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).
TABLE OF CONTENTS SPECIFICATIONS General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1 Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 2 Hydrostatic Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS CHASSIS (cont’d) Lift Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . .
TABLE OF CONTENTS ELECTRICAL SYSTEMS (con’d) Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4 Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 4 How It Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS ELECTRICAL SYSTEMS (con’d) KeyChoice™ Reverse Operating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the Key Choice™ Reverse Operating System - Unactivated . . . . . . . . Testing the KeyChoice™ Reverse Operating System - Activated . . . . . . . . . . KeyChoice™ Reverse Operating System Switch . . . . . . . . . . . . . . . . . . . . . . . . . Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
SPECIFICATIONS General Specifications Item Specification Engines 16 H.P. Kohler OHV Command Single Cylinder 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.
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) 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 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.
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.
SPECIFICATIONS Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size # 6 - 32 UNC # 6 - 40 UNF # 8 - 32 UNC # 8 - 36 UNF # 10 - 24 UNC #10 - 32 UNF 1/4 - 20 UNC 1/4 - 28 UNF Grade 1, 5, & SAE Grade 1 Bolts, Screws, SAE Grade 5 Bolts, Screws, SAE Grade 8 Bolts, Screws, 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 Str
SPECIFICATIONS Standard Torque for Dry, Zinc, and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws, and Studs with Regular Height Nuts (Class 8 or Strong Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height 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.
SPECIFICATIONS Other Torque Specifications Wheel Bolts and Lug Nuts 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 Size Recommended Torque** 7/16 - 20 UNF Grade 5 65 ± 10 ft-lb 88 ± 14 N-m 1/2 - 20 UNF Grade 5 80 ± 10 ft-lb 108 ± 14 N-m M12 X 1.25 Class 8.
SPECIFICATIONS Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals 1/64 1/32 3/64 1/16 5/64 0.015625 0.397 0.03125 0.794 0.046875 1.191 0.0625 1.588 0.078125 1.984 0.9375 2.381 0.1250 3.175 9/64 0.140625 3.572 0.15625 3.969 11/64 0.171875 4.366 0.1875 4.762 13/64 0.203125 5.159 0.21875 5.556 15/64 0.234375 5.953 0.2500 6.350 17/64 0.265625 6.747 0.28125 7.144 19/64 0.296875 7.541 0.3125 7.541 21/64 0.328125 8.334 0.34375 8.
SPECIFICATIONS U.S. to Metric Conversions To Convert Into Linear Measurement Miles Yards Feet Feet Inches Inches Inches Kilometers Meters Meters Centimeters Meters Centimeters Millimeters Area Square Miles Square Feet Square Inches Acre Square Kilometers Square Meters Square Centimeters Hectare 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 Tons Kilograms Grams 0.9078 0.4536 28.
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CHASSIS Model and Serial Number Location 3. One located on the front axle pivot area (1 total) (Figure 4). The model and serial number plate location is under the seat (Figure 3). Figure 4 Figure 3 MVC-742 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.
CHASSIS 2. Push the front of the tires out to remove normal looseness in the linkage (Figure 5). Figure 5 3. 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. MVC-747 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 7 MVC-752 Front Wheel Toe-in Adjustment 1.
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. Remove the outer hub cap, cotter pin, washer, and hub cap washer. Slide the wheel and tire off the spindle (Figure 11). MVC-098X Install the ball joint to the steering arm and check the toe-in as described in the measurement section (Figure 10). Figure 10 3. Figure 11 4. MVC-100X Remove the tie rod from the front spindle arm.
CHASSIS 5. The spindle can now be removed out the bottom of the front axle assembly (Figure 13). Figure 13 6. 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. MVC-102X Installation – reverse the order of removal. Figure 15 Front Axle Removal and Installation 1. 2. 3. MVC-757 On the front of the axle, in the center, remove the E-ring and washers (Figure 16).
CHASSIS 4. On the back side of the axle assembly, remove the bolt securing the axle pin (Figure 17). 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 17 5. mvc-761 Remove the axle pin; use a drift punch and hammer to tap the axle pin out; if needed.
CHASSIS 2. Disconnect the right and left tie rod assemblies (Figure 20). Figure 20 3. 4. 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). MVC-099X Loosen the locking nut on the eccentric. Position the steering wheel spokes so they extend outward left to right. 6. Tighten the nut to 25 – 35 ft lb (34 – 48 Nm). DO NOT OVERTIGHTEN.
CHASSIS Steering Gear Shaft Disassembly 1. Disconnect the battery cables. Remove the right side plate and battery from the tractor. 2. Remove the center steering wheel cover. Remove the nut, lock washer, and pull the steering wheel off the steering shaft (Figure 24). 4. Rotate the steering shaft until the top bolt of the universal joint faces the rear of the tractor. Remove the bolt (Figure 26). Figure 26 5. Figure 24 3.
CHASSIS 6. Rotate the steering gear shaft until the bottom bolt of the universal joint faces the front of the tractor. Remove the bolt (Figure 28). Figure 28 7. Expand the snap ring found on the steering gear shaft and slide if halfway down the shaft. Loosen the setscrew on the locking collar of the steering gear shaft and move it until it meets the snap ring (Figure 30). 6-14 Tilt steering to the rear position and remove the universal joint from the steering shaft gear.
CHASSIS 10. Remove the shims from the top of the lower bushing and set aside for installation process (Figure 32). Important: Check the bushing, shaft, and gears for wear and replace with new parts if necessary. Refer to “Steering Specifications” on page 2 - 14. Figure 32 Steering Gear Assembly 6-16 11. Installation - reverse the order of removal. Figure 33 (1) (2) (3) 1. Shims Lower Bushing Steering Gear Shaft (4) (5) (6) 6-19 Snap Ring Locking Collar Mid Bushing Place two 0.05” (1.
CHASSIS 5. Move the locking collar upward on the shaft until it touches the column support mid bushing. Tighten the collar set screw, then move the snap ring upward on the shaft until it meets the bottom of the locking collar (Figure 33). 8. Install the rubber boot over the steering shaft and console with a boot clip (Figure 35). 5 3 3 4 Figure 35 1 2 Figure 34 (1) (2) (3) Universal Joint Lower Steering Gear Shaft Retaining Bolts (4) (5) 9. 6-22 Upper Steering Shaft Steering Bushing 6.
CHASSIS Sector Gear Disassembly 1. Sector Gear Assembly Remove the battery and battery bracket from the tractor. Disconnect both steering tie rods from the sector gear. Using the access hole in the mounting bracket, remove the lock nut and carriage bolt holding the sector in place (Figure 36). Figure 38 (1) (2) (3) Figure 36 2. Remove the locking plate from the top of the sector gear (Figure 37). Figure 37 3.
CHASSIS 4. Insert the cam bushing, 3, into the bore of the sector gear (Figure 38). 5. Place the locking plate, 4, on the cam bushing (Figure 38). 6. From the bottom, insert the carriage bolt, 5, through the bearing washer, cam bushing, and the locking plate. Secure the bolt with the locknut, 6 (Figure 38). 7. Adjust the steering gear, refer to “Steering Backlash Adjustment” on page 2 - 5. 8. Fasten both steering arms onto the sector gear. Check wheel alignment and toe-in.
CHASSIS Tilt Steering Disassembly 1. Remove the steering wheel cover, nut, lock washer, and steering wheel from top of the steering shaft (Figure 42). 6. Remove the spring, 5, from the left pivot spacer and tilt control handle (Figure 41). 7. Remove the four bolts, 6, and nuts from the left and right support brackets, 8, and 9, and remove the brackets (Figure 41). 8. Remove the two side pivot bolts, 9, and spacers, 10, from the steering column. Lift the column, 11, out of the tractor (Figure 41). 9.
CHASSIS 7. Insert the top steering shaft, 4, onto the upper end of the universal joint check the front wheel alignment, wheels should be straight ahead. Install the retaining bolt, 3, through the upper end of the universal joint and steering shaft (Figure 41). 9. Align the steering wheel on the steering shaft. Secure the steering wheel with lock washer and nut. Install steering wheel cover (Figure 45).
CHASSIS Hood Removal 1. 3. Disconnect the headlight wiring harness at the plug and jack connection (Figure 46). Figure 46 2. Figure 48 MVC-003 On 2003 model units, remove the rubber O-ring, located on the left side hinge bracket, and raise the hood. Slide the hood to the left and off the hinge brackets. (Figure 47). 4. Reinstall the hood in reverse order. Unplug the seat switch, and the KeyChoice™ Reverse operating switch (Figure 49). MVC-018 Figure 49 2.
CHASSIS 3. Remove the two rear carriage bolts, washers, and nuts located in the rear of the fender assembly (Figure 50). 5. Remove the seat and fender together as one piece (Figure 52). Figure 52 Figure 50 4. MVC-122X Remove the four carriage bolts, washers, and nuts, (two on the right and two on the left), located between the footrest and fender (Figure 51). Figure 51 6. Installation - follow the removal procedure in reverse. Gas Tank Removal 1.
CHASSIS 3. Lift the gas tank from the frame, close the gas shut-off valve, and disconnect the gas line from the shut-off valve (Figure 54). Figure 54 4. 2. Figure 56 MVC-130X Carefully remove the gas tank. Remove the right and left washers and e-rings located on each end of the lift bar assembly (Figure 56). 3. MVC-800F Slide the lift bar out of the flange bushings and the rear lift plates (Figure 57). Installation Reverse the order of removal. Lift Bar Assembly Removal 1.
CHASSIS Lift Lever Assembly 3. Removal 1. Slide the right and left flange bearings inward from the pivot linkage brackets, so you will have enough clearance to remove the lift lever assembly (Figure 60). Remove the center access plate. Remove the pin clip and clevis pin retaining the two lift strap links to the lift lever (Figure 58). Figure 60 4. Figure 58 2. MVC-807F Remove the lift lever assembly from the pivot linkage brackets (Figure 61).
CHASSIS Lift Arm/Lift Lever Assembly 4. Removal 1. Remove the right and left side panels. Remove the center access plate. Disconnect the battery cables and remove the battery from the tractor. 2. Remove the two bolts holding the battery support and remove the support (Figure 62). Pull the dash upwards, with the steering shaft, and move carefully toward the front of the tractor to give you enough clearance to get to the lift assembly (Figure 64). Figure 64 5. Figure 62 3.
CHASSIS 6. Remove spring for the brake assembly (Figure 66). Figure 66 7. 8. Lift the lift assembly up and off the frame of the tractor (Figure 68). Figure 68 MVC-822F Lift the hood stand off the frame of the tractor (Figure 67). MVC-826F Installation Reverse the order of removal.
CHASSIS Electric Lift Figure 69 (1) (2) (3) (4) Actuator Spacer Clevis Pin Clip Pin (5) (6) (7) (8) Removal 1. Remove the right and left hood stand panels to the battery compartment. 2. Disconnect the negative and positive cables from the battery. 3. Remove the two screws holding the battery support and remove the support. 4. Unplug the actuator, 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.
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HYDRO-GEAR TRANSAXLE Hydro-Gear Hydrostatic Transaxle 3. Disconnect the free wheeling valve I rod and the vent hose clamp (Figure 118). Internal Service Internal service information is contained in the HydroGear Transaxle Service Manual, Form #492-0682. Under warranty, internal service work should not be performed unless authorized by your Distributor Service Manager or the Toro Company. Fluid Change The Hydro-Gear transaxle is factory filled, sealed, and does not require oil changes.
HYDRO-GEAR TRANSAXLE 5. If the tractor is equipped with cruise control, unplug the cruise control magnet wiring connectors (Figure 120). 7. Unhook the idler spring from the bottom of the idler pulley (Figure 122). Figure 122 Figure 120 6. MVC-064F Unbolt the cruise control magnet bracket from the side of the frame (Figure 121). 8. Remove the three bolts retaining the transmission fan to the pulley (Figure 123).
HYDRO-GEAR TRANSAXLE 9. Remove the damper cylinder located next to the transaxle input pulley. To remove the fastener on the end of the cylinder, insert the blade of a screwdriver between the back side of the fastener and the shaft. Apply a little pressure toward the back of the fastener and pull the damper cylinder off the shaft (Figure 124). 11. Use a floor jack under the transaxle to help lower the transaxle from the frame of the tractor (Figure 126). Figure 126 Figure 124 MVC-070F MVC-073 12.
HYDRO-GEAR TRANSAXLE 13. Remove the two nuts and washers that are located on each side of the transaxle axle housing holding the transaxle to the frame (Figure 128). 15. Continue to lower the transaxle out of the tractor frame (Figure 130). Figure 130 Figure 128 MVC-073F 14. Slowly lower the transaxle slightly and STOP. You will need to disconnect the hydro rod from the cruise control plate. Remove the cotter pin and washer (Figure 129). Figure 129 Installation - Hydro-Gear Transaxle 1.
HYDRO-GEAR TRANSAXLE 3. Install the bolt, washer, and nut through the front of the transaxle to the torque strap (Figure 132). Figure 132 4. 5. Figure 134 MVC-072F Install the drive belt around the transaxle input pulley. Install the idler spring on the idler pulley (Figure 133). Connect the damper cylinder to the control linkage (Figure 134). 6. Install the three bolts to secure the transaxle cooling fan to the transaxle pulley (Figure 135).
HYDRO-GEAR TRANSAXLE 7. Install the cruise control bracket, with magnet, with two bolts and nuts (Figure 136). Figure 136 8. 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 adjustment has been performed (Figure 138). Refer to “Brake Adjustment” on page 3 - 9. MVC-065 Reconnect the wire connector for the magnet (Figure 137). Figure 138 MVC-063 10.
HYDRO-GEAR TRANSAXLE 11. Reconnect the gas line to the gas tank and install the gas tank with two screws and washers (Figure 140). Neutral Adjustment Before making a neutral adjustment, the transaxle must be warmed up, usually 5 to 10 minutes. Steps to perform neutral adjustment: 1. Figure 140 Jack-up and support the right rear end of the tractor, allowing enough clearance to remove the right rear tire. Make sure the left tire stays on the ground (Figure 141).
HYDRO-GEAR TRANSAXLE 4. Rotate the adjusting puck in both directions and watch the axle direction. You want to adjust the puck so it is set in the mid-point between forward and reverse axle rotation. Make sure the axle is not moving (Figure 143). Transaxle Purging Procedures Due to the effects air has on efficiency in hydrostatic drive applications, it is critical that it be purged from the system.
HYDRO-GEAR TRANSAXLE CAUTION – DO NOT OVERFILL. If you overfill the transaxle while the unit is “cold”, it may overflow as it reaches normal operating temperatures. The oil level should not be above the level described on page 1 - 3. This will allow the space needed for the oil to expand as it warms up. 3. To adjust the brake, remove the cotter pin and loosen the castle nut slightly (Figure 145). Brake Always set the parking brake when you stop the machine or leave it unattended.
HYDRO-GEAR TRANSAXLE Foot Control Adjustment 3. If there is not enough ground speed in reverse and too much in forward, check the adjustment of the foot control. 1. Loosen the jam nut and turn the rod end until you achieve 1¼” (31.75mm) to 1-3/8” (34.925mm) gap between the footrest and the back side of the forward/reverse control pedal (Figure 149). Measure the distance between the footrest and the back of the forward/reverse control pedal. There should be 1¼” (31.75mm) to 1-3/8” (34.
HYDRO-GEAR TRANSAXLE Traction Belt Replacement 1. 4. If the mower deck is installed, remove the mower deck. Remove the power take off (PTO) belt between the pulley box and the electric clutch. Unhook the idler spring at the idler pulley located toward the rear of the tractor (Figure 153). Remove the existing belt from the tractor. Note: Perform belt installation, routing, and inspection procedures from beneath the tractor. 2. Disconnect the electric PTO clutch wire clutch (Figure 151). Figure 153 5.
HYDRO-GEAR TRANSAXLE 6. Route the belt over the lift bar assembly (Figure 155). Figure 155 7. 8. Route the drive belt around the flat and v-idler pulleys and then around the engine drive pulley (Figure 157). MVC-785F The belt then goes forward over the hydro pivot shaft and steering sector (Figure 156). Figure 157 9. MVC-787F Go back to the transaxle pulley and install the belt around the pulley. 10.
HYDRO-GEAR TRANSAXLE 11. Install the idler spring to the idler pulley, located toward the rear of the tractor (Figure 159). Figure 159 MVC-782F 12. Turn the electric 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 bracket (Figure 160). Figure 160 400XT Series Tractor Service Manual 13. Reconnect the electric PTO clutch wire (Figure 161).
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ELECTRICAL SYSTEMS Electrical Systems Relay Two things happen when turning the ignition switch to the “START” position. (1) Current flows from the ignition switch through the PTO (Power Take Off) switch, brake switch, seat switch, and activates the interlock relay, which sends voltage to the coil of the starter solenoid. The solenoid actuates and allows voltage to the starter motor of the engine.
ELECTRICAL SYSTEMS 2. Switch: Terminals 30, 87, and 87a are actually part of a single pole, double throw (SPDT) switch. Terminal 30 is the common lead. The switch is spring loaded so that 30 and 87a are connected when the coil is not energized. When the coil is energized, the switch is “thrown” and 30 and 87 are connected (Figure 219). Figure 219 4. Connect multimeter (ohms setting) leads to relay terminals 30 and 87a. Apply +12 VDC to terminal 85.
ELECTRICAL SYSTEMS Location The ignition switch is protected because only a small amount of current is needed to activate the coil. The solenoid is located under the front hood, mounted to the firewall of the tractor (Figure 221). Figure 222 Figure 221 MVC-833F XL Solenoid Testing How it Works 1. Disconnect the solenoid from the wiring harness. The solenoid has two primary parts. One is a coil of wire wrapped around an iron core. Whenever 12 volts is applied to the coil, it becomes a magnet.
ELECTRICAL SYSTEMS 4. You should be able to hear the solenoid “click” when you make the connection (Figure 223). C A C How It Works Detents inside the switch give it four positions: OFF, LIGHTS (ACCESSORIES), RUN, and START. The START position is spring loaded so the cylinder automatically returns to RUN once the key is released. Terminals of the ignition switch as viewed from the terminal end.
ELECTRICAL SYSTEMS Testing Location 1. Disconnect the switch from the wiring harness. The electric clutch is located on the PTO end of the engine crankshaft (Figure 227). 2. Verify that continuity exists between the terminals listed for the switch position. Verify that there is NO continuity between terminals not listed for the switch position.
ELECTRICAL SYSTEMS 3. Set the multimeter or volt/ohm meter to check resistance (ohms). 4. Connect the meter lead wires to the wires in the clutch connector (Figure 228). Figure 228 5. 8. 3-6 The meter should read between 2.40 ohms and 3.40 ohms. If the reading is above or below these readings, the field has failed and needs to be replaced. If the reading is between these two limits, measure the clutch current draw. Measuring Clutch Current Draw 1.
ELECTRICAL SYSTEMS Location 6. Mount the PTO switch back into the dash and reinstall the wiring harness. The PTO switch is located on the lower left side of the dash (Figure 230). Figure 231 Figure 230 MVC-387X 2-24 Seat Switch How it Works When the PTO switch is pulled out to the “ON” position, contacts inside the switch electrically connect various terminals. One terminal is connected to the wire that goes directly to the electric clutch.
ELECTRICAL SYSTEMS Location Hourmeter The seat switch is located on the bottom of the seat (Figure 233). Purpose The hourmeter 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). Figure 233 MVC-865F How It works When the seat is vacated, the switch is open and there is no continuity between the two terminals.
ELECTRICAL SYSTEMS Magnet Assembly - Cruise Control Purpose When engaging cruise control, the magnet assembly engages a cruise control plate that locks the control linkage to the speed that is set (Figure 235). Location The magnet assembly is located in the right rear of the tractor. The seat, fender, and fuel tank needs to be removed to gain access to the magnet assembly. Testing 1. Unplug the wires and remove the magnet assembly from the tractor. 2.
ELECTRICAL SYSTEMS Brake Switch Testing 1. Disconnect the switch from the wiring harness. 2. Using a VOM or test lamp, test the continuity or the terminals using the following diagrams (Figure 237). “OFF” Position continuity between terminals 8 and 7 only Purpose The double pole plunger type switch has four terminals. When the brake pedal is depressed, it completes the safety circuit for start.
ELECTRICAL SYSTEMS 2. Using a multimeter, follow the procedures listed below (Figure 239): A C B D Once you are sure you can safely mow in reverse or operate an attachment, 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 reminder that the reverse operating system interlock has been deactivated.
ELECTRICAL SYSTEMS 2. Pull the PTO electric clutch switch to “ON” (Figure 240). Figure 240 3. 4 - 12 The “Key Choice” warning light on the dash should come on (Figure 242). Figure 242 MVC-387X Turn the “Key Choice” key and release (Figure 241). Figure 241 4. MVC-867F 5. Move the foot pedal to reverse. 6. The PTO and PTO light on the dash should remain “ON”. 7. Push the PTO switch to “OFF”. 8. The PTO light and the “Key Choice” warning light should turn off.
ELECTRICAL SYSTEMS KeyChoice™ Reverse Operating System Switch Purpose This switch is used in the KeyChoice™ Reverse Operating System circuit. When turned to the ON position, it allows the operator to mow in reverse. How It 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 System reverse module and allows the operator to mow in reverse (Figure 244).
ELECTRICAL SYSTEMS Reverse Switch 3. Purpose Depress the plunger on the switch and check the continuity across the terminals, there should be NO continuity (Figure 246). This switch works in the KeyChoice™ Reverse Operating System circuit when the mower (PTO) is engaged. Location The switch is located under the tractor frame, next to the hydro pivot shaft and the hydro linkage (Figure 245).
ELECTRICAL SYSTEMS Location Testing - Low Voltage Testing The Low Voltage/KeyChoice™ Reverse Operating module is locate on the front side of the dash support, under the hood (Figure 247). Before replacing the Low Voltage/KeyChoice™ Reverse Operating Module, Check the following: Figure 247 MVC-843F How It Works Low Voltage - The low voltage portion of the module is a voltage comparator, checking the charge voltage from the engine regulator/rectifier system. If the charge is less than 11 volts D.C.
ELECTRICAL SYSTEMS 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 100K ohms) Diode* Pin 3 Pin 6 .5 to 1 Volt Diode* Pin 3 Pin 1 .5 to 1 Volt Diode* Pin 3 Pin 4 .5 to 1 Volt Ohms Pin 1 Pin 4 350 to 400 ohms Ohms Pin 2 Pin 4 Open (more the 100K ohms) *Note: If the multimeter does not have a diode test feature, this test can not be performed.
ELECTRICAL SYSTEMS 400XT Series Tractor Service Manual 4 - 17
400XT Series Tractor Service Manual Form No.
