Multiquip DCA400 User Manual

DCA400 Series Generator

Fuel Return Modification

The following instructions are intended to assist the user in the installation of the Fuel Return Line Kit for use on the
DCA400 Series generators affected by Service Bulletin GSP20110113. Please read all assembly instructions before
installing the kit.

REQUIRED TOOLS

 13mm socket or wrench
 Flat blade screwdriver
 Pliers
 Wire cutters

 Pipe sealant

PARTS

Verify that all parts are accounted for. See Figure 1 and
Table 1.

1

9

8

5

5

10

5

7

5

Table 1. Return Fuel Line Kit

Item

No.

10 Protector, Spiral Hose 1

11 35499 Instructions, Return Fuel Line 1

Part No. Description QTY. Remarks

1 35500 Kit, Return Fuel Line 1

2

3

4 Fitting, 3/4MP x 1/2 Barb, Brass 1

5 Clamp, Hose Worm #8 1/2-1.00 5

6

7 Fitting, Brass, 8 Barb x 8 Barb 1

8

9 Tie, Cable Ty-Rap Black 10

Fitting, Bush 1/2FP x 3/4MP

Steel/Yel Zinc

Fitting, Tee, 3/4FP x 3/4MP x

3/4FP

Hose, Fuel, 1/2" ID, Return

Extension, 53 in. (134.6 cm)

Hose, Fuel, 1/2" ID, Vent,

24 in. (61 cm)

Includes

items 2-11

1

1

1

1

WORK SAFELY!

11

INSTRUCTIONS

6

5

4

3

2

Only a qualified service technician with proper training
should perform this installation. Follow all shop safety rules
when performing this installation.

PREPARATION

1. Make sure generator is turned off and engine is cool.

2. Place the generator in an area free of dirt and debris
Make sure it is on secure level ground with chock blocks

Figure 1. Return Fuel Line Kit

DCA400 SERIES — FUEL RETURN LINE KIT INSTRUCTIONS P/N 35499 — REV. #0 (01/26/11) — PAGE 1

underneath each wheel to prevent the generator from
rolling.

3. Disconnect negative battery cable from the battery.

4. Remove front cabinet panel to gain access to generator
fuel tank.

5. Remove trailer fuel tank cover to gain access to trailer
fuel tank.

DISASSEMBLY

Figure 2 illustrates the unit’s current fuel line configuration.

2. Disconnect pick-up hose from pick-up port and discard.
See Figure 4.

Pick-Up

Hose

Trailer

Fuel Tank

Figure 2. Current Fuel Line Configuration

Generator

Fuel Tank

Engine
Return

Hose

Drain

Remove/Discard

Pick-Up Hose

Pick-Up

Port

Figure 4. Remove/Discard Pick-Up Hose

3. Disconnect engine return hose from return port. See
Figure 5.

NOTICE

Fuel leaks may occur when disconnecting hoses and
fittings. Wipe up any spilled fuel immediately.

1. Turn fuel shut-off valve to the OFF position (Figure 3).

Fuel Shut-Off

Drain

Figure 3. Fuel Shut-Off Valve (Off Position)

Valve (OFF Position)

Disconnect

Engine Return

Hose

Return

Port

Figure 5. Disconnect Engine Return Hose

DCA400 SERIES — FUEL RETURN LINE KIT INSTRUCTIONS P/N 35499 — REV. #0 (01/26/11) — PAGE 2

4. Disconnect drain hose from trailer return port. See
Figure 6.

INSTALL NEW TRAILER RETURN PORT FITTINGS

Refer to Figure 8.

Trailer

Drain

Return

Port

Disconnect
Drain Hose

Figure 6. Disconnect Drain Hose

5. Remove fittings from trailer return port. Retain the 90º
fitting, and discard the others. See Figure 7.

Retain

90º Fitting

Remove

Fittings

3

2

4

Drain

Existing 90º

Fitting

Figure 8. New Trailer Return Port Fittings

Hose

NOTICE

Apply pipe sealant to all fittings.

1. Install Item 3, tee fitting, into trailer return port.

2. Install Item 2, straight fitting, into the right side of the
tee fitting.

3. Install existing 90º fitting into Item 2. Connect to drain
hose.

Trailer

Return Port

Figure 7. Remove Trailer Return Port Fittings

4. Install Item 4, straight fitting, into the left side of the tee.

DCA400 SERIES — FUEL RETURN LINE KIT INSTRUCTIONS P/N 35499 — REV. #0 (01/26/11) — PAGE 3

INSTALL NEW RETURN EXTENSION HOSE

Refer to Figure 9.

1. Connect Item 6, return extension hose, to item 4.
Secure with clamp, Item 5.

2. Install Item 7, straight fitting, between extension hose
and existing engine return hose. Secure with clamps.

9

Engine

Return Hose

5

7

6

5

4

Figure 9. New Return Extension Hose

5

3. Install spiral tubing, Item 10, around return extension
hose. Secure with cable ties, Item 9. See Figure 10.

10

9

Figure 10. Spiral Tubing

INSTALL NEW VENT HOSE

1. Connect Item 8, vent hose, to generator pick-up port and
return port. Secure with clamps, Item 5. See Figure 11.

8

5

5

Return

Port

Pick-Up

Port

Figure 11. Vent Hose

DCA400 SERIES — FUEL RETURN LINE KIT INSTRUCTIONS P/N 35499 — REV. #0 (01/26/11) — PAGE 4

2. Secure vent hose to engine return hose and engine
feed hose with cable ties, Item 9.

REASSEMBLY/TESTING

1. Turn fuel shut-off valve to the ON position (Figure 3).

9

9

9

Engine

Feed
Hose

Figure 12. Secure Vent Hose

Engine
Return

Hose

2. Reconnect negative battery cable to the battery.

3. Start generator as referenced in the Operation Manual.

4. Check for fuel leaks.

5. Replace front cabinet panel and trailer fuel tank cover.

DCA400 SERIES — FUEL RETURN LINE KIT INSTRUCTIONS P/N 35499 — REV. #0 (01/26/11) — PAGE 5

HERE’S HOW TO GET HELP

© COPYRIGHT 2011, MULTIQUIP INC.

Multiquip Inc

the MQ logo are registered trademarks of Multiquip Inc. and may not be used, reproduced, or altered without written permission. All other trademarks are the property

The information and specifications included in this publication were in effect at the time of approval for printing. Illustrations, descriptions, references and technical data contained in
this document are for guidance only and may not be considered as binding. Multiquip Inc. reserves the right to discontinue or change specifications, design or the information published

DCA400 Series

Fuel Return Modification

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