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.

For additional information on the electrical system, please refer to the Toro Electrical

Demystification Guide (492-4404). For service information on drive systems, please refer to the Hydro-Gear (330-3000) service manual. For information information specific to the engines used on this unit, refer to the appropriate engine manufacturer’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 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

TABLE OF CONTENTS

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
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
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.2 - 3
Front Axle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.2 - 4
Steering Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.2 - 5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	.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
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	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
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2 - 17

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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

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TABLE OF CONTENTS

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

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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

SAFETY INFORMATION

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

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

Think Safety First

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 asphyxiation...

Never operate an engine in a confined area without proper ventilation.

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 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.

400XT Series Tractor Service Manual

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SPECIFICATIONS

General Specifications

Item	Specification
	16 H.P. Kohler OHV Command Single Cylinder
Engines	17 H.P. Kawasaki OHV Twin Cylinder
	19 H.P. Kawasaki OHV Twin Cylinder
	For more information on servicing the engines, contact either Briggs & Stratton or
	Kawasaki.
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	416XT net weight 530 lbs. (240.4kg)
	417XT net weight 560 lbs. (254kg)
	419XT net weight 580 lbs. (263kg)
Traction 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” (40.6cm) RH and LH
Tires	Front: 16 X 6.50 - 8 Super Turf Tread
	Rear: 23 X 10.50 - 12 Super Turf Tread
Tire Pressure	Front Tires 20 p.s.i (138 kpa)
	Rear Tires 20 p.s.i. (138 kpa)
Attachment Drive	Electric Clutch, Maintenance Free, No Adjustments
	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	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

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400XT Series Tractor Service Manual

SPECIFICATIONS

Hydrostatic Transaxle

Identification:

Hydro-Gear Model 330-3000 Transaxle

330-3000

General Specifications

	Lubrication		SAE 20W-50 API Classification SH/CD Oil
	Oil Capacity		3.8 qts. (3.6l)
			The transaxle is a sealed system and does not require periodic checking. If the
	Oil Level		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.

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SPECIFICATIONS

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.

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.

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 1
Inch Series Bolts and Screws
(A) Grade 1		(C) Grade 8
(B) Grade 5

Figure 2

Metric Bolts and Screws

(A) Class 8.8	(B) Class 10.9

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400XT Series Tractor Service Manual

SPECIFICATIONS

Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series)

		Grade 1, 5, &		SAE Grade 1 Bolts, Screws,				SAE Grade 5 Bolts, Screws,					SAE Grade 8 Bolts, Screws,
	Thread Size	8 with Thin		Studs, & Sems with Regular				Studs, & Sems with Regular					Studs, & Sems with Regular
		Height Nuts		Height Nuts (SAE J995				Height Nuts (SAE J995					Height Nuts (SAE J995
				Grade 2 or Stronger Nuts)				Grade 2 or Stronger Nuts)					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	± 30	29	± 3	330	±	30	41	± 4	460	± 45
	# 8 - 36 UNF							31	± 3	350 ± 30			43	± 4	31	± 3
	# 10 - 24 UNC	18	± 2	30	± 5	339	± 56	42	± 4	475	± 45		60	± 6	674	± 70
	#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
		ft-lb		ft-lb		N-m		ft-lb		N-m			ft-lb		N-m
	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

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.

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 ± 10% of the nominal torque value. Thin height nuts include jam nuts.

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SPECIFICATIONS

Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners)

Thread Size		Class 8.8 Bolts, Screws, and Studs with					Class 10.9 Bolts, Screws, and Studs with
			Regular Height Nuts					Regular Height Nuts (
			(Class 8 or Strong Nuts)					Class 10 or Strong Nuts)
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.

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 jam nuts.

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400XT Series Tractor Service Manual

SPECIFICATIONS

Other Torque Specifications

SAE Grade 8 Steel Set Screws

	Thread 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

Wheel Bolts and Lug Nuts

	Thread Size	Recommended Torque**
	7/16 - 20 UNF	65 ± 10 ft-lb	88 ± 14 N-m
	Grade 5
	1/2 - 20 UNF	80 ± 10 ft-lb	108 ± 14 N-m
	Grade 5
	M12 X 1.25	80 ± 10 ft-lb	108 ± 14 N-m
	Class 8.8
	M12 X 1.5	80 ± 10 ft-lb	108 ± 14 N-m
	Class 8.8

** For steel wheels and non-lubricated fasteners.

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
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

Thread Cutting Screws

(Zinc Plated Steel)

	Thread	Threads per Inch		Baseline Torque*
	Size	Type A	Type B
	No. 6	18	20	20 ± 5 in-lb
	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.

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

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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

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400XT Series Tractor Service Manual

			SPECIFICATIONS
	U.S. to Metric Conversions
	To Convert	Into			Multiply By
	Miles	Kilometers			1.609
	Yards	Meters			0.9144
Linear	Feet	Meters			0.3048
	Feet	Centimeters			30.48
Measurement
	Inches	Meters			0.0254
	Inches	Centimeters			2.54
	Inches	Millimeters			25.4
	Square Miles	Square Kilometers			2.59
Area	Square Feet	Square Meters			0.0929
	Square Inches	Square Centimeters			6.452
	Acre	Hectare			0.4047
Volume	Cubic Yards	Cubic Meters			0.7646
	Cubic Feet	Cubic Meters			0.02832
	Cubic Inches	Cubic Centimeters			16.39
Weight	Tons (Short)	Metric Tons			0.9078
	Pounds	Kilograms			0.4536
	Ounces	Grams			28.3495
Pressure	Pounds/Sq. In.	Kilopascal			6.895
Work	Foot-pounds	Newton-Meters			1.356
	Foot-pounds	Kilogram-Meters			0.1383
	Inch-pounds	Kilogram-Centimeters			1.152144
Liquid Volume	Quarts	Liters			0.9463
	Gallons	Liters			3.785
Liquid Flow	Gallons/Minute	Liters/Minute			3.785
Temperature	Fahrenheit	Celsius		1.	Subtract 32°
				2.	Multiply by 5/9

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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

3.One located on the front axle pivot area (1 total) (Figure 4).

Figure 4		MVC-746

4.NOTE: On 2004 models, there is a grease zerk located on the forward/reverse pedal.

Greasing and Lubrication

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).

Front Wheel Toe-in

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

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CHASSIS

2.Push the front of the tires out to remove normal looseness in the linkage (Figure 5).

Figure 5	MVC-747

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).

Figure 6	MVC-749

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

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.

Figure 8	MVC-095X

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400XT Series Tractor Service Manual

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).

3.Remove the outer hub cap, cotter pin, washer, and hub cap washer. Slide the wheel and tire off the spindle (Figure 11).

Figure 9	MVC-098X

4.Install the ball joint to the steering arm and check the toe-in as described in the measurement section (Figure 10).

Figure 11	MVC-100X

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).

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.

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CHASSIS

5.The spindle can now be removed out the bottom of the front axle assembly (Figure 13).

Figure 13	MVC-102X

6.Installation – reverse the order of removal.

Front Axle Removal and Installation

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 spindle arms and remove the arms from the spindles (Figure 15). Remove the wheels with steering spindles, from the axle.

Figure 15	MVC-757

3.On the front of the axle, in the center, remove the E-ring and washers (Figure 16).

Figure 16	MVC-758

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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	mvc-761

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).

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 sector gear. The sector gear is adjustable so that excessive backlash play in steering gears can be removed (Figure 19).

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.

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