AS MOTOR Sherpa AS 920 2WD Instruction manual

WORKSHOP MANUAL 1.3 03/2017 EN
Service Information
Adjustment, maintenance and repair instructions
AS-MOTOR Sherpa:
AS 920 2WD
AS 940 4WD
AS 940 4WD XL
www.as-motor.de

Workshop Manual AS-MOTOR Sherpa:
Tableof contents:
Tip: You can navigatein the documentvia mouse-overclick –clickpage number
and clickwww.as-motor.deto return to the table of contents.
Introduction:
•Preface and validity p. 3
•Deviatingdevice versions and safety instructions p. 4
•Notice–original spare parts and technical data p. 5
•Accessories p. 7
•Onlineservice portal "parts-and-more.org"(PAM) p. 8
General information:
•Frequent faultsand rectification(troubleshooting) p. 10
•Tyre sizes,wheel dimensions, tyre pressures p. 15
•ConversiontoXL wheels p. 17
•Tighteningtorquesfor bolted connections p. 18
•Fuel, lubricants,fill quantities,consumption p. 22
•Hydrostatictransmission"TuffTorq /Kanzaki" p. 23
•Maintenancetasks, cleaning and maintenanceintervals p. 24
Engine:
•Overview and maintenanceschedule p. 28
•Changingtheengineoil p. 29
•Cleaningor replacing air filterandspark plug p. 31
Drive:
•Oil change–hydrostatic transmission p. 32
•Replacingthe shaft seals of the drive axles p. 37
•Replacingthe drive belt(hydrostatictransmission) p. 39
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Mower deck:
•Bladebelt replacement p. 44
•Blade replacement and blade maintenance p. 48
•Checkingthebladeenclosure p. 51
•Blade enclosure removal p. 53
•Blade brake, blade bearing andblade clutch p. 56
•Adjustingthe blade enclosure p. 59
Operating elements:
•Removing thedriver seat and seat contact p. 61
•Parking brake p. 63
•Drive lever(restoring force) p. 65
•Accelerator cable/choke and drive speed p. 66
•Steering /steering pinion and differentiallock p. 67
•Bladedrive cable and blade emergency stopcable p. 68
Electrical system:
•Electrical components(overview) p. 69
•Circuitdiagram AS 9202WDand AS 940 4WD/XLEurope&ROW p. 70
•Circuitdiagram AS 9202WDand AS 940 4WD/XLUS-Versions p. 71
•Cabling(plug connector pin assignment) p. 72
•Checkingthebattery p. 73
•Battery does notcharge p. 74
•Troubleshootingtheelectricalsystem (overview) p. 75
•Troubleshootingno. 1- 7 p. 76
Personal notes:p. 80
Navigatequicklyand easilyin the
document.

Introduction
Prefaceand validity
Preface
This Repair Manual is designed to make it easier for you to properly make
adjustments, perform maintenance and make repairs on an AS 920 2WD, an
AS 940 Sherpa 4WD and on an AS 940 Sherpa 4WDXL.
As areference work it will be auseful aid at all times for the tasks that occur in
yourworkshop.
The online service portal "parts&more"is very helpful for all tasks.Please use
the online service portal for exploded drawings, parts lists, instructions and
orders.It shows you the correctassemblysequence,even for complexparts.
Naturally, good workshop equipment and trained specialists are the
prerequisites for faultless maintenance.Please take advantage of our regularly
offered servicetraining courses.
With this Workshop Manual we are providing avaluable tool for you and your
workshopteam.
Regards
AS-MOTOR GERMANY
SERVICE
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Validity
This WorkshopManual is based on the following deviceversions:
•AS 920 Sherpa 2WD:Serialnumber (SN:)(0) 276 16 03 00001,March 2016
•AS 940 Sherpa 4WD:Serialnumber (SN:)(0) 219 16 10 0001,October 2016
•AS 940 Sherpa 4WDXL:Serial number (SN:) (0) 264 16 11 0001,Nov.2016
The serial number of each of your AS-Motor Sherpas is provided at two points
on the device:
1. As stickerat the top of the right controlpanel
2. As an aluminium plate on the chassis, on the right underneath the seat,
permanently riveted
Explanation of the 11-digitserialnumber:
Example:
•Devicetype: (0) 264
•Year of manufacture:16
•Month:11
•Consecutivenumber:0001

Introduction
Deviatingdevice versionsand safety instructions
Deviating device versions (older or newer)
Since the market launch of the AS 940 Sherpa 4WD in 2010,technical
improvementsof the device havebeen undertakenon aconstantbasis.
If your device is older than the devices versions that are the basis of this
manual (October/November2016), please note the following:
The changes made since 2009 in general affect only minor details and parts.
There have been no major, extensive, design changes.For you this means that
this manual can also be used and is helpful for oldermodel years.
The executingmechanic can view deviating and older parts in the parts lists
and drawings on our online serviceportal "www.parts-and-more.org"(PAM).
(See section:"parts&more")
In this casethe designation of an assemblyis:"From serialnumber 0264... ".
For future device versions this Workshop Manual will be revised annually.
Please ensure on aregular basis that your version of the Workshop Manual is
the right one/or is up to date.
If for some activities there are different alternative possibilities then you will be
alerted to this situation through our symbol "Tip/note".
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Safety instructions for all activities:
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:
Before all tasks on the machine, disconnect the negative terminal of the
battery!
Place the device on aleveland non-slipsubstrate.
Only use ramps and hoists that are suitable for the device.
Safeguard the device againstrolling 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 contactwith open fire or sparks.
Do not inhale fuelfumes, they are harmful.
Usegloves, particularlyfor taskson cutting tools.
Avoid skincontactwith fuel and operating fluids.
Caution when handling batteries:Battery acid is corrosive.Protect your
handsand eyes from escapingfluid.
This symbol signals awarning.Failure to comply with the warning can
resultin accidents,injuriesand damage!

Introduction
Notice–originalspare partsand technicaldata(1/3)
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
G 0XXXXXXXX part number.
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Technical data – AS 940 Sherpa 4WD (1/2):

Introduction
Technicaldata(2/3)
Technical data – AS 940 Sherpa 4WD (2/2):
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Technical data – AS 920 Sherpa 4WD (1/2):

Introduction
Technicaldata(3/3) and accessories
Technical data – AS 920 Sherpa 4WD (2/2):
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Accessories –AS 920/940 Sherpa:
Trailer(max. 100 kg)
Trailerhitch
Snow blade
Adapter for snow blade
Adapter for snow blade with weather cab
Snow chains(only rear wheels,not for XL and RC)
Weather cab
Twin tyresrear (strongtraction, only AS 920 und AS 940 4WD)
Set XL wheels (for AS 940 4WD, not for AS 920 2WD)
Lawn/mulch accessories(mulchkit, for grass heights up to max. 40 cm)
Tilt meter
Steering wheel knob (not recommended)
Airlessfront wheels,solidPUR foam (AS 940 Sherpa 4WD XL and RC)
Spray-paint,orange, RAL 2000
Accessoryis not availableas spare partin "parts&more.org"(PAM).
Accessoriesareordered the same way that machines are ordered.

Introduction
Onlineserviceportal"parts-and-more.org"(PAM) 1/2
Online service portal "parts-and-more.org" (PAM)
For all tasks shown in this Workshop Manual the online service portal "parts-
and-more.org" is your most important companion.It offers you the following
functions for everysingle AS-MOTOR device:
Exploded drawingsof each assembly
Spare parts lists for each assembly
Modification information for parts
Currentavailability (onlinestock)of spare parts
Spare part ordering function
Management of currentshopping carts and older orders
FAQ and general technicalinformation
Guarantee claims
Deviceorders (if released)
Accessto the online serviceportal "parts-and-more.org":
Every official AS-Motor dealer has access to the online service portal via his
customernumber.
Login accessto the systemoccursvia 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 customernumber.
After receipt of the access data (parts ID and password) you can log in via
"Immediate login" and use all functionsimmediately.
For questionsconcerning"parts-and-more.org"please contact:
[e-mail] or
[e-mail]
AS-Motor Germany [phone]

Introduction
Online ServicePortal "parts-and-more.org"(PAM) 2/2
Parts search
Language
selection
Shoppingcart
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Printfunction
Magnifyingglass
function
Completeoverview
Device and
assemblyselection
Sparepartfunction
Availability
Otherusefulfunctions
Parts directselection
highlightedred
Spareparts list
Parts information
Changenotifications

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General information
Frequentfaultsand rectification(troubleshooting)1/5
Fault Possible fault Remedy
Starter does notturn Safety switches are not activated Bring drive leverinto zero position.
Bringcutting height adjustment into transportposition.
Load seatcontactswitch throughthe weight ofthe driver.
Battery is depleted:
Ignition key was not in the "Off" position
Excessivestandstill time
Storage at low temperatures
Chargebattery.
Check battery (see section: Checkingthe battery)
Charge conservation via 12 V on-boardelectricaloutlet.
Fuse is defective Check fuses, replaceif necessary.
Battery is defective Replace battery.
Engine does notstart Petrol tap is closed. Open petrol tap.
Tank ventilation screwis closed. Open tank ventilation screw.
No fuel, or insufficient fuel in the tank. Top-upfuel or if necessaryplace petrol tap in the "Reserve"
position.
Open starter flap / choke (choke on the throttle lever not
activated at start). Close starter flap / choke (activate choke on the throttle lever atstart).
Device has been tipped over –air filter is oily. Replace air filter, unscrewspark plug and start several times
with the petrol tap closed, dry spark plug and screw it back
in.
Engine flooded due to multiple start attempts Unscrewspark plug and startseveraltimes with the petrol
tap closed, dryspark plug and screw it back in.

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General information
Frequentfaultsand rectification(troubleshooting)2/5
Fault Possible cause Remedy
Engine does notstart (continued) Sparkplug connectorunplugged. Fit on spark plug connector.
Air filter contaminated. Serviceair filter (seeunderMaintenanceand cleaning)
Sparkplugsooted, damagedor wrong electrode gap. Clean sparkplug and check electrode gap(see under
section "Engine". Replace sparkplugs as needed.
No oil pressure: Insufficient engine oil. Check engine oil level, top-up. (SAE5W50)
No oil pressure: Excessiveinclination. Bring device into a level position.
Poor, contaminated, or old fuel Clean fuel system. Replace fuel filter. Use fresh fuel.
Engine starts poorly or runs irregularly Starter flap / choke closed (activated on the throttle lever) Open starter flap / choke (after starting deactivate on the
throttle lever)
Air filter contaminated Serviceair filter (seeunder section Engine)
Poor, contaminated, or old fuel Clean fuel system. Replace fuel filter. Use fresh fuel.
Sparkplugsooted, damagedor wrong electrode gap. Clean sparkplug and check electrode gap(see under
section "Engine". Replace spark plugs as needed.

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General information
Frequentfaultsand rectification(troubleshooting)3/5
Fault Possible cause Remedy
Device does not move Traction drive (hydrostat)on the lever unlocked Lock traction drive (hydrostat)on the lever
Hydrostatic drive (hydraulic oil) overheated Let cool. Check cooling air filter.
Bladeclutch doesnot engage Leverfor cutting height adjustment in transportposition Lower leverfor cutting height adjustmentto desiredcutting
height (1to 5)
Blade does notrotate V-belt is not sufficiently tensioned oris damaged. Check belt andbelt tensioner. Replace broken belt.
Bowden cable of the blade clutch is defective. Check Bowden cable,replaceif necessary.
Feather keyof the blade shaftis missing or is defective. Replace feather key.
Strong vibration in operation Imbalance on the blade system due to non-uniformre-
sharpeningor chipping /deformation ofthe blade. Resharpen and balance blade. Replace damagedblades immediately.
Blade drive shaft bent or blade bearingdamaged through
collisions. Repair of the blade shaft and blade bearing.
Engine fastening is loose. Retighten engine fastening.
Blade carrier or locking screws areloose. Check and retighten blade carrier and locking screws.
Abnormalnoises Loose fasteningelements. Localiseand eliminate the sourceof the noise.
Muffler is loose or defective. Fasten or repair muffler / manifold.
Hydrostatic drive overheated Let cool. Check cooling air filter.
Air in the hydrostatic drive, insufficient oil in the hydrostatic
drive. Vent the hydrostatic transmission, checkoil level and top up supply tank (SAE5W50,see section "Drive system")
Find leak and repair it.

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General information
Frequentfaultsand rectification(troubleshooting)4/5
Fault Possible cause Remedy
Engine gets hot Fan grille contaminated. Cleanfan grille. If necessary,even regularlyduring
operation.
Insufficient oil level in the engine. Top up engine oil. See the operating manualprovided by the
engine manufacturer.
Cooling fins of the engine are contaminated. Clean cooling fins of the engine.
Smoke coming from engine Air filter contaminated or soaked with oil, e.g. after the
machine is placed on its side or has fallen over. Serviceor replace air filter (see under Maintenance and cleaning)
Oil level toohigh. Reduce oil level to the "Max" mark.
Cut is not clean, lawn / meadow is unsightly Blade dull or worn. Sharpen / turn and balance blade. Replace damaged blades
immediately.
Drive speedis too high for the grass height or grass density. Reduce drivespeed and/or adjust the cutting height.
Mower deck of the device is heavily contaminated. Clean.
Different tyre pressure. Check tyre pressure.
Mower deck ofthe mower is not parallelto the ground. Adjust the parallelity of the mower deck.
Mow without full-throttle. Blade rotates too slowly. Accelerate full-throttle.
Use of the mulch kit in high grass. Mow high grass without mulch kit
Mulchblade (top blade)installed upside-down. Install mulch blade (top blade) correctly.
Mulching result is unsatisfactory in high growth Drive speedtoo high. Reduce drivespeed.

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General information
Frequentfaultsand rectification(troubleshooting)5/5
Fault Possible cause Remedy
Mulching result is not satisfactory on short growth / lawn Growth is dischargedtoo quickly. Install optional mulch kit. (Maximum grass heightfor mulch
kit 40 cm)
The device doesnot stop when the brake is activated Brake is incorrectlyadjusted, wornor defective. Adjust brake correctlyor repair it. (See section "Operating
elements"
Mow unitbonnetis clogged Mowing grassthat istoo tall or toowet. Adapt cutting height and mowing speed.
Blade worn. Serviceor replace blade system.
Insufficient engine speed,in spite of full throttle. Check the engine.
Engine does notswitch off Switch-off system defective. Close petrol tap.
Tyres go flat or lose air Thorns or sharp objects damage the tyres. Tyre / tube repair, tyre sealant, airless front tyres available
as accessoriesfor Sherpa XL.

General information
Tyre sizes,wheel dimensions,tyre pressures1/2
Tyre pressures
Auniform and correcttyre pressureis essentialfor the following characteristics:
Tractionuphill
Braking force downhill
Suspensioncomfort
Safety :The tyre does not come off of the rim!
Uniform mowing pattern
Rules:
Check the air pressureon aregular basis.
Examine tyres and tyre flanksregularlyfor damage.
Replace damaged tyres.
Only use original AS-MOTOR tyres.
Do not changetyre diameters or tyre sizes.This can damage the 4WD.
Tips /notes:
Inflate the tyres with our recommended tyre pressures.In our opinion, these
pressuresoffer an optimum of suspensioncomfort and traction.
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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 preventflat tyres.Particularlyin tubelesstyres.
Anti-puncture insertstrips can prevent flat tyres.
For the AS 940 Sherpa 4WD XL airless front wheels (foamed with PUR) are
available at PAM.The suspension comfort suffers greatly in this case.
Steering and ball joints are subjected to greater load and wear more quickly.
Additional weight of 7kg per frontwheel.
Pay attention to the running direction of the tyres, left /right for optimal
traction.
Slow pressureloss of atyre indicatesthat there is athorn in the tyre.
Tubed tyres cannot be easily usedwithout atube.
Next page:OverviewTABLE "Wheels"

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General information
Tyre sizes,wheel dimensions,tyre pressures2/2
Model: Front wheel (F) /
rear wheel (R): Tyre size: Recommended air pressure: Maximum air pressure: Tread: Tubed Tyres (TT) / Tubeless (TL): Standard equipment /
optional:
AS 920 Sherpa 2WD F:
R:
R: Twin tyrekit
15 x 5.00-6
18 x 9.50-6
4.00 x 10
17 psi / 1.20 bar
15 psi / 1.00 bar
24 psi / 1.65 bar
18 psi / 1.24 bar
24 psi / 1.65 bar
40 psi / 2.80 bar
Terrain
Terrain
Agriculture
TL
TL
TL
Series
Series
Optional
AS 940 Sherpa 4WD F:
R:
F: XL kit
R: XL kit
R: Twin tyrekit
15 x 5.00-6
18 x 9.50-6
4.80 x 4.00-8
20 x 10.00-8
4.00 x 10
17 psi / 1.20 bar
15 psi / 1.00 bar
23 psi / 1.60 bar
12 psi / 0.80 bar
24 psi / 1.65 bar
18 psi / 1.24 bar
24 psi / 1.65 bar
40 psi / 2.80 bar
22 psi / 1.50 bar
40 psi / 2.80 bar
Terrain
Terrain
AS
AS
Agriculture
TL
TL
TT
TL
TL
Series
Series
Optional
Optional
Optional
AS 940 Sherpa 4WDXL F:
R:
F: Airless PURfoam
4.80 x 4.00-8
20 x 10.00-8
4.80 x 4.00-8
23 psi / 1.60 bar
12 psi / 0.80 bar
Foamed
40 psi / 2.80 bar
22 psi / 1.50 bar
Foamed
AS
AS
AS
TT
TL
Airless PUR
Series
Series
Optional
Tightening torquewheelbolts:
Rearwheels: M12 100Nm
Frontwheels: M8 40 Nm

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General information
Conversionto XL wheels 1/1
TheAS9404WDcanbe retrofittedtoXL
wheels.(Accessories)
Effect:
Groundclearance: + 30 mm.
Cuttingheight: + 30 mm.
Modifiedwheeladapteron therearwheel
is includedin thescopeof delivery. Important:
Underlay4 washersundereachofthe
stop buffersofthefrontaxle.Otherwise
thefrontwheelwill touchthe tubular
frame.

General information
Tighteningtorques for bolted connections1/4
Tightening torques
Correct tightening torques are important to ensure asolid connection of
componentsand to avoid damage
Correct tightening torques are safety-relevant on rotating parts, in particular,
like blades,belt pulleysand wheels.
General tightening torques for hexagon bolts, socket head screws with
hexagonsocketand 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-relevantparts.
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.
Attention:Several bolts of the engines from Briggs &Stratton and all bolts
of the transmissionfrom Tuff-Torq /Kanzaki are inchbolts.
Next pages:TABLES –TIGHTENING TORQUES
Bolts with
standard thread
DIN quality 8.8
Screws or nuts
with under-
head serrations
Thread: Width across
flats: Torque in Nm: Torque in Nm:
M5 86 Nm 8 Nm
M6 10 12 Nm 15 Nm
M8 13 25 Nm 35 Nm
M10 17 55 Nm 70 Nm
M12 19 90 Nm 120 Nm

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General information
Tighteningtorques for bolted connections2/4
Assembly:
(in PAM) Position number in PAM: Designation: Function: Tightening torque in Nm: Dimensions and standard:
Blade with drive #322 Hex nut, self-locking
Blade fastening 90 M 12 DIN 985-8galvanized
#85 Locking screw
Belt pulley 120 M12 x 25 VERBUS-RIPP black
#111 Locking screw
Central locking screw, blade carrier
(long)
120 M12 x 50 VERBUS-RIPP black
#85 Locking screws (2pcs)
Locking screws,blade bars 120 M12 x 25 VERBUS-RIPP black
#85 Locking screws (2pcs)
Upper mulching blade and wrap
protection cup
120 M12 x 25 VERBUS-RIPP black
Engine and belt drive #10 Inch bolt!
Exhaustmanifold fastening 25 Hexagoninch bolt!
#9 Clip
Exhaustfastening 30
#5+#6 Hexagon bolt and locking nut,
fastening muffler on the frame 30 M8 x 16 DIN 933-8.8galvanized M8-8

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General information
Tighteningtorques for bolted connections3/4
Assembly:
(in PAM) Position number in PAM: Designation: Function: Tightening torque in Nm: Dimensions and standard:
Engine and belt drive
(Continued) #20 Inch bolt Hub fastening 85 7/16" x 1"-20 UNF
Hydraulic system #213 Screw-insocket 35 GE 10 S9/16 UNF OMDCF
#211 Fastening,elbow fitting 20 M8 x 35 DIN 933-8.8galvanized
#212 Elbow 30
#68 Screw-insocket 30 GE 15 L3/4 UNF OMDCF
#69 Hydraulic hosethreaded fittings 30
Transmissionrearwith wheels #49 Ventilation 20
Tuff Torq Two oil drain plugs 22 AF 14
#64 Ball collar screws (4 pcs)
Rear wheelfastening 100 M12 x 1.5 x 35-10.9 AF 17
#51 + #50 Vent screw with copper seal 20 M8 x 12 DIN 933-8.8galvanized
#422 Cover oil filter with O-ring 10 Tuff Torq
#42 + #5 Fastening transmission on frame 30 M8 x79, washer8.4 DIN 125,
locking nut M8
#55 Special nut
Fan wheel fastening 50 M10 special nut