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

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

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

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.

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.

Before

every

use

After the

first 5

operating

hours

Every

operating

hours

Every

operating

hours

Every

50 operating

hours

or yearly

Every

100

operating

hours

Checking the engine oil level

X X X - -

Changing the engine oil

- X - - X

Replacing the oil filter (if installed)

1).

- - - - -

Cleaning the air filter

- - - X -

Replacing the air filter

- - - - X

Checking the spark plug

- - - - 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.

See the operating instructions from

the engine manufacturer

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

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

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.

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

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.

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 (-)

Fault

Possible cause

Rectification

The engine does not start

Lack of fuel

 Fill up the tank

 Check tank breathing  Fuel filter

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

Maximum storage time 30 days

 Clean the carburettor

Air filter plugged

 Clean the air filter

No ignition spark

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

 Check the ignition cables

 Check the ignition system

"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

Workshop manual

3.8 Troubleshooting plan

3.8.1 Table of troubleshooting plan

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

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

See the operating instructions from the engine manufacturer

See the operating instructions from the transmission manufacturer

3.8.2 Fault display and fault elimination

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

+ 36 hidden pages

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

Specifications and Main Features

Frequently Asked Questions

User Manual