AS MOTOR Allmaher AS 65 4T B&S Workshop Manual
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AS MOTOR Allmaher AS 65 4T B&S Workshop Manual

AS MOTOR Allmaher AS 65 4T B&S Workshop Manual

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WORKSHOP MANUAL
AS-MOTOR Allmäher
AS 65 4T B&S
AS 65 2T ES
(from series start approx. 04/2015)
AS 65 2T (2. cat) (to series end approx. 03/2015)
AS 65 4T Honda
(from series start GXV 07/2016)
AS 73 4T B&S
Service Information
Adjustment, maintenance and repair instructions
03/2020 EN
®
G00052017 EN
www.as-motor.de

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Summary of Contents for AS MOTOR Allmaher AS 65 4T B&S

  • Page 1 WORKSHOP MANUAL 03/2020 EN AS-MOTOR Allmäher ® AS 65 4T B&S AS 65 2T ES (from series start approx. 04/2015) AS 65 2T (2. cat) (to series end approx. 03/2015) AS 65 4T Honda (from series start GXV 07/2016) AS 73 4T B&S Service Information Adjustment, maintenance and repair instructions G00052017 EN...

  • Page 2: Table Of Contents

    Workshop Manual AS-MOTOR Allmäher AS 65 / AS 73: ® Table of contents Navigate quickly and easily in the PDF document. Tip: You can navigate in the PDF document via mouse-over click – click page Drive: number and click www.as-motor.de to return to the table of contents. •...

  • Page 3: Introduction

    Introduction Preface and validity Preface Validity This Repair Manual is designed to make it easier for you to properly make This Workshop Manual is based on the following current device versions: adjustments, perform maintenance and make repairs on AS 65 and AS 73 (Version 06/2017) Allmähers.

  • Page 4: Deviating Device Versions And Safety Instructions

    Introduction Deviating device versions and safety instructions Deviating device versions For future device versions this Workshop Manual will be revised annually. Please ensure on a regular basis that your version of the Workshop Manual is Since the market launch of the AS 65 Allmäher, the machine has been the right one/or is up to date.

  • Page 5: Notice - Original Spare Parts Accessories And Technical Data

    Introduction Notice – original spare parts and technical data (versions 09/2017) 1/3 Original spare parts Technical data AS 65 4T B&S: (Version 09/2017) 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;...
  • Page 6 Introduction Technical data (current models, versions 09/2017) 2/3 Technical data AS 65 2T ES (EasyStart): Technical data AS 65 4T Honda GXV: workshop manual AS 65/73 Allmäher® 03/2020 EN Page www.as-motor.de...
  • Page 7 Introduction Technical data and accessories (current models, versions 06/2017) 3/3 Technical data – AS 73 4T B&S: Accessories – AS 65 and AS 73 Allmähers:  Twin tyres for steep slopes (AS 65 2T and 4T B&S(*))  Snorkel filter for AS 65 2T ES (at high dust load) ...

  • Page 8: Online Service Portal "Parts-And-More.org" (Pam) 1/2

    Introduction Online service portal "parts-and-more.org" (PAM) 1/2 Online service portal "parts-and-more.org" (PAM) Access data is issued within one to two days after "Dealer first login" using the AS-Motor customer number. For all tasks shown in this Workshop Manual the online service portal "parts- After receipt of the access data (parts ID and password) you can log in via and-more.org"...
  • Page 9 Introduction Online Service Portal "parts-and-more.org" (PAM) 2/2 Parts search Print function Language Magnifying glass selection function Shopping cart Complete overview Device and Parts direct selection assembly selection highlighted red Spare parts list Spare part function Parts information Change notifications Availability Important workshop information and workshop manuals...

  • Page 10: General Information

    General information Frequent faults and rectification (troubleshooting) 1/4 AS 65 2T (two stroke) models workshop manual AS 65/73 Allmäher® 03/2020 EN Page www.as-motor.de...
  • Page 11 General information Frequent faults and rectification (troubleshooting) 2/4 AS 65 2T models (continued) Other faults (experiential values from the past): - AS 65 2T (cat. 2. generation): Rotational speed increases significantly in idle. Cause: Outside air, carburettor or shaft seal of the crankshaft leak. First of all try other carburettor.
  • Page 12 General information Frequent faults and rectification (troubleshooting) 3/4 AS 65/73 4T models workshop manual AS 65/73 Allmäher® 03/2020 EN Page www.as-motor.de...
  • Page 13 General information Frequent faults and rectification (troubleshooting) 4/4 AS 65/73 4T models (continued) Other faults (experiential values from the past): - AS 65 2T (cat. 2. generation): Rotational speed increases significantly in idle. Cause: Outside air, carburettor or shaft seal of the crankshaft leak. First of all try other carburettor.

  • Page 14: Tyre Sizes, Wheel Dimensions, Tyre Pressures 1/2

    General information Tyre sizes, wheel dimensions, tyre pressures 1/2 Tyre pressures  High tyre pressures have a negative influence on suspension comfort and traction. A uniform and correct tyre pressure is essential for the following characteristics:  Do not underrange the recommended tyre pressures. Tyres can come off of ...
  • Page 15 General information Tyre sizes, wheel dimensions, tyre pressures 2/2 Model: Front wheel (FW) / Tyre size: Recommended Maximum air Tread: Tubed Tyres (TT) / Standard rear wheel (RW): air pressure: pressure: Tubeless (TL): equipment / optional: AS 65 4.80/4.00-8 36 psi / 2.50 bar Series RW : 12 psi / 0.80 bar to...

  • Page 16: Tightening Torques For Bolted Connections

    General information Tightening torques (turning moments) for bolted connections 1/2 Tightening torques Special tightening torques In the tables on the following pages the individual torques are presented for Correct tightening torques are important to ensure a solid connection of essential, special and safety-relevant parts. components and to avoid damage Correct tightening torques are safety-relevant on rotating parts, in particular, Tip / note:...
  • Page 17 General information Special tightening torques for bolted connections 2/2 Assembly: Position number in PAM: Designation: Tightening torque in Nm: Dimensions and standard: (in PAM) Function: Blade with fastening AS 65 and Locking screw. 120+5 AS 73 Central locking screw Locking screws (2 pcs) 120+5 Blade bearing –...

  • Page 18: Fuel, Lubricants, Fill Quantities, Consumption 1/2

    General information Fuel, lubricants, fill quantities, consumption 1/2 Fuel AS 65 4T B&S, 4T Honda and AS 73 4T B&S: The fuel must fulfil the following requirements: AS 65 2T (EasyStart)  Clean, fresh, non-leaded petrol. The AS 2-stroke, 165 ES engine must be operated with a mixture of petrol and ...
  • Page 19 General information Fuel, lubricants, fill quantities, consumption 2/2 Fill quantities – engine oil Note concerning oils for the Briggs & Stratton Intek 3 130 engine: AS 65 4T B&S Intek 3 130 344cc with filter • 1.36 – 1.40 litres AS 73 4T B&S Intek 3 130 344cc with filter •...

  • Page 20: Maintenance Tasks, Cleaning And Maintenance Intervals 1/4

    General information Maintenance tasks, cleaning and maintenance intervals 1/4 Maintenance and cleaning (general information)  Stay out of the tipping area. To ensure the full functionality, the safety and a long service life of the Clean the device: machine, regular maintenance and cleaning of the machine are essential. All necessary activities and their intervals are listed on the following pages.
  • Page 21 General information Maintenance tasks, cleaning and maintenance intervals 2/4 Check safety functions Check blades (see section "Mowing unit", Blade replacement and blade maintenance) Danger! There is a considerable danger of injury if the blades are Check parking brake (see section "Operating elements", parking brake) improperly mounted and maintained! Ensure that the parking brake functions faultlessly.
  • Page 22 General information Maintenance tasks, cleaning and maintenance intervals 3/4 Vibration (see section "Mower deck") Important for many years of proper function of an AS-Motor device: Vibration indicates imbalance in the rotating system. Causes can be:  One-sided wear of the blade ...
  • Page 23 General information Maintenance tasks, cleaning and maintenance intervals 4/4 (*) 4-stroke devices only workshop manual AS 65/73 Allmäher® 03/2020 EN Page www.as-motor.de...

  • Page 24: Engines (2-Stroke And 4-Stroke)

    Engines Overview and maintenance schedules 1/3 Overview Model: AS 165 ES (easy Start) or AS 165 cat. engine (to 03/2015) Model: B&S Intek Series 3 130 (model no.: 210000)  Design: Single-cylinder, two-stroke engine  Design: Single-cylinder, four-stroke engine  Displacement: 165 ccm ...
  • Page 25 Engines Overview and maintenance schedules 2/3 Maintenance schedule for B&S Intek Series 3 130: (AS 65 4T B&S and AS Model: Honda GXV 160 73 4T B&S)  Design: Single-cylinder, four-stroke engine with choke.  Displacement: 163 ccm  Max. Net torque: 9.6 Nm at 2,500 rpm ...
  • Page 26 Engines Overview and maintenance schedules 3/3 Maintenance schedule for Honda GXV 160 Perform at every indicated month/year or operating hour interval, whichever comes first. (1) Maintenance schedule for AS 165 ES 2-stroke engine (see also maintenance schedule) Sufficient engine cooling is particularly important for a long service life of the engine.

  • Page 27: Carburettor And Regulator Adjustment As 65 2T Es And 2T Cat. Engine 1/4

    Engines Carburettor and regulator adjustment AS 65 2T ES and 2T cat. engine 1/4 Attention: Install the carburettor precisely at a 90 degree angle to the engine. Since 2011 the AS 65 2T has had the AS 165 2T engine with catalytic converter, 2nd generation.
  • Page 28 Engines Carburettor and regulator adjustment AS 65 2T ES and 2T cat. engine 2/4 Adjustment of the air regulating Adjustment of the regulator (wind vane) for maximum rpm. screw. Close completely and then re-open slightly. Setpoint: max. 3,900 - 4,000 rpm. How far should I open it? See Fig.
  • Page 29 Engines Carburettor and regulator adjustment AS 65 2T ES and 2T cat. engine 3/4 Important: Position of the wind vane (mechanical regulator) at full throttle In this position the wind vane (throttle flap completely opened). (mechanical regulator) is precisely on the 5th cooling fin! Not further or shorter! To do this simply bend the wind vane plate into shape by hand.
  • Page 30 Engines Carburettor and regulator adjustment AS 65 2T ES and 2T cat. engine 4/4 Tip / note: Many carburettor problems are caused by old or contaminated fuel. Even an upstream fuel filter does not offer complete safety in this regard. Do not use any fuel that is more than 4-months old.

  • Page 31: Mowing Deck

    Mowing deck Blade maintenance and mounting 1/1 Attention: Dismount blade and upper wing Tighten the locking screws with blade To do this block with a 120+5 Nm! Wing blade sits above wedge. the main blade! The three locking screws. The Important safety instructions: middle screw is longer than the See section: "General information,...

  • Page 32: Replacing The Blade Belt 1/5

    Mowing deck Replacing the blade belt 1/5 Safely park the machine. Pull off the Fold the top bar forward to provide spark plug connector. space. Prop up the machine under the Unscrew the belt cover. transmission so that the wheels do not touch the ground.
  • Page 33 Mowing deck Replacing the blade belt 2/5 View of the blade clutch, blade Screw on the belt plate. brake, belt pulley and blade belt. Unhook tension spring of the brake Belt is now free on the blade belt lever. pulley. Brake lever upward, pull off by Pull the belt off of the belt pulley.
  • Page 34 Mowing deck Replacing the blade belt 3/5 Unscrew the belt guide of the belt Take off the right drive wheel. tensioner. Take off the left drive wheel. Take off the right side guard. Unscrew the left side guard. Belt holder to the right of the blade belt becomes visible.
  • Page 35 Mowing deck Replacing the blade belt 4/5 Unscrew the right belt holder. Unhook the blade drive cable from the belt holder. Belt holder on the left side with Unscrew left belt holder. blade drive cable. Unhook blade drive cable on the Blade belt is now free and can be tensioning pulley.
  • Page 36 Mowing deck Replacing the blade belt 5/5 Pull out belt to the front and thread it out between tensioning pulley engine carrier. To do this, activate the tensioning pulley by hand. Mount new belt in the reverse sequence. workshop manual AS 65/73 Allmäher® 03/2020 EN Page www.as-motor.de...

  • Page 37: Blade Bearing - Dismounting And Mounting 1/4

    Mowing deck Blade bearing – dismounting and mounting 1/4 Take off belt cover. Unscrew the fastening screw of the belt pulley. To do this block the blade. (Note: Tightening torque 120 Nm!) Unhook tension spring of the engine Take off belt pulley and feather key. brake and take off the brake lever.
  • Page 38 Mowing deck Blade bearing – dismounting and mounting 2/4 Unscrew bonnet disc. Blade bearing Caution: Blade bearing will now fall downward and out! Removed blade bearing. Grease the bearing seats Mounting of the entire blade bearing Fit upper ball bearing on the blade in detail: shaft.
  • Page 39 Mowing deck Blade bearing – dismounting and mounting 3/4 Install brass (not steel!) feather Press in the first and second ball bearings one after the other. key. Blade shaft with the three pressed- Fit on the support disc. in bearings. Fit on the blade pulley.
  • Page 40 Mowing deck Blade bearing – dismounting and mounting 4/4 Prior to mounting the blade, fit on the wrap protection cup. Tightening torque of the three blade locking screws 120 Nm. Re-install the blade bearing in the reverse sequence. workshop manual AS 65/73 Allmäher® 03/2020 EN Page www.as-motor.de...

  • Page 41: Replacing The Entire Mowing Deck 1/2

    Mowing deck Replacing the entire mowing deck 1/2 Problem – deformed mowing deck: Frame must be checked for deformation and damage. Through a strong collision of the blade with a foreign object, the bonnet can be severely warped or deformed. If the seat/fastening of the blade bearing is likewise warped, the belt can come off, the brake arm can rub or belt wear can occur.
  • Page 42 Mowing deck Replacing the entire mowing deck 2/2 Removal of the blade bearing, see section: Mowing deck, blade bearing – dismounting and mounting. Installation in the reverse sequence. Position of all parts attached on the mowing deck. All must be unscrewed.

  • Page 43: Replacing The Drive Belt 1/5

    Drive Replacing the drive belt 1/5 First the blade belt must be taken Unhook the tension spring of the off. traction drive. See section: Mowing deck, Replacing the blade belt. When the blade belt is taken off the Unhook the drive cable on the drive belt that is above it can be deflection lever of the brake.
  • Page 44 Drive Replacing the drive belt 2/5 Activate the deflection lever by Unscrew the tensioning pulley of hand and take off the cover plate of the drive belt the belt pulley Take off cover plate. Take off the drive belt with the loose tensioning pulley carrier.
  • Page 45 Drive Replacing the drive belt 3/5 Removed tensioning pulley carrier. Pull the belt to the rear to the belt Check the bearings of the roller. pulley of the transmission. Do not pull it on yet. Re-installation of the new belt. Now pull the drive belt onto the belt Introduce the tensioning pulley pulley of the engine hub.
  • Page 46 Drive Replacing the drive belt 4/5 View from the right side. Hold the tensioning pulley carrier in position and screw it back on. Attention: Do not tighten too tightly. It must be possible for the tensioning pulley carrier to move freely.
  • Page 47 Drive Replacing the drive belt 5/5 Hook the drive cable back in. Hook the tension spring of the traction drive back in. Pull the blade belt back on in the reverse sequence. See section: Mowing deck, Replacing the blade belt. workshop manual AS 65/73 Allmäher®...

  • Page 48: Removal Of Chain Drive And Limited Slip Differential 1/9

    Drive Removal of chain drive and limited slip differential 1/9 Safely park the machine and Wheel hubs and chain guard of the safeguard it from falling. Pull off the chain drive are exposed. spark plug connector. Prop up the machine under the Unscrew the three screws of the transmission so that the wheels do chain guard.
  • Page 49 Drive Removal of chain drive and limited slip differential 2/9 With a screwdriver, push the chain Repeat the same procedure on the lock to the side and open it. other side. Take off chain. Take off the circlip of the wheel hubs.
  • Page 50 Drive Removal of chain drive and limited slip differential 3/9 Pull off wheel hub. Take off the long Counter chain pinion with a chain feather key and thrust washers. and unscrew it. Sequence of the three thrust Clutch shaft with bearing plate and washers.
  • Page 51 Drive Removal of chain drive and limited slip differential 4/9 Repeat the same procedure on the Take the clutch out of the lever other side. housing. Tip/note: The clutch is extremely robust and durable, however it must be free of oil and grease.
  • Page 52 Drive Removal of chain drive and limited slip differential 5/9 Assembly of the clutch of limited Insert the cover in the four grooves. slip differential. All parts must be free of oil and grease! Insert the first copper disc. Insert the middle disc in the four Fit the metal disc on the toothed grooves.
  • Page 53 Drive Removal of chain drive and limited slip differential 6/9 Refasten the clutch. Fit the clutch shaft with feather key into the clutch. Insert the three carriage bolts into Re-insert the entire clutch. The the lever housing. three carriage bolts must fit precisely.
  • Page 54 Drive Removal of chain drive and limited slip differential 7/9 Repeat the whole procedure on the Now forcefully tighten the right left side. Do not tighten yet! chain pinion! Forcefully tighten the left chain To do this, counter the clutch shaft pinion! with a metal pin in a hole of the clutch shaft.
  • Page 55 Drive Removal of chain drive and limited slip differential 8/9 Fit on wheel hubs left and right. Latch the chain lock in place with Insert feather keys. the closed side in the direction of travel. Fit on the feather key and fasten it Chains are now still loose.
  • Page 56 Drive Removal of chain drive and limited slip differential 9/9 Forcefully tighten bearing plates left and right. Reassemble the chain covers and wheels in the reverse sequence. Hook the differential cable back in Attention: When assembling, the and counter it. If the lever is not lower-most screw of the chain activated, it must not exert any pull guard must not be too long,...

  • Page 57: Removal Of The Transmission

    Drive Transmission removal 1/3 First the blade belt must be taken Wheel hubs with chains are now off. exposed. See section: Mowing deck, Replacing the blade belt. Now the drive belt must be taken Take off the chains on both sides. off.
  • Page 58 Drive Transmission removal 2/3 Do not forget the feather key. Unscrew the shift lever. Inch bolt! Take off the wheel hub and the Position the machine on the three thrust washers. discharge plate. Safeguard it against falling! The three thrush washers and their Unhook tension spring of the brake install direction.
  • Page 59 Drive Transmission removal 3/3 Unscrew the transmission on the Pull the transmission downward and two axles. out. Unscrew the left rear threaded Re-installation: fitting. Again from the rear, move in the transmission downward and fasten it. "Triangle" mark of the deflection lever must be on the marked, first tooth of the brake lever! Unscrew the right rear threaded...

  • Page 60: Operating Elements

    Operating elements Drive cable and brake adjustment 1/3 The drive lever is on the right side Brake engaged…….. of the handlebar. When activating the drive lever the …..Tensioning pulley lever of the cable (Z), the brake (1) and the drive not tensioned. tensioning pulley lever (2) of the drive belt are tensioned via the tension spring (3).
  • Page 61 Operating elements Drive cable and brake adjustment 2/3 …..Brake released…… Target adjustment of the brake: Brake lever plate is flush with the aperture in the frame. To do this, carefully turn the …..Tensioning pulley lever of the adjustment screw of the drive tensioned.
  • Page 62 Operating elements Drive cable and brake adjustment 3/3 Brake test: Brake lever plate with marked tooth. Drive lever activated, place shift lever on "N" position. Hub can be easily moved. If not, the drive cable is over-tensioned or the adjustment screw of the transmission brake is over-tightened.

  • Page 63: Blade Clutch Cable Replacement And Adjustment 1/3

    Operating elements Blade clutch cable replacement and adjustment 1/3 AS 65: Factory setting of the upper cable stop. The lever of the blade clutch is on the left on the handlebar. For activation, the small safety button must be pressed and the lever of the blade clutch must be activated.
  • Page 64 Operating elements Blade clutch cable replacement and adjustment 2/3 AS 73: When activating the blade clutch cable, the integrated spring The AS 73 has two blade speeds package of the cable tensions the and therefore, two independent cable approx. 4 to 5 centimetres. blade clutches and blade clutch cables.
  • Page 65 Operating elements Blade clutch cable replacement and adjustment 3/3 Tip/note: Double tensioning pulleys and cables. Which blade clutch cable is which? Cables are hooked in on the 1= slow blade speed with high force tensioning pulleys. for high, dense grass. 2= high blade speed with less force for a better cutting pattern in low grass/lawn (max.

  • Page 66: Accelerator Cable Adjustment 1/2

    Operating elements Accelerator cable adjustment 1/2 AS 65/73 4T B&S: Adjustment via the cable stop. Idle position of the throttle lever. Full throttle position of the throttle AS 65 4T Honda: lever. The control bores are up to Bring throttle lever into zero +/- 2 mm one above the other.
  • Page 67 Operating elements Accelerator cable adjustment 2/2 AS 65 2T ES and 2T: Full throttle position of the throttle lever. The metal arm touches the Bring throttle lever into zero choke lever without moving it. position. Nipple of the accelerator cable projects 3 cm. Choke position of the throttle lever.

  • Page 68: Electrical System

    Electrical system Cabling 1/2 AS 65 / 73 4T B&S: Cabling from below. Switch AS 65/73 4T B&S to April Here with cable of an 2016. operating hour meter (X). Left – the bypass button of the oil pressure sensor. Cabling from below.
  • Page 69 Electrical system Cabling 2/2 Cabling on the B&S Intek engine. Cabling: Blue cable on the cable stop. Brown cable on the black cable and then to the ON/OFF switch. AS 65 4T Honda: AS 65 2T (ES): Switch AS 65 4T Honda. Cabling: Blue cable on earth of the engine block.

  • Page 70: Personal Notes

    Personal notes: workshop manual AS 65/73 Allmäher® 03/2020 EN Page www.as-motor.de...
  • Page 71 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. 03/2020 EN www.as-motor.de...

This manual is also suitable for:

Allmaher as 65 2t esAllmaher as 65 2tAllmaher as 65 4t hondaAllmaher as 73 4t b&s

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