EA190V - Subaru Industrial Power Products

EA190VSERVICE MANUAL

This manual contains information on how to routine maintain and how to do troubleshooting.Keep service manual handy, so you can refer to it at any time.This service manual describes correct methods of maintaining this engine. As a result of person casualtyand equipment damaged caused by the disregard for the rules, our company does not assume anyresponsibility.NOTICE:Copyright reserved, and no part of this publication may be reproduced without Fuji Heavy Industries Ltd’swritten permission.Safety MessagesYour safety and the safety of others are very important. We have provided important safety messages inthis manual and on the engine. Please read these messages carefully.A safety message alerts you to potential hazards that could hurt you or others. Each safety message ispreceded by a safety alert symboland 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.

I. PARTS DESCRIPTION.11-1 Part description .11-1-1 Feature .11-1-2 Model & serial number.11-2 Specification .21-3 Service limit.3II. DIMENSION AND TORQUE .42-1 Engine dimension .42-1-1 Appearance dimension.42-1-2 Installation hole position .52-1-3 P.T.O dimension figure .52-2 Torque value .62-3 Standard torque value .72-4 Important bolt torque value.7III. MAINTENANCE .83-1. Maintenance schedule.83-2 Change oil.93-3 AIR CLEANER .103-4 Fuel parts .103-4-1 Strainer clean .103-4-2 Fuel check. 113-5 Spark Plug Service.123-6 Valve clearance adjustment.133-7 Governor adjusting .14IV. DISASSEMBLING AND SERVICING.164-1 Troubleshooting.164-1-1 Starting difficult.164-1-2 Power lack .174-1-3 Speed unstable .184-1-4 Unable igniting .194-1-5 Engine overheat .194-1-6 Abnormal sound .204-1-7 Exhaust gas color abnormal.204-2 Preparation of servicing.214-2-1 Safety precautions .214-2-2 Special tools.214-3 Engine .224-3-1 Recoil starter /housing.224-3-2 Fuel tank .234-3-3 Ignition coil/flywheel .244-3-4 Muffler.264-3-5 Air cleaner .274-3-6 Carburetor.284-3-7 Throttle control .324-3-8 Cylinder head/valve train.334-3-9 Crankcase cover/governor gear .384-4-10 Crankshaft/piston/crankcase .394-5 Electric diagram.46

I. PARTS DESCRIPTION1-1 Part description1-1-1 FeatureOil dipstickSpark plugMufflerDrain plugStarter handleAir cleanerFuel tank capFuel tankEngine stop switchChokeFuel Valve1-1-2 Model & serial numberEngine modelSerial number1

1-2 SpecificationModelEA190SpecificationL W H(not including crankshaft outputterminal)425 360 290mmDry Weight14kg (iron flywheel) or 13kg (aluminum flywheel)Engine TypeSingle cylinder vertical,4-stroke,（OHC）Displacement189mlBore Stroke68mm 52mmTheoretical Maximum Power3.72kW/3,600r/minRecommended Using Power3.5 kW/3,400r/minMaximum Torque11.2N·m /2,500r/minFuel Consumption395g/Kw·hCooling SystemForced airIgnition SystemCapacitance discharge typePTO Shaft RotationCounterclockwise view from P.T.O. side2

1-3 Service limitUNIT：mmPartsEngineItemMaximum speed (No load)Cylinder compressionCylinder headSleeve I.DCylinder headFlatnessPistonStandardService limit3800 100rpm1.15Mpa at 1200rpm3650/4000-68.00-68.02Skirt O.D.Piston – to cylinder clearancePiston pin bore I.D.Piston pin O.DPiston pin-to-piston pin bore 45015.9400.0600.04 0.08/0.04 0.082.60 0.10/2.80 0.100.13 0.28/0.20 0.400.1502.3001.000Piston ringsRing side clearance: first/ secondRing width： first/secondRing end gap: first/secondConnectingrodSmall end I.DBig end I.DBig oil clearanceBig end side 0.716.09030.0660.1201.100CrankshaftCrankshaft pin 423.73027.6309.0909.00-9.049.190.6-0.7-Primary coil0.8-1.0 Ω-Secondary coil5.9-7.2 kΩ-（at flywheel）0.35 0.45mm-Valve clearanceStem O.DValveGuide I.DStem clearanceSeat widthSpring free lengthCam heightCamshaftJournal I.DCamshaftCamshaft I.D.Spark plugGapResistanceIgnition coilAir gap3

II. DIMENSION AND TORQUE2-1 Engine dimension2-1-1 Appearance dimension4

2-1-2 Installation hole position2-1-3 P.T.O dimension figure5

2-2 Torque valueNo.ItemSpecificationPerformance classTorque value（N·m ）1Cylinder headM8 6510.928 22Crankcase coverM6 308.810 13Oil drain plugM10 158.822 24Connecting rodM6 3510.913 15Valve locking nutM588 16Governor gearM6 168.810 2878 4868 4M14 1.258.828 2M6 128.8M6 808.8M6 128.8M6 128.8M6 208.8M6 208.8M6 688.8M14 (iron flywheel）7FlywheelM14 (aluminumflywheel）8Spark plug9Valve cover10Breath groove covering plate11Brake12Ignition coil13Stud supporting boltM6 838.810 214Lower shellM6 168.810 215Muffler studM8 1098.825 216Muffler nutM8825 217Air cleanerM688 218Throttle controlM6 128.810 219Governor support lock nutM687 120Recoil starterM688 221Fuel tank8.88 288 222Engine housing8.86 2M6 25M6M5 20Notice: For unspecified bolt, screw and nut, refer to the standard torque value610 210 210 210 2

2-3 Standard torque valueFastenersBolt and nutThread dia.(mm)Torque value（N·m）5mm bolt, nut4.5-66mm bolt, nut8-128mm bolt, nut18-2510mm bolt, nut29-3412mm bolt, nut49-594mm screw1.5-2.65mm screw3.5-56mm screw7-115mm flange bolt3.6-6.96mm screw7-115mm flange bolt3.6-6.96mm flange bolt10-148mm flange bolt20-2610mm flange bolt35-452-4 Important bolt torque valueItemThread dia.(mm)Torque valueN·mKg·m1.3Connecting rod boltM6 1.013Cylinder head boltM8 1.5282.8Flywheel nutM14 1.5646.4Crankcase cover boltM6 1.0101.0Valve locking nutM5 0.580.87

III. MAINTENANCE3-1. Maintenance scheduleGood 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 anymaintenance. If the engine must be run, make sure the area is well ventilated.Periodic maintenance and adjustment is necessary to keep the engine in good operating condition. Perform the serviceand inspection at the intervals shown in the Maintenance schedule below:Maintenance scheduleFrequencyItemEngine oilOilchecklevelEachtimeAir cleanerEvery 6months or100 hrsEach year or300 hrs ReplaceCheckEachseason or50 hrsFirst monthor 20 hrs Clean –replaceCheck, clean Adjust Clean Spark plugFuel ust *Clean *Fuel tankReplaceCylinderClean carbonhead/pistondepositEvery 3 yearsEach 150 hours*“*” This items should be serviced by company authorized dealer, unless you have the proper tools andmechanically proficient.NOTICEService more frequently when used in dusty areas.8

3-2 Change oil·change oilNOTICE:Drain the engine oil rapidly and completely out when theengine is hot.（1）Remove the drain plug and washer and tilt the engine todrain engine oil thoroughly.（2）Reinstall the drain plug and washer into securely by hand.（3）Tighten the oil drain plug，EA190 torque value: 20-24N.m.（4）Remove the dipstick and wipe up oil.（ 5 ） Refill the recommended clean oil （ EA190 enginecapacity：0.6L）and check oil level.Lay the engine and place it on the level ground when checking.Check as following:a). Insert the dipstick into the filling hole without screwingdown and check the oil level.b). If the oil level is too low, add the recommended engine oilup to the oil upper limit.c).Reinstall the dipstick and screw down.WasherDrain plugOil dipstickUpper limitLower limitFigureSAE VISCOSITY CLASSNOTICE:30Use 4-stroke engine oil, API service classification SE class orequivalent. Always check the API service label on the oilcontainer to assure it includes the letters SE or equivalent.10W - 305W - 30- 2040200- 20- 1006010208030100 F40 ENVIRONMENT TEMPERATURESAE10W-30 is recommended for general use. Otherviscosities 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. Additive-free and 2-strokeengine oil will damage the engine.NOTICE: For environment protecting, please properly handle with the used oil. Running with insufficient engine oilmay 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 prolongedperiods. Although this is unlikely unless you handle used oil on a daily basis, it is still advisable tothoroughly wash your hands with soap and water as soon as possible after handling used oil.9

3-3 AIR CLEANERNOTICE: A dirty air cleaner will restrict air flow to the carburetor. To prevent carburetor malfunction, clean the aircleaner each 50 hours (or three months) and service the air cleaner regularly. Service more frequently when operating theengine 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.Air cleaner shellConnecting boltNut M6Air cleaner baseAir cleanerelement① Screw off the connecting bolt and remove the air cleaner shell.② Remove foam element or paper element. Be careful to prevent dirt and debris from falling into the air cleaner basewhen opening,③ Clean the elementFoam element: Clean the foam with detergent, and then blow it dry with compressed air or squeeze it dry. Dip the elementin clean oil, and then forcefully squeeze it dry and install it back.Paper element: Tap the element lightly several times on hard surface to remove excess dirt or blow compressed air lightlyfrom the inside out. If dirty, replace in time.CAUTION: Foam element containing too much oil will jam the foam element holes.④ Check, clean or replace damaged air cleaner parts.⑤ Reassemble the air cleaner element into the shell, install foam element or paper element back, cover the shell on andscrew in the connecting bolt.3-4 Fuel partsBolt M6 25Fuel tankDon’t smoke or use flame fires nearthe flammable solvent.Tank cap3-4-1 Strainer clean(1) Drain the fuel into the container.(2)Loose the clip, remove fuel tube and pull the strainer out.(3) Check the strainer for damaged and clean the strainer inthe container.(4) After cleaning, reinsert the strainer in the fuel tank, Clipconnect fuel tube and tighten the clips.NOTICE:Check all connecting position for leaking.Fuel GaugeClipStrainerClipClipTubeTube10