ꢀ 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
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
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
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
ꢀ DCA400ꢀSeries
Fuel Return Modification
HERE’S HOW TO GET HELP
PLEASE HAVE THE MODEL AND SERIAL
NUMBER ON-HAND WHEN CALLING
United StateS
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Technical Assistance
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mexico
United Kingdom
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Carr. Fed. Mexico-Puebla KM 126.5
Momoxpan, Cholula, Puebla 72760 Mexico
Contact: [email protected]
Tel: (52) 222-225-9900
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Canada
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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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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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