Subaru EA190V User manual

EA190V
SERVICE MANUAL

This manual contains information how to routine maintain and how to do troubleshooting.
Keep this owner’s manual handy, so you can refer to it at any time.
This service manual describes correct method of the maintaining this equipment. As a result of this
disregard for the our rules caused by person casualty and equipment damaged, our company does not
assume any responsibility
NOTICE:
Copyright reserved, and no part of this publication may be reproduced without RATO Company’s
written permission.
Safety Messages
Your safety and the safety of others are very important. We have provided important safety messages in
this manual and on the generator. Please read these messages carefully.
A safety message alerts you to potential hazards that could hurt you or others. Each safety message is
preceded by a safety alert symbol and one of three words: DANGER, WARNING, or CAUTION.
These mean:
You WILL be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be KILLED or SERIOUSLY HURT if you don’t follow instructions.
You CAN be HURT if you don’t follow instructions.
Your engine or other property could be damaged if you don’t follow instructions.

CONTENT
1. INTRODUCTION
1. PARTS DESCRIPTION..............................................................................................................................................5
1-1 Part description .................................................................................................................................................5
1-1-1 Feature ...................................................................................................................................................6
1-1-2 Model & serial number..........................................................................................................................6
1-2 Specification .....................................................................................................................................................6
1-3 Service limit......................................................................................................................................................7
II. DIMENSION AND TORQUE.................................................................................................................................. 8
2-1 Engine dimension .............................................................................................................................................8
2-1-1 Appearance dimension...........................................................................................................................8
2-1-2 Installation hole position .......................................................................................................................9
2-1-3 P.T.O dimension figure ......................................................................................................................... 9
2-2 Torque value ...................................................................................................................................................10
2-3 Standard torque value .....................................................................................................................................11
2-4 Important bolt torque value ............................................................................................................................11
III. MAINTENANCE ................................................................................................................................................... 12
3-1. Maintenance schedule.................................................................................................................................... 12
3-2 Change oil.......................................................................................................................................................13
3-3 AIR CLEANER..............................................................................................................................................14
3-4 Fuel parts ........................................................................................................................................................14
3-4-1 Strainer clean.......................................................................................................................................14
3-4-2 Fuel check............................................................................................................................................15
3-5 Spark Plug Service..........................................................................................................................................16
3-6 Valve clearance adjustment....................................................................................................................... 17-18
3-7 Governor adjusting .........................................................................................................................................19
3-8 Setting the timing chain----------------------------------------------------------------------------------------------------------20
IV. DISASSEMBLING AND SERVICING.........................................................................................................................21
4-1 Troubleshooting...................................................................................................................................................... 21
4-1-1 starting difficult ...........................................................................................................................................21
4-1-2 Power lack ...................................................................................................................................................22
4-1-3 Speed unstable.............................................................................................................................................23
4-1-4 Unable igniting ............................................................................................................................................24
4-1-5 Engine overheat...........................................................................................................................................24
4-1-6 Abnormal sound ..........................................................................................................................................25
4-1-7 Exhaust gas color abnormal.........................................................................................................................25
4-2 Preparation of servicing..........................................................................................................................................26
4-2-1 Safety precautions .......................................................................................................................................26
4-2-2 Special tools ................................................................................................................................................26
4-3 Engine.....................................................................................................................................................................27
4-3-1 Recoil starter /housing.................................................................................................................................27
4-3-2 Fuel tank......................................................................................................................................................28
4-3-3 Ignition coil/flywheel .............................................................................................................................29-31
4-3-4 Muffler.........................................................................................................................................................32
4-3-5 Air cleaner ...................................................................................................................................................33
4-3-6 Carburetor...............................................................................................................................................34-36
4-3-7 Throttle control............................................................................................................................................37
4-3-8 Cylinder head/valve train .......................................................................................................................38-41
4-3-9 Crankcase cover/governor gear ...................................................................................................................42
4-3-10 Crankshaft/piston/crankcase.................................................................................................................43-48
4-4 Electric diagram......................................................................................................................................................49

5
1. PARTS DESCRIPTION
1-1 Part description
1-1-1 Feature
Starting lever
Air cleaner
Fuel tank cap
Fuel tank
Engine switch
Drain plug
Spark plug
Muffler
Oil dipstick

6
1-1-2 Model & serial number
1-2 Specification
 Model
Specification EA190
L×W×H
(not including crankshaft output terminal)
425×360×290mm
Dry Weight 11.5 or 14.5kg
Engine Type single cylinder horizontal,4-stroke,（OHC）
Displacement 189ml
Bore × Stroke 68mm×52mm
Theoretical Maximum Power 3.72kW/3,600r/min
Recommended Using Power 3.5 kW/3,400r/min
Maximum Torque 11.2N·m /2,500r/min
Fuel Consumption 395g/Kw·h
Cooling System Forced air
Ignition System capacitance discharge type
PTO Shaft Rotation vertical shaft output
Engine model
Serial number

7
1-3 Service limit
UNIT：mm
Parts Item Standard Service limit
Engine Maximum speed (No load)
Cylinder compression
3800±100rpm
1.15Mpa at 1200rpm
-
-
Cylinder head Sleeve I.D 68.00-68.02 68.160
Cylinder head War page 0-0.05 0.100
Piston
Skirt O.D.
Piston – to cylinder clearance
Piston pin bore I.D.
Piston pin O.D
Piston pin-to-piston pin bore clearance
67.989-67.971
0.011-0.049
16.004-16.01
15.994-16.00
0.004-0.016
67.850
0.120
16.450
15.940
0.060
Piston rings
Ring side clearance: first/ second
Ring width： first/second
Ring end gap: first/second
0.04～0.08/0.04～0.08
2.60±0.10/2.70±0.10
0.13～0.28/0.20～0.40
0.150
2.300
1.000
Connecting
rod
Small end I.D
Big end‘I.D
Big oil clearance
Big end side clearance
16.005-16.021
30.000-30.018
0.019-0.049
0.4-0.7
16.090
30.066
0.120
1.100
Crankshaft Crankshaft pin O.D 29.969-29.981 29.910
Valve
Valve clearance
Stem O.D
Guide I.D
Stem clearance
Seat width
Spring free length
IN
EX
IN
EX
IN
EX
IN
EX
0.10-0.15
0.15-0.20
5.440-5.455
5.430-5.445
5.500-5.520
5.500-5.520
0.045-0.080
0.055-0.090
0.85
30.50
0.4
0.4
5.310
5.300
5.590
5.590
0.100
0.120
2.000
28.500
camshaft
Cam height
Journal I.D
IN
EX
23.98
27.88
9.00-9.04
23.730
27.630
9.090
camshaft
spindle camshaft spindle O.D 8.96-8.98 8.910
Spark plug Gap 0.7-0.8 -
Ignition coil
Resistance
Air gap
Primary coil
Secondary coil
（at flywheel）
0.8-1.0 Ω
5.9-7.2 kΩ
0.40~0.60mm
-
-
-

8
II. DIMENSION AND TORQUE
2-1 Engine dimension
2-1-1 Appearance dimension

9
2-1-2 Installation hole position
2-1-3 P.T.O dimension figure
Engine Mounting Face

10
2-2 Torque value
Notice: For unspecified bolt, screw and nut, refer to the standard torque value
No Item Specification Performance class
Torque value (N·m)
1 Cylinder head M8×65 10.9 26±2
2 Crankcase cover M6×30 8.8 10±2
3 Oil drain plug M10×15 8.8 22±2
4 Connecting rod M6×35 10.9 13±1
5 Valve locking nut M5 8 6±2
6 Governor gear M6×16 8.8 10±2
M14
(iron flywheel） 8 78±4
7 Flywheel M14
(aluminum flywheel) 8 64±4
8 Spark plug M14×1.25 8.8 22±2
M6×12 8.8
9 Cylinder head cover
M6×80 8.8
8±2
10 Breath groove covering
plate M6×12 8.8 10±2
M6×12 8.8
11 Brake
M6×20 8.8
10±2
M6×20 8.8
12 Ignition coil M6×68 8.8 10±2
13 Stud supporting bolt M6×80 8.8 10±2
14 Lower shell M6×16 8.8 10±2
15 Muffler stud M8×109 8.8 12±2
16 Muffler nut M8 8 22±2
17 Air cleaner M6 8 8±2
18 Throttle control M6×12 8.8 10±2
19 Governor support lock nut M6 8 8±2
20 Recoil starter M6 8 8±2
M6×25 8.8 5±1
21 Fuel tank
M6 8 8±2
22 Engine housing M5×20 8.8 6±2

11
2-3 Standard torque value
Fasteners Thread dia.(mm) Torque value（N·m）
5mm bolt, nut 4.5-6
6mm bolt、nut 8-12
8mm bolt、nut 18-25
10mm bolt、nut 29-34
12mm bolt、nut 49-59
4mm screw 1.5-2.6
5mm screw 3.5-5
6mm screw 7-11
5mm flange bolt 3.6-6.9
6mm screw 7-11
5mm flange bolt 3.6-6.9
6mm flange bolt 10-14
8mm flange bolt 20-26
Bolt and nut
10mm flange bolt
35-45
2-4 Important bolt torque value
Torque value
Item Thread dia.(mm) N·m Kg·m
Connecting rod bolt M6×1.0 13 1.3
Cylinder head bolt M8×1.5 26 2.6
Flywheel nut M14×1.5 52 5.2
Crankcase cover bolt M6×1.0 10 1.0
Value locking nut M5×0.5 6 0.6

12
III. MAINTENANCE
3-1. Maintenance schedule
Good maintenance is essential for safe, economical, and trouble-free operation. It will also help reduce air pollution.
Exhaust gas contains poisonous carbon monoxide. Shut off the engine before performing any
maintenance. If the engine must be run, make sure the area is well ventilated.
Periodic maintenance and adjustment is necessary to keep the generator in good operating condition. Perform the service
and inspection at the intervals shown in the Maintenance schedule below:
Maintenance schedule
“*” This items should be serviced by company authorized dealer, unless you have the proper tools and
mechanically proficient.
NOTICE
Service more frequently when used in dusty areas.
Fre quency
Item
Each
time
First month
or 20 hrs
Each season
or 50 hrs
Every 6 month
or 100 hrs
Each year
or 300 hrs
Oil level
check √
Engine oil
Replace √ √
Check √
Air cleaner
Clean
–replace √
Check, clean
√
Spark plug Adjust √ Replace
Fuel strainer Clean √
Valve
clearance Check-adjust
√*
Cylinder
head Clean √*
Fuel tank Replace Every 3 years
Cylinder
head/piston
Clean carbon
deposit Each 150 hours*

13
3-2 Change oil
·Change oil
NOTICE:
Drain the engine oil rapidly and completely out when the
engine is hot.
(1) Remove the oil dipstick, drain plug and washer and tilt the
engine to drain engine oil thoroughly.
(2) Reinstall the drain plug and washer screw in it securely by
hand.
(3) Tighten the oil drain plug，EA190 torque value：20-24N.m.
(4) Remove the dipstick and clean oil.
(5) Refill the recommended clean oil and check oil level. Stop
the engine and place it on the level ground when checking.
EA190 engine capacity：0.6L ；
Check as following：
a) Insert the dipstick into the filling hole without screwing
down and check the oil level.
b) If the oil level is too low, add the recommended engine oil
up to the oil upper limit.
c) Reinstall the dipstick and screw down.
NOTICE:
Use 4-stroke engine oil, API service classification SE class
or equivalent. Always check the API service label on the oil
container to be sure it includes the letters SE or equivalent.
SAE10W-30 is recommended for general use.
Other viscosities shown in the chart may be used when the
average temperature in your area is within the indicated range.
Recommend user to use SF class or equivalent.
WARNING: Engine oil is a major factor affecting engine performance and service life. Non-detergent and 2-stroke
engine oils will damage the engine
NOTICE: For environment protecting, please properly handle with the used oil. Running with insufficient engine oil
may damage the engine severely and it will not be covered the range of the warranty
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged
periods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable to
thoroughly wash your hands with soap and water as soon as possible after handling used oil.
Lower limit
Upper limit
Figure
Washer
Oil dipstick Drain plug
SAE
VISCOSITY CLASS
ENVIRONMENT TEMPERATURE

14
3-3 AIR CLEANER
NOTICE: A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, clean the air
cleaner each 50 hours (or three month) and service the air cleaner regularly. Service more frequently when
operating the generator in extremely dusty areas.
Using gasoline or flammable solvent to clean the filter element can cause a fire or explosion.
Use only soapy water or nonflammable solvent.
Never run the engine without the air cleaner. Rapid engine wear will result.
(1) Urethane Foam Element
・Remove the element and wash it in a solution of mild detergent and warm water. Then rinse the element thoroughly in
clean water. Allow the element to dry thoroughly. Apply a tablespoon (6cc) of motor oil to the clean and dry foam
element and squeeze the element several times to distribute the oil evenly throughout the foam. Then squeeze the
foam element in a paper towel to absorb any excess oil.
(2) Dual Element Type
・For urethane foam, remove it from the paper element and wash it thoroughly with detergent. Then dry it before
installing.
・For the paper element, clean by blowing on it with compressed air from the inside or tapping on it gently to remove
dirt. Change the paper element when doing this fails to remove the dirt.
CAUTION: Polyurethane element containing too much oil will jam the strainer holes.
3-4 Fuel parts
Don’t smoke or use flame fires near
the flammable solvents.
3-4-1 Strainer clean
(1) Put the fuel into the container
(2) Lose the clip, remove oil tube and pull the strainer
out.
(3) Check the strainer for damaged and clean the
strainer in the container.
(4) After cleaning, reassemble the strainer on the fuel
tank connect oil tube and tighten the clip.
NOTICE:
Check all connecting position for leaking.
Furl tank
Tube
Strainer
Clip
Clip
Clip
Bolt M6×25
Tank cap
Air cleaner shell
Air cleaner
element
Nut M6
Air cleaner seat
Urethane Foam Element
Paper Element
Element Holder

15
3-4-2 Fuel check
1) Remove the fuel tank cap and check fuel level.
2) If the level is too low, refuel the tank. Remember
adding fuel, but, not over the fuel upper level.
WARNING ：
1) Gasoline is extremely flammable and is explosive under certain conditions.
2) Refueling in a well-ventilation area with the engine stopped. Do not smoke and allow flames or sparks
in the area where gasoline is stored or where the fuel tank is refueled.
3) Do not overfill the fuel tank (The fuel will not exceed 3/4 of the fuel tank). After refueling, make sure
the fuel tank cap is set back securely.
4) Be careful not to spill fuel when refueling. Spilled fuel or fuel vapor may ignite. If any fuel is spilled,
make sure the area is dry before starting the engine.
5) Avoid repeated or prolonged contact with skin or breathing of fuel vapor.
6) Keep out of reach of children.
EA 190 fuel tank capacity：1.0L
Only use unleaded gasoline and recommend gasoline grade # 90 over.
Unleaded gasoline can reduce gasoline engine carbon deposit and prolong the exhaust system service
life.
Never use contaminated gasoline or mixed gasoline with oil. Don’t allow the dust, foreign matter or
water entering into fuel tank.
CAUTION:
Fuel may damage the oil paint and plastic. Be careful not to spill fuel when refueling. Any damage due
to fuel spilling is not within valid warranty.
"Light knocking" or "spark exploding" sound can be hear when the engine overloading. It is normal. Do
not be worry about that.
If " knocking" or "spark exploding" sound occur at a steady speed under normal load, change grade of
gasoline; if such phenomena still happen, consult your dealer for help, otherwise the engine may be
damaged.
CAUTION:
When the engine is running, continuously "Knocking" or "spark exploding" sound occurring will
damage engine.
"Knocking" or "spark exploding" sound from misusing will not be within the valid warranty.
Fuel tank Fuel
U
（
）
pper limit 3/4position of the fuel tank

16
0.70~0.80mm
Side electrode
3-5 Spark Plug Service
Remove the spark plug cap. Clear away dirt around the
spark plug base;
Use the plug wrench to remove the spark plug;
Visually inspect the spark plug if the insulator is cracked,
if cracked, replace with new the spark plug, if deposit
around the electrode, Remove carbon or other deposits
with a stiff wire brush;
Measure the spark plug clearance with a feeler. The
clearance should be 0.7~0.8mm.
If needing adjusting, lightly tap (for gap too big) or pry
up with flat screwdriver (for gap too small) electrode.
Check that the spark plug washer is in good condition.
Install the spark plug on and screw down it with plug
wrench, compress the plug washer. Cover the spark plug
cap on.
NOTICE:
To avoid cross-threading, first, screw in spark plug by
hand, then tighten with a spark plug wrench to compress
the gasket.
If a new spark plug is used, more twist 1/2 turns after
compressing the gasket
If reinstalling the used spark plug, just more twist
1/8-1/4 turns.
Spark plug torque value：22±2N·m
The spark plug must be tightened securely, or it may
become very hot to damage the engine.
When replaced, please pay attention to model of the spark plug to avoid to damage the engine or use
recommended spark plug or the equivalent. Incorrect heat range of the spark plug may damage the
engine
·EA190 recommended spark plug model：NGK—————BPR6HS or BPR7HS
CHAMPION——RL82YC or RL87YC
TORCH————E7RTC or E6RTC
Plug wrench Spark plug cap

17
3-6 Valve clearance adjustment
Keep the clearance between engine valve rod end and driving parts for avoiding heat expanding and
cold shrinking to effect engine performance.
If the valve is too big, it can result in exhausting unsmooth, effecting engine performance and
increasing engine noise (valve abnormal), if the valve is too small, the valve will close untighten to
make the engine operating abnormal and drain valve operating face burn.
After operating one year or 300h, check and adjust the valve.
(1) Dismount the spark plug cap, spark plug, cylinder head cover bolt, cylinder head cover and gasket in
order.
CAUTION:
After the cylinder head cover is removed, engine oil may flow. Be sure to wipe up any flowed oil.
(2) Lightly pull the starting rope and set the piston at top dead
center of the compression stroke (insert screwdriver into the
hole of the spark plug hole to check the height of piston.)
(3) Measure the valve clearance： Insert the feeler into the
clearance to measure clearance.
Adjust if the valve clearance is out of the service limit.
CAUTION:
Measure the valve clearance in the cold the engine state.
Valve clearance IN：0.10-0.15mm
EX：0.15-0.20mm
Dowel Φ10×14 Cylinder head gasket
Stud M6×105
Stud M6×109
Spark plug
Cylinder head assy.
Bolt
Cover gasket
Head cover
Bolt M6×80
Bolt M6×12
Feeler
Screwdriver

18
(4) If adjustment is necessary, proceed as follows:
a) Hold valve adjusting bolt with tongs and loosen the valve lock nut
b) Turn valve adjusting bolt to obtain the specified clearance.
c) Fix the valve adjusting bolt with tongs, then fix the valve lock nut with spanner.
d) Recheck valve clearance after tightening the valve lock nut——torque value ：6±2N.m
e) Set the new gasket aligning the projection of the new gaskets with the projection of the cylinder head;
f) Install the cylinder head cover and tighten the four bolts to the specified torque.
bolt torque value ：8±2N.m
Adjusting bolt — screw in: valve clearance becomes smaller
Adjusting bolt — screw out: valve clearance becomes bigger
CAUTION:
Clearance too big: Intake and exhaust valve opening delay will shorten the intake and exhaust time, lower
the opening height of the valve and change normal distributing phase to result in power lowering from the
intake lack and exhaust incomplete. Furthermore, also make vale train parts knock increasing and wearing
quick.
Clearance too small: After running, engine parts will be heated to expand and push the valve open,
making the engine closing not tight and result in leaking, power lowering, serious carbon deposit or burn
on the valve surface, even valve impacting the piston.
Adjusting bolt
Lock nut
Rocker shaft
Rocker
Rocker

19
3-7 Governor adjusting
● Governor adjusting：
(1) Dismount the air cleaner
(2) Loosen the nut M6. Be sure that the carburetor throttle valve is fully open
(3) Rotate the governor arm shaft fully to the right (governor fully open position) to bottom by pressing
governor support, and retighten the nut., torque value: 10N.m
(4) Check to see that the governor support and throttle valve move freely.
(5) Check the maximum engine speed
●Adjusting speed：
Don’t adjust the speed because it is fixed speed. If necessary, please have it to the theorized dealer for
adjusting. If the user has an proper tools and repairing capacity, only permit the following operation:
(1) Start the engine and allow it to warm up to normal operating temperature.
(2) If the maximum speed is not conformed to specified value, adjust throttle control and hole position of
the support by adjusting governor spring.
EA190 engine maximum speed： 3800±100rpm
WARNING:
The engine has adjusted to specified speed when manufactured in the factory, if the wrong adjusted from
the user to cause the performance of the engine, it is not covered the warranty of our company.
Governor support
Throttle valve
Governor arm
Nut M6
Throttle control assy.
Governor spring

20
3-8 Setting the timing chain
・Align the timing mark on the crankshaft sprocket with the mark plate of the timing chain.
・Align the timing mark hole on the camshaft sprocket with the mark plate of the opposite end of the
timing chain.
Mark plate
Mark plate
Timing mark hole
*The mark plate does not
have a camshaft side or
crankshaft sprocket side.
Sprocket for governor gear Camshaft sprocket
Pin (Camshaft)
Washer
M5 x 8 BOLT : 1 pc.
Bolt used to prevent the
pin (camshaft) from coming out
C
rankshaft
sprocket
Timing mark