Multiquip Portable Generator DCA400 User Manual
ꢀ 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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2.„ Disconnect„pick-up„hose„from„pick-up„port„and„discard.„  
See„Figure„4.  
DiSASSembly  
Figure„2„illustrates„the„unit’s„current„fuel„line„configuration.„  
Remove/Discard  
Pick-Up Hose  
Pick-Up  
Generator  
Hose  
Fuel Tank  
Engine  
Return  
Hose  
Pick-Up  
Port  
Drain  
Figure 4. Remove/Discard Pick-Up Hose  
3.„ Disconnect„engine„return„hose„from„return„port.„See„  
Figure„5.  
Trailer  
Fuel Tank  
Figure 2. Current Fuel Line Configuration  
Disconnect  
Engine Return  
Hose  
NOTICE  
Fuel„leaks„may„occur„when„disconnecting„hoses„and„  
fittings.„Wipe„up„any„spilled„fuel„immediately.  
Return  
Port  
1.„ Turn„fuel„shut-off„valve„to„the„OFF„position„(Figure„3).  
Fuel Shut-Off  
Valve (OFF Position)  
Drain  
Figure 5. Disconnect Engine Return Hose  
T
uel
T
a
nk  
Figure 3. Fuel Shut-Off Valve (Off Position)  
DCA400 SerieS — Fuel return line kit inStruCtionS p/n 35499 — rev. #0 (01/26/11) — pAge 2  
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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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Multiquip Inc and 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  
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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