EMAK EF 95, EF 105, OM 125, EF 125, OM 95 Workshop Manual

WORKSHOP MANUAL

Garden Tractor:

EF 95 - EF 105 - EF 125 -

OM 95 - OM 105 - OM 125

Workshop manual

2

Workshop manual

1 Foreword .................................................................................................................... 5

2 General ....................................................................................................................... 6

2.1 Safety instructions ............................................................................................... 6

3 Maintenance and care ............................................................................................... 7

3.1 Maintenance table .............................................................................................. 7

3.2 Lubricating plan .................................................................................................. 8

3.2.1 Front axle ............................................................................................................... 8

3.2.2 Steering .................................................................................................................. 8

3.2.3 Front and rear wheels ............................................................................................ 8

3.2.4 Tensioning pulley rocker / pivoting and bearing points .......................................... 9

3.3 Oil change .......................................................................................................... 9

3.4 Air filter / spark plug ............................................................................................ 9

3.5 Tyre pressure ..................................................................................................... 10

3.6 Hydrostatic transmission ..................................................................................... 10

3.7 Starter battery (12V / 17 Ah) ............................................................................... 11

3.8 Troubleshooting plan .......................................................................................... 13

3.8.1 Table troubleshooting plan ..................................................................................... 13

3.8.2 Fault display and fault elimination .......................................................................... 15

4 Disassembly............................................................................................................... 18

4.1 Bonnet ................................................................................................................ 18

4.2 Discharge channel .............................................................................................. 18

4.3 Mowing implement .............................................................................................. 19

4.3.1 Disassembling the mowing implement ................................................................... 19

4.3.2 Replacing the blade ............................................................................................... 21

4.3.3 Replacing V-Belt mowing implement ..................................................................... 22

4.3.4 Replacing the bearing (blade change) ................................................................... 26

4.3.5 Replacing the tensioning pulley ............................................................................. 27

4.3.6 Disassembling the blade brake clutch ................................................................... 28

4.3.7 Replacing the mowing implement feeler rollers ..................................................... 28

4.4 Steering .............................................................................................................. 29

4.4.1 Disassembling the steering sector ......................................................................... 29

4.4.2 Disassembling the steering column ....................................................................... 29

4.4.3 Replacing the tie rod .............................................................................................. 30

4.5 Propulsion .......................................................................................................... 30

4.5.1 Removing the floor cover of the vehicle frame ...................................................... 30

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Workshop manual

4.5.2 Removing the propulsion belt ................................................................................. 31

4.5.3 Disassembling tensioning pulleys and idler pulleys ............................................... 34

4.6 Electrical grass catcher emptying ........................................................................ 34

4.7 Electric system .................................................................................................... 35

4.7.1 Replacing headlight bulb ........................................................................................ 35

4.7.2 Starter battery ......................................................................................................... 35

4.7.3 Ignition/starter switch .............................................................................................. 36

4.7.4 Removing the start relay ......................................................................................... 36

4.7.5 Removing the relay ................................................................................................. 36

4.7.6 Fuses ...................................................................................................................... 37

4.7.7 Level buzzer / level switch ...................................................................................... 37

4.7.8 Control panel control elements ............................................................................... 38

4.7.9 Transmission switch ............................................................................................... 40

5 Circuit diagrams ........................................................................................................ 42

5.1 Lawn tractor with rear discharge and electronic system ...................................... 42

5.2 Lawn tractor with rear discharge without electronic system ................................. 44

6 Adjustment work ........................................................................................................ 46

6.1 Mowing implement adjustment ............................................................................ 46

6.2 Grass catcher ...................................................................................................... 47

6.3 Brake adjustment ................................................................................................ 47

6.4 Propulsion pedals................................................................................................ 48

6.5 Fine adjustment of the steering ........................................................................... 49

6.6 Steering sector adjustment .................................................................................. 49

7 Torque setting ............................................................................................................ 50

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Workshop manual

1 Foreword

This handbook contains all the information required for maintenance and repair of Efco and Oleo-Mac lawn tractors.
The individual working processes are explained with comprehensive descriptions and illustrations.

Here, we do not discuss work that can be done without special knowledge (such as changing wheels). During the
disassembly and assembly work, ensure that you follow the instructions for removal/installation.

All the information, illustrations, guidelines and descriptions contained in this document comply with the latest state
of the data that was available for the product at the time of going to press.

Emak reserves the right to make changes, at any time and without prior notice, without obligations of any kind for
the company. The contents of this document may only be reproduced with written approval from Emak.

5

2 General

2.1 Safety instructions

Working on the machine does not usually represent a specific hazard. An exception is the work that involves
mechanical components. These activities should be carried out with the caution and attention that is usual
for this type of work.

In addition to observing the usual accident-prevention regulations that are typical for all mechanical
workshops,we recommend:

 Carry out maintenance, service and repair work only when the engine is switched off and cool.
 Prior to starting work, remove the ignition key and disconnect the negative terminal of the battery.
 Wear suitable protective gloves when you handle blades and sheet-metal parts.
 Avoid petrol leaking. Wipe up leaked petrol.
 Smoking prohibited in the vicinity of engine and tank.
 Secure the tractor such that persons cannot be injured from inadvertent actions.

CAUTION!

Workshop manual

Risk of accidents!

 Observe the safety instructions in the operating and engine instructions, and the safety

instructions on the unit.

Trailer:

The total weight of a trailer pulled by the tractor should not be higher than 50% of the tractor
weight including driver. For this tractor, the total weight of the trailer should not be higher than
250 kg.
The maximum towed and drawbar load is 40 kg.

6

Before

every

use

After the

first 5

operating

hours

Every

10

operating

hours

Every

25

operating

hours

Every

50 operating

hours

or yearly

Every

100

operating

hours

Checking the engine oil level

1)

X X X - -

-

Changing the engine oil

1)

- X - - X

-

Replacing the oil filter (if installed)

1).

- - - - -

X

Cleaning the air filter

1)

- - - X -

-

Replacing the air filter

1)

- - - - X

-

Checking the spark plug

1)

- - - - X

-

Checking the brake

- X X - -

-

Checking the tyre pressure

- X X - -

-

Checking the mowing blade

- X X - -

-

Checking the adjustment of the

mowing implement

- X X - -

-

Checking the hydrostatic transmission
oil level

- - - - X

-

Checking for loose parts

- X X - X

-

Checking V-belt

- - - X -

-

Charging the battery

- - - X X

-

Cleaning the air intake grille on

the engine

- - - - X

-

Removing grass and mowing residues
from the gearbox

- - - X -

-

Cleaning the gearbox cooling fan

- - X - -

-

Lubricating as shown in the lubricating
plan

- - - - X

-

Workshop manual

3 Maintenance and care

3.1 Maintenance table

Caution!

Risk of accidents!

 Carry out maintenance, service and repair work only when the motor is switched off and cool.
 Prior to starting work, remove the ignition key and disconnect the negative terminal of the

battery.

1)

See the operating instructions from

the engine manufacturer

With high stress and at high temperature reducing the
specified maintenance intervals may be necessary.

7

3.2 Lubricating plan

3.2.1 Front axle

WARNING!

To ensure the smooth operation of moving parts, we recommend lubricating the following
points every 50 operating hours / once a year.

 Lubricate the steering-axle stubs right and left

(lubricating nipples) with multi-purpose grease.

 Spray the front axle bearings on the frame with oil.
 Lubricate the ball heads with multi-purpose grease.

Remove the ball caps before you start lubrication
(See steering sector disassembly).

Workshop manual

3.2.2 Steering

 Grease toothing and bearing surface of the gear

segmentwith multi-purpose grease.

 Grease the pinion.

3.2.3 Front and rear wheels

 Lubricate roller bearings / hubs with multi-

purpose grease.

Remove the front and rear wheels before you start
lubricating the axles.

Ensure that the driving key is in place when you
install the rear wheels

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Workshop manual

3.2.4 Tensioning pulley rocker / pivoting and bearing points

Tensioning pulley rocker (mowing implement):

 Spray pivoting and bearing points with oil.

Pivoting and bearing points:

 Spray all pivoting and bearing points and the

pivoting points of the ropes with oil.

3.3 Oil change

CAUTION!

See also operating instructions from the engine manufacturer.

Use an oil drain extension to change oil conveniently.

 Have a suitable collecting container ready.

 Remove the 19-mm screw plug. Hold the oil drain

extension with a fork spanner to prevent it from
being screwed out of the engine.

CAUTION!

 Dispose of the used oil in accordance with

the legal regulations

 Never drain used oil into the sewerage

system or the soil.

 There are high fines on groundwater

pollution.

 You can deliver used oil to any petrol station,

or get the address of a disposal company
from the local authorities.

Alternatively, you can suck off the oil through
the oil filler neck.

3.4 Air filter / spark plug

CAUTION!

See also operating instructions from the engine manufacturer.

9

3.5 Tyre pressure

 Check the tyre pressure at regular intervals..

 Tyre pressure recommended: 0,9 - 1,0 bar

3.6 Hydrostatic transmission

Use a cloth, hand brush, long-handled paintbrush and compressed air to remove dirt and grass residues.
Check the oil level during the yearly service. Top up oil if necessary. (Engine oil 20W50)

Workshop manual

CAUTION!

See also operating instructions from the engine manufacturer.

Start-up after transmission repair

To ensure proper operation and full performance of the transmission, bleed the transmission
before the first start-up of the tractor.

This ensures that all air bubbles are removed that could have formed in the gearbox during the
transport of the tractor.

Procedure

 Park the tractor on a level surface and ensure that is

remains in place

 Do not apply the parking brake for this process.

 Actuate the bypass lever to disengage the transmission.

For 95 - 105 transmission:

 Pull out the bypass lever and secure it in the

upper position

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Workshop manual

For 125 transmission:

 Push in the bypass lever and secure it in the

upper position

 Sit on the operator's seat

 Start the engine and set the throttle to medium speed.

The parking brake remains released

 Press the forward accelerator pedal (a) for five seconds

 Press the rearward accelerator pedal (b) for five

seconds.

 Repeat this procedure 3 times.
 Set the throttle to idle position.
 Set the bypass lever back to drive.
 Drive the tractor 1.5 m forward and back. Repeat this

procedure 3 times.

➯ The tractor is now operational

.

3.7 Start battery (12V / 17 Ah)

The starter battery sits under the bonnet.

 For winter storage, store the starter battery in a cool and dry place (10°C - 15°C).
 Avoid storing the battery at temperatures below freezing point.
 Recharging the starter battery during a long storage period is recommended.

CAUTION!

The starter battery should not:
 Be stored in the immediate vicinity of a

naked flame

 Incinerated
 Be put on a radiator

WARNING!

Risk of explosion

Never short-circuit the connection terminals.

 Keep the starter battery clean. Wipe it only with a dry cloth.
 Do not use water, petrol, thinners or the like for this purpose!
 Keep the connection terminals clean and grease them with terminal grease.

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Workshop manual

CAUTION!

Damaging the display

 Never disconnect the starter battery while the engine is running.
 Never start the tractor with external power supply.

Charging the starter battery

Charging is required:

 Prior to storing for the winter break.
 During extended standstill of the machine (longer than 3 months).

DANGER!

Risk of explosion!

 The charging current of the charger must not be higher than 5 A and e the maximum permitted

charging voltage is 14.4 V.

 We recommend charging the maintenance-free and gas-tight starter battery with a

compatible charger.

 Charge the starter battery only in a dry room.

 Observe the operating instructions for the battery charger.

 Remove the ignition key.

 Open the engine cover.

CAUTION!

Danger of short circuit!

 Ensure that the polarity is correct.

 Red terminal = positive pole (+)

 Connect the charger terminals to the battery poles.

 Connect the charger to the mains, and switch it on.

 Black terminal = negative pole (-)

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Fault

Possible cause

Rectification

The engine does not start

Lack of fuel

 Fill up the tank

 Check tank breathing
 Fuel filter

1)

Poor quality, contaminated fuel, old fuel in tank
 Always use fresh fuel from clean containers.

Maximum storage time 30 days

 Clean the carburettor

1)

Air filter plugged

 Clean the air filter

1)

No ignition spark

 Clean the spark plug
 Replace the spark plug if necessary

 Check the ignition cables

1)

 Check the ignition system

1)

"Engine flooded" after several attempts to start
the engine

 Remove the spark plug, dry it, and screw

it back in.

The starter does not
respond

Weak or dead starter battery

 Charge the starter battery

Safety switch on operator's seat does not work

 Sit properly on the operator's seat.
 Replace seat contact switch if necessary.

Safety switch on brake pedal does not work

 Press down the brake pedal all the way
 Replace the brake contact switch if

necessary.

Safety switch on discharge channel does not
work

 The safety switch on the discharge

channel must be actuated when it is
installed properly.

 Replace the safety switch if necessary.

Mowing implement engaged

 Disengage mowing implement

Fuse (7.5A / 10A) is defective

 Check the fuse; replace fuse if necessary

Mowing performance
drops

Grass too long or too wet

 Correct cutting height (lower level)
 Reverse a short way to make space

Discharge channel/mowing implement
clogged

 Clean discharge channel / mowing

implement

WARNINNG!

Risk of accidents!

 Shut down the engine
 Disconnect the spark plug

connector

Air filter plugged

 Clean the air filter 1)

Wrong carburettor setting

 Check the setting

1)

Workshop manual

3.8 Troubleshooting plan

3.8.1 Table of troubleshooting plan

13

Fault

Possible cause

Rectification

Mowing performance
drops

Blade worn out

 Replace the blade (see replacing the blade)

Use only a genuine spare
blade

Driving speed too high

 Reduce the driving speed

Power loss

Engine speed (rpm)

 Adjust the engine (2850 rpm)

V-belt and pulley defective

 Repair and replace

Loose parts

 Repair or replace loose parts

Lawn tractor does not
move

No propulsion

 Feather key on rear axle not installed

No propulsion - bypass activated

 Set bypass lever to operating position

No propulsion - stiff movement of
tensioning rocker

 Ease the movement of the tensioning

rocker

Transmission oil level low

 Check the transmission oil level; top up if

necessary.2)

 Bleed the transmission

2).

Propulsion belt broken.

 Replace the propulsion belt

No clean cut / uneven
appearance of the cut
lawn.

Blade worn out, blunt

 Replace or regrind the blade (see

replacing the blade)

Use only a genuine spare
blade

Wrong cutting height

 Correct the cutting height (lower level)

Engine speed too low

 Set the engine speed to MAX (3000 rpm)

Driving speed too high

 Reduce the driving speed

Different pressure of the wheel tyres

 Correct the tyre pressure
 Check the mowing implement adjustment

Grass catcher does not
fill up

Cutting height too low

 Correct cutting height

Grass is too wet – it is too heavy to be
transported by the air stream

 Allow the lawn to dry before you try again

Blade worn out

 Replace or regrind the blade (see replacing

the blade)

Use only a genuine spare
blade

Mowing implement incorrectly adjusted

 Adjust the mowing implement

– Front 30 mm

– Rear 40 mm

Workshop manual

14

Fault

Possible cause

Rectification

Grass catcher does not
fill up

Grass in lawn too tall

 Mow in 2 passes

1 st pass: Maximum cutting height

2 nd pass: Desired cutting height

Fabric bag clogged – does not allow air to
pass

 Clean the fabric bag

Discharge channel / mowing implement soiled

- residues of last mowing process

 Clean discharge channel / mowing

implement

Level indicator does not
respond / responds
permanently

Mown grass stuck to fill level indicator lever

 Remove mown grass from fill level

indicator lever; ensure free lever
movement

Display

Fault

Fault description

Fault elimination

Err 01

Input seat contact

switch

Electronic system detects invalid
status of the seat contact switch

1 Switch the ignition off and back on

(position 2)

2 Sit down and stand up repeatedly

➯ Self-diagnosis; fault can clear

automatically

*

➯ Test / replace a) cable harness, b)

switch, electronic system

Err 02

Input brake
contact switch

Electronic system detects invalid
status of the brake contact switch

1 Switch the ignition off and back on

(position 2)

2 Press and release the brake pedal

several times

➯ Self-diagnosis; fault can clear

automatically

*

➯ Test / replace a) cable harness, b)

switch, electronic system

Err 03

Input mowing
implement switch

Electronic system detects invalid
status of the mowing implement
switch

1 Switch the ignition off and back on

(position 2)

2 Press the mowing implement switch

several times

➯ Self-diagnosis; fault can clear

automatically

*

➯ Test / replace a) cable harness, b)

switch, electronic system

Workshop manual

1)

See the operating instructions from the engine manufacturer

2)

See the operating instructions from the transmission manufacturer

3.8.2 Fault display and fault elimination

15

Display

Fault

Fault description

Fault elimination

Err 04

Input grass
catcher contact
switch

Electronic system detects invalid
status of the grass catcher contact
switch

1 Switch the ignition off and back on

(position 2)

2 Open and close the grass catcher

repeatedly

3 Press the grass catcher switch several

times

➯ Self-diagnosis; fault can clear

automatically

*

➯ Test / replace a) cable harness, b)

switch, electronic system

Err 05

Input transmission
switch

Electronic system detects invalid
status of the transmission switch

1 Switch the ignition off and back on

(position 2)

2 Press and release the reverse pedal

several times

3 Press the transmission switch several

times

➯ Self-diagnosis; fault can clear

automatically

*

➯ Test / replace a) cable harness, b)

switch, electronic system

Err 06

Input discharge
channel contact
switch

Electronic system detects invalid
status of the discharge channel
contact switch

1 Switch the ignition off and back on

(position 2)

2 Remove and reinstall the discharge

channel

3 Press the discharge channel contact

switch several times

➯ Self-diagnosis; fault can clear

automatically

*

➯ Test / replace a) cable harness, b)

switch, electronic system

Err 07

Output mowing
implement

Electronic system detects incorrect
status of the mowing implement
output

1 Switch the ignition off and back on

(position 1)

➯ Self-diagnosis; fault can clear

automatically

*

➯ Otherwise, test / replace the

electronic system

Err 08

Output start relay

Electronic system detects incorrect
status of the start relay output

1 Switch the ignition off and back on

(position 1)

➯ Self-diagnosis; fault can clear

automatically

*

➯ Otherwise, test / replace the electronic

system

Err 09

Output engine
solenoid valve

Electronic system detects incorrect
status of the engine solenoid valve
output

1 Switch the ignition off and back on

(position 1)

➯ Self-diagnosis; fault can clear

automatically

*

➯ Otherwise, test / replace the electronic

system

Workshop manual

16

Display

Fault

Fault description

Fault elimination

Err 10

Output ignition coil

Electronic system detects incorrect
status of the ignition coil output

1 Switch the ignition off and back on

(position 1)

➯ Self-diagnosis; fault can clear

automatically

*

➯Otherwise, test / replace the electronic

system

Err 11

Output internal
supply voltage

Electronic system detects incorrect
status of the internal supply voltage
output

1 Switch the ignition off and back on

(position 1)

➯ Self-diagnosis; fault can clear

automatically

*

➯ Otherwise, test / replace the electronic

system

Err 12

Output internal
supply

voltage monitoring
system

Electronic system detects
incorrect status of the internal

supply voltage monitoring system

1 Switch the ignition off and back on

(position 1)

➯ Self-diagnosis; fault can clear

automatically

*

➯ Otherwise, test / replace the electronic

system

LED indicator

Fault description

Fault rectification

Only green LED is ON

Normal operation, no fault

There is no fault

Green and red LEDs are
ON

Fault during current operation

Fault rectification according to fault shown on display

Only red LED is ON

Fault during previous operation or
controller fault

Fault rectification according to fault shown on display, or
check/replace electronic system

Workshop manual

* The display goes out for about 4 seconds in this case.

LED behaviour:

The LEDs sit on the display board.

 Open the bonnet
 Ignition in position 1.

 To see the LEDs, look from the left vehicle side of the engine compartment towards the display.

17

4 Disassembly

4.1 Bonnet

 Open the bonnet.

 Disconnect the cables from the light harness to the

headlights.

 Remove the C clips (2x) at the bonnet suspensions.

 Lightly swing back the bonnet, and pull down in

driving direction left of the bonnet suspension.

 Assemble in the reverse sequence.

4.2 Discharge channel

Workshop manual

The discharge channel consists of two telescopic parts.
The lower part is firmly engaged in the mower housing.
The upper part can be pulled out.

 Remove the grass catcher
 Remove the eye nuts on the left and right of the

discharge channel

 Pull out the discharge channel from the rear through

the rear wall.

 Assemble in the reverse sequence.
 Insert the discharge channel into the rear wall. Ensure

that the upper parts fits neatly into the lower part.

 Secure it with the two eye nuts.

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Workshop manual

4.3 Mowing implement

4.3.1 Disassembling the mowing implement

The mowing implement must be removed when the is
used in winter service, and when the V-belt is replaced.

 Turn the steering wheel fully to the left.

 Remove the grass catcher.

 Remove the discharge channel.

 Unscrew the cheese-head screw on the channel

holder by 5-6 turns.

 Lower the mowing implement to the lowest setting.

 Unhook the tension spring on the mowing

implement.

 Set the mower implement back up to the top.

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Workshop manual

 Swing the locking plate of the V-belt duct forward

(1).

 Swing the front part of the V-belt duct down (2).

 Lower the mowing implement back down to the

lowest setting.

 Remove the V-belt from the pulley of the blade

brake clutch.

 Remove the 4 locking pins from the holding clips of

the mowing implement.

 Pull off the holding clips over the pins.

 Set the mower implement back up to the top.
 Pull out the mowing implement from the side.

Incorrect operation in winter service

Install the discharge channel when you use
the tractor in winter service.

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Workshop manual

4.3.2 Replacing the blade

WARNING!

Risk of injuries - cutting

 Always wear protective gloves when you handle the blades.
 Wear protective goggles when you sharpen the blade.

 Unscrew the 17-mm hexagon head screw, and

remove it with serrated lock washer and washer.

 Pull off the blade with the blade retainer.

CAUTION!

 Balance a reground blade.
 Use only genuine spare blades for

replacement.

Assemble in the reverse sequence.

Tightening torque: 65 Nm

A blunt blade has a negative effect on the mowing performance and the appearance of the cut lawn. A poorly balanced
blade causes excessive vibrations during operation. A poorly balanced blade can damage the unit.

Sharpening:

 Always sharpen both edges of the blade with a

grinding disc of medium grade.

 Always sharpen at the bordered side so that only a

minimum of material is removed.

 A blade must be replaced when the wear of the blade

reaches 10 mm.

21

Balancing:

 Use a suitable measuring instrument to measure the

imbalance. Adjust until the difference between the two
blades is no more than 2 g.

4.3.3 Replacing V-Belt mowing implement – Mowing

implement 95 cm / 105 cm

 Disassemble the mowing implement.

Workshop manual

 Detach the V-belt duct from the support at the mowing

implement..

 Release the 6 hexagon nuts of the mowing implement

cover.

 Remove the right V-belt cover from the mowing

implement.

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Workshop manual

 Remove the left V-belt cover from the mowing

implement.

 Unscrew the screw on the tensioning pulley slightly

until the V-belt can be removed.

 Put down the V-belt.

Installing a new V-belt

Guidance and orientation of the V-belt differs
from type to type.

Refer to the information stickers on the mowing
implement.

 Place the V-belt around the slightly loosened

tensioning pulley, and screw the pulley back on.

 Arrange the V-belt around the rollers in the sequence

(2) / (3) / (4). Ensure that guidance and orientation of
the V-belt are correct.

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Workshop manual

Mowing implement 125 cm

 Disassemble the mowing implement.

 Detach the V-belt duct from the support at the mowing

implement.

 Release the Torx screw (a) and remove the cover (b)

in driving direction right.

 Release the Torx screw (c) and remove the cover (d)

in driving direction left.

 Release 6 carriage bolts (e), and remove them

together with washers and hexagon nuts.

➯Remove the middle V-belt cover

.

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Workshop manual

Tensioning pulley (g) and idler pulley are installed on the
middle V-belt cover.

 Slightly release the hexagon head screw (i) on the

tensioning pulley (g) until you can remove the V-belt (h).

Replacing toothed belt 125 cm

 Disassemble the mowing implement. Remove the

V-belt.

 Slightly release the hexagon head screws (a) and (b)

underneath the mounting plate (c) until the tensioning
rocker (d) can be moved.

 Release the locknut (f) to loosen the adjusting screw (g)

of the tensioning rocker (e).

 Release the hexagon head screw (g) and remove it

together with spring washer (h) and washer (i).

 Remove the V-belt pulley (j) and (k).

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Workshop manual

 Release 2 hexagon head screws (l) to disassemble the

toothed belt guide (m).

Assemble in the reverse sequence.

The distance between toothed belt guide (m)
and toothed belt should be 1 mm all around.

CAUTION!

Adjust the correct tension of the toothed belt.

To a load of 100 N, the toothed belt (1) must not
yield by more than 15 mm.

4.3.4 Replacing the bearing (blade change)

Prerequisites for bearing replacement

1. Disassembling the mowing implement

2. Removing the V-belt

3. Remove the blade together with the blade retainer.

 Unscrew the M10 x 1 X 35 (17mm) screw and

remove it together with cup spring and washer.

 Pulling off the V-belt pulley

 Pull off the pulley driver (1).

 Pull off the bearing seal (2).

 Remove the O-ring (3).

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Workshop manual

 Using a rubber mallet, drive the shaft and the bottom

bearing out of the bearing block.

 Remove the top bearing from the bearing block.
 Assemble in the reverse sequence.

Tightening torque: 65 Nm

4.3.5 Replacing the tensioning pulley

 Disassemble the mowing implement. (See 4.3.1

Disassembling the mowing implement).

 Disassemble the V-belt cover (see 4.3.3 Replacing

V-belt mowing implement).

 Relieve the tensioning pulley so that the V-belt can be

removed from the tensioning pulley.

 Unscrew the hexagon nut (13 mm) and remove it

together with the washer.

 The tensioning pulley can be removed
 Assemble in the reverse sequence.

Tightening torque: 20 Nm

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4.3.6 Disassembling the blade brake clutch

The blade brake clutch sits underneath the engine.

 Disassemble the mowing implement. (See

Disassembling the mowing implement)

 Disconnect the connector from the blade brake clutch.
 Release the hexagon socket screw 8 mm or 3/8 in.) and

remove it.

 Pull the blade brake clutch off the drive shaft.
 Assemble in the reverse sequence.

Ensure during assembly that the spring is
installed in the groove of the clutch.

Workshop manual

CAUTION!

Apply thread lock on the fastening screw of the
blade brake clutch.

Tightening torque: 70 Nm

4.3.7 Replacing the mowing implement feeler rollers

 Release the hexagon head screw and remove the

feeler roller.

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4.4 Steering

4.4.1 Disassembling the steering sector

 Release the hexagon nut of the tie rod attachment (a).

 Release the hexagon nut of the steering sector guide

(b).

 Release the hexagon nut of the steering sector axle and

remove the steering sector (c).

 Assemble in the reverse sequence.

Tightening torque:

(a) = 45 Nm
(b) = 65 Nm
(c) = 45 Nm

4.4.2 Disassembling the steering column

Disassembling the steering wheel

 To remove the cover (a) of the steering wheel, unclip

the hooks at the underside with a suitable tool
(screwdriver), and press them upwards.

 Release the hexagon head screw (b) and remove it

together with the cup spring (c) and the washer (d).

 Pull the steering wheel (e) off the split sleeve (f).

Remove the split sleeve (f).

 Assemble in the reverse sequence.

Use a torque spanner to tighten the hexagon head
screw (b).

Tightening torque: 20 Nm

Removing the steering column

The steering column is removed from the bottom.
Precondition: Steering wheel is removed.

 Release the hexagon head screw.

 Swing off the steering column support.

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4.4.3 Replacing the tie rod

 Pull out the steering column from below.

There are tie rods between the steering sector and the
front wheels, and between the front wheels.
Each side of a tie rod is connected via a ball head with
the steering-axle stub.

Workshop manual

 Remove the retaining spring behind the ball head, and

remove the tie rod.

Ensure that the retaining spring sits firmly when
you assemble the unit.

4.5 Propulsion

4.5.1 Removing the floor cover of the vehicle frame

To be able to remove the floor cover, remove the pedal
tops of accelerator (a+b) and brake (c) pedals.

 Loosen the cheese-head screws underneath the pedal

tops.

 Remove the pedal top.

.

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Workshop manual

 Release all 11 screws of the vehicle frame floor cover.

– 3 screws in the right foot area
– 3 screws in the left foot area
– 1 screw in the middle of the floor cover
– 4 screws in the area of the wheelhouse cover

 Remove the floor cover of the vehicle frame.

4.5.2 Removing the propulsion belt with 23-in chassis

 Detach the spring of the tensioning pulley to relieve the

propulsion V-belt.

 Remove the covers (a) of the idler pulleys (b).
 Release the hexagon head screw of the idler pulleys (b)

until you can remove the V-belt.

 Lift off the safety element at the head of the accelerator

pedal damper and pull the head of the accelerator
pedal damper off the linkage.

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Workshop manual

 Using a 17-mm fork spanner, slightly release (1) the

antirotation element (a) and pull it off the blade brake
clutch (c) (2).

 Thread the V-belt between antirotation element (a) and

blade brake clutch (c) (3).

This requires the connecting cables of the blade
brake clutch to be disconnected.

 Release hexagon head screw (a) and washer of the

propulsion linkage (b) (1).

 Swing the propulsion linkage (b) upwards (2).

 Remove the V-belt (c) between propulsion linkage (b)

and idler pulley (d) (3).

 Release the locking nut (a) (option with cruise control),

and pull off the damper (b).

 Release the hexagon nut (c) and pull off the linkage.
 Pull off the locking ring (e) (option with cruise control)

and pull off the linkage (f).

 Detach the spring (g).

With 20-in chassis

 Detach the spring of the tensioning pulley to relieve the

propulsion V-belt.

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Workshop manual

 Remove the covers (a) of the idler pulleys (b).

 Release the hexagon head screw of the idler pulleys (b)

until you can remove the V-belt.

 Lift off the safety element at the head of the accelerator

pedal damper and pull the head of the accelerator pedal
damper off the linkage.

 Using a 17-mm fork spanner, slightly release (1) the

antirotation element (a) and pull it off the blade brake
clutch (c).

 Thread the V-belt (b) between antirotation element (a)

and blade brake clutch (c).

This requires the connecting cables of the blade
brake clutch to be disconnected.

 Release the locking nut (a) and pull off the damper (b).

 Pull off the linkage (c).

 Detach the spring (d).

Assemble in the reverse sequence.

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Item

Designation:

a

Tensioning pulley (125)

b

Tensioning pulley (95 - 105)

c

Idler pulley

4.5.3 Disassembling tensioning pulleys and idler pulleys

See disassembly / removing propulsion belt

Workshop manual

4.6 Electrical grass catcher emptying

Disassembling the linear cylinder

Disassembly requires the grass catcher to be removed.

 Remove the locking rings at the two fastening bolts (b).

 Remove the two fastening bolts (b), and remove the

linear cylinders (a).

The linear cylinder (a) is assembled in the reverse
sequence.

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Workshop manual

4.7 Electric system

4.7.1 Replacing headlight bulb

 Open the bonnet.

 Pull off the lamp socket.

 Replace the bulb.

4.7.2 Starter battery
The starter battery sits under the bonnet.

CAUTION!

Damaging the display

 Never disconnect the starter battery while the engine is running.
 Never start the tractor with external power supply.

WARNING!

Risk of explosion!

To remove the starter battery:
 First, disconnect the negative terminal (-) (black or blue

cable).

 Next, disconnect the positive terminal (+) (red cable).

 Detach the rubber tape.

 Lift the battery at the front, and remove it.

Never short-circuit the connection terminals.

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Workshop manual

4.7.3 Ignition/starter switch

 Press the clamping springs (b) of the ignition/starter

switch (a), and pull the switch from the top out of the
control panel.

 Pull the connector off the switch.

Install in the reverse sequence.

4.7.4 Removing the start relay

CAUTION!

Risk of short-circuit!

 Prior to replacing the start relay, disconnect

the battery.

The start relay sits at the right side underneath the tank.
 Disconnect the hexagon nuts of the main connections

(2x).

4.7.5 Removing the relay

 Disconnect the control connecting cable.

Ensure that the connections sit firmly when
you install the start relay.

(Only in tractors without display)

The relay sits underneath the control panel, next to the
starter battery.

1 2x relay (without electrical grass catcher emptying)

2 3x relay (with electrical emptying of the grass catcher)

See circuit diagram for relay functions.

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Designation

Current in A

Cable harness (without display)

1010

Cable harness (with display)

7,5

Charge

15

Linear cylinder

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Workshop manual

In the lawn tractors without display, the relay for
electrical grass catcher emptying sits
underneaththe left wheelhouse, next to the linear
cylinder.

4.7.6 Fuses
The fuses sit underneath the control panel, next to the

starter battery.

4.7.7 Level buzzer / level switch

Remove the discharge channel to make it easier to remove the level switch.

Level buzzer

The level buzzer sit underneath the control panel, next to the starter battery.

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Workshop manual

Level shift lever grass catcher

The level shift lever can be removed without a tool

.

Level switch

 Remove 2x locking disks

 Disconnect the microswitch (a) from the housing.

Assemble in the reverse sequence.

Ensure that the connection assignments are
correct.

125 transmission: Connections 2 and 3

95-105 transmission: Connections 1 and 3

4.7.8 Control panel control elements

Speed control lever

 Release screw (a).

 Pull off the throttle (b).

Cruise control lever

 Release the hexagon socket screw (a).

 Remove hexagon socket screw (a) and washer (b).

 Pull off the cruise control lever (c).

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Workshop manual

Mowing implement switch

 Press the clamping springs of the mowing implement

switch together, and pull the switch from the top out of
the control panel.

 Pull the connector off the switch.

Reverse mowing switch (a) / distance sensors (b)

Use the same procedure to remove these two switches.

 Pull the switch from the top out of the control panel.

 Pull the connector off the switch.

Display

 Remove the steering wheel.

 Release the Torx screw (a) in the steering wheel

retainer.

 Release the Torx screws (b) from below by 2...3 turns

to disconnect the control panel from the body frame.

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Microswitch installation position and connection assignments

95-105

125

Lawn tractors without display

1 Variable
2 Variable
3 Non connected

1 Non connected

Variable

2 Variable

Lawn tractors with display

1 Black
2 Yellow
3 Green/Red

1 Green/Red
2 Yellow
3 Black

 Release the 6 cheese-head screws (a) of the display

board (b).

 Disconnect the connecting cable (c) of the display film.

 Carefully remove the display board (b).

4.3.1 Transmission switch

Transmission switch (b)

The transmission switch (b) sits at the rear of the gearbox
(e).

 Release the screw (a) and remove the switch element

(b).

 Remove the microswitch from the switch element,

disconnect and replace it.

CAUTION!

Workshop manual

Wrong installation position of the
microswitch.

 Observe the installation positions of the

individual transmission types.

 The arrow in the following figures (Table

"Microswitch installation position and
connection assignments") shows the
installation position of the microswitch.

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Workshop manual

Transmission switch switching anvil (c)

 Release the screw (d) and remove the switching anvil

(c)

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5 Circuit diagrams

5.1 Lawn tractor with rear discharge and electronic system

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5.2 Lawn tractor with rear discharge without electronic system

Workshop manual

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6 Adjustment work

6.1 Mowing implement adjustment

 Park the lawn tractor on a level surface.
 Set the mowing implement to its lowest position.

B

A = mowing implement adjustment front
B = mowing implement adjustment rear

See following steps

A = mowing implement adjustment front (left and right)

Workshop manual

 Using two fork spanners, release the locknuts at the

front frame attachment.

 Adjust the locknuts equally until the distance of the front

mowing implement at the right and the left is 30 mm at
each side.

 Tighten the locknuts.

B = mowing implement adjustment rear (left and right)

 Using two fork spanners, release the locknuts at the

rear frame attachment.

 Adjust the locknuts equally until the distance of the rear

mowing implement at the right and the left is 40 mm at
each side.

 Tighten the locknuts.

 Check the front mowing implement adjustment, if

necessary.

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Workshop manual

6.2 Grass catcher

Release the screws (a + c) to adjust the box holding arms
if the gap between box cover (d) and seat console (e) is
not correct.

 Release the screws (c) and adjust the supporting rim of

the box cover positively to the seat console (e).

 Release the screws (a) and adjust the distance

between the seat console (e) and the first edge of the
box cover (d) to 19 mm.

6.3 Brake adjustment

The brake of a tractor with 95-105 transmission can be
adjusted. The brake linkage is in the vehicle frame in
driving direction right. Merely the discharge channel need
to be removed for adjustment.

 Screw the self-locking nut (a) onto the brake linkage

until it is in contact with the spring.

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6.4 Propulsion pedals

The distance between the forward accelerator pedal (a)
and the step plate (c) should be 35 mm ± 1 when the pedal
is not pressed.

Adjusting the accelerator pedal (125)

 Release the nuts (d) on the pedal linkage and adjust the

distance of the forward pedal (a).

Workshop manual

Adjusting the accelerator pedal (95-105)

 Release the nuts (d) and move the pedal linkage (e).

 Tighten the nut (d).

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Workshop manual

6.5 Fine adjustment of the steering

For the fine adjustment of the steering wheel perform the
following setting at the thrust rod (a) front left.

 Remove the locking bracket (c) from the ball head (c).
 Loosen the locknut (17 mm) (d). Hold the ball head (c)

with pliers.

 Lift the thrust rod (a) of the ball head (c).

 Rotate the ball head (c) one revolution anticlockwise or

clockwise.

6.6 Steering sector adjustment

 Slightly release the hexagon head screw (a) of the

steering sector guide.

 While you are pushing the steering sector towards the

steering pinion (b), tighten the hexagon head screw (a).

Tightening torque: 65 Nm

49

Object

Tightening

torque

Nm (± 2 Nm)

Comment
Engine

Tighten petrol engine (4x)

25

Oil drain plug

Blade brake clutch

70

Screw lock with Loctite

Transmission

25

First, tighten the transmission screws, then the screws at
the bracing.

Steering

Steering sector guide

25

Grease bearing bush.

Grease the steering sector specifically only at
the bearing surfaces and the teeth.

Steering sector pivot

65

Steering wheel fastening screw

20

Ball head M10 x 1

50

Steering-axle stub clamping lever

20

Mowing implement

Blade

65

Distance blade to lower housing edge 7 ...
max. 12 mm. Blade offset max. 3 mm

Tensioning pulley on rocker

25

Grease the bearing bush of the tensioning
pulley rocker.
The rocker must be able to move smoothly.

Mowing implement V-belt pulley

65

Guide pulleys

45

Mowing implement bearing block

25

Mowing implement suspension
rocker

45

Mowing implement adjustment
front M12

60

Propulsion

Tensioning pulley on the frame

20

7 Torque setting

Workshop manual

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Emak S.p.A.

[e-mail] • www.emak.it

Workshop manual

42011 Bagnolo in Piano (RE) Italy
Tel. [phone] • Fax [phone]

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