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Toro 400XT Series Service Manual Download Page 6

TABLE OF CONTENTS

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400XT Series Tractor Service Manual

ELECTRICAL SYSTEMS (con’d)

KeyChoice™ Reverse Operating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 11

Testing the Key Choice™ Reverse Operating System - Unactivated . . . . . . . . 4 - 11
Testing the KeyChoice™ Reverse Operating System - Activated . . . . . . . . . . 4 - 11

KeyChoice™ Reverse Operating System Switch . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 13

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4 - 13
Location   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4 - 13
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4 - 13
Testing   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4 - 13

Reverse Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 14

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4 - 14
Location   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4 - 14
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4 - 14
Testing   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4 - 14

Module Low Voltage/KeyChoice™ Reverse Operating System . . . . . . . . . . . . . . 4 - 14

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4 - 14
Location   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4 - 15
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4 - 15
Testing - Low Voltage Testing   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  4 - 15

KeyChoice™ Reverse Operating System Module . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 15

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Summary of Contents for 400XT Series

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

Page 2: ...s service and repair instructions Tractor model years 2003 2004 are covered in this manual The manual may also be specified for use on later model products The hydrostatic transaxle is a sophisticated...

Page 3: ...and Lug Nuts 1 7 Thread Cutting Screws Zinc Plated Steel 1 7 Equivalents and Conversions 1 8 Decimal and Millimeter Equivalents 1 8 U S to Metric Conversions 1 9 CHASSIS Model and Serial Number Locat...

Page 4: ...RANSAXLE Hydro Gear Hydrostatic Transaxle 3 1 Internal Service 3 1 Fluid Change 3 1 Transaxle Removal 3 1 Installation Hydro Gear Transaxle 3 4 Neutral Adjustment 3 7 Transaxle Purging Procedures 3 8...

Page 5: ...aw 4 6 Clutch Burnishing Procedure 4 6 PTO Switch 4 6 Purpose 4 6 Location 4 7 How it Works 4 7 Testing 4 7 Seat Switch 4 7 Purpose 4 7 Location 4 8 How It works 4 8 Testing 4 8 Hourmeter 4 8 Purpose...

Page 6: ...se Operating System Activated 4 11 KeyChoice Reverse Operating System Switch 4 13 Purpose 4 13 Location 4 13 How It Works 4 13 Testing 4 13 Reverse Switch 4 14 Purpose 4 14 Location 4 14 How It Works...

Page 7: ...omponents which may increase in temperature during operation while the unit is running or shortly after it has been running Avoid fires and explosions Avoid spilling fuel and never smoke while working...

Page 8: ...System Hydro Gear Transaxle model 330 3000 Ground Speed Forward Infinite 0 to 6 8 MPH 90 10 9 km hr Reverse Infinite 0 to 3 2 MPH 0 4 8 km hr Steering Four 4 position tilt wheel Turning Radius 16 40...

Page 9: ...on SAE 20W 50 API Classification SH CD Oil Oil Capacity 3 8 qts 3 6l Oil Level The transaxle is a sealed system and does not require periodic checking If the oil needs to be checked IT CAN ONLY BE CHE...

Page 10: ...g torque feature hardness of the surface underneath of the fastener s head or similar condition which affects the installation As noted in the following tables torque values should be reduced by 25 fo...

Page 11: ...h Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts In lb In lb N cm In lb N cm In lb N cm 6 32 UNC 10 2 13 2 147 23 15 2 170 20 23 2 260 20 6 40 UNF 17 2 190 20 25 2 280 20 8 32 UNC 13 2 25 5 282...

Page 12: ...tc Note The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 of the nominal torque value Thin height nuts include j...

Page 13: ...ad Size Recommended Torque Square Head Hex Socket 1 4 20 UNC 140 20 in lb 73 12 in lb 5 16 18 UNC 215 35 in lb 145 20 in lb 3 8 16 UNC 35 10 ft lb 18 3 ft lb 1 2 13 UNC 75 15 ft lb 50 10 ft lb Type 1...

Page 14: ...4 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25...

Page 15: ...Square Centimeters Hectare 2 59 0 0929 6 452 0 4047 Volume Cubic Yards Cubic Feet Cubic Inches Cubic Meters Cubic Meters Cubic Centimeters 0 7646 0 02832 16 39 Weight Tons Short Pounds Ounces Metric...

Page 16: ...1 10 400XT Series Tractor Service Manual THIS PAGE INTENTIONALLY LEFT BLANK...

Page 17: ...area 1 One located on the inside of each wheel hub 2 total 2 One located on each end of the front axle for the spindles 2 total 3 One located on the front axle pivot area 1 total Figure 4 Figure 4 MVC...

Page 18: ...t measurement should be 1 8 to 3mm to 6mm less than the rear measurement Figure 7 If needed follow the adjustment procedure Figure 7 MVC 752 Front Wheel Toe in Adjustment 1 Remove the tie rod from one...

Page 19: ...Removal and Installation Removal 1 Disengage the PTO Set the parking brake and turn the ignition key to OFF to stop the engine Remove the key 2 Raise the front axle by putting a jack under the side y...

Page 20: ...1 Jack up the front of the tractor Put jack stands under the frame just behind the front axle assembly Figure 14 Figure 14 MVC 756 2 Using a drift punch and hammer drive the roll pin out of the front...

Page 21: ...or frame Figure 18 Figure 18 MVC 763 6 Installation reverse the order of removal Steering Gear Description The steering gear assembly is made up of a vertically mounted steering shaft and a horizontal...

Page 22: ...Figure 21 MVC 110X 5 Using a punch turn the eccentric clockwise until zero clearance is obtained between the end of the steering shaft gear and the steering sector Figure 22 Figure 22 MVC 113X 6 Tight...

Page 23: ...ng wheel off the steering shaft Figure 24 Figure 24 MVC 765 3 Remove the boot clip from the inside of the dash and remove the rubber boot from the steering shaft console Figure 25 Figure 25 MVC 766 4...

Page 24: ...ove the universal joint from the top of the tractor Figure 29 Figure 29 6 15 8 Expand the snap ring found on the steering gear shaft and slide if halfway down the shaft Loosen the setscrew on the lock...

Page 25: ...r Assembly Figure 33 6 19 1 Place two 0 05 1 27mm shims 1 between the top of the bushing 2 and the steering gear shaft 3 Note Lubricate the bushing with general purpose grease during assembly 2 Align...

Page 26: ...h 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 8 Install the rubber...

Page 27: ...re 37 6 26 3 Remove the cam bushing 3 and the sector gear 2 from the mounting bracket Figure 38 Important Inspect the sector gear teeth and cam bushing for wear and replace if necessary Sector Gear As...

Page 28: ...ector gear Check wheel alignment and toe in NOTE On 2004 models and on new replacement steering sector gears make sure the angle of the teeth are facing down Tilt Steering Figure 40 6 34 Description T...

Page 29: ...Lift the column 11 out of the tractor Figure 41 9 Slide the tilt control handle 12 off the steering column bracket Figure 41 10 Remove the bushing 13 from the top of the steering column Figure 41 Imp...

Page 30: ...the boot to console with the rubber clip Figure 44 Figure 44 MVC 766 9 Align the steering wheel on the steering shaft Secure the steering wheel with lock washer and nut Install steering wheel cover F...

Page 31: ...e brackets Figure 47 Figure 47 MVC 018 3 On 2004 and later model units raise the hood in the full up position then bring the hood back slightly and slide the hood toward the left side of the tractor F...

Page 32: ...d nuts two on the right and two on the left located between the footrest and fender Figure 51 Figure 51 MVC 012 5 Remove the seat and fender together as one piece Figure 52 Figure 52 MVC 029 6 Install...

Page 33: ...ve the gas tank Installation Reverse the order of removal Lift Bar Assembly Removal 1 Remove the bolt washer and nut retaining the lift chain to the lift bar Figure 55 Figure 55 MVC 798F 2 Remove the...

Page 34: ...Remove the two retaining rings that are located on each side of the lift lever assembly Figure 59 Figure 59 MVC 806F 3 Slide the right and left flange bearings inward from the pivot linkage brackets...

Page 35: ...igure 62 MVC 815F 3 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 63 MVC 817F 4 P...

Page 36: ...for the brake assembly Figure 66 Figure 66 MVC 822F 7 Lift the hood stand off the frame of the tractor Figure 67 Figure 67 MVC 827F 8 Lift the lift assembly up and off the frame of the tractor Figure...

Page 37: ...ctuator 1 from the wiring harness 5 Remove the clip pin 4 and clevis pin 6 that holds the actuator 1 to the actuator bracket assembly 7 6 Remove the clip pin 4 spacers 2 washers 5 and clevis pin 3 fro...

Page 38: ...2 22 400XT Series Tractor Service Manual THIS PAGE INTENTIONALLY LEFT BLANK...

Page 39: ...may correct certain performance problems Transaxle Removal 1 Disconnect the negative battery cable from the battery 2 Raise the rear of the tractor and remove the right and left rear tires Support the...

Page 40: ...wiring connectors Figure 120 Figure 120 MVC 064F 6 Unbolt the cruise control magnet bracket from the side of the frame Figure 121 Figure 121 MVC 065F 7 Unhook the idler spring from the bottom of the i...

Page 41: ...y a little pressure toward the back of the fastener and pull the damper cylinder off the shaft Figure 124 Figure 124 MVC 070F 10 Slip the belt off the transaxle input pulley Figure 125 Figure 125 MVC...

Page 42: ...dro rod from the cruise control plate Remove the cotter pin and washer Figure 129 Figure 129 MVC 074F 15 Continue to lower the transaxle out of the tractor frame Figure 130 Figure 130 MVC 077F Install...

Page 43: ...32 Figure 132 MVC 072F 4 Install the drive belt around the transaxle input pulley Install the idler spring on the idler pulley Figure 133 Figure 133 MVC 066F 5 Connect the damper cylinder to the contr...

Page 44: ...wire connector for the magnet Figure 137 Figure 137 MVC 064 9 Install the brake arm with the brake spring on the brake stud Install the castle nut but do not install the cotter pin until brake adjustm...

Page 45: ...center access plate Install the right tire 15 Operate the tractor and make sure all safety features are working Check the forward and reverse operation of the tractor If you find there is not enough s...

Page 46: ...hen a new transaxle is installed or after a transaxle has been repaired Air creates inefficiency because its compression and expansion rate is higher than that of the oil normally approved for use in...

Page 47: ...ent is required if the wheels turn and do not lock refer to Brake Adjustment on page 3 9 3 Release the brake and move the free wheeling lever to the PUSH position Wheels should rotate freely 4 If both...

Page 48: ...rd reverse pedal The location is under the tractor on the inside of the frame Figure 148 Figure 148 MVC 768F 3 Loosen the jam nut and turn the rod end until you achieve 1 31 75mm to 1 3 8 34 925mm gap...

Page 49: ...wire clutch Figure 151 Figure 151 MVC 778 3 Remove the RH bolt that holds the PTO stop assembly Loosen the LH bolt enough so you can turn the PTO stop assembly enough to disengage it from the slot in...

Page 50: ...gure 156 Figure 156 MVC 786F 8 Route the drive belt around the flat and v idler pulleys and then around the engine drive pulley Figure 157 Figure 157 MVC 787F 9 Go back to the transaxle pulley and ins...

Page 51: ...ric PTO clutch housing and align the PTO stop bracket in the slot of the clutch housing Install the RH bolt and lock washer in the PTO stop bracket and tighten Tighten the LH bolt in the PTO stop brac...

Page 52: ...3 14 400XT Series Tractor Service Manual THIS PAGE INTENTIONALLY LEFT BLANK...

Page 53: ...ay which will deactivate and ground the electronic ignition and stop the engine If you vacate the seat with the PTO switch disengaged and the park brake engaged the engine will continue to run The fol...

Page 54: ...Connect multimeter ohms setting leads to relay terminals 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...

Page 55: ...applied to the coil it becomes an electromagnet This quickly pulls the bar toward contacts and closes the switch When power is removed from the coil the spring loaded bar returns to its normally open...

Page 56: ...itch is located on the lower right side of the tractor s dash Figure 224 Figure 224 MVC 007 How It Works Detents inside the switch give it four positions OFF LIGHTS ACCESSORIES RUN and START The START...

Page 57: ...te The clutch plate always turns with the engine The field is a coil of wire on an iron core which becomes an electromagnet when power is applied The friction plate is the only piece that can slide up...

Page 58: ...a short jumper lead from terminal 2 to 4 Figure 229 7 Turn the ignition switch to the RUN position and the PTO switch to the ON position 8 If the meter reading is 3 5 amps or above the system is funct...

Page 59: ...turn the ignition to OFF and remove the key 2 Disconnect the wiring harness from the PTO switch 3 Press in on the locking tabs on each side of the switch and pull the switch out of the dash towards th...

Page 60: ...r keeps track of the actual engine hours This is accomplished by connecting the hourmeter to the engine oil pressure switch Location The hourmeter is located in the top center of the dash Figure 234 F...

Page 61: ...ows you to remove your foot from the traction control Testing 1 Unplug the wires and remove the magnet assembly from the tractor 2 Place the magnet assembly on a metal surface and apply 12VDC positive...

Page 62: ...elay On tractors with cruise control the cruise control circuit is connected to the brake switch When the brake pedal is depressed the switch opens and the cruise control magnet disengages Location Th...

Page 63: ...deactivate the reverse operating system by turning the KeyChoice switch located on the right side of the seat after engaging the PTO electric clutch A red light will illuminate on the dash as a remin...

Page 64: ...Turn the Key Choice key and release Figure 241 Figure 241 MVC 866F 4 The Key Choice warning light on the dash should come on Figure 242 Figure 242 MVC 867F 5 Move the foot pedal to reverse 6 The PTO...

Page 65: ...Works The switch is basically an on off switch spring loaded to return to off position When turned to the ON position with the PTO engaged it activates circuits in the KeyChoice Reverse Operating Syst...

Page 66: ...uit 2 With a multimeter check the continuity across the terminals There should be continuity 3 Depress the plunger on the switch and check the continuity across the terminals there should be NO contin...

Page 67: ...le from the PTO switch reverse switch and the override switch which energizes certain relays in the module If voltage is not applied to proper terminals on the KeyChoice Reverse Operating System Modul...

Page 68: ...HMS POSITION CAN SERIOUSLY DAMAGE THE METER Testing No Power To Circuit With Module Out of Circuit Meter Scale Meter Probe Negative Meter Probe Positive Meter Reading Ohms Pin 3 Pin 5 Open More than 1...

Page 69: ...400XT Series Tractor Service Manual 4 17 ELECTRICAL SYSTEMS...

Page 70: ...Form No 492 4779 Service Manual 400XT Series Tractor...

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