Duracell DG65M-R62 Series User manual

Owner’s Manual
Instructions for Assembly, Testing, Operation, Servicing, and Storage.
Portable Gas Generator:
For Outdoor Use Only!
DG65M-R62
5000 Watt Rated
6000 Watt Surge
Owner’s Manual for
DG65M-R62 Series
Portable Generator

Welcome
Thank you for your purchase of this quality Duracell product. We wish you years of success using your
new portable generator. This machine is designed to supply electrical power and must be operated
outdoors only.
This manual contains general warnings about the risks of operating a portable generator and specific
warnings about the operation and maintenance of this particular portable generator. In addition, it
outlines important maintenance and storage procedures.
Please read it carefully before operating, maintaining, repairing, and storing your new portable generator.
Keep this owner’s manual handy so you can refer to it at any time. This owner’s manual and included
engine owner’s manual are considered a permanent part of the portable generator and should remain
with the generator if resold.
The information and specifications included in this publication were in effect at the time of approval for
printing. IES reserves the right, however, to discontinue or change specifications or design at any time
without notice and without incurring any obligation whatsoever. No part of this publication may be
reproduced without written permission.
Thank you for your business.
WARNING:
READ and UNDERSTAND the Owner’s Manual completely before using this
portable generator.
Assemble, test and use only in accordance with the Owner’s Manual
instructions.
WEAR personal protective gear when filling, using, cleaning, and servicing the
portable generator.
DO NOT START the generator until you have read, understood, and followed
the instructions in this manual.
Improper use of the portable generator could result in serious injury or illness
to the operator or nearby persons/animals, and cause property damage.
Customer Service
Consult an Authorized Service Dealer regarding maintenance or repair procedures.
Please contact us with service-related questions regarding operating and assembling your new generator,
including parts you may be missing.
1-888-980-4938
[e-mail]
www.DuracellGenerators.com

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DG65M-R62
Retain for your records
Record your generator’s model number and serial number as well as the date you purchased the
generator below. This information can be found on the box and the product information label on the
generator, see sample below.
Retain this information for your records. You’ll need to refer to this information when ordering parts and
contacting customer service about maintaining your generator and its warranty.
Model number:
_________________________________________
Serial number:
__________________________________________
Date purchased:
________Month _____________Day _____________Year
Sample information label for DG65M-R62

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DG65M-R62
Table of Contents
Welcome .......................................................................................................................................................0
Customer Service......................................................................................................................................0
Important safety precautions.........................................................................................................................3
Generator Safety Labels:..........................................................................................................................4
Safety warnings.............................................................................................................................................6
Carbon Monoxide WARNINGS.................................................................................................................6
Electrical system WARNINGS ..................................................................................................................8
Burn and fire WARNINGS.........................................................................................................................8
Reference manual contains critical information........................................................................................9
Orientation to your generator........................................................................................................................9
Major components.....................................................................................................................................9
AC receptacles........................................................................................................................................10
Package contents....................................................................................................................................11
Unpacking and Assembly........................................................................................................................12
Select Suitable Location..........................................................................................................................17
Pre-operation check and Safety Rules .......................................................................................................19
Pre-operational Checks...........................................................................................................................22
Starting the Generator.................................................................................................................................25
Monitoring the fuel level ..........................................................................................................................26
Using caution when refueling the tank....................................................................................................26
Shutting Down the Generator..................................................................................................................27
Maintenance................................................................................................................................................27
Importance of maintenance.....................................................................................................................27
Maintenance safety precautions .............................................................................................................28
Maintenance schedule............................................................................................................................29
Engine Maintenance ...............................................................................................................................30
Emission Control System Information.........................................................................................................31
Storing and transporting your generator .....................................................................................................31
Troubleshooting ..........................................................................................................................................33
Generator Specifications: DG65M-R62 ......................................................................................................35
Wiring diagram DG65M-R62...................................................................................................................36
Parts list DG65M-R62:............................................................................................................................37
Contact information for Technical and Customer Assistance.....................................................................42
Wattage Reference Chart .......................................................................................................................43
Limited Warranty.........................................................................................................................................44

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DG65M-R62
Important safety precautions
This manual contains critical safety information. Please read the entire manual closely.
Because safety is paramount and using a generator carries significant responsibilities, we have outlined
warnings and the general hazards of operating generators. In addition, we have summarized the
recommended procedures for operating, repairing, maintaining, and storing your specific generator to
keep you and others safe.
It would be impossible for us to warn you of each risk and all of the hazards involved in the use of
generators. Therefore, it’s essential that you use your best judgment and take precautions when using,
maintaining, repairing, and storing your generator.
There are many safety warnings in this manual and on the generator itself to guide you:
Generator safety labels: The safety labels on your generator warn of potential danger. It’s
critical that you read them. If any labels become difficult to read or have been removed, contact
your dealer for a replacement label.
Manual safety messages: This manual contains specific instructions and severe warnings
about the ramifications of using poor judgment and not following the instructions outlined in this
manual. The ramifications range from serious injury and losing consciousness to death.
Manual headings and sections: We’ve devoted several sections of this manual to outline the
risks, hazards, and warnings when using, repairing, maintaining, and storing your generator.
Pay attention to cautions such as, “Carbon monoxide WARNINGS” or “Electric shock WARNINGS” or
“Burn and fire WARNINGS.”
Not following instructions or using poor judgment when using
and maintaining your generator can cause you or someone
else to be
KILLED
or
SERIOUSLY INJURED.

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DG65M-R62
Generator Safety Labels:

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DG65M-R62
Generator Fuel Related Safety and Information Labels:
Generator Operating Safety Labels:
Fuel On/Off
Valve Label
Fuel Tank Label for:
DG65M-R62

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DG65M-R62
Safety warnings
Carbon Monoxide WARNINGS
Only operate your generator outdoors.
Operating a generator carries serious
responsibility. There are precautions that you
need to take when operating a generator:
•Never operate your generator indoors or
near any windows or doors.
•Never operate your generator in an
enclosed or a partially enclosed area
such as a garage.
•Do not let the exhaust from your
generator build up to dangerous levels.
•Do not breathe the poisonous gas in
your generator’s exhaust.
•Become familiar with your generator. Understand all of your generator’s controls, connections,
and output receptacles. Know how to quickly stop your generator in case of an emergency.
•If anyone else operates your generator, be sure he/she is properly instructed.
•Do not let children play with or operate your generator.
•Keep your generator at least seven feet away from flammable materials.
The exhaust from your generator contains carbon monoxide.
Breathing this poisonous gas, which is odorless and colorless, can
cause unconsciousness and could even kill you.

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DG65M-R62
Electrical shock WARNINGS
•Keep your generator dry.
•Do not operate your generator when your hands are wet.
•Do not operate your generator in wet conditions such as rain, snow or fog. Do not use it near a pool
or sprinkler.
•Store your generator in a dry place. If your generator is stored outdoors and is not protected from the
weather, check the electrical components on the Control Panel before each use. Look for moisture
and ice, which could cause your generator’s electrical components to malfunction or short circuit.
This could result in electric shock or electrocution.
•Do not exceed your generator’s wattage or amperage capacity. Exceeding these limits could damage
your generator and any device attached to it.
•If you use your generator on highly conductive areas such as metal decking or steel work, use a
ground fault circuit interrupter.
•Do not use electrical cords that are damaged, worn, bare or frayed.
•Do not touch your generator’s bare receptacles or wires.
•Always properly ground your generator. Failing to ground your generator could result in electric
shock or electrocution.
Your generator is equipped with a system that connects its frame components to the ground
terminals in the AC output receptacles.
This system and the AC neutral wire are not connected.
Therefore, if you test your generator with a receptacle tester, it will not produce the same ground
circuit condition as would be the case for a home receptacle.
Your generator produces significant electrical power.
It could cause electric shock or even electrocution if not used properly.
System Ground Terminal Location

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DG65M-R62
Electrical system WARNINGS
When connecting to a building’s electrical system for standby power, this
connection must be made by a qualified electrician. This connection must
isolate your generator’s power from the utility’s power and remain in
compliance with all electrical codes and applicable laws.
•Do not connect your generator to a commercial power outlet such as a building’s electrical
system unless an isolation switch is used, and that switch was installed by a qualified electrician.
•Improperly connecting your generator to a building’s electrical system could allow electrical
current from your generator to backfeed into the utility’s lines. This could electrocute utility
employees and others who make contact with the lines during a power outage. Your generator
could also explode, burn, or cause fires when the power is restored. Consult a qualified
electrician and/or the utility company before proceeding.
Burn and fire WARNINGS
•Stop engine when refueling.
•Do not smoke when refueling your generator.
•Keep your generator at least seven feet (or 2 meters) away from buildings and equipment.
•Keep flammable materials away from your generator.
•Do not allow sparks or flames near your generator when it’s refueled and keep them away
from your stored gasoline.
•Fuel vapors are highly flammable, so they could ignite after your generator is started. Wipe
up any spilled fuel before you restart your generator.
•Do not operate your generator in enclosed or partially enclosed areas.
•Avoid touching your generator’s muffler. It becomes extremely hot when your generator is in
use. It remains hot for quite a while after you turn your generator off, so wait to move your
generator into storage until the muffler has completely cooled to avoid severe burns.
Your generator’s exhaust system becomes hot enough that it
could ignite some materials and cause severe burns.
Gasoline is highly flammable and can be explosive, so use
extreme caution when refueling and operating your generator.

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DG65M-R62
Reference manual contains critical information
It’s recommended that you keep this Owner’s Manual near your generator, so you can refer to it while
operating and maintaining it. If you resell your generator, this manual is considered to be a part of the
generator and should be passed along with it to the new owner.
The information contained in this manual as well as the specifications outlined in it were in effect upon
approval for publishing this manual. Duracell Generators reserves the right to change the specifications
and instructions. Duracell Generators also reserves the right to discontinue and modify the design of the
generator at any point without incurring any obligation and without providing notice. This document may
not be reproduced in whole or in part without written permission from Duracell Generators.
Orientation to your generator
Major components
Below are diagrams of your generator’s major components and its Control Panel:
Models DG65M-R62:
1 FRAME COMP
13 WHEEL 10’
2 AC CIRCUIT BREAKER 30A
14 ENGINE
3 MAIN BREAKER
15 ENGINE SWITCH

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DG65M-R62
AC receptacles
This generator is equipped with the following receptacles:
5-20R:125 Volt, 20 Amp Duplex Receptacles (NEMA)
You can use the receptacle to operate 120 Volt AC, single-phase, 60Hz electrical loads that
require up to a maximum of 2,400 watts (1.8 kW) at 20 Amps of current or greater.
Use only power cords rated for 125 Volt AC loads at 15 Amps, or greater.
L5-30R: 120Volt, 30Amp Twist Lock Receptacle
Use this receptacle to operate 120 Volt AC, single-phase, 60 Hz electrical loads that
require up to a maximum of 3,600 watts (3.6 kW) at 30 Amps of current or greater.
Use only power cords rated for 125 Volt AC loads at 30 Amps, or greater.
L14-30R: 240/120Volt, 30Amp Twist Lock Receptacle
Use this receptacle to operate 240/120 Volt AC, single-phase, 60 Hz electrical loads that
require up to a maximum of 5,000 watts (5.0 kW) at 21 Amps of current or greater.
Use only power cords rated for 125/250 Volt AC loads at 30 Amps, or greater.
4 GROUND TERMINAL
16 FUEL SWITCH
5 L5-30 RECEPTACLE
17 CHOKE
6 AC CIRCUIT BREAKER
18 TANK
7 ALTERNATOR
19 FUEL TUBE
8 LOW OIL LAMP
20 CHECK VALVE
9 FOOT 21 FUEL TANK CAP
10 OIL FILLER CAP
22 HOUR METER
11 AXLE
23 MUFFLER COMP
12 NUT 24 L14-30 RECEPTACLE

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DG65M-R62
Warning: Do not use electrical cords that are damaged, worn, bare or frayed. Your
generator produces significant electrical power. Using damaged, worn, bare or frayed
power cords could cause electric shock or even electrocution.
Package contents
Below is a summary of the components included in your generator set. It’s recommended that you review
the items listed below and confirm they were all included in your purchase.
Name of Component Quantity
Generator Set 1
Mobility and Assembly Kit 1
Generator Manual 1
Engine Manual 1
Mobility and Assembly Kit Includes:
The mobility kit will include:
Generator Leg (1)
Handles (2)
Tools and Axles: axles and nuts (2 each),
wrenches (2), screwdriver (1)
Leg and Handle assembly hardware
Only use electrical cords that support the amount of wattage
outlined above for each receptacle.
Inspect power cords before each use.

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DG65M-R62
Unpacking and Assembly
WARNING: LIFTING HAZARD
The portable generator is heavy. Ensure that proper lifting equipment is available to
unload and move this portable generator.The generator can crush and cause serious
injury if it rolls out of control or tips over. Two or more adults are required for
assembly.
Upon receipt, inspect generator for missing or damaged parts. Verify that it is the generator you ordered.
See “Component Identification” section of this manual for a diagram of the generator and its components.
•For missing components, contact Duracell Support at 1-888-980-4938.
•For damaged components, contact the freight company that delivered the unit and file a claim.
•If complete, fill out the product serial number information. See Limited Warranty section of this
manual.
•IMPORTANT NOTE: This generator is heavy and at least 2 (two) adults will be required to
unpack and assemble the unit.
•Additional tools to aid assembly: Rubber Mallet, #3 or #2 Phillips head screwdriver, wrenches (2-
10 mm or 2-3/8 inch, 1 – 22mm or 7/8 inch, 1-19mm or ¾ inch, 1-18mm or 11/16).
UNPACK:
a) Carefully cut the straps and tape on the top
of the box and open.
b) Remove the cardboard cover and place it on
the floor, this will be used as an assembly
base for the next steps.
c) Remove the box containing the Mobility &
Assembly kit and set it aside.

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DG65M-R62
d) With the help of another person (at least two people are
required for this step), carefully remove the generator
main unit from the box and set it upon the cardboard
cover.
e) Unpack the Mobility and Assembly Kit as shown.
ASSEMBLY:
Following are the steps for assembling the wheel kit and attaching it to the generator:
1. Locate the Wheel assembly kit:
The kit includes:
Number
Description
QUANTITY
1 Portable Generator 1
2
KOHLER ENGINE MANUAL
1
3
Wrench 10mm ×12mm
1
Wrench 14mm ×17mm 1
Flathead screw driver
1
4
Axle 16×114mm 2
Sleeve 17×22×9mm
2
M16×1.5 nut
2
Washer 16×30×2 2
5
Generator foot with rubber
2
M8×16 screw 2
M8 nut
2
6
10”Rubber foam wheel
2
7
Handle (360MM) 2
M8×50 screw
2
M8 nut 6
M8×35 screw
2
M8×16 screw
2
Handle bracket 2
Bolt 8×48
2
Open ring 2
Washer 8
2

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DG65M-R62
2. First, you’ll place the wheels on the frame.
To do this, place the washer on the axle and insert it from the inside
of the frame toward the outside of the frame as shown at right;
Then, install the spacer as shown;
Place wheel onto axle;
Secure wheel with nut and then repeat the steps above on the other
wheel: *Use M16 x 1.5 nuts
3. Next, attach the front support. On the handle side of the
generator, lift and support the bottom of the frame to enable the
assembly of the front support: *Use M8 x 16 bolts and M8 nuts.
Then, fasten the foot bar onto the generator by
threading the bolts into the holes in the frame of the
generator at the points shown. Tighten the bolts.

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DG65M-R62
4. The last step is attaching the handle.
Please note there are two different length bolts; the
longer bolt will go through the upper hole and the short
bolt through the lower hole:
Start by installing the upper bolt and nut to hold the handle in place, only tighten by hand at this
point.We will tighten the bolt later: * Use M8 x 35 bolts and M8 nuts.
Now partially remove the handle pivot bolt as shown to allow the
insertion of the lower bolt. This bolt is an M8 x 50.
Next secure the upper and lower bolts by tightening them with the
wrenches or sockets as shown.
Now reassemble the handle pivot bolt and tight enough
that the handle moves freely and will drop down from its’
own weight. Then repeat these steps for the other
handle. When complete the handles should look like the
photo.
Handle Operation:
These handles have a self locking mechanism that must
be set before raising the handle. Simply raise the locking
pin up and away from the frame into this position. Then
raise the handle, the handle should lock with the locking
pin moving forward and dropping into the locking slot. To
lower the handles just pull up on the locking pins and the
handles will drop.

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DG65M-R62
Now your generator should look like the picture below, which is ready for the next step of adding
engine oil.
5. Add engine oil and check the engine:
IMPORTANT NOTE!
Engine is shipped without engine oil! Before operation, engine must be filled with the
appropriate type and quantity of oil as specified by the engine manufacturer. Damage
to the engine will result in running the engine without the proper type and quantity of
oil. The warranty does NOT cover engine damage as a result of operating the engine
without oil as specified by the manufacturer. Please refer to the engine owner’s
manual for the type, quantity and proper method for filling the engine with oil.
•Engine is shipped without oil. You must add oil before first use.
•Check the oil level (see engine manual). To avoid the inconvenience of an
unexpected shutdown by the Oil Sentry system, always check the engine oil level
before startup.

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DG65M-R62
Select Suitable Location
Moving and Handling
To move the generator around:
•Make sure the generator is turned off and has cooled down.
•Lock the handles and use them to manually move the generator.
•Lift the handles and push the generator in front of you as you walk.
•To turn, pivot the generator on its wheels as you push it.
Elevating or lowering your generator:
•To reduce risk of injury, it is recommended that at least two adults lift the
generator.
•The generator must be off and cooled to ambient temperature (room
temperature).
•Only lift the generator by the front and rear tubular frame. Do not use the
alternator or engine as a lifting point.
For Outdoor Use ONLY
Select a Suitable Outdoor Location:
1. Never run the generator in an enclosed or partially enclosed location such as a
building, garage, barn, shed, or house. These spaces can trap poisonous gases.
Running a fan or opening windows will not provide adequate ventilation to prevent
dangerous carbon monoxide build-up.
2. Only use the generator outdoors and far away from open windows, doors, and
building or vehicle vents.
3. Place the generator so that the exhaust fumes will not be directed towards people
or building air leaks and at least 7 feet away from combustible materials.
4. Do not locate and use the generator in the presence of flammable vapors, dust,
gases, or other potentially combustible materials.
5. Ensure that working, battery-operated or battery back-up carbon monoxide alarms
are used in any dwelling/structure that is in close proximity to the running
generator.
6. Note that this generator is NOT designed or approved for use in vehicles or marine
applications. Never run the generator inside RV’s or other vehicles, on boats, or
on pick-up truck beds.
WARNING: LOCATION HAZARDS
Choose a suitable site for operating your generator to prevent possible death from
carbon monoxide poisoning or injury from fire/explosion, hot surfaces, or equipment
tip-over. Your generator can crush and cause serious injury if it rolls out of control or
tips over. Follow the instructions for safely moving the generator.

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DG65M-R62
Positioning:
1. The generator should be positioned on a firm, level (less than 3 degree slope),
heat-resistant surface with good drainage and a nearby water supply.
2. Ensure that the generator sits level and will not slide or shift during operation. If
applicable, block the generator’s wheels to prevent movement.
3. Situate the unit so there is adequate pulling room for starting the engine using the
recoil starter of the engine. Attempting to pull at an odd angle or in confined space
could rip off the cord grip and/or cause muscular injuries to the operator.
Airflow:
1. Situate the unit so there is adequate clearance around the generator to allow for
proper airflow – at least 7 feet from any non-combustible wall or obstruction.
2. Do not operate with a tarp, blanket, or cover surrounding the generator.
3. Do not place any objects against or on top of the machine.
4. The generator needs adequate, unobstructed airflow to allow for proper
combustion and adequate cooling. Proper combustion can only be obtained when
there is a sufficient supply of oxygen available for the amount of fuel being burned.
Cooling ventilation is required to prevent overheating of the engine and pressure
pump and/or the possibility of fire.
5. Situate the machine away from other heat generating equipment and do not allow
debris to accumulate or block airflow to the engine or alternator.
Exhaust:
1. Place the unit so that the exhaust fumes will not be directed towards people or
building air intakes.
2. Keep a fire extinguisher rated “ABC” nearby which is properly charged. Be familiar
with its use.
3. The exhaust gas from your generator is extremely hot and can cause combustible
materials to catch on fire.
4. Make sure the engine is at least 7 feet from all combustible materials and
buildings/structures during operation.
Install Spark Arrestor (if Required)
Equip engine with spark arrestor if machine will be used near any ignitable forest,
brush, or grassy land. (See engine Owner’s Manual provided to determine if the
engine is already equipped.) Make sure you comply with applicable local, state, and
federal codes.
WARNING: Exhaust Modification Hazard
Never attempt to attach ductwork to the muffler system to allow for installation inside
an enclosure. This could cause heat build-up and increased exhaust back-pressure,
resulting in possible exhaust leakage or damage to the Generator.