EMAK EF 95 Workshop Manual
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EMAK EF 95 Workshop Manual

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WORKSHOP MANUAL
Garden Tractor:
EF 95 - EF 105 - EF 125 -
OM 95 - OM 105 - OM 125

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Summary of Contents for EMAK EF 95

  • Page 1 WORKSHOP MANUAL Garden Tractor: EF 95 - EF 105 - EF 125 - OM 95 - OM 105 - OM 125...
  • Page 2 Workshop manual...
  • Page 3 Workshop manual Foreword ........................5 General ........................6 Safety instructions ....................6 Maintenance and care ....................7 Maintenance table ....................7 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 ..........
  • Page 4 Workshop manual 4.5.2 Removing the propulsion belt ................. 31 4.5.3 Disassembling tensioning pulleys and idler pulleys ..........34 Electrical grass catcher emptying ................ 34 Electric system ....................35 4.7.1 Replacing headlight bulb ..................35 4.7.2 Starter battery ......................35 4.7.3 Ignition/starter switch ....................

  • Page 5: Foreword

    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.

  • Page 6: General

    Workshop manual General 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: ...

  • Page 7: Maintenance And Care

    Workshop manual Maintenance and care 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 ...

  • Page 8: Lubricating Plan

    Workshop manual 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. ...

  • Page 9: Tensioning Pulley Rocker / Pivoting And Bearing Points

    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. Oil change CAUTION! See also operating instructions from the engine manufacturer.

  • Page 10: Tyre Pressure

    Workshop manual Tyre pressure  Check the tyre pressure at regular intervals..  Tyre pressure recommended: 0,9 - 1,0 bar 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) CAUTION! See also operating instructions from the engine manufacturer.
  • Page 11 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 ...

  • Page 12: Charging The Starter Battery

    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. ...

  • Page 13: Troubleshooting Plan

    Workshop manual Troubleshooting plan Table of troubleshooting plan 3.8.1 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 ...
  • Page 14 Workshop manual Fault Possible cause Rectification Mowing performance Blade worn out Replace the blade (see replacing the blade)  drops Use only a genuine spare blade Driving speed too high  Reduce the driving speed Power loss Engine speed (rpm) ...

  • Page 15: Fault Display And Fault Elimination

    Workshop manual Fault Possible cause Rectification Grass catcher does not Grass in lawn too tall  Mow in 2 passes fill up pass: Maximum cutting height pass: Desired cutting height Fabric bag clogged – does not allow air to  Clean the fabric bag pass Discharge channel / mowing implement soiled...
  • Page 16 Workshop manual Display Fault Fault description Fault elimination Input grass Electronic system detects invalid Err 04 Switch the ignition off and back on catcher contact status of the grass catcher contact (position 2) switch switch Open and close the grass catcher repeatedly Press the grass catcher switch several times...
  • Page 17 Workshop manual Display Fault Fault description Fault elimination Electronic system detects incorrect Err 10 Output ignition coil Switch the ignition off and back on status of the ignition coil output (position 1) ➯ Self-diagnosis; fault can clear automatically * ➯Otherwise, test / replace the electronic system Output internal...

  • Page 18: Disassembly

    Workshop manual Disassembly 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. ...

  • Page 19: Mowing Implement

    Workshop manual Mowing implement Disassembling the mowing implement 4.3.1 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. ...
  • Page 20 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.

  • Page 21: Replacing The Blade

    Workshop manual Replacing the blade 4.3.2 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. ...

  • Page 22: Replacing V-Belt Mowing Implement

    Workshop manual 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 ...
  • Page 23 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.
  • Page 24 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.
  • Page 25 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 ...

  • Page 26: Replacing The Bearing (Blade Change)

    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.

  • Page 27: Replacing The Tensioning Pulley

    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 ...

  • Page 28: Disassembling The Blade Brake Clutch

    Workshop manual 4.3.6 Disassembling the blade brake clutch The blade brake clutch sits underneath the engine.  Disassemble 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 ...

  • Page 29: Steering

    Workshop manual 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).

  • Page 30: Replacing The Tie Rod

    Workshop manual  Pull out the steering column from below. 4.4.3 Replacing the tie rod 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.

  • Page 31: Removing The Propulsion Belt

    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 ...
  • Page 32 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.
  • Page 33 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 ...

  • Page 34: Disassembling Tensioning Pulleys And Idler Pulleys

    Workshop manual 4.5.3 Disassembling tensioning pulleys and idler pulleys See disassembly / removing propulsion belt Item Designation: Tensioning pulley (125) Tensioning pulley (95 - 105) Idler pulley 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).

  • Page 35: Electric System

    Workshop manual 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. ...

  • Page 36: Ignition/Starter Switch

    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!

  • Page 37: Fuses

    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. Designation Current in A Cable harness (without display) 1010 Cable harness (with display)

  • Page 38: Control Panel Control Elements

    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.
  • Page 39 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.

  • Page 40: Transmission Switch

    Workshop manual  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).
  • Page 41 Workshop manual Transmission switch switching anvil (c) Release the screw (d) and remove the switching anvil ...

  • Page 42: Circuit Diagrams

    Workshop manual Circuit diagrams Lawn tractor with rear discharge and electronic system...
  • Page 43 Workshop manual...

  • Page 44: Lawn Tractor With Rear Discharge Without Electronic System

    Workshop manual Lawn tractor with rear discharge without electronic system...
  • Page 45 Workshop manual...

  • Page 46: Adjustment Work

    Workshop manual Adjustment work Mowing implement adjustment  Park the lawn tractor on a level surface.  Set the mowing implement to its lowest position. A = mowing implement adjustment front B = mowing implement adjustment rear See following steps A = mowing implement adjustment front (left and right) ...

  • Page 47: Grass Catcher

    Workshop manual 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).

  • Page 48: Propulsion Pedals

    Workshop manual 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).

  • Page 49: Fine Adjustment Of The Steering

    Workshop manual 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.

  • Page 50: Torque Setting

    Workshop manual Torque setting Tightening Object torque Comment Nm (± 2 Nm) Engine Tighten petrol engine (4x) Oil drain plug Blade brake clutch Screw lock with Loctite First, tighten the transmission screws, then the screws at Transmission the bracing. Steering Grease bearing bush.
  • Page 51 Workshop manual...
  • Page 52 Workshop manual Emak S.p.A. 42011 Bagnolo in Piano (RE) Italy Tel. +39 0522 956611 • Fax +39 0522 951555 service@emak.it • www.emak.it...

This manual is also suitable for:

Ef 105Om 125Ef 125Om 95Om 105

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