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