DCA400 SERIES — FUEL RETURN LINE KIT INSTRUCTIONS P/N 35499 — REV. #0 (01/26/11) — PAGE 1
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.
Figure 1. Return Fuel Line Kit
10
2
3
5
5
5
5
5
7
8
1
6
INSTRUCTIONS
11
4
9
WORK SAFELY!
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
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.
Table 1. Return Fuel Line Kit
Item
No. Part No. Description QTY. Remarks
1 35500 Kit, Return Fuel Line 1 Includes
items 2-11
2Fitting, Bush 1/2FP x 3/4MP
Steel/Yel Zinc 1
3Fitting, Tee, 3/4FP x 3/4MP x
3/4FP 1
4 Fitting, 3/4MP x 1/2 Barb, Brass 1
5 Clamp, Hose Worm #8 1/2-1.00 5
6Hose, Fuel, 1/2" ID, Return
Extension, 53 in. (134.6 cm) 1
7 Fitting, Brass, 8 Barb x 8 Barb 1
8Hose, Fuel, 1/2" ID, Vent,
24 in. (61 cm) 1
9 Tie, Cable Ty-Rap Black 10
10 Protector, Spiral Hose 1
11 35499 Instructions, Return Fuel Line 1
