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

Transcription

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

2 2 Workshop manual

3 1 Foreword General Safety instructions Maintenance and care Maintenance table Lubricating plan Front axle Steering Front and rear wheels Tensioning pulley rocker / pivoting and bearing points Oil change Air filter / spark plug Tyre pressure Hydrostatic transmission Starter battery (12V / 17 Ah) Troubleshooting plan Table troubleshooting plan Fault display and fault elimination Disassembly Bonnet Discharge channel Mowing implement Disassembling the mowing implement Replacing the blade Replacing V-Belt mowing implement Replacing the bearing (blade change) Replacing the tensioning pulley Disassembling the blade brake clutch Replacing the mowing implement feeler rollers Steering Disassembling the steering sector Disassembling the steering column Replacing the tie rod Propulsion Removing the floor cover of the vehicle frame

4 4.5.2 Removing the propulsion belt Disassembling tensioning pulleys and idler pulleys Electrical grass catcher emptying Electric system Replacing headlight bulb Starter battery Ignition/starter switch Removing the start relay Removing the relay Fuses Level buzzer / level switch Control panel control elements Transmission switch Circuit diagrams Lawn tractor with rear discharge and electronic system Lawn tractor with rear discharge without electronic system Adjustment work Mowing implement adjustment Grass catcher Brake adjustment Propulsion pedals Fine adjustment of the steering Steering sector adjustment Torque setting

5 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

6 2 General 2.1 Safety instructions Workshop manual 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! 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

7 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. 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 Checking the hydrostatic transmission oil level - X X 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 Removing grass and mowing residues from the gearbox X X - - Cleaning the gearbox cooling fan - - X Lubricating as shown in the lubricating plan 1) See the operating instructions from the engine manufacturer X - With high stress and at high temperature reducing the specified maintenance intervals may be necessary. 7

8 3.2 Lubricating plan 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) Steering Grease toothing and bearing surface of the gear segmentwith multi-purpose grease. Grease the pinion Front and rear wheels Lubricate roller bearings / hubs with multipurpose 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 8

9 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

10 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) 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 transmission: Pull out the bypass lever and secure it in the upper position 10

11 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. 11

12 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 (+) Black terminal = negative pole (-) Connect the charger terminals to the battery poles. Connect the charger to the mains, and switch it on. 12

13 3.8 Troubleshooting plan Table of troubleshooting plan 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) The starter does not respond 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. 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! Air filter plugged Clean the air filter 1) Wrong carburettor setting Check the setting 1) Shut down the engine Disconnect the spark plug connector 13

14 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 Grass catcher does not fill up Different pressure of the wheel tyres Correct the tyre pressure Check the mowing implement adjustment Cutting height too low Correct cutting height Grass is too wet it is too heavy to be transported by the air stream Blade worn out Allow the lawn to dry before you try again 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 14

15 Fault Possible cause Rectification Grass catcher does not fill up Level indicator does not respond / responds permanently Grass in lawn too tall Mow in 2 passes Fabric bag clogged does not allow air to pass Discharge channel / mowing implement soiled - residues of last mowing process 1 st pass: Maximum cutting height 2 nd pass: Desired cutting height Clean the fabric bag Clean discharge channel / mowing implement Mown grass stuck to fill level indicator lever Remove mown grass from fill level indicator lever; ensure free lever movement 1) See the operating instructions from the engine manufacturer 2) See the operating instructions from the transmission manufacturer Fault display and fault elimination Display Fault Fault description Fault elimination Err 01 Input seat contact switch Err 02 Input brake contact switch Err 03 Input mowing implement switch Electronic system detects invalid status of the seat contact switch Electronic system detects invalid status of the brake contact switch Electronic system detects invalid status of the mowing implement 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 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 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 15

16 Display Fault Fault description Fault elimination Err 04 Input grass catcher contact switch Err 05 Input transmission switch Err 06 Input discharge channel contact switch Err 07 Output mowing implement Electronic system detects invalid status of the grass catcher contact switch Electronic system detects invalid status of the transmission switch Electronic system detects invalid status of the discharge channel contact switch Electronic system detects incorrect status of the mowing implement output Err 08 Output start relay Electronic system detects incorrect status of the start relay output 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 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 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 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 1 Switch the ignition off and back on (position 1) Self-diagnosis; fault can clear automatically * Otherwise, test / replace the electronic system 1 Switch the ignition off and back on (position 1) Self-diagnosis; fault can clear automatically * Otherwise, test / replace the electronic system 1 Switch the ignition off and back on (position 1) Self-diagnosis; fault can clear automatically * Otherwise, test / replace the electronic system 16

17 Display Fault Fault description Fault elimination Err 10 Output ignition coil Electronic system detects incorrect status of the ignition coil output Err 11 Output internal supply voltage Err 12 Output internal supply voltage monitoring system Electronic system detects incorrect status of the internal supply voltage output 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 1 Switch the ignition off and back on (position 1) Self-diagnosis; fault can clear automatically * Otherwise, test / replace the electronic system 1 Switch the ignition off and back on (position 1) Self-diagnosis; fault can clear automatically * Otherwise, test / replace the electronic system * 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. 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 Only red LED is ON Fault during current operation Fault during previous operation or controller fault Fault rectification according to fault shown on display Fault rectification according to fault shown on display, or check/replace electronic system 17

18 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 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. 18

19 4.3 Mowing implement 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. 19

20 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. 20

21 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

22 Balancing: Use a suitable measuring instrument to measure the imbalance. Adjust until the difference between the two blades is no more than 2 g Replacing V-Belt mowing implement Mowing implement 95 cm / 105 cm Disassemble the mowing implement. 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. 22

23 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. 23

24 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. 24

25 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). 25

26 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 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). 26

27 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 Replacing the tensioning pulley Disassemble the mowing implement. (See Disassembling the mowing implement). Disassemble the V-belt cover (see 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 27

28 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. CAUTION! Apply thread lock on the fastening screw of the blade brake clutch. Tightening torque: 70 Nm Replacing the mowing implement feeler rollers Release the hexagon head screw and remove the feeler roller. 28

29 4.4 Steering 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 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. 29

30 Pull out the steering column from below 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. 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 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. 30

31 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 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. 31

32 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. 32

33 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. 33

34 4.5.3 Disassembling tensioning pulleys and idler pulleys See disassembly / removing propulsion belt Item Designation: a Tensioning pulley (125) b Tensioning pulley (95-105) c Idler pulley 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. 34

35 4.7 Electric system Replacing headlight bulb Open the bonnet. Pull off the lamp socket. Replace the bulb 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! Never short-circuit the connection terminals. 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. 35

36 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 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). Disconnect the control connecting cable. Ensure that the connections sit firmly when you install the start relay Removing the 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. 36

37 In the lawn tractors without display, the relay for electrical grass catcher emptying sits underneaththe left wheelhouse, next to the linear cylinder 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) 7,5 Charge 15 Linear cylinder 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. 37

38 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 transmission: Connections 1 and 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). 38

39 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 turns to disconnect the control panel from the body frame. 39

40 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) 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! 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. Microswitch installation position and connection assignments 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 40

41 Transmission switch switching anvil (c) Release the screw (d) and remove the switching anvil (c) 41

42 5 Circuit diagrams 5.1 Lawn tractor with rear discharge and electronic system 42

43 43

44 5.2 Lawn tractor with rear discharge without electronic system Workshop manual 44

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46 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) 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. 46

47 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 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. 47

48 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). Adjusting the accelerator pedal (95-105) Release the nuts (d) and move the pedal linkage (e). Tighten the nut (d). 48

49 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

50 7 Torque setting Object Engine Tightening torque Nm (± 2 Nm) Comment Tighten petrol engine (4x) 25 Oil drain plug Blade brake clutch 70 Screw lock with Loctite Transmission 25 Steering First, tighten the transmission screws, then the screws at the bracing. Grease bearing bush. Steering sector guide 25 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 Tensioning pulley on rocker 25 Distance blade to lower housing edge 7... max. 12 mm. Blade offset max. 3 mm 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 Mowing implement adjustment front M12 Propulsion Tensioning pulley on the frame

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52 Emak S.p.A Bagnolo in Piano (RE) Italy Tel Fax