PDF Technical Manual John Deere F510 F525 Front Mower - 2 MB
This is the complete technical manual for John Deere F510 and F525 Residential Front Mowers.
It provides detailed service information, including diagnostics, repairs, and maintenance procedures.
The manual is written for technicians and contains everything needed to service these mowers to factory standards.
It's an indispensable guide for any serious repair work.
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--- Page 1 ---
F510 and F525
Residential
Front Mowers
John Deere Horicon Works
TM1475 (23OCT95)
LITHO IN U.S.A.
ENGLISH
--- Page 3 ---
Contents
10
TM1475 (23OCT95) 10-2 F510/F525 Front Mowers
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--- Page 4 ---
Safety
DISPOSE OF WASTE PROPERLY
10 Improperly disposing of waste can threaten the
05 environment and ecology. Potentially harmful waste used
10
with John Deere equipment include such items as oil,
-UN-26NOV90
fuel, coolant, brake fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not
use food or beverage containers that may mislead
someone into drinking from them.
TS1133
Do not pour waste onto the ground, down a drain, or
into any water source.
Air conditioning refrigerants escaping into the air can
damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN -19-03MAR93
LIVE WITH SAFETY
Before returning machine to customer, make sure
machine is functioning properly, especially the safety
systems. Install all guards and shields.
-19-07OCT88
TS231
DX,LIVE -19-25SEP92
TM1475 (23OCT95) 10-05-10 F510/F525 Front Mowers
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--- Page 5 ---
Repair Specifications/Repair Specifications
Group 20—Cylinder Block and Internal Components—Continued
10 Item Specification
15
8 Support Shaft
Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.93 mm (1.021 in.)
Nuts Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 N·m (65 lb-in.)
Piston
Maximum Ring Groove Clearance
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.17 mm (0.007 in.)
Second Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.20 mm (0.008 in.)
Minimum Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.18 mm (0.007 in.)
Maximum Ring End Gap
Compression Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.90 mm (0.035 in.)
Oil Ring Side Rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30 mm (0.051 in.)
Minimum Pin O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.98 mm (0.865 in.)
Maximum Pin Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.04 mm (0.868 in.)
Maximum Piston-to-Piston Pin Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.06 mm (0.002 in.)
Piston O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.83—88.86 mm (3.4885—3.498 in.)
Piston-to-Cylinder Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.11—0.15 mm (0.0043—0.0059 in.)
Connecting Rod
Maximum Crankshaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.07 mm (1.617 in.)
Maximum Piston Pin Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.06 mm (0.868 in.)
Maximum Connecting Rod-to-Piston Pin Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003 in.)
Maximum Connecting Rod-to-Crankpin Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.14 mm (0.006 in.)
End-Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N·m (177 lb-in.)
Crankshaft
Minimum PTO Side Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.90 mm (1.492 in.)
Minimum Flywheel Side Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.95 mm (1.376 in.)
Minimum Connecting Rod Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.93 mm (1.611 in.)
Maximum Crankcase Cover Plain Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.06 mm (1.498 in.)
Ball Bearing O.D.-New Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79.98-80.00 mm (3.149-3.150 in.)
Maximum T.I.R. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.)
End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.09—0.22 mm (0.004—0.009 in.)
Oil Seal Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.)
Cylinder Bore
Standard Cylinder Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.98—89.00 mm (3.503—3.504 in.)
Maximum Cylinder Bore I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.08 mm (3.507 in.)
Piston-to-Cylinder Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.11—0.15 mm (0.0043—0.0059 in.)
Continued on next page MX,1015CL,6 -19-23OCT95
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--- Page 6 ---
Fuel and Lubricants
GASOLINE STORAGE
10 IMPORTANT: Keep all dirt, scale, water or other
20 foreign material out of gasoline.
2
Keep gasoline in a safe, protected area and in a clean,
properly marked “UNLEADED GASOLINE” container. DO
NOT use de-icers to attempt to remove water from
gasoline. DO NOT depend on fuel filters to remove water
from gasoline. It is recommended that a water separator
be installed in the storage tank outlet.
BE SURE to properly discard unstable or contaminated
gasoline.
Whether the unit is either stored or used during the
winter, it is recommended that you add John Deere
Gasoline Conditioner and Stabilizer (TY15977) or an
equivalent to the gasoline. BE SURE to follow directions
on container and properly discard empty container.
It is recommended that gasoline be stored ONLY in an
approved POLYETHYLENE PLASTIC container
WITHOUT any metal screen or filter. This will help
prevent any accidental sparks from occurring.
MX,1020CL,2 -19-23OCT95
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Fuel and Lubricants
10
20
12
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--- Page 8 ---
Remove and Install Engine/Install Engine
20
05
6
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--- Page 9 ---
Cylinder Head and Valves/Inspect and Replace Stem Seals
REMOVE AND INSTALL VALVES AND
SPRINGS
1. Remove cylinder head. (See Remove and Install
Cylinder Head Assembly in this group.)
-UN-31AUG88
2. Compress intake valve spring with JDM70 Valve
20 Spring Compressor and remove collet halves (A).
15
6 3. Remove spring retainer (B) and spring (C).
M50033
4. Remove exhaust valve rotator with a magnet.
5. Support exhaust valve from below and press down on
spring retainer.
6. Remove retainer, spring and valves.
-UN-31AUG88
7. Inspect and replace stem seals as necessary. (See
Inspect and Replace Stem Seals in this group.)
8. Inspect and analyze valves. (See Inspect Valves in
this group.)
M50034
9. Inspect springs, valves, guides and seats. (See
procedures in this group.)
10. Install valves, springs, and retainers.
MX,2015CL,A6 -19-23OCT95
INSPECT AND REPLACE STEM SEALS
Remove valves and springs. (See Remove and Install
Valve and Springs in this group.)
-UN-31AUG88
IMPORTANT: Inspect seal. If seal is not damaged, DO
NOT remove it. Bottom spring retainer
can only be removed with valve stem
seal. Removal of retainer or seal
damages stem seal. If necessary to
M50111
replace stem seal, remove with
screwdriver.
MX,2015CL,A7 -19-23OCT95
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--- Page 10 ---
Cylinder Block and Internal Components/Service Parts Kits
SERVICE PARTS KITS
The following kits are available through your parts
catalogue.
Camshaft and Tappet Kit
20 Camshaft Axial Play Shim Kit
20
2 Piston Ring Kit
Oversized Piston
Oversized Piston Rings
Undersized Connecting Rod
Crankshaft End Play Shim Kit
Cylinder Block
Overhaul Gasket Kit
Short Block Kit
Oil Pump Kit
Governor and Shaft Kit
MX,2020CL,A2 -19-04MAY92
TM1475 (23OCT95) 20-20-2 F510/F525 Front Mowers
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--- Page 11 ---
Cylinder Block and Internal Components/Piston and Connecting Rod
REMOVE AND INSTALL PISTON AND
CONNECTING ROD
1. Remove cylinder head. (See Remove and Install
Cylinder Head Assembly in Group 15.)
-UN-05APR89
2. Remove crankcase cover. (See Remove and Install
20 Crankcase Cover in this group.)
20
12 3. Remove carbon and varnish from top of cylinder bore
M52984
with a ridge reamer.
4. Remove cap screws and connecting rod cap (A).
5. Push piston and connecting rod from cylinder bore.
6. Make repairs as necessary.
MX,2020CL,A15 -19-23OCT95
7. Deglaze cylinder bore. (See Deglaze Cylinder Bore in
this group.)
8. Stagger piston ring end gaps 180Ëš apart, but do not
align with oil ring side rail end gaps.
-UN-31AUG88
9. Apply a light film of oil to piston and rings. Compress
rings with a ring compressor.
10. Apply a light film of oil to cylinder bore, connecting
M50074
rod bearing surface and cap screws.
11. Install piston assembly in cylinder bore with engraved
match mark/arrow on piston head facing flywheel side of
engine.
12. Install connecting rod cap and cap screws. Tighten
cap screws to 20 N·m (177 lb-in.).
MX,2020CL,A16 -19-23OCT95
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--- Page 12 ---
Cylinder Block and Internal Components/Crankshaft
REMOVE, INSPECT AND INSTALL
CRANKSHAFT
1. Remove camshaft. (See Remove and Install Camshaft
in this group.)
-UN-09JAN91
2. Remove piston and connecting rod. (See Remove and
20 Install Piston and Connecting Rod in this group.)
20
22 3. Remove balancer. (See Remove and Install
M54495
Reciprocating Balancer in this group.)
4. Remove crankshaft.
IMPORTANT: A bent crankshaft must be replaced; it
cannot be straightened.
5. Check crankshaft alignment (TIR). (See Check
Crankshaft Alignment (TIR) in this group.)
6. Clean and inspect crankshaft. Replace if parts are
scratched or damaged.
7. Analyze crankshaft and connecting rod wear. (See
Analyze Crankshaft and Connecting Rod Wear in this
group.)
8. Measure crankshaft main bearing journals and
connecting rod journal. Replace crankshaft if
measurements are less than specifications.
JOURNAL SPECIFICATIONS (MINIMUM)
Main Bearing Journal Connecting
PTO Side Flywheel Rod Journal
Side
PA420A 34.92 mm 34.95 mm 40.93 mm
(1.375 in.) (1.376 in.) (1.611 in.)
PA540A 37.90 mm 34.95 mm 40.93 mm
(1.492 in.) (1.376 in.) (1.611 in.)
MX,2020CL,A25 -19-23OCT95
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--- Page 13 ---
Cylinder Block and Internal Components/Oil Pump—PA420A
INSPECT OIL PUMP—PA420A
1. Inspect all parts for wear or damage. Replace as
necessary.
A—Plate
B—Spring
C—Ball
20 D—Gear
20 E—Cover
32 F—Screen
G—Outer Rotor
H—Rotor Shaft With Gear
-UN-09JAN91
M80019
MX,2020CL,A39 -19-23OCT95
2. Measure outside diameters of shaft. Replace both
shaft and outer rotor if less than specification.
SPECIFICATIONS
Minimum Shaft O.D.
-UN-09JAN91
Large O.D. . . . . . . . . . . . . . . . . . . . . . . . . 12.63 mm (0.497 in.)
Small O.D. . . . . . . . . . . . . . . . . . . . . . . . . . 7.94 mm (0.313 in.)
M80150
MX,2020CL,A40 -19-04MAY92
3. Measure rotor shaft bearings. Replace oil pump cover
or crankcase cover if greater than specifications.
SPECIFICATIONS
Maximum Rotor Shaft Bearing I.D.
-UN-09JAN91
-UN-09JAN91
Oil Pump Cover . . . . . . . . . . . . . . . . . . . . . 12.76 mm (0.502 in.)
Crankcase Cover . . . . . . . . . . . . . . . . . . . . . 8.07 mm (0.318 in.)
M80151
M80152
MX,2020CL,A41 -19-04MAY92
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--- Page 14 ---
Contents
30
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Carburetor/Remove and Install Carburetor
REMOVE AND INSTALL
CARBURETOR—PA540A
N CAUTION: Gasoline is explosive. DO NOT
expose to spark or flame. Serious personal
-UN-09JAN91
injury may result. Wipe-up any spilled fuel
IMMEDIATELY. Allow engine to cool completely
before working on exhaust or fuel system.
NOTE: Early model shown. Other models similar.
M54484
1. Turn fuel shutoff valve to OFF position.
30 2. Disconnect fuel hose (C).
20
A—Air Cleaner Assembly
4
3. Remove two nuts (D) and washer (B). B—Washer
C—Fuel Hose
D—Nuts
4. Disconnect wiring lead (E) and fuel shutoff solenoid E—Ground Wiring Lead
lead.
5. Remove air cleaner assembly (A).
MX,3020CL,4 -19-23OCT95
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Contents
40
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Starter/Test Armature
TEST STARTER ARMATURE
IMPORTANT: DO NOT clean armature with solvent.
Solvent can damage insulation on
windings. Use only mineral spirits and
-UN-25AUG88
a brush.
1. Locate short circuits by rotating armature on a growler
while holding a hacksaw blade or steel strip on armature.
The hacksaw blade will vibrate in area of short circuit.
M24861
2. Shorts between bars are sometimes caused by dirt or
copper between bars. Inspect for this condition.
IF TEST INDICATES SHORT CIRCUITED WINDINGS;
clean the commutator of dust and fillings. Check
armature again.
40 IF TEST STILL INDICATES SHORT CIRCUIT; replace
10 armature.
6
M98,2030A,K -19-23OCT95
3. Test for grounded windings using an ohmmeter or test
light.
NOTE: Armature windings are connected in parallel, so
each commutator bar needs to be checked.
-UN-31AUG88
IF TEST SHOWS CONTINUITY; a winding is grounded
and the armature must be replaced.
M50112
M98,2030A,AH -19-23OCT95
4. Test for open circuited windings using an ohmmeter or
test light.
IF TEST SHOWS NO CONTINUITY; there is an open
circuit and armature must be replaced.
-UN-31AUG88
M50113
M98,2030A,M -19-23OCT95
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--- Page 18 ---
Hydrostatic Transmission and Differential/Inspect Charge Pump
INSPECT CHARGE PUMP
1. Inspect inner (A) and outer (B) rotors and pump
housing for wear or damage.
2. Measure outside diameter of outer rotor.
3. Measure thickness of outer rotor.
NOTE: Replace rotors as a set if not within
specifications.
4. Measure inside diameter (C) of pump housing.
5. Measure depth of pump housing.
Replace housing if not within specifications.
SPECIFICATIONS
-UN-19JUN95
Outer Rotor O.D. (Minimum) . . . . . . . . . . . . . . 40.45 mm (1.593 in.)
Outer Rotor Thickness (Minimum) . . . . . . . . . . 12.95 mm (0.510 in.)
Pump Housing I.D. (Maximum) . . . . . . . . . . . . 40.80 mm (1.606 in.)
Pump Housing Depth (MAX) . . . . . . . . . . . . . . 13.15 mm (0.518 in.)
50
M53014
10
4
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Hydrostatic Transmission and Differential/Inspect Axle Assembly
REMOVE AND INSTALL AXLE ASSEMBLIES
NOTE: Axle assemblies can be removed without
disassembling transaxle.
-UN-05APR89
1. Remove snap ring (A).
2. Install puller in threaded axle hole (B). Remove
axle/bearing assembly carefully to avoid seal damage.
M52985
NOTE: Seal removal from right side of differential
housing requires differential disassembly. (See
Disassemble Differential in this group.)
3. Remove seal (C), if necessary.
4. Install seal 2 mm (0.079 in.) below ball bearing
shoulder. Flat side of seal faces out.
-UN-05APR89
5. Install axle/bearing assembly until bearing bottoms in
housing.
6. Install snap ring.
M52986
50
10
14
MX,5010CL,A1 -19-23OCT95
INSPECT AXLE ASSEMBLY
IMPORTANT: Dry parts with compressed air. Lint
from cloth rags can damage
transmission.
-UN-29AUG88
N CAUTION: Do not allow compressed air to spin
dry bearings. Bearing can shatter causing
injury.
M38073
1. Clean ball bearing with solvent and dry with
compressed air, while keeping the bearing from
spinning.
2. Check ball bearing for axial (A) and radial (B) free
play. Rotate bearing slowly. Replace if free play is
excessive or bearing does not operate smoothly.
MX,5010CL,A2 -19-23OCT95
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Hydrostatic Transmission and Differential/Assemble Fixed Displacement Motor
ASSEMBLE FIXED DISPLACEMENT MOTOR
1. If new needle bearing is being installed, place housing
on surface plate with sealing surface (A) face down.
Press bearing in and install snap ring.
-UN-05APR89
2. Install ball bearing flush with inside face (B) of
eccentric.
NOTE: Needle bearing is not used in
M52996
PA420A/PA540A-AS01 and AS02 motors.
3. For PA420A/PA540A-AS00 and BS00 motors, install
needle bearing flush with outside face (C) of eccentric.
-UN-05APR89
M53001
50
10
24
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--- Page 21 ---
Steering Shaft and Gears/Steering Shaft and Gears
8. Remove cotter pin, washers and bushing (A).
9. Disconnect drag link (B) from lever.
10. Remove cap screws attaching foot rest (C) to frame.
-UN-13APR89
11. Loosen spring by backing out cap screw (D).
12. Remove cap screws attaching bracket (E) to frame.
M53084
13. Remove gear assembly.
14. Disassemble arm (F), gear (G) and bushing (H).
A—Bushing
B—Drag Link
C—Foot Rest
D—Cap Screw
E—Bracket
-UN-13APR89
F—Steering Arm
G—Sector Gear
H—Bushing
M53085
MX,6005CL,A5 -19-04MAY92
60 INSPECT STEERING SHAFT AND GEARS
05
2 1. Inspect bushings (A) for wear.
2. Inspect gears (B) and (C) for cracks, damage or wear.
3. Inspect arm (D) spline for damage.
4. Inspect plate (E) for cracks or damage.
5. Replace any worn or damaged parts.
6. Tighten draglink rod to ball joint nut to 34 N·m (25
lb-ft).
A—Bushing
B—Sector Gear
C—Pinion Gear
D—Steering Arm
E—Gear Plate
-UN-20APR89
M53092
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Contents
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--- Page 23 ---
Mower Deck Repair/Pivoting Jacksheave Assembly
REPAIR PIVOTING JACKSHEAVE ASSEMBLY—F510 (S.N. 130001— )
-UN-12MAY95
M81629
A—Cap E—Sheave I—Bushing M—Roller
B—Snap Ring F—Spacer J—Pin (2 used) N—Pin
C—Bushing G—Ball Bearing K—Bracket O—Bracket
D—Ball Bearing H—Arm L—Pivot
NOTE: Remove bearings (D) and (G) only if being 3. Replace worn bushings (C) and (I).
replaced.