AS MOTOR AS 1040 YAK 4WD User manual

Workshop Manual 01/2019 DE
AS 1040 YAK 4WD
Service Information
Adjustment, maintenance and repair instructions
www.as-motor.de
AS-MOTOR Ride-On Flail Mower

Manual AS 1040 YAK 4WD
Index:
Tipp: Über Mouse-Over-Click kann im Dokument navigiert werden -Click
Seitenzahl und Click auf www.as-motor.de um ins Inhaltsverzeichnis zurück zu kommen.
Einleitung:
•Safety Instruction p. 3
•Online-Service-Portal „parts-and-more.org“p. 4
•Maintenance work,Cleaning and Service p. 6
Technical Data:
•Technical Data p. 7
•Maintenance schedule p. 8
Generall:
•Tyre sizes p. 9
•Tightening Torque p. 11
•Faults p. 12
Engine:
•Individual components p. 13
•Adjustment,regulation p. 14
Drive line:
•Force progression p. 15
•Belt arrangement p. 16
•Belts tensioner p. 17
•Position arragement p. 18
Mower Deck:
•Belts changing p. 19
•Bearing mower deck changing p. 21
•Flail shaft remove p. 23
•Mower deck changing p. 25
•Innovations p. 28
•Flail shaft Force progression p. 39
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Drive line Transmission:
•Belt Hydrostat changing p. 31
Hydrostat:
•Oil changing p. 33
Drive lever:
•Arrangement p. 35
Hydraulik:
•View from below p. 37
•Hydraulic shema p. 38
•Installation of the lines p. 39
•Axle drive p. 40
Steering:
•Position Steering p. 41
•Adjusting the differential p. 42
•Front Axle p. 43
•Adjusting the pedals p. 44
Saet:
•Adjustment screw p. 45
Belt tensioner:
•Structure p. 46
Elektric:
•Wire harness p. 47
•Electrical system p. 48
•Arrangement of the components p. 49
Personal notes p. 51

Introduction
Safety instructions
Safety instructions
Only authorised AS-MOTOR Workshops are allowed to execute the activities
cited in this manual.
Comply with the following instructions and the warnings in the respective
sections, otherwise accidents with severe injuries can occur and/or the device
can be damaged.
Prior to starting work:
Place the device on alevel and non-slip substrate.
Only use ramps and hoists that are suitable for the device.
Safeguard the device against rolling off and falling over.
Let the device cool for at least 20 minutes.
Close the fuel tap and the tank ventilation.
Never place the device with petrol in the tank, inside abuilding where petrol
fumes can come into contact with open fire or sparks.
Do not inhale fuel fumes, they are harmful.
Use gloves, particularly for tasks on cutting tools.
Avoid skin contact with fuel and operating fluids.
Caution when handling batteries:Battery acid is corrosive. Protect your
hands and eyes from escaping fluid.
Disconnect the battery via the negative terminal.
This symbol signals awarning.Failure to comply with the warning can
result in accidents, injuries and damage!
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Important note:
ATTENTION WELDING TASKS
Prior to performing welding tasks on the device unplug the plug connector from
the control device (receiver).Always attach the welding device earth very close
to the welding point.Otherwise there is danger of irreparably damaging the
control device.
Original spare parts
Important note:
Only original AS-MOTOR spare parts ensure safety, keep the guarantee intact
and protect against damage.Consequently only use original AS-MOTOR spare
parts;do not use any imitation or counterfeit parts.
Installation of non-original parts invalidates the guarantee claim and the
operating authorisation. Accidents with severe or fatal injuries can be the
result.
All original wear parts, all original blades and many original spare parts bear
the stamped AS-MOTOR logo, as well as the EXXXXX and/or GXXXXXXXX
part numbers.

Introduction
Online service portal "parts-and-more.org" (PAM)
Online service portal "parts-and-more.org" (PAM)
For all tasks shown in the Workshop Manual the online service portal "parts-
and-more.org" is your most important companion.It offers you the following
functions for every single AS-MOTOR device:
Exploded drawings of each assembly
Spare parts lists for each assembly
Modification information for parts
Current availability (online stock) of spare parts
Spare part ordering function
Management of current shopping carts and older orders
FAQ and general technical information
Guarantee claims
Access to the online portal "parts-and-more.org":
Every official AS-Motor dealer has access to the online service portal via his
customer number.
Login access to the system occurs via the website:
www.parts-and-more.org
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Access data is issued within one to two days after "Dealer first login" using the
AS-Motor customer number.
After receipt of the access data (parts ID and password) you can log in via
"Immediate login" and use all functions immediately.
For questions concerning "parts-and-more.org" please contact:
[e-mail] or
[e-mail]
AS-Motor Germany [phone]

Introduction
Online service portal "parts-and-more.org" (PAM)
Parts search
Language
selection
Shopping cart
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Print function
Magnifying glass
function
Complete overview
Device and
assembly selection
Information –FAQ
Spare part function
Availability
Parts –direct
selection highlighted red
Spare parts list
Parts information
Change notifications

Introduction
Maintenance tasks, cleaning and maintenance intervals
Maintenance and cleaning (general information)
To ensure the full functionality, the safety and a long service life of the
machine, regular maintenance and cleaning of the machine are essential.
All necessary activities and their intervals are listed on the following pages.
Prior to maintenance
Danger! Danger of injury if maintenance and cleaning tasks are
performed when the engine is running. Only execute maintenance tasks when
the engine is running if this is explicitly required.
Prior to all maintenance and cleaning tasks when the engine is at a standstill:
Let the device cool for at least 20 minutes.
Close the fuel tap and the tank ventilation.
Disconnect the negative terminal of the battery.
Warning! The device can tip or fall over and cause severe injuries.
The device can be lifted or tilted to execute maintenance, repair or cleaning
tasks on the underside of the device.
Only lift the device on a level substrate.
Only use hoists and ramps that are suitable.
Only attach hoists on the main frame, only the main frame can bear the
weight.
Safeguard the device against tipping over or falling.
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Stay out of the tipping area.
Clean the device:
Thoroughly clean the device after each use. Particularly the underside and
the blade enclosure.
Clean the air grille, engine cooling unit and engine.
Clean the transmission housing and transmission fan.
Danger of fire! Particularly ensure clean parts on the exhaust system.
For cleaning use brooms, brushes, damp cloths and wood or plastic
spatulas.
Do not clean with a high-pressure cleaner!
Do not use any aggressive cleaning agents.
Thorough visual inspection:
Check the following for safe operation of the machine:
Nuts, bolts, screws, fuel lines, air filter for firm seat
Ignition cable and ignition connector for damage
Covers, protective cloths, muffler
Tank, fuel tap, carburettor, engine, transmission, battery, hydraulic system
for leaks

Technical data and maintenance schedule
Technical data
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Technische Daten AS1040 YAK 4WD
Einsatzbereich/ Application 0-30°C / 32-86°F
Motor/Engine
Bauart/Design 2 Zylinder-4 Takt Motor
Hersteller/Manufactorer Briggs&Stratton
Typ/Type Vanguard, V-Twin; code: 386447 0414-G1
Hubraum/Displacement 627 cm³/627ccm
Leistung/ Power 15,5 kW /21,1 hp
max Drehzahl/max rpm 3000 /1min
Startvorrichtung /Starter Elektr.
Batterie/Battery 12V 30Ah
Sicherungen/Fuses Haupt/Main 25 A
Sicherungen/Fuses rest 25A
Fahrantrieb/Driveline Permanenter Allrad ,permanent FWD
Hinten/rear Hinterachse m. Differentialsperre/ Rear Axle w diff loc.
Vorne/front
Pendelnd gelagerte Portalachse, 2 Hydromotoren und Königswelle/Pendulum-mounted gantry
axis, 2 hydraulic motors and vertical shaft
Geschwindigkeit vorwärts/Speed foreward 0-6,8km/h / 0-4,22mph
Geschwindigkeit Rückwärts/Speed reverse 0-6,3km/h /0-3,91mph
Wendekreis/ Turning Circle 1,4m 55 inch
Schneidwerk/Cutting Schlegel-Mähwerk ,56 Y-Schlegel/Flail mower w 56 Y-Flails
Schnittbreite/Cutting wide 100 cm /39,37 inch
Schnitthöhe/Cutting height 30-110 mm /1,18-4,33 inch
Transportstellung/Transport 120 mm 4,72 inch
Maße und Gewichte / Dimensions
L/B/H 205/130/123 cm 80,71/51,18/48,43 inch
Gewicht/weight 337kg / 742,96 lb
Füllmengen/Capacities
Kraftstofftank, Fuel 16 l /4,22 US Gal.
Motoröl/ Engine Oil 1,7l / 0,45 US Gal. 5W50 Öl/oil
Getriebeöl /Transmission 6,8 l / 1,8 US Gal. 5W50 Öl/oil
Geräuschpegel DIN EN 12733/ Noise level
gemessener Schallleistungspegel /measured
sound power level L/wa
102,6 dB
Schalldruck am Bedienplatz/Sound pressure at
the operator station L/pa
92,7 dB
Vibrations -Emissionswert/Vibration emission
value
Hand-Arm Schwingungen/Hand-arm vibrations
ah,w
1,1m/s² gemäß DIN EN 12733
Messunsicherheit/measurement uncertainty U 0,15 m/s²
Reifen
Vorne/front 15x5.00-6 (inclued/enthält 0,5L Reifenpannenschutz/tyreprotect
Hinten/rear 18x9.50-8 ( inclued/enthält 1,0l Reifenpannenschutz/Tyreprotect

Maintenance schedule
Maintenance schedule
Hydrostatic oil change,same
maintenance interval as AS
940 Sherpa.
The implementation can be
found on page 33.
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Group Action
A B
Machine
Check for safe working condition (basic view)
Cleaning
Service
Mower Clean. See chapter Cleaning mower
Fuel Tank, Fuel pipe Check fuel level
Is the fuel cap closed
Fuel Check leaks and good condition
Grill Cleaning
Cooling Cleaning
Ignition check/Replace
air filter Service
Blade
Check for wear and damage. See chapter Checking
the knife and flute shaft
change
Screw-on point Clean knife blade
Blade brake
The brake works safely and the knife stops in 7
seconds
Drive Lever
If the device is stationary when the lever is in neutral
position when the footbrake is applied
Devices with foot brake: Does the lever go to zero
when the foot brake is applied?
Belt
Are the belts properly tensioned, with no cracks and
in good condition?
Cabels
Check function and ease of operation
accelerator
check function
Chassis und
protection
Check for rust and cracks and check the welds
Are all guards and covers in place, properly attached
and functional
Decals
Decals readable
Engine
Binding information See operating instructions for
engine manufacturers
Check oil level (see operating instructions engine
manufacturer)
Oil Change
Oil filter change
Parking brake
check/Adjusting/change
Brake
function of the brake
Flammable material
Material remove
Steering
check clearance
Tyre
check Tyre and Tyre pressure
Safty switch
seat, cutting height adjustment and travel drive
Ignition lock
ceck function
Hydrostat Transmissio
Check oil level
eliminate oil leaks
Oil change after 50h afterwards all 200h
Battery
Check charge status
A
Before and after each use
B
Annually or every 50 h
By the end user with the engine stopped
By the end user while the engine is running
authorized workshop
Service

General information
Tyre sizes, wheel dimensions, tyre pressures 1/2
Tyre pressures
Auniform and correct tyre pressure is essential for the following characteristics:
Traction uphill
Braking force downhill
Suspension comfort
Safety :The tyre does not come off of the rim!
Uniform mowing pattern
Rules:
Check the air pressure on aregular basis.
Examine tyres and tyre flanks regularly for damage.
Replace damaged tyres.
Only use original AS-MOTOR tyres.
Do not change tyre diameters or tyre sizes. This can damage the 4WD.
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Tips /notes:
Inflate the tyres with our recommended tyre pressures.In our opinion, these
pressures offer an optimum of suspension comfort and traction.
High tyre pressures have anegative influence on suspension comfort and
traction.
Do not underrange the recommended tyre pressures.Tyres can come off of
the rims.
Do not exceed the maximum tyre pressures.
AS-Motor mowers come from the factory with atyre pressure that is higher
than the recommended pressure.
Tyre sealant can prevent flat tyres.Particularly in tubeless tyres.
Anti-puncture insert strips can prevent flat tyres.
Pay attention to the running direction of the tyres, left /right for optimal
traction.
Slow pressure loss of atyre indicates that there is athorn in the tyre.
Tubed tyres cannot be easily used without atube.
Next page: Overview TABLE "Wheels"

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General information
Tyre sizes, wheel dimensions, tyre pressures 2/2
Model: Front wheel (FW) /
rear wheel (RW):
Tyre size: Recommended
air pressure:
Maximum air
pressure:
Tread: Tubed Tyres (TT) /
Tubeless (TL):
Standard
equipment /
optional:
AS 1040 4WD FW:
RW:
15x5.00-6
18x9.50-8
17 psi / 1.20 bar
15 psi / 1.00 bar
18 psi / 1.24 bar
24 psi / 1.65 bar
AS
AS
TL
TL
Series
Series
Tightening torque for wheel bolts / wheel screws:
Rear wheels: M12 100 Nm (73.75 lb-ft)
Front wheels: M8 40 Nm (29.50 lb-ft)

General information
Tightening torques for bolted connections 1/1
Tightening torques
Correct tightening torques are important to ensure a solid connection of
components and to avoid damage
Correct tightening torques are safety-relevant on rotating parts, in particular,
like flails, belt pulleys and wheels.
The following tightening torques always apply for hexagon bolts, socket head
screws with hexagon socket and standard thread in 8.8 quality:
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Special tightening torques
In the tables on the following pages the individual torques are presented for
essential, special and safety-relevant parts.
Tip /note:
You will find the listed bolts /threaded fittings based on the position number
(#XXX) in the exploded drawings of the respective assembly at parts-and-
more.org (PAM).The position numbers are the numbers in circles on each part
in the exploded drawing.In the parts list below the drawing the position number
(Pos.) is also shown and cited by name.
Bolts with
standard thread
DIN quality 8.8
Bolts or nuts
with under-head
serrations
Thread: Width across
flats:
Torque in Nm:
(lb-ft)
Torque in Nm:
(lb-ft)
M5 8 6 Nm (4.5) 8 Nm (5.9)
M6 10 12 Nm (8.6) 15 Nm (11.1)
M8 13 25 Nm (18.5) 35 Nm (25.9)
M10 17 55 Nm (40.6) 70 Nm (51.7)
M12 19 90 Nm (66.4) 120 Nm (88.6)

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General information
Frequent faults and rectification (troubleshooting)
Fault Possible fault Remedy
Poor engine performance Air filter, clean or replace petrol filter
Poor drive performance V-belts of the angular gear unit is loose (attention there are
2 different ones)

Engine
Individual components
Engine earth
Oil drain plug
Oil filter
Shut-off valve –carburettor
rpm adjustment –accelerator
cable
From above
Oil cooler
Oil pressure switch (green
cable)
Fuel pump
Oil filler neck
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Engine
Adjustment, regulation
Final rpm 3600 rpm
Idle rpm
1600 +/-100 rpm
Final rpm adjustment
by bending the lug
Idle by bending the stop
Cable holder
Idle screw
Full-load adjustment
Idle stop
Regulator spring
Centrifugal force regulator (always
regulates in the off direction)
Engine code
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Drive
Force progression

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Force progression
Belt arrangement
Drive belt for transmission G07857057
Drive belt for flail shaft
G07857035
Drive belt for transmission
G07857056
Angular gear unit

Force progression
Belt tensioner
Belt tensioner for reduction
gearing
View from the outside
Belt tensioner for transmission
Belt tensioner for reduction
gearing –view into the frame
Belt for the transmission
From above
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Force progression
Position arrangement
Engine
Flail shaft
Output side
Angular gear unit –
hydrostatic
transmission
Hydrostatic
transmission

Belt drive
Replacing the mower unit V-belts (1/2)
Unhook Bowden cable of the
mower unit coupling
Take off the cover to the right in
the direction of travel pay
attention to the spacer sleeves
Unscrew screwslide bolt
upward
Remove the lever of the blade
brake unhook spring
Remove belt guide from the
front
Unscrew bolt and detach belt
guide
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Flail mower unit
Replacing the mower unit V-belts (2/2)
Installation in the reverse
sequence
Take off belt
When installing the (if required)
belt tension lever, ensure that
the sliding discs are correctly
seated sliding disc must rest
on the bearing
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Z A