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JOHN DEERE F510 RESIDENTIAL FRONT MOWER Service Repair Manual Instant Download (TM1475).pdf
- 1. F510 and F525 Residential FrontMowers John Deere Horicon Works TM1475 (23OCT95) LITHO IN U.S.A. ENGLISH
- 2.
- 3. FOREWORD This manual iswritten for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. N This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes. DX,TMIFC -19-22MAY92 Introduction TM1475 (23OCT95) F510/F525 Front Mowers 131295 PN=3
- 4. JOHN DEERE DEALERS Thisis a complete revision for TM1475—F510 and F525 Residential Front Mowers. Discard TM1475 dated (01MAY92) and replace with this manual. New information added to this manual includes: 1. Updated engine repair procedures and specifications. 2. New engine adjustment procedures. 3. New electrical wiring harness diagrams. 4. New electrical schematics and diagnostic diagrams. 5. Updated electrical tests. 6. New mower deck repair procedures. 7. New lift linkage repair procedures. 8. New snowthrower repair information. 9. New snowthrower diagnostic information. 10. New snowthrower adjustment procedures. 11. New Power Flow™ repair information. 12. New Power Flow™ diagnostic information. TM1475,DPS -19-23OCT95 TM1475 (23OCT95) F510/F525 Front Mowers 131295 PN=4
- 5. SECTION 10—GENERAL INFORMATION Group05—Safety Group 10—General Specifications Group 15—Repair Specifications Group 20 —Fuel and Lubricants Group 25—Serial Number Location SECTION 20—ENGINE REPAIR Group 05—Remove and Install Engine Group 10—Blower Housing and Flywheel Group 15—Cylinder Head and Valves Group 20—Cylinder Block and Internal Components SECTION 30—FUEL AND AIR SYSTEM REPAIR Group 05—Fuel Tank Group 10—Fuel Pump Group 15—Air Cleaner Group 20—Carburetor SECTION 40—ELECTRICAL REPAIR Group 05—Electric PTO Clutch Group 10—Starter Group 15—Ignition and Charging System SECTION 50—POWER TRAIN REPAIR Group 10—Hydrostatic Transmission and Differential SECTION 60—STEERING REPAIR Group 05—Steering Shaft and Gears Group 10—Wheels SECTION 65—BRAKE REPAIR Group 05—Brake Repair SECTION 80—MISCELLANEOUS Group 05—Mower Deck Repair Group 10—Blade Drive Belt Group 15—38-Inch Snowthrower Group 20—Power Flow™ Blower Assembly Group 25—Engine Shroud and Fenders Group 30—Weight Transfer System SECTION 210—SPECIFICATIONS/OPERATIONAL CHECKOUT PROCEDURE Group 05—Operational Checkout Procedure Group 10—Test and Adjustment Specifications SECTION 220—ENGINE OPERATION, TESTS, AND Group 05—Engine Component Location Group 10—Theory of Operation Group 15—Diagnosis, Tests, and Adjustments SECTION 230—FUEL/AIR OPERATION, TESTS, AND ADJUSTMENTS Group 05—Component Location Group 10—Theory of Operation Group 15—Diagnosis, Tests, and Adjustments SECTION 240—ELECTRICAL SYSTEM OPERATION, TESTS, AND ADJUSTMENTS Group 05 —Component Location Group 10—Theory of Operation Group 15—Diagnosis, Tests, and Adjustments Group 20—Wiring Schematic and Harness Diagram SECTION 250—POWER TRAIN OPERATION, TESTS, AND ADJUSTMENTS Group 05—Power Train Component Location Group 10—Theory of Operation Group 15—Power Train Diagnosis SECTION 260—STEERING OPERATION, TESTS, AND ADJUSTMENTS Group 05—Component Location Group 10—Theory of Operation Group 15—Diagnostics Group 20—Adjustments SECTION 265—BRAKE OPERATION, TESTS, AND ADJUSTMENTS Group 05—Component Location Group 10—Theory of Operation Continued on next page COPYRIGHT© 1995 DEERE & COMPANY Moline, Illinois All rights reserved A John Deere ILLUSTRUCTION™ Manual Previous Editions Copyright 1992, 1989 Deere & Company All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. TM1475-19-23OCT95 Contents TM1475 (23OCT95) i F510/F525 Front Mowers 131295 PN=546 10 20 30 40 50 60 65 80 210 220
- 6. Group 15—Diagnostics Group 20—Adjustments SECTION280—MISCELLANEOUS OPERATION, TESTS, AND ADJUSTMENTS Group 05—Component Location Group 10—Theory of Operation Group 15—Diagnosis and Adjustments—Snowthrower Group 20—Diagnosis—Power Flow™ Blower Assembly Index Contents TM1475 (23OCT95) ii F510/F525 Front Mowers 131295 PN=547 10 20 30 40 50 60 65 80 210 220
- 7. Section 10 GENERAL INFORMATION Contents Page Group05—Safety . . . . . . . . . . . . . . . . 10-05-1 Group 10—General Specifications Machine Specifications . . . . . . . . . . . . . 10-10-1 Group 15—Repair Specifications Engine Configuration Chart . . . . . . . . . . 10-15-1 Repair Specifications . . . . . . . . . . . . . . 10-15-2 Tune-Up Adjustments . . . . . . . . . . . . . . 10-15-13 Metric Cap Screw Torque Valves . . . . . . 10-15-14 Inch Cap Screw Torque Values . . . . . . . 10-15-15 Group 20 —Fuel and Lubricants Group 25—Serial Number Location Serial Number Information . . . . . . . . . . . 10-25-1 Product Identification Number . . . . . . . . . 10-25-1 Engine Serial Number . . . . . . . . . . . . . . 10-25-1 TM1475 (23OCT95) 10-1 F510/F525 Front Mowers 131295 PN=514 10
- 8. RECOGNIZE SAFETY INFORMATION Thisis the safety-alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Follow recommended precautions and safe operating practices. T81389 -UN-07DEC88 UNDERSTAND SIGNAL WORDS A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual. TS187 -19-30SEP88 FOLLOW SAFETY INSTRUCTIONS Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer. Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction. Keep your machine in proper working condition. Unauthorized modifications to the machine may impair the function and/or safety and affect machine life. If you do not understand any part of this manual and need assistance, contact your John Deere dealer. TS201 -UN-23AUG88 DX,ALERT -19-03MAR93 DX,SIGNAL -19-03MAR93 DX,READ -19-03MAR93 Group 05 Safety TM1475 (23OCT95) 10-05-1 F510/F525 Front Mowers 131295 PN=6 10 05 1
- 9. HANDLE FLUIDS SAFELY—AVOIDFIRES When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously. TS227 -UN-23AUG88 PREVENT BATTERY EXPLOSIONS Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16˚C (60˚F). TS204 -UN-23AUG88 PREPARE FOR EMERGENCIES Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone. TS291 -UN-23AUG88 DX,FLAME -19-04JUN90 DX,SPARKS -19-03MAR93 DX,FIRE2 -19-03MAR93 Safety TM1475 (23OCT95) 10-05-2 F510/F525 Front Mowers 131295 PN=7 10 05 2
- 10. PREVENT ACID BURNS Sulfuricacid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added. 4. Avoiding spilling or dripping electrolyte. 5. Use proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. 2. Apply baking soda or lime to help neutralize the acid. 3. Flush your eyes with water for 15—30 minutes. Get medical attention immediately. If acid is swallowed: 1. Do not induce vomiting. 2. Drink large amounts of water or milk, but do not exceed 2 L (2 quarts). 3. Get medical attention immediately. TS203 -UN-23AUG88 HANDLE CHEMICAL PRODUCTS SAFELY Direct exposure to chemical products can cause severe skin irritation and injury. Hazardous fumes can be generated when handling the chemicals. Wear close fitting clothing and a face mask when handling chemicals. Dispose of chemical waste and packaging material properly. A Material Safety Data Sheet provides specific details on chemical products and physical dangers, safety procedures, and emergency response techniques. User awareness and training is required under U.S. workplace and environmental laws. See your John Deere dealer for information on chemical products used with John Deere equipment. TS272 -UN-23AUG88 DX,POISON -19-21APR93 DX,MSDS -19-28SEP90 Safety TM1475 (23OCT95) 10-05-3 F510/F525 Front Mowers 131295 PN=8 10 05 3
- 11. AVOID HIGH-PRESSURE FLUIDS Escapingfluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. X9811 -UN-23AUG88 PARK MACHINE SAFELY Before working on the machine: • Lower all equipment to the ground. • Stop the engine and remove the key. • Disconnect the battery ground strap. • Hang a “DO NOT OPERATE” tag in operator station. TS230 -UN-24MAY89 DX,FLUID -19-03MAR93 DX,PARK -19-04JUN90 Safety TM1475 (23OCT95) 10-05-4 F510/F525 Front Mowers 131295 PN=9 10 05 4
- 12. SUPPORT MACHINE PROPERLY Alwayslower the attachment or implement to the ground before you work on the machine. If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. TS229 -UN-23AUG88 WEAR PROTECTIVE CLOTHING Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. TS206 -UN-23AUG88 SERVICE MACHINES SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts. TS228 -UN-23AUG88 DX,LOWER -19-04JUN90 DX,WEAR -19-10SEP90 DX,LOOSE -19-04JUN90 Safety TM1475 (23OCT95) 10-05-5 F510/F525 Front Mowers 131295 PN=10 10 05 5
- 13. WORK IN VENTILATEDAREA Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area. TS220 -UN-23AUG88 WORK IN CLEAN AREA Before starting a job: • Clean work area and machine. • Make sure you have all necessary tools to do your job. • Have the right parts on hand. • Read all instructions thoroughly; do not attempt shortcuts. T6642EJ -UN-18OCT88 REMOVE PAINT BEFORE WELDING OR HEATING Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: • If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. • If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. TS220 -UN-23AUG88 DX,AIR -19-04JUN90 DX,CLEAN -19-04JUN90 DX,PAINT -19-03MAR93 Safety TM1475 (23OCT95) 10-05-6 F510/F525 Front Mowers 131295 PN=11 10 05 6
- 14. AVOID HEATING NEARPRESSURIZED FLUID LINES Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. TS953 -UN-15MAY90 ILLUMINATE WORK AREA SAFELY Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. TS223 -UN-23AUG88 REPLACE SAFETY SIGNS Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement. TS201 -UN-23AUG88 USE PROPER LIFTING EQUIPMENT Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual. TS226 -UN-23AUG88 DX,TORCH -19-03MAR93 DX,LIGHT -19-04JUN90 DX,SIGNS1 -19-04JUN90 DX,LIFT -19-04JUN90 Safety TM1475 (23OCT95) 10-05-7 F510/F525 Front Mowers 131295 PN=12 10 05 7
- 15. SERVICE TIRES SAFELY Explosiveseparation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts. TS952 -UN-12APR90 AVOID HARMFUL ASBESTOS DUST Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer. Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated. Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos. Keep bystanders away from the area. TS220 -UN-23AUG88 DX,TIRECP -19-24AUG90 DX,DUST -19-15MAR91 Safety TM1475 (23OCT95) 10-05-8 F510/F525 Front Mowers 131295 PN=13 10 05 8
- 16. PRACTICE SAFE MAINTENANCE Understandservice procedure before doing work. Keep area clean and dry. Never lubricate, service, or adjust machine while it is moving. Keep hands, feet , and clothing from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool. Securely support any machine elements that must be raised for service work. Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris. Disconnect battery ground cable (-) before making adjustments on electrical systems or welding on machine. TS218 -UN-23AUG88 USE PROPER TOOLS Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications. TS779 -UN-08NOV89 DX,SERV -19-03MAR93 DX,REPAIR -19-04JUN90 Safety TM1475 (23OCT95) 10-05-9 F510/F525 Front Mowers 131295 PN=14 10 05 9
- 17. DISPOSE OF WASTEPROPERLY Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, 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. 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. TS1133 -UN-26NOV90 LIVE WITH SAFETY Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields. TS231 -19-07OCT88 DX,DRAIN -19-03MAR93 DX,LIVE -19-25SEP92 Safety TM1475 (23OCT95) 10-05-10 F510/F525 Front Mowers 131295 PN=15 10 05 10
- 18. MACHINE SPECIFICATIONS F510 F525 ENGINEPA420A PA540A Manufacturer KHI KHI Cycle 4 4 Output 10.4 kW (14 hp) 12.7 kW (17 hp) Displacement 423 cc (25.8 cu. in.) 535 cc (32.64 cu. in.) Cylinders 1 1 Crankshaft Alignment Vertical Vertical Bore 89 mm (3.5 in.) 89 mm (3.5 in.) Stroke 68 mm (2.68 in.) 86 mm (3.38 in.) Speed, fast (no load) 3250 ±50 rpm 3250 ±50 rpm Speed, idle (no load) 1450 rpm 1450 rpm Ignition Solid state Solid state Starter Electric Electric Cooling Air Air Unitized Eng/Trans Oil Reservoir Capacity: Without filter 2.4 L (2.5 qt) 2.6 L (2.7 qt) With filter 2.6 L (2.7 qt) 2.8 L (2.9 qt) Total system 3.4 L (3.5 qt) 3.9 L (4.1 qt) Air Cleaner Dry Replaceable Dry Replaceable w/foam precleaner w/foam precleaner POWER TAKE-OFF Electric Electric CONSTRUCTION Block Aluminum Aluminum Cylinder Liner Cast iron Cast iron Cylinder Head Aluminum Aluminum ELECTRICAL SYSTEM Charging System Flywheel Alternator; 13 AMP, Flywheel Alternator; 15 AMP, Regulated Regulated Battery Voltage 12 12 Reserve Capacity @ 25 Amp 35 minutes 35 minutes Cold Cranking Amp @ -18˚C (0˚F) 255 255 Spark Plug RN11YC or NGK-BPR5ES RN11YC or NGK-BPR5ES Plug Gap 0.7-0.8 mm (0.28-0.031 in.) 0.7-0.8 mm (0.28-0.31 in.) FUEL SYSTEM Fuel Tank Location Left side Left side Capacity 10.4 L (2.75 U.S. gal) 10.4 L (2.75 U.S. gal) Fuel Type Unleaded Gasoline Unleaded Gasoline DRIVE TRAIN Transmission Type Hydrostatic Hydrostatic Manufacturer KHI KHI No. of Speeds Infinite Infinite Travel Speeds Forward (Max) 8 km/h (5 MPH) 8 km/h (5 MPH) Reverse (Max) 4 km/h (2.5 MPH) 4 km/h (2.5 MPH) MX,1010CL,A1 -19-23OCT95 Group 10 General Specifications TM1475 (23OCT95) 10-10-1 F510/F525 Front Mowers 131295 PN=16 10 10 1
- 19. MACHINE SPECIFICATIONS (CONTINUED) F510F525 DRIVE TRAIN-CONTINUED Differential Bevel gear Bevel gear Gear Ratio 25:1 25:1 Speed & Direction Control 2 Pedal foot control 2 Pedal foot control DIMENSIONS Height to Top of Steering Wheel 1067 mm (42 in.) 1067 mm (42 in.) Height to Top of Hood 572 mm (22.5 in.) 572 mm (22.5 in.) Width With 38 in. Mower 1300 mm (50 in.) With 46 in. Mower 1448 mm (57 in.) With 48 in. Mower 1500 mm (59 in.) Length Without Mower 1648 mm (65 in.) 1648 mm (64 in.) With 38 in. Mower 2100 mm (82 in.) With 46 in. Mower 2010 mm (79 in.) With 48 in. Mower 2000 mm (80 in.) Ground Clearance 89 mm (3.5 in.) 89 mm (3.5 in.) Wheelbase 885 mm (35 in.) 885 mm (35 in.) Min. Turn Radius Left Hand 191 mm (7.5 in.) 191 mm (7.5 in.) TIRES Type Drive Soft Track Turf Soft Track Turf Steering Rib Rib Size Drive 18x8.50-8 18x8.50-8 Steering 13x6.50-6 13x6.50-6 Inflation Pressure Drive 96 kPa (14 psi) 96 kPa (14 psi) Steering 96 kPa (14 psi) 96 kPa (14 psi) STEERING Type Manual - Rear Wheel Manual - Rear Wheel BRAKES Type Internal Wet Band Internal Wet Band Location Internal to Drive Internal to Drive FRAME Welded steel Welded steel MOWER DECK Cutting Width 965 mm (38 in.) 1212 mm (48 in.) or 1168 (46 in.) Cutting Height 25-89 mm (1-3.5 in.) 25-89 mm (1-3.5 in.) WEIGHT (APPROX) 314 kg (692 lbs) 316 kg (696 lbs) with 46 in. deck 336 kg (740 lbs) with 48 in. deck (Specifications and design subject to change without notice.) MX,1010CL,A2 -19-23OCT95 General Specifications/Machine Specifications TM1475 (23OCT95) 10-10-2 F510/F525 Front Mowers 131295 PN=17 10 10 2
- 20. ENGINE CONFIGURATION CHART ThePA420A and PA540A engines have an engine configuration number following the engine model number to help separate engine changes. Use the engine configuration number to determine the proper service specifications and procedures to follow in this technical manual. ENGINE CONFIGURATION CHART F510 (Engine S.N. -3887) . . . . . . . . . . . . . . . PA420A-AS00 (Engine S.N. 3888-4898) . . . . . . . . . . . . . . . PA420A-BS00 (Engine S.N. 4899-7322) . . . . . . . . . . . . . . . PA420A-AS01 (Engine S.N. 7323- ) . . . . . . . . . . . . . . . PA420A-AS02 F525 (Engine S.N. -7891) . . . . . . . . . . . . . . . PA540A-AS00 (Engine S.N. 7892-11999) . . . . . . . . . . . . . . PA540A-BS00 (Engine S.N. 12000-21944) . . . . . . . . . . . . . PA540A-AS01 (Engine S.N. 21945- ) . . . . . . . . . . . . . PA540A-AS02 MX,1015CL,1 -19-23OCT95 Group 15 Repair Specifications TM1475 (23OCT95) 10-15-1 F510/F525 Front Mowers 131295 PN=18 10 15 1
- 21. REPAIR SPECIFICATIONS SECTION 20—ENGINEREPAIR—PA420A Group 10—Blower Housing and Flywheel Item Specification Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 N·m (101 lb-ft) Minimum Flywheel Screen Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.059 in.) Group 15—Cylinder Head and Valves Item Specification Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Breather Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1—2 mm (0.040—0.080 in.) Rocker Arm Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.94 mm (0.509 in.) Maximum Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.07 mm (0.515 in.) Push Rod Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) Valves and Springs Minimum Spring Free Length PA420A-AS00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.50 mm (1.476 in.) PA420A-BS00, AS01 and AS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.50 mm (1.398 in.) Minimum Valve Stem O.D. Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.930 mm (0.2728 in.) Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.915 mm (0.2722 in.) Valve Stem O.D.-New Parts Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.972-6.987 mm (0.2745-0.2751 in.) Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.965-6.980 mm (0.2742-0.2748 in.) Valve Stem to Guide Clearance-New Parts Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.013-0.043 mm (0.0005-0.0017 in.) Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020-0.050 mm (0.0008-0.0020 in.) Maximum Valve Guide I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.07 mm (0.278 in.) Valve Guide I.D.-New Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.000-7.015 mm (0.2756-0.2762 in.) Valve Stem to Guide Clearance-New Parts Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.013-0.043 mm (0.0005-0.0017 in.) Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020-0.050 mm (0.0008-0.0020 in.) Valve Guide Bushing Height PA420A-BS00, AS01 and AS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 mm (0.472 in.) Valve Guide Bushing Finished I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0-7.02 mm (0.275-0.276 in.) Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.) Continued on next page MX,1015CL,1A -19-23OCT95 Repair Specifications/Repair Specifications TM1475 (23OCT95) 10-15-2 F510/F525 Front Mowers 131295 PN=19 10 15 2
- 22. Group 15—Cylinder Headand Valves—Continued Item Specification Valve Seating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10—1.46 mm (0.043—0.057 in.) Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45˚ Minimum Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.020 in.) Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30˚ Cylinder Head Cylinder Head Distortion (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm Studs Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 N·m (27 lb-ft) Cap Screw Torque In Sequence (Lubricated) Initial Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 N·m (24 lb-ft) Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 N·m (38 lb-ft) Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N·m (177 lb-in.) Group 20—Cylinder Block and Internal Components Item Specification Crankcase Cover Oil Capacity Without Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4 L (2.5 qt) With Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 L (2.7 qt) Total System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 L (3.5 qt) Cap Screw Torque PA420A-BS00, AS00 and AS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N·m (204 lb-in.) Cap Screw Torque PA420A-AS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 N·m (257 lb-in.) Hydrostatic Pump Cover Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N·m (226 lb-in.) Oil Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N·m (217 lb-in.) Magnet Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 N·m (53 lb-in.) Camshaft Minimum End Journal O.D. PTO Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.91 mm (0.823 in.) Flywheel Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.91 mm (0.784 in.) Minimum Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.75 mm (1.447 in.) Maximum Bearing I.D. Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.08 mm (0.790 in.) Crankcase Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.08 mm (0.830 in.) Reciprocating Balancer Link Rod Minimum Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53.95 mm (2.124 in.) Maximum Small End I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.06 mm (0.475 in.) Maximum Large End I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.12 mm (2.131 in.) Bushing Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.040 in.) Balancer Weight Maximum Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.10 mm (1.027 in.) Bushing Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.) Continued on next page MX,1015CL,2 -19-23OCT95 Repair Specifications/Repair Specifications TM1475 (23OCT95) 10-15-3 F510/F525 Front Mowers 131295 PN=20 10 15 3
- 23. Group 20—Cylinder Blockand Internal Components—Continued Item Specification 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—88.85 mm (3.4885—3.498 in.) Piston-to-Cylinder Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13—0.17 mm (0.005—0.0067 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.92 mm (1.375 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.07 mm (1.381 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.) 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.13—0.17 mm (0.005—0.0067 in.) Continued on next page MX,1015CL,3 -19-23OCT95 Repair Specifications/Repair Specifications TM1475 (23OCT95) 10-15-4 F510/F525 Front Mowers 131295 PN=21 10 15 4
- 24. Group 20—Cylinder Blockand Internal Components—Continued Item Specification Rebore Cylinder Oversize Diameter 0.50 mm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.48—89.50 mm (3.523—3.524 in.) Oil Pump Minimum Rotor Shaft O.D. Large O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.63 mm (0.497 in.) Small O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.94 mm (0.313 in.) Maximum Rotor Shaft Bearing I.D. Oil Pump Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.76 mm (0.502 in.) Crankcase Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.07 mm (0.318 in.) Outer Rotor Minimum Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.92 mm (0.470 in.) Minimum O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28.95 mm (1.140 in.) Outer Rotor Bearing Maximum Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.14 mm (0.478 in.) Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.20 mm (1.149 in.) Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.00 mm (0.750 in.) Governor Shaft Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.2-32.8 mm (1.267-1.291 in.) Lever Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N·m (62 lb-in.) MX,1015CL,3A -19-04MAY92 Repair Specifications/Repair Specifications TM1475 (23OCT95) 10-15-5 F510/F525 Front Mowers 131295 PN=22 10 15 5
- 25. SECTION 20—ENGINE REPAIR—PA540A Group10—Blower Housing and Flywheel Item Specification Flywheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 N·m (127 lb-ft) Minimum Flywheel Screen Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50 mm (0.059 in.) Group 15—Cylinder Head and Valves Item Specification Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.) Breather Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1—2 mm (0.040—0.080 in.) Rocker Arm Minimum Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.94 mm (0.509 in.) Maximum Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.07 mm (0.515 in.) Push Rod Maximum Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) Valves and Springs Minimum Spring Free Length PA540A-AS00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.50 mm (1.476 in.) PA540A-BS00, AS01 and AS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.50 mm (1.398 in.) Minimum Valve Stem O.D. Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.930 mm (0.2728 in.) Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.915 mm (0.2722 in.) Valve Stem O.D.-New Parts Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.972-6.987 mm (0.2745-0.2751 in.) Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.965-6.980 mm (0.2742-0.2748 in.) Valve Stem to Guide Clearance-New Parts Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.013-0.043 mm (0.0005-0.0017 in.) Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020-0.050 mm (0.0008-0.0020 in.) Maximum Valve Guide I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.07 mm (0.278 in.) Valve Guide I.D.-New Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.000-7.015 mm (0.2756-0.2762 in.) Valve Stem to Guide Clearance-New Parts Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.013-0.043 mm (0.0005-0.0017 in.) Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.020-0.050 mm (0.0008-0.0020 in.) Valve Guide Bushing Height PA540A-BS00, AS01 and AS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5 mm (0.372 in.) Valve Guide Bushing Finished I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.0-7.02 mm (0.275-0.276 in.) Maximum Valve Stem Bend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.) Continued on next page MX,1015CL,4 -19-23OCT95 Repair Specifications/Repair Specifications TM1475 (23OCT95) 10-15-6 F510/F525 Front Mowers 131295 PN=23 10 15 6
- 26. Group 15—Cylinder Headand Valves—Continued Item Specification Valve Seating Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10—1.46 mm (0.043—0.057 in.) Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45˚ Minimum Valve Margin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.020 in.) Valve Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30˚ Cylinder Head Cylinder Head Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.05 mm (0.002 in.) Studs Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 N·m (27 lb-ft) Cap Screw Torque In Sequence (Lubricated) Initial Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 N·m (24 lb-ft) Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 N·m (38 lb-ft) Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N·m (177 lb-in.) Group 20—Cylinder Block and Internal Components Item Specification Crankcase Cover Oil Capacity Without Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6 L (2.7 qt) With Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 L (2.9 qt) Total System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 L (4.1 qt) Cap Screw Torque PA540A-BS00, AS00 and AS01 . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 N·m (204 lb-in.) Cap Screw Torque PA540A-AS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 N·m (239 lb-in.) Hydrostatic Pump Cover Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 N·m (226 lb-in.) Oil Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 N·m (217 lb-in.) Magnet Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 N·m (53 lb-in.) Camshaft Minimum End Journal O.D. PTO Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.91 mm (0.823 in.) Flywheel Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.91 mm (0.823 in.) Minimum Lobe Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.10 mm (1.461 in.) Maximum Bearing I.D. Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.08 mm (0.830 in.) Crankcase Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.08 mm (0.830 in.) Reciprocating Balancer Link Rod Minimum Journal O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.94 mm (2.281 in.) Maximum Small End I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.06 mm (0.475 in.) Maximum Large End I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.15 mm (2.289 in.) Bushing Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 mm (0.040 in.) Balancer Weight Maximum Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.10 mm (1.027 in.) Bushing Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.50 mm (0.020 in.) Continued on next page MX,1015CL,5 -19-23OCT95 Repair Specifications/Repair Specifications TM1475 (23OCT95) 10-15-7 F510/F525 Front Mowers 131295 PN=24 10 15 7
- 27. Group 20—Cylinder Blockand Internal Components—Continued Item Specification 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 Repair Specifications/Repair Specifications TM1475 (23OCT95) 10-15-8 F510/F525 Front Mowers 131295 PN=25 10 15 8
- 28. Group 20—Cylinder Blockand Internal Components—Continued Item Specification Rebore Cylinder Oversize Diameter 0.50 mm (0.020 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89.46—89.48 mm (3.522—3.523 in.) Oil Pump Minimum Rotor Shaft O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.63 mm (0.497 in.) Maximum Rotor Shaft Bearing I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.76 mm (0.502 in.) Outer Rotor Minimum Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.92 mm (0.391 in.) Minimum O.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.47 mm (1.596 in.) Outer Rotor Bearing Maximum Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17 mm (0.401 in.) Maximum I.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.77 mm (1.605 in.) Minimum Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.00 mm (0.750 in.) Governor Shaft Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.2-32.8 mm (1.267-1.291 in.) Lever Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 N·m (62 lb-in.) SECTION 30—FUEL AND AIR REPAIR Item Specification Breather Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1—2 mm (0.040—0.080 in.) SECTION 40—ELECTRICAL Item Specification PTO Clutch Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.46 mm (0.018 in.) PTO Mounting Cap Screw Torque Ogura . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 N·m (45 lb-ft) Warner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 N·m (55 lb-ft) Starter Brush Length (Minimum) PA420A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm (0.240 in.) PA540A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 mm (0.413 in.) Ignition Coil Air Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.30 mm (0.012 in.) MX,1015CL,6A -19-23OCT95 MX,1015CL,6B -19-23OCT95 MX,1015CL,7 -19-23OCT95 Repair Specifications/Repair Specifications TM1475 (23OCT95) 10-15-9 F510/F525 Front Mowers 131295 PN=26 10 15 9
- 29. SECTION 50—POWER TRAIN ItemSpecification Variable Displacement Pump 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 (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.15 mm (0.518 in.) Pump Cover Torque Initial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18. N·m (159 lb-in.) Final . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.5 N·m (225 lb-in.) Short Cap Screw Torque-PA420A/PA540A-AS01 and AS02 . . . . . . . . . . . . . . . . . . . . 20 N·m (177 lb-in.) Oil Line, Joint Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 N·m (74 lb-ft) Oil Line, Joint Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 N·m (58 lb-ft) Relief Valve Spring Free Length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 mm (1.26 in.) Check Valve Spring Free Length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 mm (0.55 in.) Relief Valve Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.5 N·m (217 lb-in.) Check Valve Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N·m (177 lb-in.) Check Valve Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N·m (177 lb-in.) Swashplate Bearing Cap Screw Torque-PA420A/PA540A-AS01 and AS02 . . . . . . . . . . . . 1.6 N·m (12 lb-in.) Fixed Displacement Pump Cylinder Piston O.D. (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.98 mm (0.787 in.) Piston Ring-to-Groove Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 mm (0.024 in.) Piston Spring Free Length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 mm (1.063 in.) Cylinder Bore I.D. (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.05 mm (0.789 in.) Cylinder Spring Free Length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.5 mm (1.36 in.) Cylinder Spring Free Length (NEW) PA420A/PA540A-AS00 and BS00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.6 mm (1.80 in.) PA420A/PA540A-AS01 and AS02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.7 mm (1.76 in.) Shaft Journal O.D. (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.90 mm (0.46 in.) Control Shaft Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.5 N·m (217 lb-in.) Axle Assemblies Axle Housing Seal Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 mm (0.079 in.) Transmission Axle Run-out (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 mm (0.06 in.) Oil Seal Journal O.D. (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 mm (0.984 in.) Needle Bearing Journal O.D. (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.9 mm (0.982 in.) Differential Axle Run-out (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 mm (0.024 in.) Axle Housing Cap Screw Initial Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 N·m (22 lb-ft) Final Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 N·m (31 lb-ft) Isolator Mount Cap Screw Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.5 N·m (255 lb-in.) MX,1015CL,7A -19-23OCT95 Repair Specifications/Repair Specifications TM1475 (23OCT95) 10-15-10 F510/F525 Front Mowers 131295 PN=27 10 15 10
- 30. SERIAL NUMBER INFORMATION Whenworking on machines or components that are covered by warranty, it is IMPORTANT that you include the machine’s Product Identification Number and the Component Serial Number on the warranty claim form. The location of Component Serial Number plates are shown below. RECORD PRODUCT IDENTIFICATION NUMBER The mower’s 13 digit product identification number is located on the left-hand rear corner of the frame. M61965 -UN-15MAR89 RECORD ENGINE SERIAL NUMBER The engine serial number (A) is located on the left side of the blower housing. M62297 -UN-15MAR89 MX,1025CL,1 -19-23OCT95 MX,1025CL,2 -19-04MAY92 MX,1025CL,3 -19-04MAY92 Group 25 Serial Number Location TM1475 (23OCT95) 10-25-1 F510/F525 Front Mowers 131295 PN=46 10 25 1
- 31. Section 20 ENGINE REPAIR Contents Page Group05—Remove and Install Engine Remove Engine . . . . . . . . . . . . . . . . . . 20-05-1 Repair Isolators . . . . . . . . . . . . . . . . . . 20-05-3 Install Engine . . . . . . . . . . . . . . . . . . . 20-05-4 Group 10—Blower Housing and Flywheel Engine Configuration Chart . . . . . . . . . . 20-10-1 Service Parts Kits . . . . . . . . . . . . . . . . 20-10-1 Remove and Install Blower Housing . . . . 20-10-2 Flywheel Screen Adjustment . . . . . . . . . 20-10-2 Remove and Install Flywheel . . . . . . . . . 20-10-3 Group 15—Cylinder Head and Valves Engine Configuration Chart . . . . . . . . . . 20-15-1 Essential Tools . . . . . . . . . . . . . . . . . . 20-15-1 Service Equipment and Tools . . . . . . . . . 20-15-1 Other Materials . . . . . . . . . . . . . . . . . . 20-15-2 Service Parts Kits . . . . . . . . . . . . . . . . 20-15-2 Rocker Arm Assembly—PA420A/PA540A Remove and Install . . . . . . . . . . . . . . 20-15-3 Inspect . . . . . . . . . . . . . . . . . . . . . . 20-15-3 Cylinder Head Assembly Remove and Install . . . . . . . . . . . . . . 20-15-4 Valves and Springs Remove and Install . . . . . . . . . . . . . . 20-15-6 Inspect and Replace Stem Seals . . . . . . 20-15-6 Inspect Valve Springs . . . . . . . . . . . . . . . . . . 20-15-7 Cylinder Head . . . . . . . . . . . . . . . . . 20-15-7 Replace Cylinder Head Studs . . . . . . . . 20-15-7 Valves Inspect . . . . . . . . . . . . . . . . . . . . . . 20-15-8 Analyze . . . . . . . . . . . . . . . . . . . . . . 20-15-9 Valve Guides . . . . . . . . . . . . . . . . . . 20-15-11 Replace Valve Guide Bushings . . . . . . . 20-15-11 Recondition Valve Seats . . . . . . . . . . . . 20-15-13 Lap . . . . . . . . . . . . . . . . . . . . . . . . 20-15-14 Check Valve Clearance . . . . . . . . . . . . . 20-15-14 Group 20—Cylinder Block and Internal Components Engine Configuration Chart . . . . . . . . . . 20-20-1 Other Materials . . . . . . . . . . . . . . . . . . 20-20-1 Service Parts Kits . . . . . . . . . . . . . . . . 20-20-2 Page Remove and Install Crankcase Cover . . . 20-20-3 Crankcase Cover Magnet . . . . . . . . . . . 20-20-4 Camshaft Remove and Install . . . . . . . . . . . . . . 20-20-4 Inspect . . . . . . . . . . . . . . . . . . . . . . 20-20-5 Inspect Bearings . . . . . . . . . . . . . . . . 20-20-6 Inspect Automatic Compression Release . 20-20-7 Remove/Inspect/Install Tappets . . . . . . . . 20-20-7 Reciprocating Balancer Remove and Install . . . . . . . . . . . . . . 20-20-8 Disassemble and Assemble . . . . . . . . 20-20-9 Inspect . . . . . . . . . . . . . . . . . . . . . . 20-20-10 Replace Bushings . . . . . . . . . . . . . . . 20-20-11 Piston and Connecting Rod Remove and Install . . . . . . . . . . . . . . 20-20-12 Disassemble, Inspect and Assemble . . . 20-20-13 Piston Rings Remove and Install . . . . . . . . . . . . . . 20-20-13 Check End Gap . . . . . . . . . . . . . . . . 20-20-14 Inspect Piston . . . . . . . . . . . . . . . . . . . . . . . 20-20-14 Analyze Piston Ring Wear . . . . . . . . . . . . . . . 20-20-16 Piston Wear . . . . . . . . . . . . . . . . . . . 20-20-18 Connecting Rod . . . . . . . . . . . . . . . . 20-20-20 Crankshaft and Connecting Rod Wear . . . 20-20-21 Crankshaft Remove, Inspect and Install . . . . . . . . 20-20-22 Regrind . . . . . . . . . . . . . . . . . . . . . . 20-20-23 Inspect Plain Bearing . . . . . . . . . . . . . 20-20-24 Inspect Ball Bearing . . . . . . . . . . . . . 20-20-24 Check Alignment (TIR) . . . . . . . . . . . . 20-20-25 Measure End Play . . . . . . . . . . . . . . . 20-20-25 Adjust End Play . . . . . . . . . . . . . . . . 20-20-26 Inspect Oil Seals . . . . . . . . . . . . . . . . . . . . . 20-20-27 Cylinder Block . . . . . . . . . . . . . . . . . 20-20-28 Deglaze Cylinder Bore . . . . . . . . . . . . . 20-20-29 Rebore Cylinder Block . . . . . . . . . . . . . 20-20-30 Oil Pump—PA420A Disassemble and Assemble . . . . . . . . 20-20-31 Inspect . . . . . . . . . . . . . . . . . . . . . . 20-20-32 Continued on next page TM1475 (23OCT95) 20-1 F510/F525 Front Mowers 131295 PN=516 20
- 32. Page Oil Pump—PA540A Disassemble andAssemble . . . . . . . . 20-20-34 Inspect . . . . . . . . . . . . . . . . . . . . . . 20-20-35 Remove, Inspect and Install Oil Filter Manifold . . . . . . . . . . . . . . . . . . . . . 20-20-38 Inspect and Replace Governor . . . . . . . . . . . . . . . . . . . . . 20-20-38 Governor Arm . . . . . . . . . . . . . . . . . 20-20-39 Contents TM1475 (23OCT95) 20-2 F510/F525 Front Mowers 131295 PN=517 20
- 33. REMOVE ENGINE 1. Disconnectbattery cables. (Disconnect negative cable at engine first.) 2. Remove mower deck. NOTE: Oil reservoir capacity is approximately 3.4 L (3.5 qt). 3. Remove drain plug (A) and drain oil reservoir. M81636 -UN-23MAY95 4. Remove front wheels. (See Remove and Install Wheels in Section 60, Group 10.) 5. Remove snap ring (A). Remove mower deck arms. 6. Remove seat platform (B). (See Remove and Install Seat Platform in Section 80, Group 15.) 7. Remove fenders. (See Right Fender—Service Removal and Left Fender Replacement in Section 80, Group 15.) 8. Close fuel shut-off valve (C). M53037 -UN-13APR89 MX,2005CL,A1 -19-23OCT95 MX,2005CL,A1A -19-23OCT95 Group 05 Remove and Install Engine TM1475 (23OCT95) 20-05-1 F510/F525 Front Mowers 131295 PN=48 20 05 1
- 34. 9. Disconnect wires(C) and (D). 10. Disconnect harness (A). 11. Disconnect linkages (B) and (E). 12. Remove shield, cap screws (F) and muffler. 13. Remove braces (I). 14. Remove bracket (H). 15. Disconnect and drain fuel inlet line at fuel pump. 16. Remove cap screws (G). 17. Remove engine. A—Engine Harness B—Brake Linkage C—Purple Wire (Solenoid) D—Red Wires (Battery Cable and Pigtail) E—Shift Linkage F—Muffler Cap Screws G—Engine Mount Cap Screws (3) H—Fender Bracket I—Frame Braces (2) M81620 -UN-29APR95 M81621 -UN-29APR95 MX,2005CL,A2 -19-23OCT95 Remove and Install Engine/Remove Engine TM1475 (23OCT95) 20-05-2 F510/F525 Front Mowers 131295 PN=49 20 05 2
- 35. REPAIR ISOLATORS 1. Inspectisolators for wear, oil contamination, and damage. Replace isolators as needed. IMPORTANT: Misalignment or oil applied to the isolators will reduce the dampening of the isolators. Be careful to install the isolators correctly. 2. Push PTO clutch isolator into crankcase cover until surface (A) is even with outer flange (B) of the seat. PTO Clutch Isolator 3. Install the engine mount isolator with the letters “UP” (C) away from the mounting bracket (D). Also the molded rubber projection (E) must be centered between the marks (F), if equipped, or centered on the mounting bracket. Tighten mounting bracket cap screws. 4. Install the axle mount isolators with the letters “UP” (G) aligned with the axle housing rib (H). Push the isolator into the housing until seated against the housing shoulder (I). Tighten mounting bracket cap screws. A—PTO Clutch Isolator Surface B—Seat Outer Flange Engine Mount Isolator C—Letters “UP” D—Mounting Bracket E—Molded Rubber Projection F—Mounting Bracket Marks G—Letters “UP” H—Axle Housing Rib I—Housing Shoulder Axle Mount Isolator M46170 -UN-22APR92 M46171 -UN-22APR92 M46172 -UN-22APR92 MX,2005CL,5 -19-04MAY92 Remove and Install Engine/Repair Isolators TM1475 (23OCT95) 20-05-3 F510/F525 Front Mowers 131295 PN=50 20 05 3
- 36. INSTALL ENGINE 1. Lowerengine into frame. Connect cap screws (G). 2. Connect fuel line. 3. Install bracket (H). 4. Install braces (I). 5. Install muffler using cap screws (F). Install muffler shield. 6. Connect linkages (B) and (E). 7. Connect harness (A). 8. Connect wires (C) and (D). A—Engine Harness B—Brake Linkage C—Purple Wire (Solenoid) D—Red Wires (Battery Cable and Pigtail) E—Shift Linkage F—Muffler Cap Screws G—Engine Mount Cap Screws (3) H—Fender Bracket I—Frame Braces (2) M81620 -UN-29APR95 M81621 -UN-29APR95 MX,2005CL,A3 -19-23OCT95 Remove and Install Engine/Install Engine TM1475 (23OCT95) 20-05-4 F510/F525 Front Mowers 131295 PN=51 20 05 4
- 37. 9. Install seatplatform (B) and fenders. (See Remove and Install Seat Platform in Section 80, Group 15.) NOTE: Inspect O-rings and nylon bushings before installing mower deck arms. Replace damaged parts. Lubricate O-rings and bushings before installing mower deck arms. 10. Install mower deck arms. Install snap ring (A). 11. Install wheels. (See Remove and Install Wheels in Section 60, Group 10.) 12. Install mower deck. 13. Fill crankcase to correct level with proper oil. (See Engine Oil in Section 10, Group 20.) 14. Connect battery cables. 15. Open fuel shut-off valve (C). 16. Adjust throttle. (See Throttle Cable Adjustment in Section 220, Group 15.) 17. Adjust shift linkage. (See Direction Pedal Travel Adjustment and Direction Pedal Neutral Adjustment in Section 250, Group 15.) 18. Adjust brake pedal travel (See Brake Travel Adjustment in Section 265, Group 20.) M53037 -UN-13APR89 MX,2005CL,A4 -19-23OCT95 Remove and Install Engine/Install Engine TM1475 (23OCT95) 20-05-5 F510/F525 Front Mowers 131295 PN=52 20 05 5
- 38. ENGINE CONFIGURATION CHART ThePA420A and PA540A engines have an engine configuration number following the engine model number to help separate engine changes. Use the engine configuration number to determine the proper service specifications and procedures to follow in this technical manual. ENGINE CONFIGURATION CHART F510 (Engine S.N. -3887) . . . . . . . . . . . . . . . PA420A-AS00 (Engine S.N. 3888-4898) . . . . . . . . . . . . . . . PA420A-BS00 (Engine S.N. 4899-7322) . . . . . . . . . . . . . . . PA420A-AS01 (Engine S.N. 7323- ) . . . . . . . . . . . . . . . PA420A-AS02 F525 (Engine S.N. -7891) . . . . . . . . . . . . . . . PA540A-AS00 (Engine S.N. 7892-11999) . . . . . . . . . . . . . . PA540A-BS00 (Engine S.N. 12000-21944) . . . . . . . . . . . . . PA540A-AS01 (Engine S.N. 21945- ) . . . . . . . . . . . . . PA540A-AS02 SERVICE PARTS KITS The following kits are available through your parts catalog: Blower Housing Engine Cover Kit Decal Kit Flywheel Screen and Spacer Kit Dipstick Tube Kit MX,1015CL,1 -19-23OCT95 MX,2010CL,A0 -19-04MAY92 Group 10 Blower Housing and Flywheel TM1475 (23OCT95) 20-10-1 F510/F525 Front Mowers 131295 PN=54 20 10 1
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- 40. REMOVE AND INSTALLBLOWER HOUSING 1. Disconnect spark plug cap. 2. Remove air cleaner assembly. 3. Remove fuel pump. (See Remove and Install Fuel Pump in Section 30, Group 10.) 4. Remove cover (A). 5. Remove dipstick tube. 6. Remove protector and screen (D). A—Cylinder Head Cover B—Flywheel Screen Screws 7. Remove blower housing (C). C—Blower Housing D—Flywheel Screen 8. Install blower housing, screen and protector. 9. Adjust flywheel screen. (See Flywheel Screen Adjustment in this group.) 10. Install cylinder head cover and dipstick tube. 11. Install fuel pump. 12. Install air cleaner assembly. M53040 -UN-13APR89 FLYWHEEL SCREEN ADJUSTMENT Adjust gap (C) between the blades under screen (A) and blower housing (B) to specifications using spacers from Flywheel Screen and Spacer Kit. SPECIFICATIONS Minimum Gap . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 mm (0.059 in.) M38037 -UN-29AUG88 MX,2010CL,A2 -19-23OCT95 MX,2010CL,A2A -19-23OCT95 Blower Housing and Flywheel/Flywheel Screen Adjustment TM1475 (23OCT95) 20-10-2 F510/F525 Front Mowers 131295 PN=55 20 10 2