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DCA400 SerieS — Fuel return line kit inStruCtionS p/n 35499 — rev. #0 (01/26/11) — pAge 1
 DCA400SeriesGenerator
 
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
2
Fitting,„Bush„1/2FP„x„3/4MP„
Steel/Yel„Zinc
1
3
Fitting,„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
6
Hose,„Fuel,„1/2"„ID,„Return„„
Extension,„53„in.„(134.6„cm)
1
7
Fitting,„Brass,„8„Barb„x„8„Barb
1
8
Hose,„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