ꢀ DCA400ꢀSeriesꢀGenerator
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.
requireDtoolS
table 1. return Fuel line kit
„„13mm„socket„or„wrench
item
no.
part no.
Description
qty. remarks
„„Flat„blade„screwdriver
„„Pliers
Includes„
items„2-11
1
35500
Kit,„Return„Fuel„Line
1
„„Wire„cutters
„„Pipe„sealant
Fitting,„Bush„1/2FP„x„3/4MP„
Steel/Yel„Zinc
2
3
1
1
Fitting,„Tee,„3/4FP„x„3/4MP„x„
3/4FP
pArtS
4
Fitting,„3/4MP„x„1/2„Barb,„Brass
Clamp,„Hose„Worm„#8„1/2-1.00
1
Verify„that„all„parts„are„accounted„for.„See„Figure„1„and„
Table„1.
5
6
7
8
5
1
1
1
Hose,„Fuel,„1/2"„ID,„Return„„
Extension,„53„in.„(134.6„cm)
1
Fitting,„Brass,„8„Barb„x„8„Barb
Hose,„Fuel,„1/2"„ID,„Vent,„„
24„in.„(61„cm)
9
8
9
Tie,„Cable„Ty-Rap„Black
Protector,„Spiral„Hose
10
1
5
5
10
11
7
5
35499
Instructions,„Return„Fuel„Line
1
10
5
Work SAFely!
11
Only„a„qualified service technician„with„proper„training„
should„perform„this„installation.„Follow„all„shop„safety„rules„
when„performing„this„installation.
6
3
2
5
4
INSTRUCTIONS
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„
underneath„each„wheel„to„prevent„the„generator„from„
rolling.
Figure 1. Return Fuel Line Kit
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.
DCA400 SerieS — Fuel return line kit inStruCtionS p/n 35499 — rev. #0 (01/26/11) — pAge 1
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4.„ Disconnect„drain„hose„from„trailer„return„port.„See„
Figure„6.
inStAll neWtrAiler return port FittingS
Refer„to„Figure„8.
Trailer
Return
Port
Drain
3
2
4
Disconnect
Drain Hose
Drain
Hose
Existing 90º
Fitting
Figure 6. Disconnect Drain Hose
5.„ Remove„fittings„from„trailer„return„port.„Retain„the„90º„
fitting,„and„discard„the„others.„See„Figure„7.
Figure 8. New Trailer Return Port Fittings
NOTICE
Apply„pipe„sealant„to„all„fittings.
Retain
90º Fitting
1.„ Install„Item„3,„tee„fitting,„into„trailer„return„port.
2.„ Install„Item„2,„straight„fitting,„into„the„right„side„of„the„
tee„fitting.
Remove
Fittings
3.„ Install„existing„90º„fitting„into„Item„2.„Connect„to„drain„
hose.
4.„ Install„Item„4,„straight„fitting,„into„the„left„side„of„the„tee.
Trailer
Return Port
Figure 7. Remove Trailer Return Port Fittings
DCA400 SerieS — Fuel return line kit inStruCtionS p/n 35499 — rev. #0 (01/26/11) — pAge 3
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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
10
9
5
5
7
6
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.„
5
4
Figure 9. New Return Extension Hose
8
3.„ Install„spiral„tubing,„Item„10,„around„return„extension„
hose.„Secure„with„cable„ties,„Item„9.„See„Figure„10.
5
Return
5
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
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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).
2.„ Reconnect„negative„battery„cable„to„the„battery.
3.„ Start„generator„as„referenced„in„the„Operation„Manual.
4.„ Check„for„fuel„leaks.
Engine
Return
9
Hose
5.„ Replace„front„cabinet„panel„and„trailer„fuel„tank„cover.
9
9
Engine
Feed
Hose
Figure 12. Secure Vent Hose
DCA400 SerieS — Fuel return line kit inStruCtionS p/n 35499 — rev. #0 (01/26/11) — pAge 5
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ꢀ DCA400ꢀSeries
Fuel Return Modification
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
United StateS
Multiquip Corporate Office
MQ Parts Department
18910 Wilmington Ave.
Carson, CA 90746
Contact: [email protected]
Tel. (800) 421-1244
Fax (800) 537-3927
800-427-1244
310-537-3700
Fax: 800-672-7877
Fax: 310-637-3284
Service Department
Warranty Department
800-421-1244
310-537-3700
Fax: 310-537-4259
Fax: 310-943-2238
800-421-1244
310-537-3700
Fax: 310-943-2249
Technical Assistance
800-478-1244
mexico
United Kingdom
MQ Cipsa
Multiquip (UK) Limited Head Office
Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: [email protected]
Tel: (52) 222-225-9900
Unit 2, Northpoint Industrial Estate, Tel: 0161 339 2223
Fax: (52) 222-285-0420 Globe Lane,
Dukinfield, Cheshire SK16 4UJ
Contact: [email protected]
Fax: 0161 339 3226
Canada
Multiquip
4110 Industriel Boul.
Laval, Quebec, Canada H7L 6V3
Contact: [email protected]
Tel: (450) 625-2244
Tel: (877) 963-4411
Fax: (450) 625-8664
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of their respective owners and used with permission.
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
in this publication at any time without notice and without incurring any obligations.
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