Toro 105-4654 Installation Instructions

Brake Service Kit

2001 Domestic T-Bar Gear-Drive Mid-Size Mowers

Model No. 105-4654

Installation Instructions

Loose Parts

Note: Use the chart below to identify parts for assembly.

DESCRIPTION QTY. USE

Form No. 3350-770

Template No. 1, Lefthand Template No. 2, Righthand

Brake Plate Link Brake Link Retaining Ring, 3/8 inch Retaining Ring, 5/16 inch

Brake Arm Brake Mounting Hub Flange Nut, 3/8 inch Flat Washer Screw, 3/8 x 1-3/4 inch Cotter Pin Decal

Important

and right brakes.

This kit needs to be installed on both left

1 1

2 2 2 4

2 2 2 4 2 2 2

Drilling Holes for Brakes

Installing the Brake Links

Installing the Brakes

Removing Existing Brakes

Warning

105–4661

 2003 by The Toro Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196

Mechanical or hydraulic jacks may fail to support machine and cause a serious injury.

• Use jack stand when supporting machine.

• Do not use hydraulic jacks.

Removing the Wheel Hub

1. Disengage the power take off (PTO), set the parking

brake, and turn the ignition key to off. Remove the key.

2. Raise the rear of the machine onto jack stands high

enough to raise the drive wheels off of the ground.

3. Remove the left and right drive tires (Fig. 2).

4. Disengage the parking brake.

Original Instructions (EN)

Printed in the USA

5. Disconnect the left and right brake rods from the brake

arms (Fig. 1).

6. Disconnect the left and right control rods and brake

rods from the idler brackets (Fig. 1).

m–5316

Figure 1

1. Hairpin cotter

2. Trunnion

3. Idler bracket

4. Wing nut

5. Hole F

6. Washer

7. Rod fitting

8. Clevis pin

9. Control rod

10. Brake rod

7. Remove the traction belts from the double pulleys

attached to the wheel hubs (Fig. 2). Move them to the rear over the traction drive pulley.

Note: Do not remove the belts completely from the machine.

8. Remove the hub dust caps (Fig. 2).

9. Remove the cotter pins from axle nuts, axle nuts, spacer

washers (if used) and wheel hub assemblies (Fig. 2).

Note: Do not get grease on brake band and brake drum. Cover the wheel hubs to avoid getting dirt into them.

m–5550

Figure 2

1. Wheel hub assembly

2. Axle nut

3. Cotter pin

4. Spacer (if used)

5. Double pulley

6. Traction belt

7. Tire

8. Hub dust cap

9. Nut

Removing the Brake Bands

1. Remove the retaining rings holding brake arms to

frame. Discard retaining rings (Fig. 3).

2. Remove the brake band bolts from the frame by

removing the nuts on the inside of the frame (Fig. 3).

3. Remove the brake band and brake arm assemblies from

the machine (Fig. 3).

4. Remove the bolts and nuts from the brake bands. These

nuts and bolts can be discarded (Fig. 3).

5. Remove the clevis pins and retaining rings holding the

brake bands to brake arms. The clevis pins, retaining rings and brake arms can be discarded.

m–5551

Figure 3

1. Brake arm (Left hand shown)

2. Brake band

3. Bolt

4. Nuts

5. Clevis pin

6. Retaining ring

Drilling Holes for Brakes

1. Locate and cut out templates number 1 (lefthand) and number 2 (righthand) as indicated on the templates. Fold the templates on the indicated fold line.

Note: Make sure the circle is cut out on both templates.

2. Slide template number 1 (lefthand) onto the brake pivot

pin and place the fold onto frame. The fold must match up with the corner of the frame. Tape the template in this position (Fig. 4).

m–5553

Figure 4

1. Template No. 1, Left side (Use template No. 2 for right side.)

2. Brake pivot pin

3. Corner of frame

Installing the Brake Links

Note: Brake band may need to be straightened.

1. Check to make sure brake band is straight. Lay band

onto table to see if it is bent (Fig. 5).

2. If needed, bend band so it is straight.

3. Center punch the hole that is needed to be drilled and

remove the template (Fig. 4).

Note: The hole location is very important.

4. Cut off the left brake pivot pin and grind flush with

frame. Do not damage side of frame.

5. Drill a 1/8 inch pilot hole into the frame at the punch

mark. Then drill a 25/64 inch into the 1/8 inch hole.

6. Apply paint to the side of the frame where the pivot pin

was removed.

7. Repeat these steps on the right side of the frame using

template number 2.

m–5569

Figure 5

1. Bent brake band, bend it straight

2. Straight brake band, correct position

3. Loop in band

3. Place a brake link assembly so the pins are pointing up (Fig. 6).

4. Install the brake band onto the brake link assembly. Install the band loops over the two 5/16 inch pins.

5. Install the new brake arm onto the 3/8 inch pin of the brake link assembly.

6. Place the brake link plate onto the assembly (Fig. 6).

7. Install 2 retaining rings (5/16 inch) on each of the

5/16 inch pins. This will hold the ends of the brake band on each assembly (Fig. 6).

8. Install a retaining ring (3/8 inch) on the 3/8 inch pin.

This will connect the brake arm to the link (Fig. 6).

9. Repeat these steps for the opposite side.

7. Install cotter pin into axle nut (Fig. 2). Note: If notch in axle nut does not line up with hole in end

of axle, loosen nut slightly and install cotter pin.

8. Refill wheel hub with grease and install grease cap

(Fig. 2).

9. Install decal onto machine in the position shown in

figure 7.

10.Repeat these steps for the opposite side.

6 1

m–7114

Figure 6

Left Side Brake Link Assembly

1. Brake link assembly

2. Brake band

3. Brake link plate

4. Retaining rings, 5/16 inch

5. 5/16 inch pins

6. 3/8 inch pin

7. Retaining ring, 3/8 inch

8. Brake arm (Left hand shown)

Installing the Brake

1. Place washer onto mounting bolt (3/8 x 1–3/4 inch)

(Fig. 7).

2. Lubricate the outside of brake mounting hub with

never–seize (Fig. 7).

Important Check to make sure the brake arm moves

freely on the brake mounting hub. If required remove any excess paint from the brake arm.

3. Install the brake assembly to the machine using

mounting bolt, washers, brake mounting hub and flange nut ( 3/8 inch) (Fig. 7). Tighten the bolt and nut to 30 ft–lbs (41 N⋅m).

4. Wipe any dirt or debris from the axle ends.

5. Place wheel hub assemblies onto axle while holding

brake bands in place (Fig. 2).

6. Reinstall spacer washers (when needed) and axle nuts

(Fig. 2). Tighten axle nut to 15 to 20 in–lbs. at the maximum.

m–7115

Figure 7

1. Brake assembly

2. Mounting bolt (3/8 x 1–3/4 inch)

3. Washer

4. Flange nut, 3/8 inch

5. Brake mounting hub

6. Brake rod

7. Brake arm

8. Decal

9. Brake drum

10. Hair pin cotter

Installing the Control Rods and Brake Rods

1. Install traction belts onto pulleys.

2. Install brake rods to brake arms with hairpin cotters and

washers previously removed (Fig. 7).

3. Install brake rod trunions into idler bracket hole F with washers and hairpin cotters previously removed (Fig. 8).

4. Thread rod fittings equal distance onto each control rod. For a starting point, thread fittings on approximately 1–3/4 inch (44 mm) from the start of the threads (Fig. 8).

5. Slide clevis pins through rod fittings and mounting holes in idler brackets (from outside) (Fig. 8). Secure with washers and hairpin cotters (Fig. 8).

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