Fuji Generator Repair Manual

The Fuji Generator is a reliable power generation system designed for residential and commercial use, featuring advanced engine technology, automatic voltage regulation, multiple power outlets, low-oil shutdown protection, electric start capability, fuel-efficient operation, and durable construction. Below are comprehensive sections covering safety procedures, technical specifications, maintenance guidelines, troubleshooting, and repair procedures.

1. Safety Precautions 2. Technical Specifications 3. Component Overview 4. Maintenance Schedule 5. Common Repairs 6. Engine Troubleshooting 7. Electrical System Repair 8. Fuel System Maintenance 9. Parts Replacement Guide 10. Warranty Information 11. Troubleshooting Guide

Safety Precautions

Critical safety measures for operating and repairing Fuji generators.

Hazard	Precaution
Electric Shock	Always disconnect spark plug before servicing
Fuel Fire	Work in well-ventilated area; no smoking
Hot Surfaces	Allow engine to cool before maintenance
Moving Parts	Keep hands clear during operation
Carbon Monoxide	Operate outdoors only
Battery Acid	Wear protective gloves and eyewear
Fuel Spills	Clean immediately with absorbent materials
Electrical Overload	Do not exceed rated wattage capacity

Technical Specifications

Power Output: 5000W continuous, 5500W peak
Engine Type: 4-stroke OHV single cylinder
Displacement: 389cc
Fuel Capacity: 4.5 gallons
Run Time: 10 hours at 50% load
Outlet Types: 120V 20A duplex, 120V 30A twist-lock, 240V 30A
Starting System: Electric start with recoil backup
Dimensions: 28"L x 22"W x 24"H
Weight: 125 lbs

Component Overview

Key components: Engine assembly, alternator, control panel, fuel system, electrical system.

Component	Function
Engine	Primary power source
Alternator	Generates electrical power
Control Panel	Power outlets and controls
Fuel Tank	Stores gasoline
Carburetor	Mixes air and fuel
Spark Plug	Ignites fuel mixture
Oil Filter	Filters engine oil
Voltage Regulator	Maintains stable voltage output

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

After first 20 hours: Change oil, check all connections
Every 50 hours: Clean air filter, check spark plug
Every 100 hours: Change oil filter, inspect fuel system
Every 200 hours: Replace spark plug, clean carburetor
Seasonal: Stabilize fuel, check battery charge

WARNING! Always use recommended oil type and follow service intervals.

Common Repairs

Step-by-step procedures for frequent repair scenarios.

Spark Plug Replacement: Disconnect wire, clean area, remove old plug, gap new plug, install
Oil Change: Warm engine, drain oil, replace filter, refill with recommended oil
Air Filter Cleaning: Remove cover, clean foam element, re-oil if necessary
Carburetor Cleaning: Drain fuel, remove carburetor, disassemble, clean jets, reassemble
Belt Replacement: Loosen mounting bolts, remove old belt, install new belt, adjust tension

Engine Troubleshooting

Diagnosing and resolving engine-related issues.

Symptom	Possible Cause	Solution
Won't start	Empty fuel tank, bad spark plug	Refill fuel, replace spark plug
Runs rough	Dirty air filter, clogged fuel line	Clean/replace filter, clear fuel line
Overheating	Low oil, dirty cooling fins	Check oil level, clean cooling system
Excessive vibration	Loose mounting bolts, worn mounts	Tighten bolts, replace mounts
Oil leaks	Loose drain plug, worn gaskets	Tighten plug, replace gaskets

Electrical System Repair

Maintaining and repairing generator electrical components.

Outlet Replacement: Disconnect power, remove panel, disconnect wires, install new outlet
Voltage Regulator: Test output, disconnect battery, replace regulator, reconnect
Battery Maintenance: Check voltage, clean terminals, test charging system
Wiring Inspection: Check for frayed wires, loose connections, corrosion
Circuit Breaker Reset: Locate breaker, push reset button, test operation

CAUTION! Always disconnect battery before electrical work.

Fuel System Maintenance

Proper care of fuel system components.

Fuel Filter: Replace every 200 hours or when clogged
Fuel Lines: Inspect for cracks or leaks regularly
Carburetor: Clean every 100 hours or when performance decreases
Fuel Stabilizer: Add for storage periods over 30 days
Tank Cleaning: Drain and clean annually

Parts Replacement Guide

Genuine Fuji parts and replacement procedures.

Part Number	Description	Replacement Interval
FG-5001	Spark Plug	200 hours
FG-5002	Oil Filter	100 hours
FG-5003	Air Filter	50 hours
FG-5004	Fuel Filter	200 hours
FG-5005	Drive Belt	500 hours
FG-5006	Voltage Regulator	As needed

Warranty Information

Fuji Generator limited warranty coverage.

Residential Use: 3 years limited warranty
Commercial Use: 1 year limited warranty
Coverage: Parts and labor for manufacturing defects
Exclusions: Normal wear, improper maintenance, accidents
Registration: Required within 30 days of purchase

For warranty claims: Contact Fuji Customer Service at 1-800-FUJI-GEN

Troubleshooting Guide

Problem	Cause	Solution
No power output	Circuit breaker tripped	Reset breaker, reduce load
Engine stalls under load	Clogged fuel filter	Replace fuel filter
Low voltage output	Faulty voltage regulator	Test and replace regulator
Excessive noise	Loose components	Tighten all bolts and mounts
Battery not charging	Bad alternator	Test and replace alternator
Fuel leakage	Cracked fuel lines	Replace fuel lines
Overheating	Dirty cooling system	Clean cooling fins and vents

Technical Support: 1-800-FUJI-GEN (1-800-385-4436)

Online Resources: www.fujigenerators.com/support