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Table of contents
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Toro 72200, 72201, 72202, 72211, 72212 Service Manual

400XT Series Tractor
Service
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.
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 piece of machinery. Maintain strict cleanliness control during all stages of service and repair. Cover or cap all hose ends and fittings whenever they are exposed. Even a small amount of dirt or other contamination can severely damage the system.
We are hopeful that you will find this manual a valuable addition to your service shop. If you have questions or comments regarding this manual, please contact us at the following address:
The Toro Company Consumer Service Department 8111 Lyndale Avenue South Bloomington, MN 55420-1196
The Toro Company reserves the right to change product specifications or this manual without notice.
Copyright© All Rights Reserved
©2003 The Toro Company
SPECIFICATIONS
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1
Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 2
Hydrostatic Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 3
Identification: Hydro-Gear Model 330-3000 Transaxle . . . . . . . . . . . . . . . . . . . . .1 - 3
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 3
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 4
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 4
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) . . . . . . . .1 - 5
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) . . . . . . . . .1 - 6
Other Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 7
SAE Grade 8 Steel Set Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 7
Thread Cutting Screws (Zinc Plated Steel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 7
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 7
Wheel Bolts 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

TABLE OF CONTENTS

CHASSIS
Model and Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Greasing and Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Front Wheel Toe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Front Wheel Toe-in Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2
Front Wheel and Spindle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Front Axle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 4
Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
Steering Backlash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
Steering Gear Shaft Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 7
Steering Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9
Sector Gear Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 11
Sector Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 11
Tilt Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 12
Tilt Steering Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 13
Tilt Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 13
Steering Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 14
Hood Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 15
Seat and Fender Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 15
Gas Tank Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 17
400XT Series Tractor Service Manual iii
TABLE OF CONTENTS
CHASSIS (cont’d)
Lift Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 17
Lift Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 18
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 18
Lift Arm/Lift Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 20
Electric Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 21
HYDRO-GEAR TRANSAXLE
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
Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
Checking the Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
Foot Control Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
Traction Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
ELECTRICAL SYSTEMS
Electrical Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
How it Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
iv 400XT Series Tractor Service Manual
ELECTRICAL SYSTEMS (con’d)
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5
Electric (PTO) Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5
Coil Resistance Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 5
Measuring Clutch Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 8
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 8
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 8
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 8
Magnet Assembly - Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9
Switch, Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9
How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 9
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 10
Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 10
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 10
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 10
How it Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 10
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 10
TABLE OF CONTENTS
400XT Series Tractor Service Manual v
TABLE OF CONTENTS
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
vi 400XT Series Tractor Service Manual
General Information
This symbol means WARNING or PERSONAL SAFETY INSTRUCTION
- read the instruction because it has to do with your safety. Failure to comply with the instruction may result in personal injury or even death.
This manual is intended as a service and repair manual only. The safety instructions provided herein are for troubleshooting, service, and repair of the 400XT Series tractors. The 400XT Series tractors
Think Safety First

SAFETY INFORMATION

tractors and attachment operator’s manuals contain safety information and operating tips for safe operating practices. Operator’s manuals are available through your Toro parts source or:
The Toro Company Publications Department 8111 Lyndale Avenue South Bloomington, MN 55420
Avoid unexpected starting of engine...
Always turn off the engine and disconnect the spark plug wire(s) before cleaning, adjusting, or repair.
Avoid lacerations and amputations...
Stay clear of all moving parts whenever the engine is running. Treat all normally moving parts as if they were moving whenever the engine is running or has the potential to start.
Avoid burns...
Do not touch the engine, muffler, or other components 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 with any type of fuel or lubricant. Wipe up any spilled fuel or oil immediately. Never remove the fuel cap or add fuel when the engine is running. Always use approved, labeled containers for storing or transporting fuel and lubricants.
Avoid injury from batteries...
Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes, and clothing. Battery gases can explode. Keep cigarettes, sparks, and flames away from the battery.
Avoid injury due to inferior parts...
Use only original equipment parts to ensure that important safety criteria are met.
Avoid injury to bystanders...
Always clear the area of bystanders before starting or testing powered equipment.
Avoid injury due to projectiles...
Always clear the area of sticks, rocks, or any other debris that could be picked up and thrown by the powered equipment.
Avoid modifications...
Never alter or modify any part unless it is a factory approved procedure.
Avoid asphyxiation...
Never operate an engine in a confined area without proper ventilation.
400XT Series Tractor Service Manual 1 - 1
Avoid unsafe operation...
Always test the safety interlock system after making adjustments or repairs on the machine. Refer to the Electrical section in this manual for more information.

SPECIFICATIONS

General Specifications
Item Specification
16 H.P. Kohler OHV Command Single Cylinder 17 H.P. Kawasaki OHV Twin Cylinder
Engines
RPM Setting, All Models High RPM Setting (no load) – 3250 + or -100 RPM
Construction Frame: 2” X 2” X 1/4” Welded Angle Frame
Fuel Capacity 3.9 Gallons (14.7 liter)
Wheel Base 49.5” (125.7cm)
Overall Length 71.0’ (180.3cm)
Overall Width 35.5” (90.1cm) without the mower
Weight
Traction System Hydro-Gear Transaxle model 330-3000
Ground Speed Forward - Infinite 0 to 6.8 MPH 90 (10.9 km/hr)
Steering Four (4) position tilt wheel
Tires Front: 16 X 6.50 - 8 Super Turf Tread
Tire Pressure Front Tires 20 p.s.i (138 kpa)
Attachment Drive Electric Clutch, Maintenance Free, No Adjustments
19 H.P. Kawasaki OHV Twin Cylinder For more information on servicing the engines, contact either Briggs & Stratton or Kawasaki.
416XT net weight 530 lbs. (240.4kg) 417XT net weight 560 lbs. (254kg) 419XT net weight 580 lbs. (263kg)
Reverse - Infinite 0 to 3.2 MPH (0 - 4.8 km/hr)
Turning Radius: 16” (40.6cm) RH and LH
Rear: 23 X 10.50 - 12 Super Turf Tread
Rear Tires 20 p.s.i. (138 kpa)
416XT: 15 amp Regulated DC Charging System Battery Voltage - 12 volt negative ground Battery Type: BCI Group U1, 260 CCA
417XT: 13 amp Regulated DC Charging Battery Voltage - 12 volt negative ground Battery Type: BCI Group U1, 340 CCA
Electrical System
1 - 2 400XT Series Tractor Service Manual
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
Hydrostatic Transaxle
Identification: Hydro-Gear Model 330-3000 Transaxle
330-3000
SPECIFICATIONS
General Specifications
Lubrication
Oil Capacity
Oil Level
SAE 20W-50 API Classification SH/CD Oil
3.8 qts. (3.6l)
The transaxle is a sealed system and does not require periodic checking. If the oil needs to be checked, IT CAN ONLY BE CHECKED COLD. There is a plug 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
SPECIFICATIONS
Torque Specifications
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.
These torque specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in the service manual. The following factors shall be considered when applying torque: cleanliness of the fastener, use of a thread sealant (Loctite), degree of lubrication on the fastener, presence of a prevailing 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% for lubricated fasteners to achieve the similar stress as a dry fastener. Torque values may also have to be reduced when the fastener is threaded into aluminum or brass. The specific torque value should be determined based on the aluminum or brass material strength, fastener size, length of thread engagement, etc.
Fastener Identification
Inch Series Bolts and Screws
(A) Grade 1 (B) Grade 5
Figure 1
(C) Grade 8
The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut) and mating part, then back off fastener 1/4 of a turn. Measure the torque required to tighten the fastener until the lines match up.
Figure 2
Metric Bolts and Screws
(A) Class 8.8 (B) Class 10.9
1 - 4 400XT Series Tractor Service Manual
SPECIFICATIONS
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)
Grade 1, 5, &
Thread Size
# 6 - 32 UNC
# 6 - 40 UNF 17 ± 2 190 ± 20 25 ± 2 280 ± 20
# 8 - 32 UNC
# 8 - 36 UNF 31 ± 3 350 ± 30 43 ± 4 31 ± 3
# 10 - 24 UNC
#10 - 32 UNF 48 ± 4 540 ± 45 68 ± 6 765 ± 70
1/4 - 20 UNC 48 ± 7 53 ± 7 599 ± 79 100 ± 10 1125 ± 100 140 ± 15 1580 ± 170
1/4 - 28 UNF 53 ± 7 65 ± 10 734 ± 113 115 ± 10 1300 ± 100 160 ± 15 1800 ± 170
5/16 - 18 UNC 115 ± 15 105 ± 17 1186 ± 169 200 ± 25 2250 ± 280 300 ± 30 3390 ± 340
5/16 - 24 UNF 138 ± 17 128 ± 17 1446 ± 192 225 ± 25 2540 ± 280 325 ± 30 3670 ± 340
3/8 - 16 UNC 16 ± 2 16 ± 2 22 ± 3 30 ± 3 41 ± 4 43 ± 4 58 ± 5
3/8 - 24 UNF 17 ± 2 18 ± 2 24 ± 3 35 ± 3 47 ± 4 50 ± 4 68 ± 5
7/16 - 14 UNC 27 ± 3 27 ± 3 37 ± 4 50 ± 5 68 ± 7 70 ± 7 68 ± 9
7/16 - 20 UNF 29 ± 3 29 ± 3 39 ± 4 55 ± 5 75 ± 7 77 ± 7 104 ± 9
1/2 - 13 UNC 30 ± 3 48 ± 7 65 ± 9 75 ± 8 102 ± 11 105 ± 10 142 ± 14
1/2 - 20 UNF 32 ± 3 53 ± 7 72 ± 9 85 ± 8 115 ± 11 120 ± 10 163 ± 14
5/8 - 11 UNC 65 ± 10 88 ± 12 119 ± 16 150 ± 15 203 ± 20 210 ± 20 285 ± 27
5/8 - 18 UNF 75 ± 10 95 ± 15 129 ± 20 170 ± 15 230 ± 20 240 ± 20 325 ± 27
3/4 - 10 UNC 93 ± 12 140 ± 20 190 ± 27 265 ± 25 359 ± 34 374 ± 35 508 ± 47
3/4 - 16 UNF 115 ± 15 165 ± 25 224 ± 34 300 ± 25 407 ± 34 420 ± 35 569 ± 47
7/8 - 9 UNC 140 ± 20 225 ± 25 305 ± 34 430 ± 45 583 ± 61 600 ± 60 813 ± 81
7/8 - 14 UNF 155 ± 25 260 ± 30 353 ± 41 475 ± 45 644 ± 61 660 ± 60 895 ± 81
8 with Thin
Height Nuts
In-lb In-lb N-cm In-lb N-cm In-lb N-cm
10 ± 2 13 ± 2 147 ± 23
13 ± 2 25 ± 5 282 ± 30
18 ± 2 30 ± 5 339 ± 56
ft-lb ft-lb N-m ft-lb N-m ft-lb N-m
SAE Grade 1 Bolts, Screws, Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws, Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
15 ± 2 170 ± 20 23 ± 2 260 ± 20
29 ± 3 330 ± 30 41 ± 4 460 ± 45
42 ± 4 475 ± 45 60 ± 6 674 ± 70
SAE Grade 8 Bolts, Screws, Studs, & Sems with Regular
Height Nuts (SAE J995
Grade 2 or Stronger Nuts)
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant such as oil, graphite, or thread sealant such as Loctite.
Note: The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is approximately
value. Thin height nuts include jam nuts.
± 10% of the nominal torque
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
SPECIFICATIONS
Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws, and Studs with
Thread Size
M5 X 0.8 57 ± 5 in-lb 640 ± 60 N-cm 78 ± 7 in-lb 885 ± 80 N-cm
M6 X 1.0 96 ± 9 in-lb 1018 ± 100 N-cm 133 ± 13 in-lb 1500 ± 150 N-cm
M8 X 1.25 19 ± 2 ft-lb 26 ± 3 N-m 27 ± 2 ft-lb 36 ± 3 N-m
M10 X 1.5 38 ± 4 ft-lb 52 ± 5 N-m 53 ± 5 ft-lb 72 ± 7 N-m
M12 X 1.75 66 ± 7 ft-lb 90 ± 10 N-m 92 ± 9 ft-lb 125 ± 12 N-m
M16 X 2.0 166 ± 15 ft-lb 225 ± 20 N-m 229 ± 22 ft-lb 310 ± 30 N-m
M20 X 2.5 325 ± 33 ft-lb 440 ± 45 N-m 450 ± 37 ft-lb 610 ± 50 N-m
Note: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners are defined as threads coated with a lubricant such as oil, graphite, or thread sealant such as Loctite.
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.
Regular Height Nuts
(Class 8 or Strong Nuts)
Note: The nominal torque values listed above are
based on 75% of the minimum proof load specified in SAE J1199. The tolerance is approximately
nominal torque value. Thin height nuts include jam nuts.
Class 10.9 Bolts, Screws, and Studs with
Regular Height Nuts (
Class 10 or Strong Nuts)
± 10% of the
1 - 6 400XT Series Tractor Service Manual
Other Torque Specifications
SPECIFICATIONS
SAE Grade 8 Steel Set Screws
Recommended Torque
Thread Size
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
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size Baseline Torque*
No. 6 - 32 UNC 20 ± 5 in-lb
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
7/16 - 20 UNF
Grade 5
1/2 - 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non-lubricated fasteners.
Thread
Size
No. 6 18 20 20 ± 5 in-lb
Threads per Inch
Type A Type B
65 ± 10 ft-lb 88 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
80 ± 10 ft-lb 108 ± 14 N-m
Thread Cutting Screws
(Zinc Plated Steel)
Baseline Torque*
No. 8 - 32 UNC 30 ± 5 in-lb
No.10 - 24 UNC 38 ± 7 in-lb
1/4 - 20 UNC 85 ± 15 in-lb
5/16 - 18 UNC 110 ± 20 in-lb
3/8 - 16 UNC 200 ± 100 in-lb
Conversion Factors
in-lb X 11.2985 - N-cm
ft-lb X 1.3558 = N-m
No. 8 15 18 30 ± 5 in-lb
No. 10 12 16 38 ± 7 in-lb
No. 12 11 14 85 ± 15 in-lb
* Hole size, material strength, material thickness and finish must be considered when determining specific torque values. All torque values are based on non­lubricated fasteners.
N-cm X - 0.08851 = in-lb
N-cm X 0.73776 - ft-lb
400XT Series Tractor Service Manual 1 - 7
SPECIFICATIONS
Equivalents and Conversions
Decimal and Millimeter Equivalents
Fractions Decimals mm Fractions Decimals mm
1/64 0.015625 0.397 33/64 0.515625 13.097
1/32 0.03125 0.794 16/32 0.53125 13.484
3/64 0.046875 1.191 35/64 0.546875 13.891
1/16 0.0625 1.588 9/16 0.5625 14.288
5/64 0.078125 1.984 37/64 0.578125 14.684
3/32 0.9375 2.381 19/32 0.59375 15.081
1/8 0.1250 3.175 5/8 0.6250 15.875
9/64 0.140625 3.572 41/64 0.640625 16.272
5/32 0.15625 3.969 21/32 0.65625 16.669
11/64 0.171875 4.366 43/64 0.671875 17.066
3/16 0.1875 4.762 11/16 0.6875 17.462
13/64 0.203125 5.159 45/64 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 25/32 0.78125 19.844
19/64 0.296875 7.541 51/64 0.796875 20.241
5/16 0.3125 7.541 13/16 0.8125 20.638
21/64 0.328125 8.334 53/64 0.828125 21.034
11/32 0.34375 8.731 27/32 0.84375 21.431
23/64 0.359375 9.128 55/64 0.859375 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.390625 9.922 57/64 0.890625 22.622
13/32 0.40625 10.319 29/32 0.90625 23.019
27/64 0.421875 10.716 59/64 0.921875 23.416
7/16 0.4375 11.112 15/16 0.9375 23.812
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
1/2 0.5000 12.700 1 1.000 25.400
1 mm = 0.03937 in. 0.001 in. = 0.0254 mm
1 - 8 400XT Series Tractor Service Manual
SPECIFICATIONS
U.S. to Metric Conversions
To Convert Into Multiply By
Linear Measurement
Area
Volume
Weight
Pressure
Work
Liquid Volume
Liquid Flow
Miles Yards Feet Feet Inches Inches Inches
Square Miles Square Feet Square Inches Acre
Cubic Yards Cubic Feet Cubic Inches
Tons (Short) Pounds Ounces
Pounds/Sq. In. Kilopascal 6.895
Foot-pounds Foot-pounds Inch-pounds
Quarts Gallons
Gallons/Minute Liters/Minute 3.785
Kilometers Meters Meters Centimeters Meters Centimeters Millimeters
Square Kilometers Square Meters Square Centimeters Hectare
Cubic Meters Cubic Meters Cubic Centimeters
Metric Tons Kilograms Grams
Newton-Meters Kilogram-Meters Kilogram-Centimeters
Liters Liters
1.609
0.9144
0.3048
30.48
0.0254
2.54
25.4
2.59
0.0929
6.452
0.4047
0.7646
0.02832
16.39
0.9078
0.4536
28.3495
1.356
0.1383
1.152144
0.9463
3.785
Temperature
Fahrenheit Celsius 1. Subtract 32°
2. Multiply by 5/9
400XT Series Tractor Service Manual 1 - 9
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1 - 10 400XT Series Tractor Service Manual

CHASSIS

Model and Serial Number Location
The model and serial number plate location is under the seat (Figure 3).
Figure 3
MVC-742
Greasing and Lubrication
3. One located on the front axle pivot area (1 total) (Figure 4).
Figure 4
4. NOTE: On 2004 models, there is a grease zerk located on the forward/reverse pedal.
MVC-746
Front Wheel Toe-in
The machine should be greased every 50 hours or yearly, whichever occurs first. You should grease more frequently when operating conditions are extremely dusty or sandy.
Grease Type: General-purpose grease.
There are 5 grease fittings located in the front axle 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).
If there is uneven tire wear, lawn scuffing, or hard steering, toe-in may need to be adjusted. The front toe-in measurement should be 1/8” to ¼” (3 to 6mm). This should be checked every 100 hours or once a year, whichever occurs first.
MEASUREMENT:
1. Disengage the PTO, set the parking brake, and turn the ignition key to OFF to stop the engine. Remove the key.
400XT Series Tractor Service Manual 2 - 1
CHASSIS
2. Push the front of the tires out to remove normal looseness in the linkage (Figure 5).
Figure 5
3. Measure the distance between both the front rims at spindle level, in front and rear of the wheels. You can also measure between the tread mold marks if the tires are new (Figure 6).
MVC-747
4. The front measurement should be 1/8” to ¼” (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
Figure 6
1. Remove the tie rod from one steering arm.
2. Loosen the jam nut securing the ball joint to the steering rod. Rotate the ball joint one turn: clockwise to increase toe-in; counterclockwise to decrease toe-in (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.
MVC-749
Figure 8
2 - 2 400XT Series Tractor Service Manual
MVC-095X
CHASSIS
3. Hold the flats on the ball joint to align with the flats on the tie rod and tighten the jam nut (Figure 9).
Figure 9
4. Install the ball joint to the steering arm and check the toe-in as described in the measurement section (Figure 10).
MVC-098X
3. Remove the outer hub cap, cotter pin, washer, and hub cap washer. Slide the wheel and tire off the spindle (Figure 11).
Figure 11
4. Remove the tie rod from the front spindle arm. With a drift punch and hammer, drive the roll pin out of the front spindle arm (Figure 12).
MVC-100X
Figure 10
MVC-099X
Figure 12
MVC-732X
Front Wheel and Spindle 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 you are removing the wheel or spindle from.
400XT Series Tractor Service Manual 2 - 3
CHASSIS
5. The spindle can now be removed out the bottom of the front axle assembly (Figure 13).
Figure 13
6. Installation – reverse the order of removal.
MVC-102X
Front Axle Removal and Installation
2. Using a drift punch and hammer, drive the roll pin out of the front spindle arms and remove the arms from the spindles (Figure 15). Remove the wheels with steering spindles, from the axle.
Figure 15
3. On the front of the axle, in the center, remove the E-ring and washers (Figure 16).
MVC-757
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
Figure 16
MVC-758
2 - 4 400XT Series Tractor Service Manual
CHASSIS
4. On the back side of the axle assembly, remove the bolt securing the axle pin (Figure 17).
Figure 17
5. Remove the axle pin; use a drift punch and hammer to tap the axle pin out; if needed. Lower the axle assembly out of the tractor frame (Figure
18).
mvc-761
Steering Gear
Description
The steering gear assembly is made up of a vertically mounted steering shaft and a horizontal sector gear. The sector gear is adjustable so that excessive backlash play in steering gears can be removed (Figure 19).
Figure 18
6. Installation - reverse the order of removal.
MVC-763
Figure 19
6-8
Steering Backlash Adjustment
Use the following procedure if there is excessive steering backlash.
1. Remove battery and battery tray from the tractor.
400XT Series Tractor Service Manual 2 - 5
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