24hr Customer service

1-8-GENERATOR

Installation Instructions for the

SGP 3100i Extended Run Fuel System

for Champion P.E. Models 2800 - 3400

Watt Inverters



 

Step 1.  Disassembly of the Inverter 

Removal of the plastic handles can be done by using a phillips screwdriver and removing the 4 screws that hold the handle assembly together.  After removing the half handle covers, you will remove the 4 - 6mm bolts that hold the lid cover to the chassis frame and remaining screws/bolts holding the black end housing over the computer module.   Remove the gas cap holding screw on chain and then remove the yellow lid off and away from the Inverter for now. Replace the fuel cap onto the tank.

 

Step 2.   Remove end cover of Inverter (black) to expose air cleaner assy. and computer module.  You will find 2 - 6mm bolts on the lower portion on this cover. Removal of the end cover is easy upon removing the bolts and screws. Place the screws in a handy container for reassembly later. You will note two hoses coming from the engine that connect to the carbon cannister (for emission system)  Note the correct hose connection for reassembly later when you replace the end cover.


 

Step 3.   Next remove the computer module from its mount.

2 - 6mm bolts hold the module down with holding plates. Carefully lift the computer module up and out of the rubber mounts that are just below the holding plates. (Note - a little WD-40 sprayed onto the rubber mounts before assembly will allow easy sliding).   After its mount removal, release the molex plug-in that comes from the stepper motor on top of the carburetor. This is the only plugin to release during the installation. Place the computer module off to the side and be sure not to stress any wiring. Using a piece of string will offer a holding mechanism if you wish.

 

Step 4  Remove the air cleaner cover latch and swing wide for removal from the hinged side. A little tweaking of the cover will allow this removal. The cover is quite flexible. Next, remove air filter element and hold down nuts and stress plate inside the air cleaner box.  After removing the airbox, you can slide the carburetor off in order to put the new manifold block. Careful removal of the gaskets can be done and reused. In the event of gasket damage, a new gasket can be done with gray style silicone gasket maker. (Sorry, vendor sent me the wrong gaskets for this installation, I have requested the correct one)  Replace the old carburetor manifold block with the new one, carefully locating the hoses and fuel pump in a general position for final mounting. Connect rubber strap for fuel pump onto the lower right hand valve cover bolt for mounting.

 

Step 5 - Connect labeled hose for the fuel inlet on the carburetor from the new fuel pump after removing original hose that comes from the petcock (Panel fuel ON/OFF valve) Leave hose connected to fuel valve and it will connect onto the barbed straight thru Tee fitting that does not have any hose connected  the Tee fitting. This is inbound from main tank fuel valve.

 

This hose will supply the fuel from the Auxiliary fuel can. When you have ⅜” drilled hole, you can insert the barb end thru the hole and slide ring nut onto the hose and secure into the top lid.  An alignment point for drilling the hole is show within the pictorial. You may want to drill one or two smaller holes for clean cutting. A pocket knife will trim the excess plastic at the hole for a clean fit of the coupler. Securely tighten ring nut, but do not over tighten.




 

Step 6  -   Read the instructions throughly prior to your effort and each step will make sense as you proceed.  You are sure to have a perfect working unit when you follow the directions. Review the pictorial for a visual understanding of the steps you will follow.


 

Step 7 - Connecting hose to any barb fitting can be done easily by using a cup of hot water. Place the hose into the water to make it more supple and then slide it onto the center Tee barb as far as possible. You will get a good tight and secure connection without any clamp needed.  Wire ties have been included for additional hose security if you choose. Also use wire ties for any security on the hoses if you want to keep a smooth curve on each hose. Be sure not to draw any wire tie too tight that might restrict the flow of fuel or vacuum to the fuel pump.

 

Step 8 -  Re-assembly of the lid and all other attachments can now be done in an opposite fashion from the removal. Be sure to plug in the molex plug in the computer module. There is a security finger lock on this plug-in.

 

Step 8 -  Choose a plastic gas can to use and locate a high point for drilling ⅞” hole for the sealing grommet to fit into. (NOTE - a 11/16” wood drill bit will make a nice hole into the plastic can)  Trim any excess plastic and open can lid to remove any residual plastic debris that may have entered during drilling. Place provided rubber grommet in this hole before inserting hose into the can.  Push hose thru until it is about ½” from bottom of can. All fuel is filtered prior to entry into the fuel pump.

The pictorial on the can assembly will show you our recommendation. You can choose any can of your choice for your auxiliary use.  Coil the hose when not in use and strap to can handle for security with provided Velcro strap.

 

You will note a rubber sealing cap for the quick coupling on the lid to be used when you are not using the fuel can for extending use.  Remove cap only when needed. Reinstall rubber cap when you are not needed the Aux. can or you are getting the can refueled. This rubber cap will prevent a full tank from any leakage out of the connection as well as dirt entry into the opening.  An extra rubber cap is included if you lose the original rubber cap.

 

Be sure to use treated fuel when putting the Inverter into storage.  Let Inverter run with the fuel tank valve in OFF position, the auxiliary fuel tank disconnected, and in about 3-5 minutes the engine will stop. This clears the fuel metering jets inside the carburetor and also lowers the float to prevent the float valve tip from sticking shut as the fuel dries off.  Your unit will start up effortlessly the next time you need it.


 

Extended fuel system operating recommendations 

 

1. Remove rubber cap off of the tank lid on the Inverter and couple the auxiliary tank hose connection on to the fitting with a firm push until you hear the lock snap securely.  

 

2.  To begin the flow of fuel from the Aux. can, you must run the Inverter on the main tank for about 3 minutes to purge the air out of the external fuel hose. You will see the fuel coming thru the hose as this happens. When the fuel inside the clear hose is near the Inverter, simply turn the main tanks fuel valve to OFF position.

Your inverter will now be using only the Aux. fuel supply can.  If you run your can dry, you will still have your main tank as reserve supply for a few hours while you refuel the can.

 

If you have any questions during your installation, please call our 24/7 Techline no. 1-8GENERATOR or 1-843-637-2867 for more assistance.  We will forward you some pictures illustrating positioning of the pump and fuel lines and a separate pictorial for the gas can installation of fuel hose.

Let us know if you haven’t received the pictorials by the time your kit arrives.  

 

We are sure you will enjoy the longer run ability of your generator and the safety provided not having to fill a hot inverter. Always use common sense when refueling any generator. Turn it off and let it cool unless you are connecting the Aux. fuel can.

 

The Super Gen Products Team appreciates your purchase.

 

Copyright 2018 - Super Gen Products LLC

 

Hose Specifications:

1. Upper lid hose - ¼” x  3” long

2. Tee to Vac. pump fuel inlet -  ¼” x 10” (NOTE_ #2 hose can be cut for fuel filter to fit appropriately)

 3.  Vacuum hose from pump to manifold block -  ¼” x 6”

 4.  Vacuum pump fuel outlet to carburetor nipple - ¼” x 16 1/2 “

 

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