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Toro 400XT Series Service Manual

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400XT Series Tractor
Service
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Summary of Contents for Toro 400XT Series

  • Page 1 400XT Series Tractor Service Manual...

  • Page 2: About This Manual

    ABOUT THIS MANUAL This service manual was written expressly for Toro service technicians. The Toro Company has made every effort to make the information in this manual complete and correct. Basic shop safety knowledge and mechanical/electrical skills are assumed. The Table of Contents lists the systems and the related topics covered in this manual.

  • Page 3: Table Of Contents

    Installation ........... . .2 - 17 400XT Series Tractor Service Manual...
  • Page 4 Testing ............4 - 3 400XT Series Tractor Service Manual...
  • Page 5 Testing ............4 - 10 400XT Series Tractor Service Manual...
  • Page 6 Purpose ............4 - 15 400XT Series Tractor Service Manual...

  • Page 7: Safety Information

    8111 Lyndale Avenue South manual only. The safety instructions provided herein Bloomington, MN 55420 are for troubleshooting, service, and repair of the 400XT Series tractors. The 400XT Series tractors Think Safety First Avoid unexpected starting of engine... Avoid injury from batteries...

  • Page 8: General Specifications

    417XT: 13 amp Regulated DC Charging Battery Voltage – 12 volt negative ground Battery Type: BCI Group U1, 340 CCA 25 amp, Charge Circuit 30 amp, Main Circuit 10 amp, Light Circuit 10 amp, Dash Circuit 1 - 2 400XT Series Tractor Service Manual...

  • Page 9: Hydrostatic Transaxle

    IT CAN ONLY BE CHECKED COLD. There is a plug Oil Level located on the right rear side of the transaxle. Using a ¼ inch Allen wrench, slowly remove the plug. Oil level should be to the bottom of the port. 400XT Series Tractor Service Manual 1 - 3...

  • Page 10: Torque Specifications

    Fastener Identification Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in the service manual.

  • Page 11: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series)

    Note: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. 400XT Series Tractor Service Manual 1 - 5...

  • Page 12: Standard Torque For Dry, Zinc, And Steel Fasteners (Metric Fasteners)

    Note: Torque values may have to be reduced when installing fasteners into threaded aluminum or brass. The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. 1 - 6 400XT Series Tractor Service Manual...

  • Page 13: Other Torque Specifications

    All torque values are based on non- lubricated fasteners. Conversion Factors in-lb X 11.2985 - N-cm N-cm X - 0.08851 = in-lb ft-lb X 1.3558 = N-m N-cm X 0.73776 - ft-lb 400XT Series Tractor Service Manual 1 - 7...

  • Page 14: Equivalents And Conversions

    29/64 0.453125 11.509 61/64 0.953125 24.209 15/32 0.46875 11.906 31/32 0.96875 24.606 31/64 0.484375 12.303 63/64 0.984375 25.003 0.5000 12.700 1.000 25.400 1 mm = 0.03937 in. 0.001 in. = 0.0254 mm 1 - 8 400XT Series Tractor Service Manual...

  • Page 15: U.s. To Metric Conversions

    Newton-Meters 1.356 Work Foot-pounds Kilogram-Meters 0.1383 Inch-pounds Kilogram-Centimeters 1.152144 Quarts Liters 0.9463 Liquid Volume Gallons Liters 3.785 Gallons/Minute Liters/Minute 3.785 Liquid Flow Fahrenheit Celsius 1. Subtract 32° Temperature 2. Multiply by 5/9 400XT Series Tractor Service Manual 1 - 9...
  • Page 16 THIS PAGE INTENTIONALLY LEFT BLANK 1 - 10 400XT Series Tractor Service Manual...

  • Page 17: Chassis

    OFF to stop the engine. Remove the key. One located on the inside of each wheel hub (2 total). One located on each end of the front axle for the spindles (2 total). 400XT Series Tractor Service Manual 2 - 1...

  • Page 18: Front Wheel Toe-In Adjustment

    (Figure 8). IMPORTANT: If more than one turn is required to meet specifications, alternate between the right and left steering rods to maintain steering wheel alignment. Figure 6 MVC-749 Figure 8 MVC-095X 2 - 2 400XT Series Tractor Service Manual...

  • Page 19: Front Wheel And Spindle Removal And Installation

    OFF to stop the engine. Remove the key. Raise the front axle by putting a jack under the side you are removing the wheel or spindle from. 400XT Series Tractor Service Manual 2 - 3...

  • Page 20: Front Axle Removal And Installation

    Front Axle Removal and Installation E-ring and washers (Figure 16). Jack-up the front of the tractor. Put jack stands under the frame, just behind the front axle assembly (Figure 14). Figure 16 MVC-758 Figure 14 MVC-756 2 - 4 400XT Series Tractor Service Manual...

  • Page 21: Steering Gear

    Figure 19 Steering Backlash Adjustment Use the following procedure if there is excessive steering backlash. Remove battery and battery tray from the tractor. Figure 18 MVC-763 Installation - reverse the order of removal. 400XT Series Tractor Service Manual 2 - 5...
  • Page 22 Connect the tie rod ends to the steering arms. Turn the wheels left and right. Recheck for zero clearance (Figure 23). Figure 21 MVC-110X Figure 23 MVC-115X 10. Reinstall the battery tray and battery. 11. Check wheel alignment and toe-in. 2 - 6 400XT Series Tractor Service Manual...

  • Page 23: Steering Gear Shaft Disassembly

    (Figure 27). Figure 24 MVC-765 Remove the boot clip from the inside of the dash and remove the rubber boot from the steering shaft console (Figure 25). Figure 27 6-12 Figure 25 MVC-766 400XT Series Tractor Service Manual 2 - 7...
  • Page 24 (Figure 29). bushing and through the opening in the mounting bracket. Tilt the shaft towards the front of the tractor and remove it (Figure 31). Figure 29 6-15 Figure 31 6-17 2 - 8 400XT Series Tractor Service Manual...

  • Page 25: Steering Gear Assembly

    Install snap ring, 4; locking collar, 5; and upper bushing, 6, onto the steering gear shaft. Insert the steering gear shaft through the opening in the mounting bracket and onto the lower bushing. Note: The shims must be in place. 400XT Series Tractor Service Manual 2 - 9...
  • Page 26 Install the retaining bolt 3, through the upper end of the universal joint and upper steering. Note: Ensure that electrical wiring can not come into contact with upper steering shaft of universal joint in any position. 2 - 10 400XT Series Tractor Service Manual...

  • Page 27: Sector Gear Disassembly

    Remove the cam bushing, 3, and the sector gear, 2, from the mounting bracket (Figure 38). Figure 39 Important: Inspect the sector gear teeth and cam bushing for wear and replace if necessary. 400XT Series Tractor Service Manual 2 - 11...

  • Page 28: Tilt Steering

    (3) Retaining Bolt (4) Upper Steering Shaft (5) Spring Extension (6) Bolts (7) Detent Bracket (8) Support Bracket (9) Retaining Bolt (10) Spacer-Yoke (11) Column (12) Tilt Lever (13) Steering Bushing Figure 41 6-35 2 - 12 400XT Series Tractor Service Manual...

  • Page 29: Tilt Steering Disassembly

    4, from the tractor (Figure 41). and secure (Figure 41). Tilt steering to the rear position and detach the universal joint from the steering gear shaft. Take the universal out of the tractor from the top side. 400XT Series Tractor Service Manual 2 - 13...

  • Page 30: Steering Specifications

    Mid (Metal) ID 0.755 – 0.760” (19.2 – 19.3mm) OD 0.988 – 1.00” (25.3 – 25.4mm) Bottom (Metal) ID 0.753 – 0.758” (19.1 – 19.2mm) OD 1.380 – 1.385” (35.0 – 35.2mm) 2 - 14 400XT Series Tractor Service Manual...

  • Page 31: Hood Removal

    Reverse operating switch (Figure 49). Figure 47 MVC-018 Figure 49 MVC-865F To make it easier to remove the fasteners for the fender assembly, jack the tractor up in the rear and remove both rear tires. 400XT Series Tractor Service Manual 2 - 15...

  • Page 32: Gas Tank Removal

    Gas Tank Removal Follow the procedure for removing the rear fender and seat. Remove the two screws and spacers in the front of the gas tank (Figure 53). Figure 51 MVC-012 Figure 53 MVC-129X 2 - 16 400XT Series Tractor Service Manual...

  • Page 33: Installation

    Installation Reverse the order of removal. Lift Bar Assembly Removal Remove the bolt, washer, and nut retaining the lift chain to the lift bar (Figure 55). Figure 57 MVC-803F Figure 55 MVC-798F 400XT Series Tractor Service Manual 2 - 17...

  • Page 34: Lift Lever Assembly

    Figure 58 MVC-804F Remove the two retaining rings that are located on each side of the lift lever assembly (Figure 59). Figure 61 MVC-809F Assembly Figure 59 MVC-806F Reverse the order of removal. 2 - 18 400XT Series Tractor Service Manual...

  • Page 35: Lift Arm/Lift Lever Assembly

    Remove the 4 screws and 2 nuts from the base of the dash. Remove the bolt and nut located in the center of the hood stand, just below the large decal (Figure 63). Figure 65 MVC-821F Figure 63 MVC-817F 400XT Series Tractor Service Manual 2 - 19...

  • Page 36: Installation

    Lift the lift assembly up and off the frame of the 66). tractor (Figure 68). Figure 66 Figure 68 MVC-822F MVC-826F Lift the hood stand off the frame of the tractor Installation (Figure 67). Reverse the order of removal. Figure 67 MVC-827F 2 - 20 400XT Series Tractor Service Manual...

  • Page 37: Electric Lift

    Reverse the order of removal. Unplug the actuator, 1, from the wiring harness. Remove the clip pin, 4, and clevis pin, 6, that holds the actuator, 1, to the actuator bracket assembly, 7. 400XT Series Tractor Service Manual 2 - 21...
  • Page 38 THIS PAGE INTENTIONALLY LEFT BLANK 2 - 22 400XT Series Tractor Service Manual...

  • Page 39: Hydro-Gear Transaxle

    Gear Transaxle Service Manual, Form #492-0682. Under warranty, internal service work should not be performed unless authorized by your Distributor Service Manager or the Toro Company. Fluid Change The Hydro-Gear transaxle is factory filled, sealed, and does not require oil changes. However in the event of oil contamination or degradation, oil replacement may correct certain performance problems.
  • Page 40 Remove the three bolts retaining the transmission Unbolt the cruise control magnet bracket from the fan to the pulley (Figure 123). side of the frame (Figure 121). Figure 123 MVC-067C Figure 121 MVC-065F 3 - 2 400XT Series Tractor Service Manual...
  • Page 41 (Figure 127). Figure 124 MVC-070F 10. Slip the belt off the transaxle input pulley (Figure 125). Figure 127 MVC-072F Figure 125 MVC-171X 400XT Series Tractor Service Manual 3 - 3...

  • Page 42: Installation - Hydro-Gear Transaxle

    (Figure 129). Secure the transaxle to the frame brackets with four carriage bolts, washers, and nuts (Figure 131). Figure 129 MVC-074F Figure 131 MVC-078F 3 - 4 400XT Series Tractor Service Manual...
  • Page 43 Install the three bolts to secure the transaxle pulley. Install the idler spring on the idler pulley cooling fan to the transaxle pulley (Figure 135). (Figure 133). Figure 135 MVC-067 Figure 133 MVC-066F 400XT Series Tractor Service Manual 3 - 5...
  • Page 44 MVC-065 Reconnect the wire connector for the magnet (Figure 137). Figure 138 MVC-063 10. Connect the free wheeling valve rod and vent hose clamp (Figure 139). Figure 137 MVC-064 Figure 139 MVC-060 3 - 6 400XT Series Tractor Service Manual...

  • Page 45: Neutral Adjustment

    “Foot Control Adjustment” on page 3 - 10. Figure 142 1703-07 Start the engine and run at 3/4 to full throttle. 400XT Series Tractor Service Manual 3 - 7...

  • Page 46: Transaxle Purging Procedures

    In this case, adjust for the smallest amount of reverse creep possible. Correctly adjusted, a very light tap on the foot control pedal should be all that is needed to stop the reverse creep. 3 - 8 400XT Series Tractor Service Manual...

  • Page 47: Brake

    IMPORTANT: With the parking brake released, the rear wheels must rotate freely when you push the tractor. If the 0.020” (.508mm) clearance cannot be achieved, new brake pucks may need to be installed. 400XT Series Tractor Service Manual 3 - 9...

  • Page 48: Foot Control Adjustment

    If adjustment is needed, unbolt the hydro control control pedal. rod where it connects to the hydro forward/reverse pedal. The location is under the tractor on the inside of the frame (Figure 148). Figure 150 MVC-770F Figure 148 MVC-768F 3 - 10 400XT Series Tractor Service Manual...

  • Page 49: Traction Belt Replacement

    Loosen the LH bolt enough so you can turn the PTO stop assembly enough to disengage it from the slot in the electric PTO clutch housing (Figure 152). Figure 154 MVC-783F Figure 152 MVC-780F 400XT Series Tractor Service Manual 3 - 11...
  • Page 50 10. Check the routing of the belt around both the engine and transaxle pulleys, the front flat and v- idlers and the rear flat and v-idler pulleys (Figure 158). Figure 156 MVC-786F Figure 158 belt routing top 3 - 12 400XT Series Tractor Service Manual...
  • Page 51 Install the RH bolt and lock washer in the PTO stop bracket and tighten. Tighten the LH bolt in the PTO stop bracket (Figure 160). Figure 160 MVC-796F 400XT Series Tractor Service Manual 3 - 13...
  • Page 52 THIS PAGE INTENTIONALLY LEFT BLANK 3 - 14 400XT Series Tractor Service Manual...

  • Page 53: Electrical Systems

    “START” position. (1) Current flows from the ignition switch through the PTO (Power Take Off) The 400XT Series Garden Tractors use relays to direct switch, brake switch, seat switch, and activates the current flow to different areas of the tractor. The most...

  • Page 54: Testing

    30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85. 4 - 2 400XT Series Tractor Service Manual...

  • Page 55: Location

    “normally open” position. The solenoid closes and opens the switch very quickly. This minimizes the “arcing” that can damage other types of switches. 400XT Series Tractor Service Manual 4 - 3...

  • Page 56: Ignition Switch

    PTO, lights, safety, and accessory I = Safety & Ignition Circuit circuits if so equipped. Location The ignition switch is located on the lower right side of the tractor’s dash (Figure 224). Figure 224 MVC-007 4 - 4 400XT Series Tractor Service Manual...

  • Page 57: Testing

    Coil Resistance Measurement Disengage the PTO, set the parking brake, turn the ignition key to OFF and remove the key. Disconnect clutch wire connector. 400XT Series Tractor Service Manual 4 - 5...

  • Page 58: Measuring Clutch Current Draw

    The PTO switch is typically used to turn on the Electric (4), Figure 229. PTO Clutch and to function as part of the safety interlock system. Turn the ignition switch to the “RUN” position and the PTO switch to the “ON” position. 4 - 6 400XT Series Tractor Service Manual...

  • Page 59: Location

    Verify that there is continuity between the appropriate terminals in the “ON” and “OFF” positions, Figure 231. Figure 232 MVC-390X Replace the switch if your test results do not correspond with those given in Figure 231. 400XT Series Tractor Service Manual 4 - 7...

  • Page 60: Location

    If so, and the meter is not running, replace the meter. If 12 volts is not present, check the connections and the engine oil pressure switch. The meter is a permanently sealed unit and is not repairable. 4 - 8 400XT Series Tractor Service Manual...

  • Page 61: Magnet Assembly - Cruise Control

    There are 3 positions to the switch; OFF, START, and RUN. The start position is spring loaded so that the switch automatically returns to the "RUN" position. 400XT Series Tractor Service Manual 4 - 9...

  • Page 62: Testing

    When the brake pedal is depressed, it pushes on the plunger, closing and opening the contacts in the switch. “RUN” Position continuity Testing between terminals 7-8 / 2-3 Disconnect the switch from the wiring harness. Figure 237 MVC-163art 4 - 10 400XT Series Tractor Service Manual...

  • Page 63: Keychoice™ Reverse Operating System

    400XT Series Tractor Service Manual 4 - 11...
  • Page 64 The PTO and PTO light on the dash should remain “ON”. Push the PTO switch to “OFF”. The PTO light and the “Key Choice” warning light should turn off. Figure 241 MVC-866F 4 - 12 400XT Series Tractor Service Manual...

  • Page 65: Keychoice™ Reverse Operating System Switch

    Figure 243 MVC-866F two terminals. There should be NO continuity. Turn the key to the “ON” position and hold, since the switch is spring loaded. There should be continuity across the two terminals. 400XT Series Tractor Service Manual 4 - 13...

  • Page 66: Reverse Switch

    PTO is engaged, it will Testing stop the electric PTO clutch. Disconnect the switch from the wiring circuit. With a multimeter, check the continuity across the terminals. There should be continuity. 4 - 14 400XT Series Tractor Service Manual...

  • Page 67: Location

    If voltage is not applied to proper terminals on the KeyChoice™ Reverse Operating System Module, the electric PTO clutch will stop. Figure 248 MVC-869F 400XT Series Tractor Service Manual 4 - 15...
  • Page 68 Note: A 12 volt battery is needed for this test. USE CAUTION WHEN MEASURING RESISTANCE WITH A POWERED CIRCUIT. CONTACTING A VOLTAGE SOURCE WITH A METER IN OHMS POSITION CAN SERIOUSLY DAMAGE THE METER. 4 - 16 400XT Series Tractor Service Manual...
  • Page 69 ELECTRICAL SYSTEMS 400XT Series Tractor Service Manual 4 - 17...

  • Page 70: Service Manual

    400XT Series Tractor Service Manual Form No. 492-4779...

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