Toro 105-4655 Installation Instructions

FORM NO. 3326-693

Brake Service Kit

2001 International T–Bar, Gear–Drive, Mid–Size Mowers

Part No. 105–4655

Loose Parts

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

DESCRIPTION QTY. USE

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

Brake Plate Link Brake Link Retaining Ring, 3/8 in. Retaining Ring, 5/16 in.

Brake Arm, Lefthand Brake Arm, Righthand Brake Mounting Hub Flange Nut, 3/8 in. Flat Washer Screw, 3/8 in. x 1–3/4 in. Cotter Pin

1 1

2 2 2 4

1 1 2 2 4 2 2

Drilling Holes for Brakes

Installing the Brake Links

Installing the Brakes

INSTALLATION

INSTRUCTIONS

Bracket Screw, 1/4 x 1/2 in.

Important

and right brakes.

Printed in USA

This kit needs to be installed on both left

The Toro Company – 2001

Installing the Guards

105–4662

Installation Instructions

Removing the Guards

1. Remove four screws holding each traction belt guard

in place and remove covers.

2. Remove two screws holding each front belt guard

mounting bracket. Discard the screws and brackets.

Removing Existing Brakes

Warning

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.

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.

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

4. Disengage the parking brake.

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).

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.

Installation Instructions

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 bands 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.

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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).

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 3mm pilot hole into the frame at the punch mark. Then drill a 10 mm into the 3 mm 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.

Installation Instructions

5. Install the new lefthand brake arm onto the 3/8 in. pin

of the brake link assembly.

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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.

1 2

Note: There are two different brake arms. There is one for the right side and one for the left side. Make sure the brake arm is installed as shown in figure 6.

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

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

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

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

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

9. Repeat these steps for the opposite side.

6 1

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Figure 6

1. Brake link assembly

2. Brake band

3. Brake link plate

4. Retaining rings, 5/16 in.

5. 5/16 in. pins

6. 3/8 in. pin

7. Retaining ring, 3/8 in.

8. Brake arm (Left hand shown)

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 in. pins.

Installing the Brake

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

(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 in.) (Fig. 7). Tighten the bolt and nut to 30 ft–lbs (41 N–m).

Installation Instructions

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.

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

in end of axle, loosen nut slightly and install cotter pin. If needed, the spacer washer may be removed to insert 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.

3. Mark the hole to be drilled as indicated on the

template (Fig. 8).

4. Mark the left guard at the cut off line as indicated on

the template (Fig. 8).

5. Drill a 7 mm hole into the lefthand guard.

6. Cut belt guard off at the the indicated line.

7. Install new left belt guard bracket with 2 screws (1/4 x

1/2 in.) (Fig. 8).

8. Install left belt guard to bracket and machine with 3

screws (1/4 x 1/2 in.) (Fig. 8).

9. Repeat these procedures for the righthand belt guard. Use template No. 4 (righthand).

4 2

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Figure 7

1. Brake assembly

2. Mounting bolt (3/8 x 1–3/4 in.)

3. Washer

4. Flange nut, 3/8 in.

5. Brake mounting hub

6. Brake rod

7. Brake arm

8. Decal

9. Brake drum

Installing the Guards

1. Locate and cut out templates No.3 (lefthand) and No. 4 (righthand).

2. Place template No. 3 (lefthand) onto the lefthand belt guard. Tape the template in this position (Fig. 8).

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Figure 8

1. Guard (Left hand shown)

2. Bracket

3. Template No. 3, Left side

4. Bolts, 1/4 x 1/2 in.

Installing the Control Rods and Brake Rods

1. Install traction belts onto pulleys.

2. Install brake rods to brake arms with hairpin cotters

previously removed (Fig. 7).

3. Install brake rod trunions to idler brackets with

washers and hairpin cotters previously removed (Fig. 9).

4. Thread rod fittings equal distance onto each control

rod. For a starting point, thread fittings on approximately 1–3/4 in. (44 mm) from the start of the threads (Fig. 9).

5. Slide clevis pins through rod fittings and mounting

holes in idler brackets (from outside) (Fig. 9). Secure with washers and hairpin cotters (Fig. 9).

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