ꢀ 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
13mmsocketorwrench
item
no.
part no.
Description
qty. remarks
Flatbladescrewdriver
Pliers
Includes
items2-11
1
35500
Kit,ReturnFuelLine
1
Wirecutters
Pipesealant
Fitting,Bush1/2FPx3/4MP
Steel/YelZinc
2
3
1
1
Fitting,Tee,3/4FPx3/4MPx
3/4FP
pArtS
4
Fitting,3/4MPx1/2Barb,Brass
Clamp,HoseWorm#81/2-1.00
1
Verifythatallpartsareaccountedfor.SeeFigure1and
Table1.
5
6
7
8
5
1
1
1
Hose,Fuel,1/2"ID,Return
Extension,53in.(134.6cm)
1
Fitting,Brass,8Barbx8Barb
Hose,Fuel,1/2"ID,Vent,
24in.(61cm)
9
8
9
Tie,CableTy-RapBlack
Protector,SpiralHose
10
1
5
5
10
11
7
5
35499
Instructions,ReturnFuelLine
1
10
5
Work SAFely!
11
Onlyaqualified service technicianwithpropertraining
shouldperformthisinstallation.Followallshopsafetyrules
whenperformingthisinstallation.
6
3
2
5
4
INSTRUCTIONS
prepArAtion
1. Makesuregeneratoristurnedoffandengineiscool.
2. Placethegeneratorinanareafreeofdirtanddebris
Makesureitisonsecurelevelgroundwithchockblocks
underneatheachwheeltopreventthegeneratorfrom
rolling.
Figure 1. Return Fuel Line Kit
3. Disconnectnegativebatterycablefromthebattery.
4. Removefrontcabinetpaneltogainaccesstogenerator
fueltank.
5. Removetrailerfueltankcovertogainaccesstotrailer
fueltank.
DCA400 SerieS — Fuel return line kit inStruCtionS p/n 35499 — rev. #0 (01/26/11) — pAge 1
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2. Disconnectpick-uphosefrompick-upportanddiscard.
SeeFigure4.
DiSASSembly
Figure2illustratestheunit’scurrentfuellineconfiguration.
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. Disconnectenginereturnhosefromreturnport.See
Figure5.
Trailer
Fuel Tank
Figure 2. Current Fuel Line Configuration
Disconnect
Engine Return
Hose
NOTICE
Fuelleaksmayoccurwhendisconnectinghosesand
fittings.Wipeupanyspilledfuelimmediately.
Return
Port
1. Turnfuelshut-offvalvetotheOFFposition(Figure3).
Fuel Shut-Off
Valve (OFF Position)
Drain
Figure 5. Disconnect Engine Return Hose
T
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. Disconnectdrainhosefromtrailerreturnport.See
Figure6.
inStAll neWtrAiler return port FittingS
RefertoFigure8.
Trailer
Return
Port
Drain
3
2
4
Disconnect
Drain Hose
Drain
Hose
Existing 90º
Fitting
Figure 6. Disconnect Drain Hose
5. Removefittingsfromtrailerreturnport.Retainthe90º
fitting,anddiscardtheothers.SeeFigure7.
Figure 8. New Trailer Return Port Fittings
NOTICE
Applypipesealanttoallfittings.
Retain
90º Fitting
1. InstallItem3,teefitting,intotrailerreturnport.
2. InstallItem2,straightfitting,intotherightsideofthe
teefitting.
Remove
Fittings
3. Installexisting90ºfittingintoItem2.Connecttodrain
hose.
4. InstallItem4,straightfitting,intotheleftsideofthetee.
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
RefertoFigure9.
1. ConnectItem6,returnextensionhose,toitem4.
Securewithclamp,Item5.
2. InstallItem7,straightfitting,betweenextensionhose
andexistingenginereturnhose.Securewithclamps.
9
Engine
Return Hose
10
9
5
5
7
6
Figure 10. Spiral Tubing
inStAll neW vent hoSe
1. ConnectItem8,venthose,togeneratorpick-upportand
returnport.Securewithclamps,Item5.SeeFigure11.
5
4
Figure 9. New Return Extension Hose
8
3. Installspiraltubing,Item10,aroundreturnextension
hose.Securewithcableties,Item9.SeeFigure10.
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. Secureventhosetoenginereturnhoseandengine
feedhosewithcableties,Item9.
reASSembly/teSting
1. Turnfuelshut-offvalvetotheONposition(Figure3).
2. Reconnectnegativebatterycabletothebattery.
3. StartgeneratorasreferencedintheOperationManual.
4. Checkforfuelleaks.
Engine
Return
9
Hose
5. Replacefrontcabinetpanelandtrailerfueltankcover.
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
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in this publication at any time without notice and without incurring any obligations.
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