AS MOTOR AS 1040 YAK 4WD Adjustment & Maintenance Manual
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AS MOTOR AS 1040 YAK 4WD Adjustment & Maintenance Manual

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

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Summary of Contents for AS MOTOR AS 1040 YAK 4WD

  • Page 1 Workshop Manual 01/2019 DE AS-MOTOR Ride-On Flail Mower AS 1040 YAK 4WD Service Information Adjustment, maintenance and repair instructions www.as-motor.de...
  • Page 2 48 • Mower deck changing p. 25 • Arrangement of the components p. 49 • Innovations p. 28 • Flail shaft Force progression p. 39 Personal notes p. 51 WH AS 1040 YAK 4WD 01/2019 EN Page 2 www.as-motor.de...

  • Page 3: Safety Instructions

     Disconnect the battery via the negative terminal.  This symbol signals a warning. Failure to comply with the warning can result in accidents, injuries and damage! WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 4 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 WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 5 Magnifying glass selection function Shopping cart Complete overview Device and Parts – direct assembly selection selection highlighted red Spare part function Spare parts list Information – FAQ Parts information Availability Change notifications WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 6  Only use hoists and ramps that are suitable. for leaks  Only attach hoists on the main frame, only the main frame can bear the weight.  Safeguard the device against tipping over or falling. WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...

  • Page 7: Technical Data

    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 WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...

  • Page 8: Maintenance Schedule

    Check charge status Before and after each use Annually or every 50 h By the end user with the engine stopped By the end user while the engine is running authorized workshop WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...

  • Page 9: General Information

     Slow pressure loss of a tyre indicates that there is a thorn in the tyre.  Do not change tyre diameters or tyre sizes. This can damage the 4WD.  Tubed tyres cannot be easily used without a tube.  Next page: Overview TABLE "Wheels" WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 10 15 psi / 1.00 bar 24 psi / 1.65 bar Series Tightening torque for wheel bolts / wheel screws: Rear wheels: 100 Nm (73.75 lb-ft)  Front wheels: 40 Nm (29.50 lb-ft)  WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...

  • Page 11: Tightening Torques

    (lb-ft) 6 Nm (4.5) 8 Nm (5.9) 12 Nm (8.6) 15 Nm (11.1) 25 Nm (18.5) 35 Nm (25.9) 55 Nm (40.6) 70 Nm (51.7) 90 Nm (66.4) 120 Nm (88.6) WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 12 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) WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...

  • Page 13: Individual Components

    Individual components Oil drain plug rpm adjustment – accelerator cable Oil filter From above Engine earth Fuel pump Oil filler neck Shut-off valve – carburettor Oil cooler Oil pressure switch (green cable) WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 14 Full-load adjustment Idle stop Idle by bending the stop Regulator spring Centrifugal force regulator (always regulates in the off direction) Final rpm 3600 rpm Engine code Idle rpm 1600 +/- 100 rpm WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 15 Drive Force progression WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 16 Force progression Belt arrangement Drive belt for transmission G07857057 Drive belt for flail shaft G07857035 Drive belt for transmission Angular gear unit G07857056 WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 17 Belt tensioner Belt tensioner for transmission Belt for the transmission From above Belt tensioner for reduction gearing View from the outside Belt tensioner for reduction gearing – view into the frame WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 18 Force progression Position arrangement Engine Hydrostatic transmission Angular gear unit – hydrostatic Output side Flail shaft transmission WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...

  • Page 19: Belt Drive

     unhook spring attention to the spacer sleeves Unhook Bowden cable of the Unscrew bolt and detach belt mower unit coupling guide Unscrew screw slide bolt Remove belt guide from the upward front WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 20 Take off belt Installation in the reverse sequence When installing the (if required) belt tension lever, ensure that the sliding discs are correctly seated  sliding disc must rest on the bearing WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 21 Detach belt pulley Remove circlip and knock out the bearing Detach belt pulley from the Installation in the reverse shaft with a puller  pay sequence attention to the feather key WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 22 Replacing the bearing of the flail shaft (2/2) Detach safety bracket Twist and pull off bearing block  knock-out bearing Remove battery  first Installation in the reverse disconnect the negative sequence terminal Detach cover WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 23 Preliminary tasks, see Pull off the belt pulley "Replacing the flail mower unit V-belts" Remove safety bracket and Detach bearing block battery Detach belt pulley Detach cover on the left side WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 24 Remove flail shaft by moving it downward and to the left Detach bearing guide and skid Installation in the reverse sequence  pay attention to the install position of the bearing guide WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 25  first disconnect the negative terminal Detach Bowden cable and Unscrew bolts and remove the remove eye cover of the drive shaft Pull Bowden cable through the Take-off V-belts spring package WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 26  counter the springs on both sides with AF 27 Offload flail mower unit  prop Unscrew the screw of the it up mower unit holder  counter with AF 27 WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 27 Flail mower unit Removing the flail mower unit (3/3) Lift the machine with a crane Pull the flail mower unit to the side Installation in the reverse sequence WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 28 Flail mower unit Innovations Cleaning nozzle connection From S/N 033118060032 New bearing installed Flail shaft installed Screw must completely fill out the nut WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 29 Flail mower unit Force progression From the engine Belt drive WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 30 Force progression Position arrangement Engine Hydrostatic transmission Angular gear unit – hydrostatic Output Flail shaft transmission side WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 31 Detach the blade clutch cable Prop up vehicle right rear and take off rear wheel Take off V-belt of the mower Detach belt cover unit drive WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 32 Take off the fan grille Installation in the reverse sequence  when installing the fan grille pay attention to the sealing lip on the air duct WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 33 -Put the oil pan under the rear axle container only when filling and (about 4.5 liters) bleeding the front axle. -Remove underrun protection -Unscrew cover (3/8 inch) Remove oil filter WH AS 1040 YAK 4WD 01/2019 EN Seite 33 www.as-motor.de...
  • Page 34 The device may only be started with a fully vented hydrostatic drive. If the hydrostatic drive is not fully vented, it will be damaged. Seite 34 WH AS 1040 YAK 4WD 01/2019 EN www.as-motor.de...

  • Page 35: Drive Lever

    Drive lever Arrangement Drive lever with cruise control function WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 36 4 friction discs (419) hold the drive lever in position (cruise control function) Brake must be adjusted in such a manner that at activation of the pedal, the lever always goes automatically into the middle position. WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...

  • Page 37: Hydraulic System

    Hydraulic system View from below WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 38 Hydraulic system Hydraulic system diagram AS 1040 YAK 4WD Rear axle Front axle 6.8 l fully-synthetic engine oil 5W-50 WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 39 Hydraulic system Installation of the lines Transmission rear axle Front axle Oil change same as for AS 940 WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 40 When cornering this motor runs faster or slower. The servomotor is activated via a linkage. It must be ensured that the linkage is not bent. This can cause a blocking of the front angle. Adjustment unit Adjustment motor WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 41 Steering Position of the steering column lever in the toothed segment WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 42 Steering Adjusting the differential 90 degrees Adjust lever vertically to the axle WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...

  • Page 43: Front Axle

    At the stop of the axle on the damper, this cause a braking and damping of the pendulum path. This keeps the machine stable on uneven terrain. WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...

  • Page 44: Adjusting The Pedals

    Brake lever Play on the cable approx. 6-8 mm – cable should be adjusted in such a manner that at ½ distance the drive lever goes automatically into the brake position (middle) WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 45 Seat springs Adjustment screw WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...

  • Page 46: Belt Tensioner

    Structure: sleeve (146), spring (148), linkage (144), piston (145) For repair ensure that all moving parts can move freely 1 cm between sleeve and joint head WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...

  • Page 47: Electrical System

    Fuses Power outlet Ignition lock Starter relay mounted for the motor + to fuse Tachometer cable Engine connector, cable to shut-off valve Safety relay Switch for blade clutch WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 48 Electrical system Electrical circuit diagram – AS 1040 YAK 4WD WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...

  • Page 49: Arrangement Of The Components

    Orange shut-off valve carburettor Frame next to the battery Green oil pressure switch Red power supply Micro switch Fuses Drive lever Ignition lock Micro switch Generator regulator 12 V Blade clutch WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 50 Arrangement of the components Central connector – engine Starter relay at the bottom on the engine on a rubber bearing If the rubber of the bearing is damaged, replace the bearing WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...

  • Page 51: Personal Notes

    Personal notes WH AS 1040 YAK 4WD 01/2019 EN Page www.as-motor.de...
  • Page 52 AS-MOTOR Germany GmbH & CO.KG Ellwanger Strasse 15 74424 Bühlertann, Germany www.as-motor.de info@as-motor.de www.parts-and-more.org All rights reserved. Reprint, duplication or publication without approval are prohibited. Subject to technical changes. www.as-motor.de...

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