxiation.
15. If your generator comes equipped
with a transport dolly, make sure
this unit is secure during operation
and when transporting to prevent
unexpected movement or rolling.
16. Use extreme caution when lifting
this generator. Do not use dolly
handles to lift this generator, use
only designated lifting hook to lift
this generator. This generator is
heavy so proper lifting techniques
should be used.
SAVE THESE INSTRUCTIONS
CARBON MONOXIDE-POISONOUS
GAS Use generator outdoors, away
from open windows, vents, or doors.
Generator exhaust contains carbon
monoxide - a poisonous gas that can kill
you. You CAN NOT smell or see this gas.
Never use a generator in enclosed or
partially-enclosed spaces.
Generators can produce high levels
of carbon monoxide very quickly.
When you use a portable generator,
remember that you cannot smell or
see carbon monoxide. Even if you can’t
smell exhaust fumes, you may still be
exposed to carbon monoxide.
If you start to feel sick, dizzy, or weak
while using a generator, get to fresh
air RIGHT AWAY. DO NOT DELAY. The
carbon monoxide from generators can
rapidly lead to full incapacitation and
death.
If you experience serious symptoms,
get medical attention immediately.
Inform medical staff that carbon
monoxide poisoning is suspected. If you
experienced symptoms while indoors,
have someone call the fire department
to determine when it is safe to re-enter
the building.
Never operate the generator in an
explosive atmosphere, near combustible
materials or where ventilation is not
sufficient to carry away exhaust fumes.
Exhaust fumes can cause serious injury
or death.
NEVER use a generator indoors,
including in homes, garages, basements,
crawl spaces, and other enclosed or
partially-enclosed areas, even with
ventilation. Opening doors and
windows or using fans will not prevent
carbon monoxide build-up in the home.
Follow the instructions that come
with your generator. Locate the
unit outdoors and away from doors,
windows, and vents that could allow
the carbon monoxide gas to come
indoors.
ONLY run generator outdoors and away
from air intakes.
NEVER run generator inside homes,
garages, sheds, or other semi-enclosed
spaces. These spaces can trap poisonous
gases EVEN IF you run a fan or open
doors and windows.
If you start to feel sick, dizzy, or weak
while using the generator, shut if off
and get fresh air RIGHT AWAY. See a
doctor. You may have carbon monoxide
poisoning.
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Dayton Operating Instructions and Parts Manual
Models 2ZRP8, 2ZRP9
Install battery-operated carbon
monoxide alarms or plug-in carbon
monoxide alarms with battery backup in your home, according to the
manufacturer’s installation instructions.
The carbon monoxide alarms should
be certified to the requirements of
the latest safety standards for carbon
monoxide alarms. (UL 2034, IAS 6-96, or
CSA 6.19.01).
Test your carbon monoxide alarm
frequently and replace dead batteries.
SAFETY WARNING WHEN REFUELING
Gasoline is extremely flammable and its
vapors can explode if ignited.
Observe all safety regulations for the
safe handling of fuel. Handle fuel in
safety containers. If the container does
not have a spout, use a funnel.
Do not overfill the fuel tank, leave
room for the fuel to expand.
Do not refill fuel tank while the
engine is running. Before refueling the
generator, turn it off and let it cool
down. Gasoline spilled on hot engine
parts could ignite. Fill the tank only on
an area of bare ground. While fueling
the tank, keep heat, sparks and open
flame away. Carefully clean up any
spilled fuel before starting engine.
Always fill fuel tank in an area with
plenty of ventilation to avoid inhaling
dangerous fumes.
NEVER store fuel for your generator in
the home. Gasoline, propane, kerosene,
and other flammable liquids should
be stored outside of living areas in
properly-labeled, non-glass safety
containers. Do not store them near
a fuel-burning appliance, such as a
natural gas water heater in a garage. If
the fuel is spilled or the container is not
sealed properly, invisible vapors from
the fuel can travel along the ground
and can be ignited by the appliance’s
pilot light or by arcs from electric
switches in the appliance.
GROUND FAULT CIRCUIT INTERRUPTER
PROTECTION. These generators are
equipped with two GFCI (Ground
Fault Circuit Interrupters) 120V duplex
receptacles for protection against
the hazards of electrical shock from
defective attachments such as, tools,
cords, and cables.
A GFCI is a device that interrupts
electricity from either the utility or
generator by means of a special type of
circuit breaker if a fault current flow to
the ground occurs.
A GFCI can be used only with generators
that have the neutral wire internally
bonded to the frame, and the frame
properly grounded to the earth. A GFCI
will not work on generators that do not
have the neutral wire bonded to the
frame, or on generators which have not
been properly grounded. All Dayton
generators have internally bonded
ground wires. A GFCI will not work if
the unit is not properly grounded.
A GFCI may be required by OSHA
regulations, the National Electric Code
and/or local and federal codes when
operating a generator.
For additional protections against shock
hazards due to defective equipment
attached to the twist-lock receptacles,
consider the use of a GFCI on each of
these receptacles as well.
GFCIs and GFCI protected cord sets and
cables may be purchased from local
electrical supply houses.
The GFCIs may not
function unless
the generator is properly grounded.
Follow the correct procedure specified
in the section labeled “GROUNDING
INSTRUCTIONS”
Only the 120V
Duplex Receptacles
are protected by the GFCI.
ELECTRICAL HAZARDS. This product
must be grounded. If it should
malfunction or breakdown, grounding
provides a path of least resistance for
electric current to reduce the risk of
electric shock.
Improper connection
of the equipmentgrounding conductor can result in a risk
of electrocution. Check with a qualified
electrician or service person if you
are IN doubt as to whether the unit is
properly grounded.
This generator is equipped with a
grounding terminal for your protection.
Always complete the ground path from
the generator to an external ground
source as instructed in the section
labeled “Grounding Instructions” in the
Preparation section of this manual.
The generator is a potential source of
electrical shock if not kept dry. Keep
the generator dry and do not use in
rain or wet conditions. To protect from
moisture, operate it on a dry surface
under an open, canopy-like structure.
Dry your hands if wet before touching
the generator.
Risk of electric shock if you operate
this generator with a faulty GFCI
(Ground Fault Circuit Interrupter). Test
GFCI before each use, see Operations
Instructions for further information.
If GFCI fails test, DO NOT use your
generator. Contact your Dayton
Customer Service Representative.
Plug appliances directly into the
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Dayton Operating Instructions and Parts Manual
Dayton® Generator
2ZRP8, 2ZRP9
generator. Or, use a heavy duty,
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outdoor-rated extension cord that is
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rated (in watts or amps) at least equal
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to the sum of the connected appliance
loads. Check that the entire cord is free
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of cuts or tears and that the plug has
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all three prongs, especially a grounding
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pin.
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NEVER try to power the house wiring
by plugging the generator into a
wall outlet, a practice known as
“back feeding”. This is an extremely
dangerous practice that presents an
electrocution risk to utility workers and
neighbors served by the same utility
transformer. It also bypasses some of
the built-in household circuit protection
devices.
If you must connect the generator to
the house wiring to power appliances,
have a qualified electrician install the
appropriate equipment in accordance
with local electrical codes. Or, check
with your utility company to see if
it can install an appropriate power
transfer switch.
For power outages, permanently
installed stationary generators are
better suited for providing backup
power to the home. Even a properly
connected portable generator can
become overloaded. This may result in
overheating or stressing the generator
components, possibly leading to a
generator failure.
Installation
ASSEMBLY FOR WHEELS AND
HANDLES:
Use the following items for installation:
Isolator (3), Bolts (2), Locknut (1),
Underbracket Assembly (4), Bolts (5),
Washers (6), Collar/Shaft (8), Wheels (9),
Washers (10), Axle Bracket (7), Washers
(12), Axle (11), Bolts (13), Handle
Assembly (14), Locknut (15).
1. Raise the generator off the work
surface to allow clearance to mount
the Wheel Kit onto the unit.
NOTE: Make sure the generator is stable
and secure before installing the Wheel
Kit.
2. Assemble the Isolators (3) to the
Underbracket Assembly (4) using
two Locknuts (1) and two Bolts (2),
tighten bolts securely.
3. Using four Locknuts (1), four Washers
(6), and four Bolts (5) assemble the
Underbracket Assembly (4) onto
the alternator end of the generator.
Tighten all bolts securely inside of rail.
4. Fasten the Axle Support Brackets (7)
to the engine end of the generator
using four Bolts (5), four Washers
(6) and four Locknuts (1). Tighten all
bolts securely.
5. Using two Collars (8), six Washers
(10) and Axle (11) mount both
Wheels (9) onto the generator.Make
sure the axle is centered with the
generator.
6. Attach the Handle Assemblies (14
& 15) to the frame using four Bolts
(13), eight Washers (12), and four
Locknuts (16), tighten bolts.
GROUNDING INSTRUCTIONS
This product must be grounded. If it
should malfunction or breakdown,
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Dayton Operating Instructions and Parts Manual
Models 2ZRP8, 2ZRP9
grounding provides a path of least
resistance for electric current to reduce
the risk of electric shock.
Improper connection
of the equipmentgrounding conductor can result in a risk
of electrocution. Check with a qualified
electrician or service person if you
are in doubt as to whether the unit is
properly grounded.
The wing nut and ground terminal
on the frame must always be used to
connect the generator to a suitable
ground source. The ground path should
be made with #8 size wire. Connect the
terminal of the ground wire between
the two star washers and wing nut then
tighten the wing nut fully. Connect
the other end of the wire securely to a
suitable ground source.
The National Electric Code contains
several practical ways in which to
establish a good ground source.
Examples given below illustrate a few
of the ways in which a good ground
source may be established.
A metal underground water pipe in
direct contact with the earth for at least
10 feet can be used as a grounding
source. If an pipe is unavailable, an 8
foot length of pipe or rod may be used
as the ground source. The pipe should
be 3/4 inch trade size or larger and the
outer surface must be noncorrosive.
If a steel or iron rod is used it should
be at least 5/8 inch diameter and if a
nonferrous rod is used it should be at
least 1/2 inch diameter and be listed
as material for grounding. Drive the
rod or pipe to a depth of 8 feet. If a
rock bottom is encountered less than
4 feet down, bury the rod or pipe in a
trench. All electrical tools and appliances
operated from this generator, must be
properly grounded by use of a third wire
or be “Double Insulated”.
It is recommended to:
1. Use electrical devices with 3 prong
power cords.
2. Use an extension cord with a 3 hole
receptacle and a 3 prong plug at the
opposite ends to ensure continuity
of the ground protection from the
generator to appliance.
We strongly recommend that all
applicable federal, state and local
regulations relating to grounding
specifications be checked and followed.
LINE TRANSFER SWITCH
If this generator is used for standby
service, it must have a transfer switch
between the utility power service and
the generator. The transfer switch not
only prevents the utility power form
feeding into the generator, but is also
prevents the generator form feeding
out into the utility company’s lines. This
is intended to protect the serviceman
who may be working on a damaged
line.
THIS INSTALLATION MUST BE DONE BY A
LICENSED ELECTRICIAN AND ALL LOCAL
CODES MUST BE FOLLOWED.
ENGINE OIL
Use oil viscosity based on the expected
air temperature range during the
period between oil changes.
Use a high quality detergent oil with
API classifications of SJ or higher.
Check oil level before each operation
and ensure that it is maintained.
THIS ENGINE
CRANKCASE IS NOT
FILLED WITH OIL AT THE FACTORY, SO BE
SURE TO FILL IT BEFORE OPERATING THE
ENGINE.
NOTE: These engines are equipped with
a “Low Oil” shut-off system for engine
protection. If the engine fails to start,
check engine crankcase for oil.
Pre-Operation
FUELING
To fill with oil:
1. Level the engine to ensure accurate
inspection and to prevent overfilling.
2. Unscrew the oil gauge, wipe the
dipstick dry. Reinsert the oil gauge
back into the oil fill gauge opening.
Remove the oil gauge and check the
oil level.
3. The oil level should be between the full
and low marks on the dipstick.
NOTE: When checking the oil be sure the
engine is level.
4. Fill with oil as required through the
oil fill gauge opening.
5. Replace the oil gauge and screw in firmly.
6. Wipe up any spilled oil.
EXPLOSIVE FUEL!
GASOLINE IS
EXTREMELY FLAMMABLE AND ITS
VAPORS CAN EXPLODE IF IGNITED.
STORE GASOLINE ONLY IN APPROVED
CONTAINERS, IN WELL VENTILATED,
UNOCCUPIED BUILDINGS AND AWAY
FROM SPARKS OR FLAMES.
DO NOT FILL THE FUEL TANK WHILE THE
ENGINE IS HOT OR RUNNING, SINCE
SPILLED FUEL COULD IGNITE IF IT COMES
IN CONTACT WITH HOT PARTS OR SPARKS
FROM IGNITION. DO NOT START THE
ENGINE NEAR SPILLED FUEL.
NEVER USE GASOLINE AS A CLEANING
AGENT.
DO NOT OVERFILL THE
FUEL TANK, LEAVE
ROOM FOR THE FUEL TO EXPAND.
GENERAL RECOMMENDATIONS
• Purchase gasoline in small quantities and
store in clean, approved containers.
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Dayton Operating Instructions and Parts Manual
Dayton® Generator
2ZRP8, 2ZRP9
• To minimize gum deposits in your fuel
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system and to insure easy starting,
do not use gasoline left over from
the previous season.
• Do not add oil to the gasoline.
FUEL TYPE
• For best results use only clean, fresh,
unleaded gasoline with a pump
sticker octane rating of 87 or higher.
• Unleaded gasoline is recommended as
it leaves less combustion chamber
deposits.
Gasoline/Alcohol Blends:
Gasohol (up to 10% ethyl alcohol,
90% unleaded gasoline by volume) is
approved, as a fuel. Other gasoline/
alcohol blends are not approved.
Gasoline/Ether Blends:
Methyl Tertiary Butyl Ether (MTBE)
and unleaded gasoline blends (up to a
maximum of 15% MTBE by volume) are
approved as a fuel. Other gasoline/ether
blends are not approved.
BATTERY INSTALLATION
SHOULD ONLY
BE DONE BY AN
AUTHORIZED DEALER.
HIGH ALTITUDE
At high altitude, the standard carburetor
air/fuel mixture will be too rich.
Performance will decrease, and fuel
consumption will increase. A very rich
mixture will also foul the spark plug and
cause hard starting. Operation at an
altitude that differs from that at which
this engine was certified, for extended
periods of time, may increase emissions.
High altitude performance can be
improved by specific modifications to the
carburetor. If you always operate your
generator at altitudes above 5,000 feet
(1,500 meters), have your dealer perform
this carburetor modification. This engine,
when operated at high altitude with
the carburetor modifications for high
altitude use, will meet each emission
standard throughout its useful life.Even
with carburetor modification, engine
horsepower will decrease about 3.5%
for each 1,000-foot (300-meter) increase
in altitude. The effect of altitude on
horsepower will be greater than this if
no carburetor modification is made.
NOTE:When the carburetor has been
modified for high altitude operation,
the air/fuel mixture will be too lean for
low altitude use. Operation at altitudes
below 5,000 feet (1,500 meters) with
a modified carburetor may cause
the engine to overheat and result in
serious engine damage. For use at low
altitudes, have your servicing dealer
return the carburetor to original factory
specifications.
Operation
RECOIL START
NOTE: Read Operator’s Manual carefully
before operating this unit. Always
make sure the unit is level and properly
grounded. Check engine oil before
starting.
1. Open fuel valve on unit or engine.
(See Below)
2. Turn the idle control switch to the OFF
position.
3. Move choke lever to full choke. If restarting a warm engine, the choke
should be left in the off position.
(See Below)
4. Turn the engine ignition switch to the
ON position.
5. Pull recoil to start engine.
6. Once engine has started, slowly
move choke lever to no choke.
NOTE: When engine fails to start after
several attempts, repeat the starting
procedures mentioned above with the
choke lever in the off position.
7. Allow the unit to run for two (2)
minute warm-up.
8. Make sure the generator is
grounded. See Preparing the
Generator; Grounding Instructions.
9. Turn main breaker to ON position
(GEN-6000 units only).
10. Test the GFCI receptacle(s) on the
unit. Push the test button. The
reset button should pop out and
there should be no power at the
receptacle. Apply a test load or lamp
to each receptacle to verify. IF THE
RESET BUTTON DOES NOT POP OUT,
DO NOT USE THE RECEPTACLES(S).
SEE DEALER FOR SERVICE
IMMEDIATELY.
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Dayton Operating Instructions and Parts Manual
Models 2ZRP8, 2ZRP9
11. If GFCI receptacle(s) test correctly,
firmly push the reset button to
restore power. A distinctive click
should be heard or felt when this is
complete. IF THE RECEPTACLE(S) DO
NOT RESET PROPERLY, DO NOT USE
THE RECEPTACLE(S). SEE DEALER
FOR SERVICE IMMEDIATELY.
12. Turn idle control switch to ON position.
Loads can now be applied to unit.
NOTE: This engine is equipped with a
“Low Oil” shutdown system for engine
protection. The engine stops when the
oil level gets too low. The engine will
not restart without adding oil. Refer to
Preparing the Generator; Engine Fuel
Capacity for instructions on adding oil.
NOTE: While the engine is idling, the
generator voltage is automatically
reduced to reduce generator
temperatures. The voltage will return
to normal levels immediately upon the
application of load.
ELECTRIC START
NOTE: Read Operator’s Manual carefully
before operating this unit. Always
make sure the unit is level and properly
grounded. Check engine oil before
starting.
1. Open fuel valve on unit or engine.
2. Turn the idle control switch to the OFF
position.
3. Move choke lever to full choke. If restarting a warm engine, the choke
should be left in the off position.
4. Turn the engine ignition switch to the
ON position.
5. Start the engine by turning the key
switch fully clockwise until the
engine starts, then release the
switch.
NOTE: Do not crank the engine
continuously for more than 30 seconds
at a time. If the engine does not start,
allow for a 3 minute cool down period
between starting attempts. Failure to
follow these guidelines can damage the
starter motor.
If the starter does not turn the engine
over, shut offthe starter immediately.
Do not make further attempts to
start the engine until the condition
is corrected. Do not jump start using
another battery.
6. Once engine has started, slowly move
choke lever to no choke.
7. Allow the unit to run for two (2)
minute warm-up.
8. Turn main breaker to ON position
(GEN-6000 units only).
9. Test the GFCI receptacle(s) on the
unit. Push the test button. The
reset button should pop out and
there should be no power at the
receptacle. Apply a test load or lamp
to each receptacle to verify. IF THE
RESET BUTTON DOES NOT POP OUT,
DO NOT USE THE RECEPTACLES(S).
SEE DEALER FOR SERVICE
IMMEDIATELY.
10. If GFCI receptacle(s) test correctly,
firmly push the reset button to
restore power. A distinctive click
should be heard or felt when this is
complete. IF THE RECEPTACLE(S) DO
NOT RESET PROPERLY, DO NOT USE
THE RECEPTACLE(S). SEE DEALER
FOR SERVICE IMMEDIATELY.
11. Turn idle control switch to ON
position. Loads can now be applied
to unit.
NOTE: This engine is equipped with a
“Low Oil” shutdown system for engine
protection. The engine stops when the
oil level gets too low. The engine will
not restart without adding oil. Refer to
Preparing the Generator; Engine Fuel
Capacity for instructions on adding oil.
SHUTDOWN
1. Remove all load by turning off
electrical appliances and unplugging
electric cords.
2. Allow engine to run at idle speed to
cool for two (2) minutes.
NOTE: Failure to allow the engine to
cool at idle for two (2) minutes may
result in damage to the generator.
3. Turn engine key or ignition switch off.
4. Close fuel valve on unit or engine.
Maintenance
GENERATOR MAINTENANCE
Keep all air vents clear.
Keep the generator clean. DO NOT
spray with water.
Periodically check all fasteners and
tighten, see the periodic maintenance
chart.
GFCI TEST RECORDS: As with any other
safety devices, the GFCIs supplied with
these generators must be checked
every month to insure that they are
functioning properly. To test the GFCIs,
follow the instructions and then enter
the date of the test below.
1. With the generator running and the
idle control switch in the “START”
position, push the “TEST” button.
The “RESET” button should pop
out. This should result in the power
being off at both outlets of the
duplex receptacle. Verify this by
plugging a test lamp into each
outlet.
IF THE RESET BUTTON
DOES NOT POP
OUT, DO NOT USE THE RECEPTACLE(S).
SEE AUTHORIZED Dayton Customer
Service Representative FOR SERVICE
IMMEDIATELY.
2. If the GFCI test correctly, restore
power by FIRMLY pushing the
“RESET” button back in until you
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Dayton Operating Instructions and Parts Manual
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hear or feel a distinctive “click”. IF
THE GFCI FAILS TO RESET PROPERLY,
DO NOT USE EITHER OUTLET OF THE
DUPLEX RECEPTACLE. Have the unit
serviced by an authorized Dayton
Customer Service Representative
immediately.
3. High vibration or severe mechanical
shock loads may cause the GFCIs to
trip. IF EITHER GFCI TRIPS BY ITSELF
AT ANY TIME, reset it and perform
test procedures 1 and 2.
4. Repeat steps 1-3 for the second GFCI.
ALTHOUGH THE
ABOVE TEST
PROCEDURES WILL INDICATE PROPER
GFCI OPERATION ON AN UNGROUNDED
OR IMPROPERLY GROUNDED
GENERATOR, THE GENERATOR MUST
Maintenance Chart
Procedure
Check Fuel X
Check Engine Oil X
Check for loose or lost nuts and bolts X
Check for leaks X
Check cylinder and head fins for
dust and dirt X
Check battery electrolyte level X
Check fuel lines (replace if necessary) X
Clean air cleaner foam element (**) X
Tighten nuts and bolts (*) X
Change engine oil X
Clean fuel filter X
Replace air cleaner paper element X
Clean dust and dirt from cylinder and X
cylinder head fins (**) X
Clean and regap spark plug X
Add fuel stabilizer X
Run unit dry X
* Perform these operations after the first 5 hours of use, then at the recommended intervals.
** Service more frequently under dusty conditions.
NOTE: These items must be performed with the proper tools. See your Dayton Customer Service Representative
for service, unless you have the proper equipment and mechanical proficiency.
STILL BE GROUNDED PER THE
GROUNDING INSTRUCTIONS LISTED ON
PAGE 14 FOR THE GFCI TO FUNCTION
PROPERLY AND PROTECT THE USER FROM
ELECTRICAL FAULTS.
EVAPORATIVE EMISSION COMPONENTS:
The unit you have purchased includes
the following components that are in
compliance with 2008 California Air
Resources Board Evaporative Emission
Standards;
1. Fuel Hose
2. Fuel Hose Fittings
These components should be inspected
on a daily basis for cracks, leaks, and
abnormal wear. If cracking, leaks or
abnormal wear has occurred, the
components should be replaced
immediately.
Daily
Every
25 hrs.
Every
100 hrs.
IDLE CONTROL ADJUSTMENT:
NOTE: The automatic idle speed is set
between 2640 and 2940 RPM.
The idle speed has been pre-set at
the factory and should rarely require
readjustment. We recommend that
all adjustments of this nature be
made by a Dayton Customer Service
Representative.
Erratic idle operation of the engine
usually indicates a need for carburetor
adjustment to provide a smooth idle.
The idle control will not function
properly when the idle speed is
below the recommended limits or the
carburetor is improperly adjusted.
ENGINE:
The engine for this generator is
Every
200 hrs.
Before
Storage
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Dayton Operating Instructions and Parts Manual
OIL DRAIN PLUG
Models 2ZRP8, 2ZRP9
governed to operate at speeds close
to 3600 RPM (60Hz) throughout the
operating load range. The no load
speed (before a load is applied) will be
just a bit higher than the load speed
and is normally set to 3750 RPM.
DO NOT TAMPER
WITH THE
GOVERNOR MECHANISM, CHANGE THE
SETTING EXPERIMENTALLY, OR PUSH
THE THROTTLE OPEN IN AN ATTEMPT TO
GENERATE MORE ELECTRICAL CURRENT;
EQUIPMENT DAMAGE OR PERSONAL
INJURY MAY RESULT.
GOVERNOR SPEED ADJUSTMENT SHOULD
BE MADE ONLY BY A Dayton Customer
Service Representative.
CHECKING ENGINE OIL:
Check oil level before each operation
and ensure that it is maintained per
Preparing the Generator; Engine Oil
Capacity section.
CHANGING ENGINE OIL:
Change oil after the first 20 hours of
operation. Thereafter it should be
changed every 100 hours.
1. Make sure the unit is on level ground.
Run the engine to warm the oil.
2. Stop the engine.
3. Remove the oil drain plug.
Oil being drained
may be hot. To
reduce the risk of burn injury, handle
with care. Dispose of used oil properly.
4. Drain oil while engine is warm, into a
suitable container.
5. Reinstall the oil drain plug.
6. Remove oil gauge and refill with new oil.
7. Check the oil level as instructed in
Preparing the Generator; Engine Oil
Capacity section.
8. Wipe up any spilled oil.
AIR CLEANER:
RISK OF FIRE OR
EXPLOSION. DO NOT
USE GASOLINE OR LOW FLASH-POINT
SOLVENTS TO CLEAN THE ELEMENT.
CLEAN THE ELEMENT IN A WELL
VENTILATED AREA. ENSURE THAT NO
SPARKS OR FLAMES ARE NEAR THE
WORKING AREA, THIS INCLUDES ANY
APPLIANCE WITH A PILOT LIGHT.
CAUTION: NEVER RUN THE ENGINE
WITHOUT THE AIR FILTER, SERIOUS
DANGER CAN RESULT.
Check the air cleaner daily or before
starting the engine. Check for and
correct heavy buildup of dirt and
debris along with loose or damaged
components.
1. Unsnap the air cleaner cover and
remove the elements.
2. Clean the elements:
FOAM PRE-CLEANER ELEMENT: Wash
the foam pre-cleaner element in warm
water with detergent. Rinse the foam
pre-cleaner element thoroughly until
all traces of detergent are eliminated.
Squeeze out excess water, but do not
wring. Allow the foam pre-cleaner
element to air dry.
Saturate the foam pre-cleaner element
with new engine oil. Squeeze out all
excess oil. DO NOT put engine oil on
the foam damper.
NOTE: Clean the foam pre-cleaner
element every 25 hours of operation
(more often under extremely dusty or
dirty condition)
PAPER AIR CLEANER ELEMENT: Do
not wash the paper element or use
pressurized air, as this will damage the
element. Clean by gently tapping the
element to remove dust. Replace the
element if damaged, bent or extremely
dirty. Handle new element carefully; do
not use if the sealing surfaces are bent
or damaged.
NOTE: Replace the paper element every
100 hours (more often under extremely
dusty conditions.)
Reinstall the foam pre-cleaner element
and the paper air cleaner element.
Close air cleaner cover and clasp shut.
CLEANING AND GAPPING SPARK PLUG:
Recommended Spark Plug:
Engine Honda
Spark Plug NGK BPR6ES
Spark Plug Gap 0.7 - 0.8 mm
(0.03 in.)
Torque - New 8.7-10.9 ft-lb
Torque - Retighten 16.6-19.5 ft-lb
If the plug is contaminated with
carbon,remove it using a plug cleaner
or wire brush. Check the spark plug gap
and reset it if necessary. The spark plug
gaps are listed below. To change the
gap, bendthe side-electrode only, using
a spark plug tool. Install and tighten the
spark plug. Connect the spark plug lead.
SPARK ARRESTOR:
If the generator has been running, the
muffler will be very hot. Allow it to cool
before proceeding.
NOTE: Remove and clean spark arrester
every 100 hours or as necessary.
NOTE: Product users on United States
forest service land, and in some states,
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Dayton Operating Instructions and Parts Manual
Dayton® Generator
2ZRP8, 2ZRP9
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(See recommendations)
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must comply with fire prevention
regulations.
Clean the spark arrester as follows:
1. Loosen the screw by the exhaust port
of the muffler and remove the spark
arrester.
2. Use a brush to remove carbon deposits
from the spark arrester screen.
Inspect the screen for breaks or tears
and replace it if necessary.
3. Install the spark arrester in the reverse
order of removal.
Spark arrestors are available
from your local Dayton Customer
Service Representative. Other user
lrequirements may apply, check with
your Federal, State or local authorities.
Storing Generator
SHORT TERM (1-6 MONTHS):
1. Add gasoline conditioner and
stabilizer at the specified
concentration.
2. Run the unit for two (2) minutes to
ensure the mixed fuel is in the entire
fuel system. Close the fuel valve and
run the unit until it stops.
3. Remove the spark plug, pour 1-2
teaspoons (5-10cc) of engine oil into
the cylinder, slowly pull the starter
handle 2 or 3 times, reinstall the
spark plug and tighten securely.
4. Clean the exterior surface of the
generator and apply a rust inhibitor.
5. Store the generator in a dry, well
ventilated place.
LONG TERM (MORE THAN 6 MONTHS):
1. Add gasoline conditioner and
stabilizer at the specified
concentration.
2. Run the generator until the fuel
tank and carburetor are dry. As the
engine is beginning to die, move the
choke lever to the choke position.
NOTE: Turn off the idle control to
decrease the run time.
3. Remove the spark plug, pour 1-2
teaspoons (5-10cc) of engine oil into
the cylinder, slowly pull the starter
handle 2 or 3 times, reinstall the
spark plug and tighten securely.
4. Clean the exterior surface of the
generator and apply a rust inhibitor.
5. Store the generator in a dry, well
ventilated place.
FUEL SHOULD BE
DRAINED IN A WELL
VENTILATED AREA AND STORED IN A
CONTAINER APPROVED FOR GASOLINE.
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Dayton Operating Instructions and Parts Manual
Models 2ZRP8, 2ZRP9
Troubleshooting Chart
Symptom Possible Cause(s) Corrective Action
Engine will not start
Engine switch is off.
Fuel Tank empty.
Fuel Valve is off.
Turn engine switch to the ON position.
Fill tank per instructions in this manual.
Turn Fuel Valve on.
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Generator has no output.
Inadequate engine oil.
No spark at spark plug.
Circuit breakers tripped.
Inadequate cord sets or extension cords.
Check oil level. This engine is equipped
with a low oil sensor. The engine cannot
be started unless the oil level is above
the prescribed lower limit.
Remove the spark plug cap. Clean any
dirt from around the plug base, then
remove the spark plug. Install the spark
plug in the plug cap. Turn the engine
switch on.
Grounding the electrode to any engine
ground, pull the recoil starter to see if
sparks jump across the gap. If there is no
spark, replace the plug.
Reinstall the plug and start engine
according to instructions in this manual.
Consult Customer Service.
Reset circuit breakers.
Check cord sets or extension cords
capabilities in section Controls; Cable
Size in this manual.
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Consult Dayton Customer Service.
Dayton Operating Instructions and Parts Manual
2ZRP8, 2ZRP9
Dayton® Generator
LIMITED WARRANTY
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DAYTON ONE-YEAR LIMITED WARRANTY. DAYTON® Generator, MODELS COVERED IN THIS MANUAL, ARE WARRANTED BY
DAYTON ELECTRIC MFG. CO. (DAYTON) TO THE ORIGINAL USER AGAINST DEFECTS IN WORKMANSHIP OR MATERIALS UNDER
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NORMAL USE FOR ONE YEAR AFTER DATE OF PURCHASE. ANY PART WHICH IS DETERMINED TO BE DEFECTIVE IN MATERIAL
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OR WORKMANSHIP AND RETURNED TO AN AUTHORIZED SERVICE LOCATION, AS DAYTON DESIGNATES, SHIPPING COSTS
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PREPAID, WILL BE, AS THE EXCLUSIVE REMEDY, REPAIRED OR REPLACED AT DAYTON’S OPTION. FOR LIMITED WARRANTY
S
CLAIM PROCEDURES, SEE “PROMPT DISPOSITION” BELOW. THIS LIMITED WARRANTY GIVES PURCHASERS SPECIFIC LEGAL
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RIGHTS WHICH VARY FROM JURISDICTION TO JURISDICTION.
LIMITATION OF LIABILITY. TO THE EXTENT ALLOWABLE UNDER APPLICABLE LAW, DAYTON’S LIABILITY FOR CONSEQUENTIAL
AND INCIDENTAL DAMAGES IS EXPRESSLY DISCLAIMED. DAYTON’S LIABILITY IN ALL EVENTS IS LIMITED TO AND SHALL NOT
EXCEED THE PURCHASE PRICE PAID.
WARRANTY DISCLAIMER. A DILIGENT EFFORT HAS BEEN MADE TO PROVIDE PRODUCT INFORMATION AND ILLUSTRATE
THE PRODUCTS IN THIS LITERATURE ACCURATELY; HOWEVER, SUCH INFORMATION AND ILLUSTRATIONS ARE FOR THE SOLE
PURPOSE OF IDENTIFICATION, AND DO NOT EXPRESS OR IMPLY A WARRANTY THAT THE PRODUCTS ARE MERCHANTABLE,
OR FIT FOR A PARTICULAR PURPOSE, OR THAT THE PRODUCTS WILL NECESSARILY CONFORM TO THE ILLUSTRATIONS OR
DESCRIPTIONS. EXCEPT AS PROVIDED BELOW, NO WARRANTY OR AFFIRMATION OF FACT, EXPRESSED OR IMPLIED, OTHER
THAN AS STATED IN THE “LIMITED WARRANTY” ABOVE IS MADE OR AUTHORIZED BY DAYTON.
Technical Advice and Recommendations, Disclaimer. Notwithstanding any past practice or dealings or trade custom,
sales shall not include the furnishing of technical advice or assistance or system design. Dayton assumes no obligations
or liability on account of any unauthorized recommendations, opinions or advice as to the choice, installation or use of
products.
Product Suitability. Many jurisdictions have codes and regulations governing sales, construction, installation, and/or use
of products for certain purposes, which may vary from those in neighboring areas. While attempts are made to assure
that Dayton products comply with such codes, Dayton cannot guarantee compliance, and cannot be responsible for how
the product is installed or used. Before purchase and use of a product, review the product applications, and all applicable
national and local codes and regulations, and be sure that the product, installation, and use will comply with them.
Certain aspects of disclaimers are not applicable to consumer products; e.g., (a) some jurisdictions do not allow the exclusion
or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you; (b) also,
some jurisdictions do not allow a limitation on how long an implied warranty lasts, consequently the above limitation
may not apply to you; and (c) by law, during the period of this Limited Warranty, any implied warranties of implied
merchantability or fitness for a particular purpose applicable to consumer products purchased by consumers, may not be
excluded or otherwise disclaimed.
Prompt Disposition. A good faith effort will be made for prompt correction or other adjustment with respect to any
product which proves to be defective within limited warranty. For any product believed to be defective within limited
warranty, first write or call dealer from whom the product was purchased. Dealer will give additional directions. If unable to
resolve satisfactorily, write to Dayton at address below, giving dealer’s name, address, date, and number of dealer’s invoice,
and describing the nature of the defect. Title and risk of loss pass to buyer on delivery to common carrier. If product was
damaged in transit to you, file claim with carrier.
Manufactured for Dayton Electric Mfg. Co., 5959 W. Howard St., Niles, Illinois 60714-4014 U.S.A.
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Dayton Operating Instructions and Parts Manual
Notes
2ZRP8, 2ZRP9
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13
Dayton Operating Instructions and Parts Manual
For Repair Parts, call 1-800-323-0620
24 hours a day – 365 days a year
Please provide following information:
-Model number
-Serial number (if any)
-Part description and number as shown in parts list
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2ZRP8, 2ZRP9
Figure 1 – Repair Parts Illustration for GEN-6000-0GH0 091008
14
Dayton Operating Instructions and Parts Manual
Models 2ZRP8, 2ZRP9
Repair Parts 2ZRP8
Ref. Part
No. Description No. Qty.
1 Engine 1-0152 1
2 Locknut 30-0159 3
3 Washer 28-0022 6
4 Locknut 30-0157 16
5 Washer 28-0003 24
6 Isolator 33-0028 4
7 Mounting Bracket 5-0236A01 4
8 Screw 27-0066 8
9 Bolt 27-0121 3
10 Isolation Plate 5-0243A01 1
11 Generator 32-0825 1
12 Bolt 27-0116 4
13 Lockwasher 29-0110 1
14 Lockwasher 29-0112 1
15 Washer 28-0005 2
16 Locknut 30-0161 1
17 Conduit 32-0255 2
18 Strain Relief 32-0586 1
19 Locknut 32-0587 1
20 Washer 28-0002 10
21 Lockwasher 29-0006 4
22 Bolt 27-0015 4
23 Locknut 30-0155 1
24 Electric Box 20-0831A01 1
25 Bracket Capacitor 20-0797A01 2
26 Capacitor 32-0846 2
27 Bolt 27-0022 1
28 Locknut 30-0152 10
29 Breaker 32-0834 2
30 Breaker 32-0835 2
31 Cover-Decal Plate 20-0833A01 1
32 Decal-Operation (See 34-9038) N/A Sep. 1
33 Rocker Switch 32-0626 1
34 Bolt 27-8881 22
35 Hour Meter 32-0668 1
Ref. Part
No. Description No. Qty.
36 Bolt 27-9574 14
37 External Lockwasher 29-1013 34
38 Decal-Panel (See 34-9083) N/A Sep. 1
39 Control Panel 20-1118A01 1
40 Breaker 32-0836 2
41 Receptacle 32-0832 1
42 Receptacle 32-0833 1
43 Bolt 27-8942 2
44 Receptacle 32-0830 2
45 Bolt 27-0740 2
46 Idle Down Board 32-0896 1
47 Terminal Strip 32-0227 1
48 Decal-Silver Sticker N/A 1
49 Decal- Ground Pictorial
(See 34-9038) N/A Sep. 1
50 External Lockwasher 29-1009 30
51 Bolt 27-8807 1
52 Decal-Gen N/A Sep. 2
53 Hex Nut 30-6001 3
54 Fuel Tank Assy (See 850-0008) N/A 1
55 Decal-Warning (See 34-9038) N/A Sep. 1
56 Decal-Gen N/A Sep. 2
57 Fuel Tank Isolator 14-0103 4
58 Bolt 27-0016 4
59 Fuel Tank Assy 850-0008 1
60 Clamp Worm 42-0004 2
61 Fuel Hose (Two Feet Required) 15-0261 1
62 Decal-Grainger 800# 34-1444 1
63 Conduit (Two Feet Required) 32-0253 1
64 Isolation Plate 5-0242A01 1
65 Bolt 27-0167 1
66 Muffler 45-0085 1
67 Spacer Generator 33-0431 2
Decal Set (Inc. 32, 38, 49, 55) 34-9038
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Dayton Operating Instructions and Parts Manual
For Repair Parts, call 1-800-323-0620
24 hours a day – 365 days a year
Please provide following information:
-Model number
-Serial number (if any)
-Part description and number as shown in parts list
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2ZRP8, 2ZRP9
Figure 2 – Repair Parts Illustration for Generator-7500-0GHE 091008
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Dayton Operating Instructions and Parts Manual
Models 2ZRP8, 2ZRP9
Repair Parts 2ZRP9
Ref. Part
No. Description No. Qty.
1 Locknut 30-0159 3
2 Washer 28-0022 6
3 Locknut 30-0157 19
4 Washer 28-0003 30
5 Isolator 33-0028 4
6 Isolator Mounting Bracket 5-0236A01 4
7 Bolt 27-0069 1
8 Bolt 27-0067 8
9 Bolt 27-0121 3
10 Isolation Plate 5-0243A01 1
11 Bolt 27-0121 1
11 Alternator 32-0826 1
12 Bolt 27-0116 4
13 Lockwasher 29-0110 1
14 Lockwasher 29-0112 1
15 Washer 28-0005 2
16 Locknut 30-0161 1
17 Strain Relief 32-0586 1
18 Locknut 32-0587 1
19 Washer 28-0002 17
20 Bolt 27-0015 8
21 Lockwasher 29-0006 9
22 Electric Box Assembly 20-0831A01 1
23 Capacitor Clamp Bracket 20-0797A01 2
24 Bolt 27-0120 2
24 Capacitor 32-0846 2
25 Bolt 27-0022 1
26 Locknut 30-0152 10
27 GFCI Duplex Receptacle 32-0830 2
28 Toggle Breaker 32-0834 2
29 Toggle Breaker 32-0836 1
30 Control Panel 20-1118A01 1
31 Decal Cover Plate 20-0833A01 1
32 Decal- Operation (See 34-9038) N/A Sep. 1
33 Rocker Switch 32-0626 1
34 Bolt 27-8881 22
35 Hour Meter 32-0668 1
37 Volt Meter 32-0838 1
36 Screw 27-9574 10
37 Lockwasher 29-1013 30
38 Decal- Control Panel
(See 34-9038) N/A Sep. 1
Ref. Part
No. Description No. Qty.
40 Screw 27-8942 2
41 Bolt 27-0740 2
42 Receptacle- L5-30 32-0832 1
43 Toggle Breaker 32-0837 1
44 Receptacle- L14-30 32-0831 1
39 Terminal Strip 32-0227 1
45 Idle Down Board 32-0896 1
46 Conduit Fitting 32-0255 2
47 Decal- GEN-7500-0MHE 34-2237 2
48 Decal- Data Plate N/A 1
49 Decal- Ground Pictorial
(See 34-9038) N/A Sep. 1
50 Lockwasher 28-1009 4
51 Screw 27-8807 1
52 Bolt 27-0017 2
53 Battery Bracket 20-0832A01 1
54 Locknut 30-0155 2
55 Battery 32-0058 1
56 Hex Nut 30-6001 3
57 Battery Strap 33-0430 1
61 Battery Cable Cover 33-0429 1
58 Terminal Ring 32-0097 4
59 Cable 32-0065 2
60 Battery Cable Cover 33-0004 1
62 Bolt 27-0066 2
63 Frame Assembly 5-0231A01 1
64 Decal- Warning (See 34-9038) N/A Sep. 1
65 Decal- Generator 34-2238 1
66 Fuel Tank Isolator 14-0103 4
67 Fuel Tank Assembly 856-0008 1
68 Bolt 27-0016 4
69 Clamp Worm 42-0004 2
70 Hose Fuel *(One Foot Required) 15-0261 1
71 Decal- Grainger 800# 34-1444 1
72 Conduit Flex
*(Two Feet Required) 32-0253 1
73 Alternator Plate 5-0244A01 1
74 Bolt 27-0167 1
75 Muffler 45-0085 1
76 Spacer 33-0431 2
77 Engine- 13.0 HP Honda 1-0153 1
Decal Set (Inc. 33, 40, 51, 66) 34-9038
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Dayton Operating Instructions and Parts Manual
For Repair Parts, call 1-800-323-0620
24 hours a day – 365 days a year
Please provide following information:
-Model number
-Serial number (if any)
-Part description and number as shown in parts list
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2ZRP8, 2ZRP9
Figure 3 – Repair Parts Illustration for 32-0825 082605
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Dayton Operating Instructions and Parts Manual
Models 2ZRP8, 2ZRP9
Repair Parts List for 2ZRP8 Generator
Ref. Part
No. Description No. Qty.
1 Nut 30-3007 4
2 Alternator Flange 52-0071 1
3 Lockwasher 29-0110 4
4 Bolt 27-8042 4
5 Bolt 27-9593 2
6 Hex Nut 30-6001 2
7 Bolt 27-9585 1
8 Capacitor 32-0874 1
Ref. Part
No. Description No. Qty.
9 Alternator Cap 52-0076 1
10 Alternator End Cover 52-0073 1
11 Self Tapping Screw 27-9586 1
12 External Lockwasher 29-1013 1
13 Terminal Ring 52-0077 1
14 Terminal Spade 32-0878 4
Complete Assembly (Inc. 1-14) 32-0825
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Dayton Operating Instructions and Parts Manual
For Repair Parts, call 1-800-323-0620
24 hours a day – 365 days a year
Please provide following information:
-Model number
-Serial number (if any)
-Part description and number as shown in parts list
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2ZRP8, 2ZRP9
Figure 4 – Repair Parts Illustration for 32-0826 082605
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Dayton Operating Instructions and Parts Manual
Models 2ZRP8, 2ZRP9
Repair Parts List for 2ZRP9 Generator
Ref. Part
No. Description No. Qty.
1 Nut 30-3007 4
2 Alternator Flange 52-0072 1
3 Lockwasher 29-0110 4
4 Bolt 27-8062 4
5 Bolt 27-9593 2
6 Hex Nut 30-6001 2
7 Bolt 27-9584 1
8 Capacitor 32-0875 1
Ref. Part
No. Description No. Qty.
9 Alternator Cap 52-0877 1
10 Alternator End Cover 52-0074 1
11 Self Tapping Screw 27-9586 1
12 External Lockwasher 29-1013 1
13 Terminal Ring 52-0077 1
14 Terminal Spade 32-0878 4
Complete Assembly (Inc. 1-14) 32-0826
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Dayton Operating Instructions and Parts Manual
For Repair Parts, call 1-800-323-0620
24 hours a day – 365 days a year
Please provide following information:
-Model number
-Serial number (if any)
-Part description and number as shown in parts list
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2ZRP8, 2ZRP9
Figure 5 – Repair Parts Illustration for 856-0008
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Dayton Operating Instructions and Parts Manual
Models 2ZRP8, 2ZRP9
Repair Parts List for Fuel Tank
Ref. Part
No. Description No. Qty.
1 Fuel Guage 12-0178 1
2 Fuel Cap 12-0177 1
3 Fuel Filter 19-0554 1
Ref. Part
No. Description No. Qty.
4 Fuel Tank 12-0176 1
5 Fuel Shut-off Valve 19-0553 1
Complete Assembly (Inc. 1-5) 856-0008
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2ZRP8, 2ZRP9
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For Repair Parts, call 1-800-323-0620
24 hours a day – 365 days a year
Please provide following information:
-Model number
-Serial number (if any)
Dayton Operating Instructions and Parts Manual
-Part description and number as shown in parts list
24
Figure 6 – Repair Parts Illustration for 2ZRP8 Wire Diagram
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