Autojack IG2200i Installation manual

IG2200i
2000W Inverter Generator
IG2200i
ORIGINAL INSTRUCTIONS
SAFETY AND OPERATING MANUAL

IG2200i
TABLE OF CONTENTS
Welcome to Autojack!
Dear Customer, Congratulations on your purchase. Before using the
product for the first time please be sure to read these instructions for use.
They provide you with allinformation necessary for using the product safely and to
ensure its long service life.
Closely observe allsafety information in these instructions!
General Power Tool Safety Warnings………………………………….…......01
Symbols & Cable Rating Chart ……….…………………………………….………04
Machine Details and Product features……….…………………………….….05
Assembly.................………………………………………………………………....07
Operation…………………………………………………………………………………….11
Maintenance and Service…………………………………….……………………..14
Troubleshooting……………………………………………………..………………..17
Autojack Guarantee…………………………………………………………………….18
Declaration of conformity……………………………………………………………20
Parts list/Parts Diagram……………………….……………………………………...21

IG2200i 01
WARNING Read all safety warnings and
all instructions. Failure to follow the warnings
and instructions may result in electric shock, fire
and/or serious injury.
Save all warnings and instructions for
future reference. The term "power tool" in
the warnings refers to your electric (corded)
power tool or battery-operated (cordless) power
tool.
1. Work area safety
a)Keep work area clean and well lit. Cluttered
or dark areas invite accidents.
b) Do not operate power tools in explosive
atmospheres, such as in the presence of
flammable liquids, gases or dust. Power tools
create sparks which may ignite the dust or
fumes.
c) Keep children and bystanders away while
operating a power tool. Distractions can cause
you to lose control.
2. Electrical safety
a) Power tool plugs must match the outlet.
Never modify the plug in any way. Do not use
any adapter plugs with grounded power tools.
Unmodified plugs and matching outlets will
reduce risk of electric shock.
b) Avoid body contact with grounded surfaces,
such as pipes, radiators, ranges and
refrigerators.There is an increased risk of electric
shock if your body is grounded.
c) Do not expose power tools to rain or wet
conditions. Water entering a power tool will
increase the risk of electric shock.
d) Do not abuse the cord. Never use the cord for
carrying, pulling or unplugging the power tool.
Keep cord away from heat, oil, sharp edges or
moving parts. Damaged or entangled cords
increase the risk of electric shock.
e) When operating a power tool outdoors, use an
extension cord suitable for outdoor use. Use of a
cord suitable for outdoor use reduces the risk of
electric shock.
f) If operating a power tool in a damp location is
unavoidable, use a residual current device (RCD)
protected supply. Use of an RCD reduces the risk
of electric shock.
3. Personal safety
a) Stay alert, watch what you are doing and use
common sense when operating a power tool. Do
not use a power tool while you are tired or under
the influence of drugs, alcohol or medication. A
moment of inattention while operating power
tools may result in serious personal injury.
b) Use personal protective equipment. Always
wear eye protection. Protective equipment such
as dust mask, non-skid safety shoes, hard hat, or
hearing protection used for appropriate conditions
will reduce personal injuries.
c) Prevent unintentional starting. Ensure the
switch is in the off position before connecting to
power source and/or battery pack, picking up or
carrying the tool. Carrying power tools with your
finger on the switch or energising power tools that
have the switch on invites accidents.
d) Remove any adjusting key or wrench before
turning the power tool on. A wrench or a key left
attached to a rotating part of the power tool may
result in personal injury.
GENERAL POWER TOOL SAFETY WARNINGS

IG2200i 02
e) Do not overreach. Keep proper footing and
balance at all times. This enables better control
of the power tool in unexpected situations.
f) Dress properly. Do not wear loose clothing or
jewellery. Keep your hair, clothing and gloves
away from moving parts. Loose clothes,
jewellery or long hair can be caught in moving
parts.
g) If devices are provided for the connection of
dust extraction and collection facilities, ensure
these are connected and properly used. Use of
dust collection can reduce dust-related hazards.
4. Power tool use and care
a) Do not force the power tool. Use the correct
power tool for your application. The correct
power tool will do the job better and safer at the
rate for which it was designed.
b) Do not use the power tool if the switch does
not turn it on and off. Any power tool that
cannot be controlled with the switch is
dangerous and must be repaired.
c) Disconnect the plug from the power source
and/or the battery pack from the power tool
before making any adjustments, changing
accessories, or storing power tools. Such
preventive safety measures reduce the risk of
starting the power tool accidentally.
d) Store idle power tools out of the reach of
children and do not allow persons unfamiliar
with the power tool or these instructions to
operate the power tool. Power tools are
dangerous in the hands of untrained users.
e) Maintain power tools. Check for misalignment
or binding of moving parts, breakage of parts and
any other condition that may affect the power
tool’s operation. If damaged, have the power tool
repaired before use. Many accidents are caused
by poorly maintained power tools.
f) Keep cutting tools sharp and clean. Properly
maintained cutting tools with sharp cutting edges
are less likely to bind and are easier
g) Use the power tool, accessories and tool bits
etc. in accordance with these instructions, taking
into account the working conditions and the work
to be performed. Use of the power tool for
operations different from those intended could
result in a hazardous situation.
GENERAL POWER TOOL SAFETY WARNINGS

IG2200i 03
6. Additional Safety Instructions for
Generators
a).Keep the generator at least 1 m (3 ft.) from
buildings orother equipment, ortheengine may
overheat.
b).Place the generator ona solid, flat surface.
c).Make sure the surrounding area is free from
any material that could burn or be damaged by
heat.
d).Never move or tilt the generator whilst itis
switched on.
e).Alwaysswitch the engine OFF when refuelling.
f).Always refuel in a well-ventilated area.
g).Never overfill the tank, fill to the level
specified.
h).Never smoke whilst refuelling and avoid
smoking or usinga naked flame near the
generator.
i).Never start the engine if there isspilled fuel.
Any spillage must be wiped clean and the
generator allowed drying before attempting to
start theengine.
j).Never usethe generator inwet conditions
unless itis well protected/covered. Under these
conditions, adequate ventilation MUST be
provided.
k).Never operate the generator with wet hands
l).Never usewater orany other liquids toclean
the generator.
m).Make sure you ground (earth) the generator.
n).Always makesure the applied load does not
exceed the generator rating. Overloading the
generator isdangerous and could cause serious
damage.
o).Always disconnect the generator when carrying
out any maintenance.
p).Always allowthe generator toreach operating
speed before connecting a load.
q).Never allow thegenerator to run out offuel
when a load isconnected.
r).Never transport the generator with fuel inthe
tank.
s).Never connect the generator toa commercial or
residential power supply; e.g. ringmain.
t).Never allow the generator air vents to become
blocked.
GENERAL POWER TOOL SAFETY WARNINGS

IG2200i 04
SYMBOLS AND POWER RATING CHART
Danger! – Read the operating
instructions to reduce the risk of
injury.
Caution! Wear safety goggles.
Caution! Wear ear defenders. The
impact of noise can cause damage
to hearing.

IG2200i 05
MACHINE DETAILS AND PRODUCT FEATURES
Machine Details
Specifications:
Engine
Engine model – XY156F
Type – petrol
Displacement – 60m3
Ignition type – C.D.I
Fuel tank capacity – 4.1L
Maximum run time at 3/4 load– 3.5h
Engine oil capacity – 0.52L
Guaranteed sound power – 58dB
(Taken at 7m)
Generator
Rated Frequency – 50Hz
Rated AC voltage – 230V
Max output power – 2200W
Continuous output power – 2000W
Output type – modified sine wave
Rated DC voltage – 12V
Rated DC current – 4A
Rated output current – 4.354A
Rated power factor – 1
Performance Class – G1
Quality Class – A
IP Rating – IP23M
Package Contents:
InverterGenerator
12Volt Connecting Lead Assembly
Spark Plug Box Spanner
Cross-Head Screwdriver
Intended Use
Designed to generate electric energy
Using equipment in ways other than its
intended use the user and not the
manufacture will be liable for any damage or
injuries caused.
Also note that this equipment is not designed
for commercial or industrial use. Warranty will
be voided if used for these purposes.
1. Fuel tank
2. Spark plug
3. Muffler
4. Carrying handle
5. Choke lever
6. Air filter
7. Fuel pump
8. Fuel cock
9. Recoil starter
10.Oil filler cap
11.Fuel tank cap
12.Fuel filter
13.AC pilot light
14.Overload indicator light
15.Oil warning light
16.Economy control switch
17.DC 12V output
18.USB output
19.Parallel outlets
20.Ground (earth) terminal
21.AC receptacle
22.DC protector
23.Output reset

IG2200i 06
MACHINE DETAILS AND PRODUCT FEATURES

IG2200i 07
Assembly
Before using the generator
IMPORTANT: Generators should ALWAYS be
earthed. Make sure you earth the generator.
Before using your generator check that:
-The generator is in good condition and free
from any damage.
-The generator is clean and free from fuel or oil
spillage.
-The generator is correctly located for use
-There is no leakage.
Note: To avoid accidental spillage offuel, always
use a funnel to fill the fuel tank. If fuel is spilt it
must be removed from the unit before
attempting to start the engine.
Earthing
WARNING:It isadvisable to properly earth your
generatorbefore starting using a wire and a
small metal earth spike. The wire and earth are
not supplied with the unit.
An earth spike and cable can be purchased at
your localcamping supplier, oralternatively an
earth spike can be made, and itissuggested you
get advice from a qualified electrician.
Tomake a spike use a copper tube orcopper rod
12mm diameter, a minimum length of 200mm
and with an M6 machine screw one end.
The cableused should bea maximum length of 1
metre anda minimum of 1.0mm2to carry a 10
amp load.
Attach the cable to the generator at the earth
point screw on the generator.
When pushing the spike into the ground the
generator must not be running and it is suggested
that the spike is pushed into the ground by at least
100mm.
Earth of generators is covered in BS7430:2011, If
you have any doubts about this subject consult a
qualified electrician.
Oil warning system
When the oil level falls below the lower level, the
engine stops automatically. Unless you refill with
oil, the engine will not start again.

IG2200i 08
PRE-OPERATION CHECK
ECONOMYCONTROL SWITCH
When the economy control switch is turned
ON, the economy control unit controlsthe
engine speed according to the connected
load. The results are better fuel connection
and less noise.
DC CIRCUIT PROTECTOR
The DC circuit protector turns off automatically
when the load exceeds the generator rated
out?
CAUTION:Reduce the load to within
specified generator rated output if the
DC circuit protector turn off.
FUEL TANK CAP AIR VENTKNOB
The fuel tank cap is provided with an air vent knob
to stop fuel flow. The air vent knob must be turned
once clockwise from the closed position. This will
allow fuel to flow to the carburetor and the engine
to run.
When the engine is not in use, tighten the air vent
knob counter clockwise until it is finger-tight to
stop fuel flow.
OUTPUT RESET
Push the reset button for continuous 2seconds,
thegenerator will recover the ACoutput when
the generator stopsACoutput under overload
protect. NOTE: Please reduce theload of the
generator toensure that the total load is within
the rated power.

IG2200i 09
PRE-OPERATION CHECK
PRE-OPERATION CHECK
NOTE:Pre-
operation checks should be made
each time the generator is used.
CHECK ENGINE FUEL
-Make sure there issufficient fuel inthe tank.
-If fuel islow, refill with unleaded automotive
fuel.
-Be sure to use the fuel filter screen on the fuel
filter neck.
-Recommended fuel: Unleaded fuel
-Fuel tankcapacity:
WARNING:
-Do not refill tank while engine isrunning or
hot.
-Close fuel cock before refueling with fuel.
-Be careful not to let dust, dirt, water or other
foreign objects into the fuel.
-Do not fill above the top of the fuel filter orit
may overflow when the fuel heats up later and
expands.
-Wipe off spilt fuel thoroughly before starting
engine.
CHECK ENGINE OIL
-Remove oil filler cap and check the engine oil
level.
-If oil level is below the lower level line, refill with
suitable oil toupper level line. Do not screw in
the oil filler cap when checking oil level.
-Change oil if contaminated.
-Oil capacity: (see page 20-21)
-Recommended engine oil:
API Service “SJ”

IG2200i 10
PRE-OPERATION CHECK
GROUND (Earth)
WARNING:It is advisable to properly earth your
generator before starting using a wire and a
small metal earth spike. The wire and earth spike
are not supplied with the unit.
Parallel
Parallel running of two generators through
the using parallel terminal operation the
special terminal. The parallel operation needs
two generators with parallel function and a
special cable.
(a)Connect the special cable
(b)Start two generators separately
(c)The two generators running well, and green
light is on, the parallel is ok. Then you can
connect the device.
NOTE:
-Turn theeconomic switches oftwogenerators
on or off at the same time.
-The twogenerator’s parallel rated output is
90% of the total oftwogenerator’s rated
output.
-To shut down. Disconnect the electric device
firstly, and stop the two generators, disconnect
ct the special cable at the end.
-Don’t coconnect ordisconnect the special
cable when the generators are running.
The parallel running is only applicable tothe
same model.

E
IG2200i 11
OPERATION
NOTE: The generator has been shipped without
engine oil. Fill with oil or it will not start.
Do not tilt the generator when adding engine oil.
This could result in overfilling and damage to the
engine.
STARTING THE ENGINE
NOTE: Before starting the engine, do not
connect the electric apparatus.
Recoil start
1. Open the fuel tank air vent to the OPEN
position.
2. Turn the fuel cock lever to the ON position.
3. When running for the first time use the
generator sets, pressing the primer bulb 6 times
after refueling.
4.Turn the choke lever to the CHOKE
position.
5.Pull the starter handle slowly until resistance is
felt. This is the “Compression” point. Return the
handle to its original position and pull swiftly. Do
not fully pull out the rope. After starting, allow the
starter handle to return to its original position
while still holding the handle. Grasp the carrying
handle firmly to prevent the generator from falling
over when pulling the recoil starter.

IG2200i 12
OPERATION
6.Warm up the engine.
7.Turn the choke lever back to the │ │RUN
position.
8.Warm up the engine without a load for a few
minutes.
USING ELECTRIC POWER
1. AC APPLICATION
(a) Check the AC pilot lamp for proper voltage.
(b) Turn off the switch (es) of the electrical
appliance(s) before connecting to the generator.
(c) Insert the plug(s) of the electrical appliance(s)
into the receptacle.
CAUTION: Be sure the electric apparatus is
turned off before plugging in.
Be sure the total load is within generator rated
output.
Be sure the socket load current is within socket
rated current.
The economy control switch must be turned to
OFF when using electric devices that require a
large starting current, such as a compressor or
asubmersible pump.
2．OVERLOAD INDICATOR LIGHT
The overload indicator light comes on when an
overload ofa connected electrical device is
detected, the inverter unit overheats, orthe AC
output voltage rises. The electronic breaker will
then activate, stopping power to the generator in
order to protect the generator and any connected
electric devices. The output pilot light (green) will
flicker and the overload indicator light (red) will
turn on, then the engine will stop running. If so
please follow the following steps:
(a)Turn off any connected electric devices and stop
the engine.
(b)Reduce the total wattage of connected electric
devices within the application range.
(c)Check for blockages in the cooling air inlet and
around the control unit. If any blockages are
found, remove.
(d)After checking, restart the engine.

IG2200i 13
OPERATION
CAUTION:
The generator AC output automatically resets
when theengine isstopped and then restarted.
The overload indicator light may come on for a
few seconds at first when using electric
devices that requirere a large starting current,
such asa compressor or a submersible pump.
However, this isnot a malfunction.
3. DC APPLICATION (option)
This usageis applicable to 12V battery charging
only.
(a) Charging instruction for battery.
(b) Disconnect the leads for the battery.
(c) Loosen the filler cap.
(d) Fill distilled water tothe upper limit, ifthe
battery fluid is low level.
Measure the specific gravity forthe battery fluid
by using the hydrometer, and calculate the
charging time in according with the table shown
on right side.
The specific gravity for the fully charged battery
shall be within 1.26 to1.28. Itis recommended
toconfirm every hour.
(b)Connect between theDC output socket and the
battery terminals using the charging leads. The
leads should be connected making sure ofthe (+)
and (-) polarity.
(c)The DC circuit protector isto be set to ONafter
confirming the connection, ifthe protector isin
OFF position.
CAUTION:
Be sure the economy control switch is turned OFF
while charging the battery.

IG2200i 14
OPERATION AND MAINTENANCE AND SERVICE
STOPPING THE ENGINE
1. Turn off the power switch of the electric
apparatus or disconnect any electric devices.
2. Turn the fuel cock lever to OFF.
3. Turn the fuel tank cap air vent knob counter
clockwise to the CLOSED position.
ENGINE OIL REPLACEMENT
1.Place the machine on a level surface and warm
up the engine for several minutes. Then stop the
engine and turn the fuel cock knob to OFF. Turn
the fuel tank cap air vent knob counter clockwise
to the CLOSED position.
2. Loosen the screw and remove the cover.
3. Remove the oil filler cap.
4. Place an oil pan under the engine. Tilt the
generator to drain the oil completely.
5. Replace the generator on a level surface.
6. Add engine oil to the upper level.
7.Install the oil filler cap.
8.Install the cover and tighten the screw
Recommended engine oil: (SAE 10W30)
API Service “ SJ”
CAUTION:
Be sure no foreign material enters the crankcase.
Do not tilt the generator when adding engine oil.
This could result in overfilling and damage to the
engine

IG2200i 15
MAINTENANCE AND SERVICE
AIR FILTER
Maintaining anair filter is very important. Dirt
induced through improperly installed,
improperly serviced, orinadequate elements
damages and wears out engines. Keep the
element always clean.
1. Remove the cover.
2. Remove the air filter cover and element.
3. Wash the element in solvent and dry.
4. Oil the element and squeeze out excess oil.
The element should be wet but not dripping.
5. Insert the element into the air filter.
6. Install the cover.
CAUTION:
The engine should never run without the
element; excessive piston and/or cylinder wear
may result.
CLEANING AND ADJUSTING SPARK PLUG
1. Remove the cover.
2. Check for discoloration and remove the carbon.
3. Check the spark plug type and gap.
4. Install the spark plug.
5. Install the cover.
CAUTION:
Standard electrode colour: Tan Colour.
Standard Spark Plug: CM6RA (TORCH)
Spark Plug Gap: 0.6-0.7 mm (0.024-0.028 in)
FUEL TANK FILTER
1. Remove the fuel tank cap and filter.
2. Clean the filter with solvent. If damaged,
replace.
3. Wipe the filter and insert it.
! WARNING
Be sure the tank cap is tightened securely.

IG2200i 16
MAINTENANCE AND SERVICE
MUFFLER SCREEN
WARNING
The engine and muffler will be very hot after the
engine has been run.
Avoid touching the engine and muffler while
they are still hot with any part of your body or
clothing during inspection or repair.
1.Remove the cover.
2.Remove the muffler screen.
3.Use the flathead screw driver to pry the spark
arrester out from the muffler.
4.Remove the carbon deposits on the muffler
screen and spark arrester using a wire brush.
5.Install the muffler screen.
6.Install the cover.

IG2200i 17
Troubleshooting
Problem
Cause
Solution
The generator
fails to start
Fuel in tank
Fuel tank cap air vent
knob to OPEN, fuel cock
knob to ON.
Not enough oil in the
generator
Add more oil
No fuel
Add more fuel
Spark plug not working
correctly
Change the spark plug
The generator
fails to generate
electricity
The device you are trying
to power is faulty
Make sure the device
you want to power is
working properly
The overload indicator is
on
Remove the appliance
immediately, do not
connect any appliance
that requires more than
power
(DC supply only) The DC
overload protector has
activated
Press the reset button
The generator is
difficult to start
The air filter is dirty Clean the air filter
If this does not solve your problem, please contact the AUTOJACK service
department.

IG2200i 18
AUTOJACK GUARANTEE
1.Guarantee
1.1 Autojack guarantees that for a period of 12
months from the date of purchase the
components of qualifying products (see clauses
1.2.1 to 1.2.8) will be free from defects caused
by faulty construction or manufacture
1.2 During this period, Autojack, will repair or
replace free of charge any parts which are
proved to be faulty in accordance with
paragraph 1.1 providing that:
1.2.1 You follow the claims procedure set out in
clause 2.
1.2.2 Autojack and its Authorised Dealers are
given reasonable opportunity after receiving
notice of the claim to examine the product.
1.2.3 If asked to do so by Autojack or its
Authorised Dealer, you return the product at
your own cost to Autojack’s or the supplying
Authorised Dealer’s Premises, For the
examination to take place clearly stating the
Returns Material Authorisation Number given by
Autojack or an Authorised Dealer.
1.2.4 The fault in question is not caused by
industrial use, accidental damage, fair wear and
tear, wilful damage,neglect, incorrect electrical
connection, misuse, alteration or repair of the
product without approval.
1.2.5 The product has been used in a domestic
environment only.
1.2.6 The fault does not relate to consumable
items such as blades, bearings, drive belts or other
wearing parts which can reasonably be expected
to wear at different rates depending on usage.
1.2.7 The product has not been used for hire
purposes.
1.2.8 The product has been purchased by you, as
the guarantee is not transferable from a private
sale.
2. Claims Procedure
2.1 In the first instance please contact the
Authorised Dealer who supplied the product to
you. In our experience many initial problems with
machines that are thought to be fault due to faulty
parts are actually solved by correct setting up or
adjustment of the machine. A good Authorised
Dealer should be able to resolve the majority of
these issues much more quickly than processing a
claim under the guarantee. If a return is requested
by the Authorised Dealer or Autojack, you will be
provided with a Returns Material Authorisation
Number which must be clearly stated on the
returned package, and any accompanying
correspondence. Failure to provide a Returns
Material Authorisation Number may result in item
being refused delivery.