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1. BATT CHG INDICATOR ACCESSORY 50 FUSE 2 FUSE MAIN SOL Bt IGN NEG CONTACTS COIL COIL TERM HORN SW PIB OUT J03 Jo5 J06 J08 JOT Jol oz 109 J13 02503 4 85678 1 0 1 0 1 1 1 1 1 0 1 0 1 o E gt 5 ul RS RED WHITE 5 3 2 a E I ORANGE ORANGE T SP03 4 RED 5 02 5 01 U 5 WHITE h ORANGE a 2 1 RED WHITE BLACK SPOS BLUE BLUEMHITE A 8 1 BLACK 5 i 3 x BROWN o 6 5 1 1 8 1 10 WHITE BLACK BLUEMHITE 1 2 YELLOW ORANGE 3 BLACK PINK 4 BLUE 3 YELLOW 4 VIOLET BLACK 5 BLACK BLUEMHITE 6 8 1 c WHITE 8 D 9 10 W BROWN E SP08 13 16 GREEN n L 15 2A 4 v 16 5 x m m xj m A BLACK 8 TAN p TAN 9 TAN SP09 GRAY SP13 BLACK BLACK SPII BLUE SPI29 B BLACK SK 04 RED WHITE BLUE BLUE A A BLUE 8 ORANGE x z 5 ORANGE GREEN a BLUE 2 5 B 5 ORANGE x 9 x LT s d 5 9 3 8 2 a ca d a gt 123 45 678 8 B 1 1 A B
2. BU PK IGNITION SWITCH aS DEHS AM OFF RUN F2 10A R rr E ACCESSORIES CONTACTOR HORN E SOLENOID ENERGIZED IN RUN i rd L v OR HORN SWITCH i BATT CHG Q HOOK UP UTI PSS rete See eT RW E a r HEADLIGHTS 24V Cera Stee ete ole se setters oe 1 0 2 ete ZEN INTERLOCK STATE OF CHARGE FL2 ES OR GN e CHARGER INDICATOR ue I SWITCH i s CHARGER NOT o 8 4589 4589 PLUGGED IN c LIGHT SWITCH NE BU i 1 2 BK 1_355 4 Los i dpa BU BU A B 1 ARAARA T Y a OPTIONS VON FORWARD T A Y p OPTION 4 3 NC 48 VDC INPUT 1244156 pn wt PROGRAMMER oo i PK 1 2 FOR REV PORT Aer 4 ACCELERATOR PEDAL SWITCH cowracron Y Pee PEDAL NOT PUSHED IN T lt 3 ACCELERATOR PEDAL Be Tonon LI HI LOW SPEED SWITCH Y lt 4 HI LOW vd 4GA T POSITION 1 5 CHARGER 10 GA VIO BK N amp 4 i F1 l 48V BATT ARRAY 1 BK eae lt 6 HIGH TEMP LOW BATTERY MEC N
3. NA 022027 u ROTATION TO E EXPAND BRAKE SHOES Figure 5 1 Backing plate 8 Actuator lever 2 Hold down pin 9 Adjusting screw 3 Bottom shoe to shoe spring 10 PTFE coated washer 4 Top shoe to shoe spring 11 Push rod 5 Auto adjust spring 12 Shim washer 6 Shoecup spring loaded 13 Protective boot 7 Brake shoe Transaxle and Brakes Rev B Page 4 10 Rev C Pivot pin Wave washer Washer Adjusting lever Retaining clip Anchor abutment Workman e2050 e2065 Disassembly Fig 5 1 Remove auto adjust spring and shoe to shoe springs from brake shoes 2 Remove hold down pins and shoe cups securing the brake shoes to the backing plate 3 Remove brake shoes from backing plate Inspection 1 Inspect brake drums IMPORTANT Brake drum machining is not recom mended Replace brake drums as a set to maintain equal braking forces A Clean drums with denatured alcohol Check braking surface diameter in at least three places If the diameter exceeds 6 320 inches 16 05 cm re place both brake drums B Replace drums that are cracked deeply grooved tapered significantly out of round scored exces sively rusted or heat spotted C Minor scoring can be removed with sandpaper 2 Inspect brake shoe linings IMPORTANT Replace brake shoes as a set all
4. 3 Suspension and Steering 3 SERVICE AND REPAIRS 5 Check Tire 5 Inspect Tires and Wheels 5 Upper Steering 6 Steering Gearbox 8 Front Wheels Workman 2050 10 Lower Steering Workman e2050 12 Front Wheels and Lower Steering Workman 2065 ues EU PR RR 14 A arm and Frame Pivot Yoke 16 Seat Base sss edu A EE EET AA 20 Eront Hood uas eve e RE ER 22 Cargo Bed isses Ex EA 24 Workman e2050 e2065 Page 5 1 Chassis Rev B Specifications Item Description Front tire 22 x 9 5 10 4 ply pressure 8 to 22 PSI 0 55 to 1 52 bar Rear tire 22 x 9 5 10 4 ply pressure 8 to 22 PSI 0 55 to 1 52 bar Front wheel cap screw torque Workman e2050 135 to 165 ft lb 183 to 224 Wheel lug nut torque front and rear 45 to 65 ft lb 61 to 88 Chassis Rev B 5 2 Workman e2050 e2065 Troubleshooting Suspension and Steering Problem Possible Cause Front end is noisy Front wheel lug nuts are loose Front wheel bearings are loose or worn Front end components are loose or worn Steering gear is loose Rear end is noisy Rear wheel lug nuts are loose Transaxle problem see Chapter 4 Transaxle and Brakes
5. 20 ESOS Pus gra c eade 22 Fusible Links 23 Accelerator Switch 24 Accelerator Potentiometer 25 d nC per E MIC ae 26 Workman e2050 e2065 Page 3 1 SERVICE AND REPAIRS Battery Service Battery Specifications Removal Installation Charging Inspection and Maintenance Battery Storage Traction Motor Brushes Traction Motor Traction Motor Service Battery Charger LESTER ELECTRICAL TECHNICIAN SERVICE GUIDE Electrical System Rev B Electrical System Electrical Diagrams The electrical schematic circuit drawings and wire har ness drawings for the Workman e2050 and 2065 located in Chapter 6 Electrical Diagrams Electrical System Rev B Page 3 2 Workman e2050 e2065 General Information The Workman e2050 and e2065 use a 48 volt DC elec trical system that is an isolated circuit The vehicle frame is not used for any ground connections The vehicle controller monitors operator and vehicle in puts to determine voltage to the traction motor If a prob lem exists that will prevent normal vehicle operation an LED on the controller and the vehicle status light on the dash panel will flash
6. System Battery Storage If the vehicle will be stored for any period of time check battery electrolyte level adjust level if needed and then connect battery charger to vehicle Allow charger to re main connected to vehicle during storage to prevent bat tery discharge and potential battery damage Electrical System Rev B Page 3 32 If the vehicle will be stored for more than 30 days and the battery charger cannot be used for some reason charge the batteries fully Either store batteries on a shelf or in the vehicle Store the batteries in a cool atmosphere to avoid quick deterioration of the charge in the batteries To prevent batteries from freezing make sure they are fully charged before storage During the storage period charge the batteries at least once every three 3 months to prevent battery damage Before returning the vehicle to service make sure to fully charge the batter ies Workman e2050 e2065 Traction Motor Brushes The traction motor in the Workman e2050 e2065 uses eight 8 brushes Traction motor brushes should be in spected every 500 hours of operation or annually Inspection 1 Make sure that on off switch is OFF Raise and latch bed to allow access to traction motor 2 Open the battery circuit by carefully removing one of the battery cables see Opening Battery Circuit in the General Information section of this chapter 3 Unlatch headband of traction motor and reposition
7. Figure 13 Parking brake cover 4 Brake equalizer Brake cable 2 used 5 Parking brake lever Seat base Chassis Rev B Front Hood Figure 14 1 Hood 6 Bumper 10 Flange head screw 2 used 2 Flange head screw 6 used 7 Flat washer 2 used 11 Flange head screw 2 used 3 Dash 8 Cap screw 2 used 12 Headlight mount 2 used 4 Flange nut 6 used 9 Flat washer 4 used 13 Headlight 2 used 5 Fender LH shown Chassis Rev B 5 22 Workman 2050 2065 Removal Fig 14 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from the on off switch 2 Open the battery circuit by carefully removing one of the battery cables see Opening Battery Circuit in the General Information section of Chapter 3 Electrical System 3 Remove screws attaching the wire harness connec tors to each headlight 4 Remove two 2 cap screws item 8 and flat washers item 7 that secure bumper to vehicle Remove bumper 5 Remove both flange head screws item 11 securing the center lower hood to the front frame support 6 Remove flange nut item 4 both flat washers item 9 and flange head screw item 10 securing the hood to each fender front 7 Remove both flange nuts item 4 and flange head screws item 2 securing the hood to the top of each fender 8 Remove two 2 flange head screws item 2 secur ing the hood to the dash Remove hood from the
8. SEVCON J23 HORN MOTOR PiS TEMP J34 J35 BATT CHG INDICATOR ACCESSORY SOL FUSE 2 USE MAIN SOL B IGN NEG CONTACTS COIL COIL TERM HORN SW PIB OUT 3 J4 5 J6 J8 Jl J2 29 leg 637 1 1 I 1 g c t c o E 5 PINK 4 a RED WHITE El 2 ORANGE ORANGE SP3 RED i SP2 SPI E WHITE ORANGE a 1 RED WHITE 2 BLACK 5 5 BLUE BLUEMHITE A B 2 BLACK 3 8 a x BROWN o D 5 m 1 8 WHITE BLACK BLUEMHITE SPTO 2 YELLOW ORANGE 1 3 BLACK PINK 2 4 BLUE 3 YELLOW 4 VIOLET BLACK 5 BLACK BLUE WHITE 6 SP6 1 WHITE 8 1 9 10 BROWN 12 13 18 GREEN 14 5 8 15 2A M V 16 28 3 3 m m A BLACK SP9 B TAN TAN GRAY BLACK SP13 Siak z SPI A BLUE SPI BLACK Xn 8 BLUE BLUE RED WHITE A A BLUE B E a ORANGE 2 GREEN z E e BLUE e 2 8 ORANGE x M 5 x l 5 ND z 3 E 5 E 3 5 5 5 a gt i Workman 2050 12345678 A B A B A B NUNG AE Electrical Harness T M fit P Wiring Diagram HEADLIGHT B TERM BOX LIFT BOX LIFT OPTIONS CHARGER ACC Y LIFT SWITCH ACTUATOR SWITCH FRONT HOOK UP SWITCH SENSOR REV ALARM SEVCON MOTOR P CONTROLLER INPUTS J25 PROGRAMMING ACC Y LIFT ACTUATOR
9. 3 9 Electrical System Rev B Electrical System Battery Charger Problems Battery charger does not turn on Battery charger does not turn off Battery charger fuse blows The AC outlet circuit breaker or fuse blows when using the battery charger Electrical System Rev B Page 3 10 Possible Causes AC outlet fuse circuit breaker blown AC outlet is faulty Vehicle wiring is loose or damaged see electrical schematic in Chapter 6 Electrical Diagrams Fusible link FL1 is damaged Vehicle charger interlock switch or circuit wiring faulty Vehicle charger receptacle or circuit wiring damaged Battery charger is faulty Battery charger is faulty NOTE Charging new batteries or charging batteries in cold temperatures may require extended charge time to achieve full charge Vehicle battery polarity is reversed vehicle battery cables incorrectly attached Vehicle charger receptacle polarity is reversed Battery charger is faulty Overloaded AC circuit Battery charger is faulty Workman e2050 e2065 Adjustments Accelerator Switch Adjustment 1 Position vehicle on a level surface turn On Off switch OFF and remove key Apply parking brake 2 Make sure that at complete brake pedal travel the park detent and pawl are fully engaged If needed ad just the accelerator pedal stop cap screw to allow full en gagement Fig 11 3 Disengage the parking brake 4 With the acce
10. 2 Make sure machine is in safe operating condition by keeping all nuts bolts and screws tight 3 Do not use open pans of flammable cleaning fluids for cleaning parts 4 Keep battery area free of excessive grease grass leaves and dirt 5 Disconnect batteries before servicing the machine Carefully remove one of the battery cables from the bat tery pack as the first step in any repair Once a battery cable has been removed the electrical system on the vehicle can be safely worked on Take care during re pairs however to not allow tools or vehicle components to complete the battery circuit that was opened with the cable removal Reattach the removed cable to the bat tery pack as the last step in any repair 6 When using metal uninsulated tools around batter ies do not allow tools to contact both positive and nega tive battery terminals simultaneously 7 Remove jewelry and watches before servicing elec trical components of the vehicle 8 Battery acid is poisonous and can cause burns Avoid contact with skin eyes and clothing Protect your face eyes and clothing when working with batteries 9 Battery gases can explode Keep cigarettes sparks and flames away from the batteries Always service store and charge the vehicle batteries in a well ventilated area Workman e2050 e2065 Page 1 3 10 Never use an open flame to check level or leakage of battery electrolyte 11 When connecting the battery charger
11. 23 Electrical System Rev B Accelerator Switch The accelerator switch is a four terminal two circuit switch that is located on the control pedal frame Fig 38 Workman 2050 and e2065 use only one of the switch circuits terminals 3 and 4 When the accelerator pedal is depressed the switch allows a closed circuit in put for the controller to allow traction motor operation When the accelerator pedal is released the switch pro vides an open circuit no input for the controller to pre vent traction motor operation Testing 1 Park vehicle on a level surface turn On Off switch OFF and remove key from switch 2 Locate accelerator switch on pedal frame under Figure 38 dashboard of vehicle 1 Accelerator pedal 4 Screw 2 used 2 Accelerator switch 5 Stop screw 3 Unplug wiring harness connector from accelerator 3 Plate 6 Lock nut switch 4 With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the switch terminals for both switch positions Verify continuity between switch termi nals using the following table PLUNGER NO POSITION CONTINUITY CONTINUITY a T END VIEW SIDE VIEW IN 5 When reconnecting wiring harness connector to switch after testing harness connector and switch ter minal area should be filled with dielectric gel se
12. 3 5 CHARGER RH GE 4589 GE 4589 PLUGGED IN LIGHT SWITCH BU S OR MEL 2 ots N Fi 355A 9 3 BK M pm onm i t ft NI Er Y OPTION eae 4 8 NC on voc INPUT 123456 E 1 2 NO PROGRAMMER EDA PK lt 2 FOR REV PORT MAIN ACCELERATOR PEDAL SWITCH i OPTIONS PEDAL NOT PUSHED IN BU lt 8 ACCELERATOR PEDAL B4 SOLENOID a HI LOW SPEED SWITCH Y 4 HILOW TGA 9 IN OFF POSITION 5 CHARGER 10GA Re F1 48V BATT ARRAY 6 HIGH TEMP LOW BATTERY 6V x8 i MOTOR TEMP SENSOR a DEEP CYCLE T 7 BACKUP ALARM 180 C W BK c FIELD F1 A1 ARMATURE lt lt 8 MAIN CONTACTOR x DIAGNOSTIC LED 3 DRIVE MOTOR CES 9 DIAGNOSTIC LIGHT _ 2 i T 1 10 ACCELERATOR FIELD F2 A2 ARMATURE TATE OF CHARGE x BACKUP ALARM cw NG 11 PROGRAMMING sc HORN toy ACCELERATOR 10 GA gt SENSE BK g 12 12 VDC OUTPUT 100 mA F2 SETUP 224 6 IGN 4GA NG 13 M1 HR ENABLE 3 5 7 FET OUT NI T 4 8 et T e GY SEVCON B 5 CONTROLLER HOUR METER 16 NG at PROGRAMMING SPLICE Workman e2050 e2065 Electrical Schematic Contactors shown de energized 6 3 Rev B 10
13. 5 8 11 UNC 65 10 88 12 5 8 18 UNF 75 10 95 15 129 20 3 4 10 UNC 93 12 140 20 190 27 3 4 16 UNF 115 15 165 25 224 34 7 8 9 UNC 140 20 225 25 305 34 n N o x wo lo 10 2 1342 s 7 8 14 UNF 155 25 260 30 353 41 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 mini NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based Product Records and Maintenance Rev B Page 2 4 mum proof load specified in SAE J429 The tolerance is approximately 10 of the nominal torque value Thin height nuts include jam nuts Workman 2050 2065 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Regular Height Nuts Class 8 or Stronger Nuts Thread Size M5 X 0 8 57 5 inb 96 9 in lb Class 8 8 Bolts Screws and Studs with Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 640 6
14. R Clamp Cap screw 2 per caliper used Lock washer 2 per caliper used Socket head screw 4 per rotor used Washer head screw 2 used Lock nut Cap screw Lock nut Rear brake RH Rear brake LH Wheel hub assembly 2 used Workman e2050 e2065 Bleed Brake System Workman 2065 1 Connect a suitable transparent hose to bleeder valve on a wheel cylinder or caliper Submerge other end of hose in a glass container partially filled with clean brake fluid 2 Have a helper pump brake pedal several times then hold pedal down firmly 3 With pedal firmly depressed open bleeder valve un til pedal fades to floor Close bleeder valve before re leasing pedal 4 Repeat procedure until a continuous flow of brake fluid with no air bubbles is released from bleeder valve Make sure fluid level is maintained in brake fluid res ervoir at all times Workman e2050 e2065 Page 4 15 5 Repeat steps 1 to 4 for other brake cylinders and cali pers After servicing the brakes always check the brakes in a wide open level area that is free of other persons and obstructions 6 After bleeding of brakes is completed test vehicle to make sure brakes are operating correctly and brake pedal is solid Transaxle and Brakes Rev B 2 x S o LS a Front Brake Calipers Workman e2065 Loctite 242 45 to 65 ft lb 61 to 88 Figure 8
15. The vehicle may move or fall Personal injury or damage to the machine may result HOW TO AVOID THE HAZARD Make sure vehicle is parked on a solid level surface such as a concrete floor e Make sure On Off switch is OFF and key is removed from the switch before getting off the vehicle Before raising the vehicle remove any attachments that may interfere with the safe and proper raising of the vehicle Always chock or block wheels to prevent the vehicle from rolling Make sure proper hoists solid wooden blocks and jack stands are used to raise and support the vehicle Jacking Locations 1 Jack front of the vehicle on the front of the frame be hind the towing tongue Fig 1 2 Jack rear of the vehicle under each rear axle tube Do not jack vehicle below the transaxle case Fig 2 Towing Vehicle IMPORTANT Frequent or long distance towing of the Workman e2050 e2065 is not recommended In case of emergency the vehicle can be towed for a short distance See Operator s Manual for towing in formation Transporting Vehicle When moving the vehicle long distances use a trailer or flatbed truck Make sure vehicle is secured to the trailer properly See Operator s Manual for transport informa tion Safety Rev B 1 4 Figure 1 1 Front frame 2 Towing tongue Figure 2 2 Transaxle case 1 Axle tube IMPORTANT If vehicle is towed make sure that on off switch is in the OFF posit
16. D Replace the brake pads if the friction material is worn to less than 1 32 0 8 mm Installation Fig 8 1 If brake pads were removed from caliper install pads Fig 9 A If brake pads are being replaced it will be neces sary to push caliper pistons back into the caliper bore before installing new pads B Slide brake pads into caliper Make sure that fric tion material on pads is toward brake rotor position C Secure pads into caliper with two 2 pins Make sure that pins snap into caliper slots Install anti rattle clip to caliper pin and brake pads 2 Slide brake caliper onto brake rotor Make sure that rotor is between brake pads Workman e2050 e2065 Page 4 17 3 Align caliper mounting holes with spindle Secure caliper with two 2 cap screws and lock washers 4 Install brake hose to caliper 5 Install front wheel assembly Torque lug nuts from 45 to 65 ft lb 61 to 88 N m 6 Lower machine to ground 7 Bleed brakes see Bleed Brake System in this sec tion After servicing the brakes always check the brakes in a wide open level area that is free of other persons and obstructions 8 Check brake operation Figure 9 1 Brake pad 2 Pin 2 used 3 Anti rattle clip Transaxle and Brakes Rev B S x 2 o o LS a Brake Master Cylinder Workman 2065 Figure 10 4 Clevis pin 5 Cotter pin 1 Master
17. Preface The purpose of this publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the Workman 2050 and 2065 REFER TO THE OPERATOR S MANUAL FOR OPER ATING MAINTENANCE AND ADJUSTMENT IN STRUCTIONS Space is provided in Chapter 2 of this book to insert the Operator s Manuals and Parts Cata logs for your machine Replacement Operator s Manu als are available on the Internet at www toro com The Toro Company reserves the rightto change product specifications or this publication without notice Part No 04127SL Rev D Service Manual Workman e2050 amp 2065 This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 2004 2006 2007 2011 This page is intentionally blank Workman e2050 e2065 Table Of Contents Chapter 1 Safety Safety Instructions 1 2 Jacking and Other Instructions 1 4 Safety and Instruction
18. ment parts Hold brush shunts in position and torque brush screws from 18 to 22 in lbs 2 to 2 5 Fig 60 Make sure brushes move freely in the holders and that shunts do not interfere with brush spring movement 4 Make sure the brush box assembly is tight on the commutator end head Replace brush box assemblies in the commutator end head if they are physically dam aged or brush holders are loose on the brush plate 5 Brush springs should be checked for proper tension using the following procedure Fig 59 A Place paper strip between brush face and com mutator Hook spring scale as shown B Pull spring scale on a line directly opposite the line of force exerted by the brush spring When the paper strip begins to move freely read the spring ten sion on the scale Brush tension for a new brush should be 65 ounces 1820 grams and for a worn brush should be 40 ounces 1120 grams Frame and Field Service 1 Motors that have been disassembled for servicing should be given a complete inspection of the frame and field assembly If damage to the field coils or frame is found replace traction motor Individual frame and field components are not available 2 Accumulated carbon dust grease and other foreign material can produce a ground path from the field wind ing to the frame The frame and field should be cleaned with Safety Kleen 105 washing solvent or equivalent After cleaning the frame and field must be oven dri
19. 1 LH brake caliper 6 Brake rotor 10 Brake master cylinder 2 RH brake caliper 7 Socket head screw 4 per rotor used 11 Wheel assembly 3 Lock washer 2 per caliper used 8 Spindle LH shown 12 Lug nut 4 Cap screw 2 per caliper used 9 A arm LH shown 13 Front brake hose 5 Wheel hub assembly Transaxle and Brakes Rev B Page 4 16 Workman e2050 e2065 Removal Fig 8 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Chock wheels not being jacked up Jack front wheel off the ground and place blocks beneath the frame 3 Remove front wheel from machine see Lower Steering and Front Wheel Removal 4 Clean hydraulic brake line area of brake caliper to prevent contamination Loosen and disconnect brake line from caliper Plug brake line and position it away from caliper 5 Remove two 2 cap screws and lock washers that secure the brake caliper to the spindle 6 Slide brake caliper from brake rotor and remove cali per from machine 7 If necessary remove brake pads from caliper Fig 9 A Remove anti rattle clip from caliper B Remove pins from caliper by prying with a flat blade screwdriver through loop in pins C Slide brake pads from caliper For assembly pur poses note orientation of inner and outer pads as the pads are not the same
20. Check front wheel alignment and adjust if required see Operator s Manual Chassis Rev B Steering Gearbox Dg OU EOM 9 Gasket 8 Hex washer head screw 4 used 9 Seal 10 Sector gear 11 Flat washer 12 Ball bearing 13 Output shaft spacer Chassis Rev B 27 to 33 ft lb pt ae 37 to 45 N m 90 to 110 in Ib 10 2 to 12 4 N m Note alignment marks Figure 2 Stepped washer Flange head screw with patch lock Ball bearing Input shaft spacer Flat washer Cap screw 5 8 175 to 225 in Ib 19 8 to 25 4 N m Grease fitting Steering housing cover Steering housing Pinion gear Oil seal Pitman arm Workman e2050 e2065 Disassembly Fig 2 IMPORTANT Do not reuse flange head screw with patch lock item 9 after it has been removed 1 Remove flange head screw with patch lock item 9 and stepped washer item 8 from Pitman arm Discard flange head screw 2 Remove cap screw item 13 and flat washer item 12 from pinion gear shaft 3 Remove four 4 hex washer head screws item 2 securing the housing cover and gasket to the steering housing Remove cover and gasket from the housing Replace gasket if damaged 4 Inspect gears Sector and pinion gear teeth must be free of damage that prevents them of free movement 5 Remove pinion gear item 17 from the housing IMPORTANT N
21. Remove eight 8 flange head screws item 10 that secure seat base to vehicle Locate and retrieve flat washers item 11 from screws that secure front of seat base 7 Carefully lift seat base from vehicle Installation Fig 11 1 Position seat base to the vehicle NOTE Do not tighten fasteners securing the seat base until all fasteners are in place 2 Install four 4 flange head screws item 10 through holes in front frame and into rear seat base threaded in serts Install four 4 flange head screws item 10 and flat washers item 11 through holes in front frame and into front seat base threaded inserts 3 Starting at the middle of the vehicle tighten flange head screws to secure seat base to vehicle 4 On Workman e2065 install parking brake assembly to seat base see Parking Brake Workman 2065 the Service and Repairs section of Chapter 4 Trans axle and Brakes 5 Connect charger wire harness to vehicle wire har ness Secure receptacle plate to seat base with four 4 screws item 12 6 Install seats to vehicle 7 Reconnect removed battery cable to battery termi nals Install lock washer and nut on battery terminals Torque nuts from 115 to 125 in lb 13 to 14 1 1 Figure 12 Negative cable to vehicle 2 Positive cable to vehicle WORKMAN e2065 Workman 2050 2065 Page 5 21
22. headband to allow inspection of a brush at the top of the motor Figure 48 4 f end of brush is even with the brush holder Figs 48 1 Brush 3 Brush spring tensioned and 50 brushes should be removed from motor for in 2 Brush holder 4 Brush spring released spection and measurement see Traction Motor Service in this section 5 most instances wear of all traction motor brushes should be similar to wear found on the top brushes If in spection of remaining brushes is needed or if brushes require replacement traction motor should be removed from vehicle see Traction Motor and Traction Motor Service in this section 6 If vehicle is often operated in severely dirty environ ments brush should be removed from motor to allow in spection of mating surface of brush Fig 49 If brush surface is rough pitted arced or scored additional brush and or motor inspection should be completed see Traction Motor and Traction Motor Service in this section Figure 49 7 Visually inspect commutator surface of motor arma 1 Removed brush 2 Cap screw ture If commutator surface is rough pitted arced or scored additional motor inspection should be com pleted see Traction Motor and Traction Motor Service in this section 8 After brush inspection make sure brush is correctly installed in brush holder and tensioned by spring Refit headband to traction motor and latch headband 9 Carefully connect r
23. 1 2 SOL CONTACTS 3 15 ACCY SOL COIL SP B a 50 ur FOR REV SW 1 ACTUATOR r P7 DIAGNOSTIC LED 19 R HEADLIGHT J28 HIGH LOW SPEED SW J29 HIGH LOW SPEED SW HP 7 S i3 J20 P12 CHARGER HOOK UP P8 ACCEL POT 55 iy Lj ILLE d H P2 spn SP10 PEDAL SW Workman e2050 Electrical Harness Drawing Page 6 7 J32 IGN SW J33 FOR REV SW ACCELERATOR PS PEDAL SW 128 HI LOW SPEED SW 2 DIAGNOSTIC LED ACCEL POT OPTIONS REAR P6 P2I HEAD LIGHT SECOND POLE P22
24. 9 8 A 8 B P25 JIS P20 PIT o P2 Flo HEADLIGHT L HEADLIGHT R HEADLIGHT B BOX LIFT BOX LIFT OPTIONS CHARGER ACC Y LIFT SWITCH SWITCH ACTUATOR 48 VDC HOOK UP SWITCH SEVCON DI J323 HORN J24 MOTOR 5 TEMP SENSOR P REV ALARM J35 SEVCON MOTOR CONTROLLER INPUTS J25 PROGRAMMING ACC Y LIFT ACTUATOR Workman e2065 Electrical Harness Wiring Diagram Page 6 10 Rev B
25. Ammeter 3 Lower case 7 Circuit breaker 11 Fuse 4 SCRassembly 8 cordset 12 Diode assembly For service of the battery charger see the Lester Electri cal Technician Service Guide at the end of this chapter Electrical System Rev B Page 3 42 Workman e2050 e2065 Chapter 4 TORO Transaxle and Brakes Table of Contents SPECIFICATIONS 3 TROUBLESHOOTING 4 4 ADJUSTMENTS 6 Adjust Brakes Workman e2050 6 SERVICE AND REPAIRS 8 Rear Wheels and Brakes 8 Brake Service Workman e2050 10 Rear Brake Service Workman e2065 12 Hydraulic Brake System Workman e2065 14 Bleed Brake System Workman e2065 15 Front Brake Calipers Workman e2065 16 Brake Master Cylinder Workman e2065 18 Brake Master Cylinder Service Workman e2065 19 Parking Brake Workman 2065 20 s o T atiSaxle erasa e acit trea yg cd 22 Transaxle Service 26 2 m SPICER OFF HIGHWAY COMPONENTS MODEL 12 ELECTRIC MAINTENANCE MANUAL Workman e2050 e2065 Page 4 1 Transaxle and Brakes Rev B This page is intentionally blank Transaxle and Brakes Rev B Page 4 2 Workman e2050 e2065 Specifications Item Description Tra
26. N m Syracuse Y USWA x ELA ZAZ T 2500 AND CURRENT DATE 55 to 60 in Ib 6 2 to 6 8 N m Figure 17 Workman e2050 e2065 Workman 2050 2065 This page is intentionally blank Page 4 25 Transaxle and Brakes Rev 6 o 5 8 55 c n S Transaxle Service Figure 18 1 Oil seal 13 Bearing 2 Wheel stud 5 used per side 14 Cap screw 4 used 3 Axle shaft 15 Bearing cap 4 Ball bearing 16 Bearing cap bolt 2 used per cap 5 Input shaft 17 Plug 6 Ball bearing 18 Cover plate 7 O ring 19 Screw 10 used 8 Retaining ring 20 Lock nut 4 used 9 Endcap plug 21 Final drive gear 10 Ball bearing 22 Differential assembly 11 Vent elbow 23 O ring 12 Transaxle housing 24 Intermediate shaft amp gear NOTE For service of the transaxle see the Spicer Off Highway Components Model 12 Electric Maintenance Manual at the end of this chapter Transaxle and Brakes Rev B Page 4 26 25 26 27 28 30 31 32 Plug 34 35 Flange head screw 4 per brake LH brake assembly Oil seal Retaining ring Bearing retaining ring Retaining ring Ball bearing Lock nut 4 used per brake Ball bearing RH brake assembly Workman 2050 2065 Chapter 5 TORO Chassis Table of Contents SPECIFICATIONS 2 TROUBLESHOOTING
27. Run Circuit Forward Power Current Control Current wea oe ez Indication Current 6 5 Rev B 10 BU PK FUSE HOLDERS rt ty F2 10A n ACCESSORIES j CONTACTOR HORN SOLENOID 1 NOT ENERGIZED OFF R HORN SWITCH BATT CHG HOOKUP _ RW HEADLIGHTS 24V Y Y id 2 ste INTERLOCK STATE OF CHARGE E GN L CHARGER INDICATOR Ne SWITCH A o 5n CHARGER GE 4589 GE 4589 PLUGGED IN LIGHT SWITCH BU A 42 BK HOUR METER OR 2 Ll 9 3 BU W BK SU FL3 EE BU FORWARD REVERSE 242222 Y OPTIONS IN FORWARD 4 3 NO OB 148VDCINPUT 123456 PROGRAMMER ES BK 1 D 280 2 FOR REV PORT MAIN ACCELERATOR PEDAL SWITCH PK x lt P A PEDAL NOT PUSHED IN CONTACTOR T E OPTIONS F lt 3 ACCELERATOR PEDAL BH SOLENOID gt Yo ve NOT ENERGIZED X REAR HI LOW SPEED SWITCH cL A HILOW ZOR T IN OFF HI POSITION NQ 5 CHARGER 10 5 F1 48V BATT ARRAY 6 HIGH TEMP LOW BATTERY 6V x8 SENSOR En gt DEEP CYCLE T 7 BACKUP ALARM CHARGING 180 W BK x lt FIELD F1 A1 ARMATURE BKGNGSTIGTER lt lt 1 8 MAIN CONTACTOR 3 DRIVE MOTOR 2 GN 9 DIAGNOSTIC LIGHT Hp T lt lt 10 ACCELERATOR POT FIELD F2 A2 ARMATURE BACKUP ALARM cw NG 11 PROGRAMMING HORN ACCELERATOR POT 10GA
28. a fault code to assist in identifying the problem Opening Battery Circuit To prevent allowing a current path through tools used during vehicle electrical circuit repairs remove one of the battery cables from the battery pack as the first step in any repair Fig 1 Once a cable has been removed the electrical system on the vehicle can be safely worked on Take care during repairs however to not al low tools or vehicle components to complete the battery circuit that was opened with the cable removal Reattach the removed cable to the battery pack as the last step in any repair Secure cable on each battery ter minal with lock washer and nut Torque nuts from 115 to 125 in lb 13 to 14 1 Battery pack cable routing is shown in Figure 2 Workman e2050 e2065 Page 3 3 After performing any repair on electrical components on the vehicle make sure that wiring is routed and secured So as to prevent abrasion or contact with moving parts ES Figure 1 Figure 2 1 Negative cable to vehicle 2 Positive cable to vehicle Electrical System Rev B T System Vehicle Operation Workman 2050 and e2065 electrical system use a 48 volt battery pack an electric traction motor a ve hicle controller and numerous other electrical compo nents to allow vehicle operation Eight 6 volt deep cycle batteries that are connected in ser
29. and adjusting screw B Six ledges on which the brake shoes rest Entire surfaces of PTFE coated washers C D Entire surface of pivot pin E Slot in push rod that contacts actuator lever Surfaces of adjusting lever that contact wave washer washer and pivot pin G Surfaces of the actuator bracket that contact the star wheel of the adjusting screw 2 Position brake shoes to backing plate Secure shoes to plate with shoe cups and hold down pins 3 Secure brake shoes with shoe to shoe springs and auto adjust spring Transaxle and Brakes Rev B 2 x Ls o KU LS a Rear Brake Service Workman 2065 110 to 120 in Ib 12 4 to 13 6 N m 110 to 120 in Ib 12 4 to 13 6 N m 110 to 120 in Ib 12 4 to 13 6 N m Figure 6 Brake backing plate Washer head screw Brake shoe Lower spring Wheel cylinder Belleville washer Adjuster lever Dust cover Disassembly Fig 6 CAUTION Be careful when removing springs from brake shoes The springs are under heavy load and may cause personal injury 1 Remove upper and lower springs from brake shoes 2 Remove shoe hold down cups and springs that se cure the brake shoes to the backing plate 3 Remove brake shoes from backing plate Parking brake lever LH shown 10 Flat washer 11 Bolt 12 Shoe hold down cup and spring 13 Upper spring 4 If required slide p
30. contactor wire and cable connections If problem continues contactor replacement may be necessary Electrical System 5 Flashes The charger cord is plugged Turn on off switch OFF unplug charger cord from vehicle into the vehicle charger and turn on off switch ON receptacle If controller does not reset correctly check charger interlock switch 6 Flashes Accelerator control Adjust accelerator switch and potentiometer see accelerator switch and Accelerator Switch and Accelerator Potentiometer potentiometer is out of adjustment calibration in the Adjustments section of this adjustment chapter 7 Flashes Battery voltage is out of Inspect and test vehicle batteries and battery cable range connections see Battery Service in the Service and Repairs section 8 Flashes The controller is overheated vehicle will continue to operate but at reduced power until the controller temperature lowers 9 Flashes The traction motor is Stop vehicle and allow motor to cool before continuing overheated battery operation Traction motor high temperature switch may discharge indicator displays be faulty more than 1 bar The battery is nearly Charge the batteries immediately to prevent battery discharged and the vehicle damage is in the energy saving mode reduced speed and battery discharge indicator displays 1 bar with red light illuminated Workman e2050 e2065 Page 3 27 Electrical System Rev B Service and Repa
31. cover Workman e2050 e2065 Removal Fig 1 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from the switch 2 Open the battery circuit by carefully removing one of the battery cables see Opening Battery Circuit in the General Information section of Chapter 3 Electrical System 3 Remove front hood to gain access to the steering mechanism see Front Hood Removal in this section 4 Remove steering wheel cover carefully from the steering wheel Remove nut and lock washer securing the steering wheel to the steering shaft Pull steering wheel from the shaft 5 Remove cap screw and lock washer securing the lower steering shaft knuckle to the steering gearbox shaft Pull knuckle from the gearbox shaft 6 Remove four 4 flange lock nuts and carriage bolts securing the steering column to the mounting plate on the frame 7 Remove dust cover from the steering shaft Replace cover if damaged Slide steering shaft out of the steering column 8 Disconnect both tie rods from the Pitman arm on the steering gearbox see Lower Steering Removal in this section 9 Remove three 3 flange lock nuts and cap screws securing the steering gearbox to the tower plate on the front frame Remove gearbox from the tower plate Installation Fig 1 1 Position steering gearbox to the tower plate of the front frame with the Pitman arm facing down and to the rear The gearbox shaft must be
32. each wheel with five 5 lug nuts Torque lug nuts in a criss cross pattern from 45 to 65 ftHb 61 to 88 5 Lower vehicle from jackstands 6 Connect wires to traction motor Fig 17 IMPORTANT When connecting cables to motor ter minals A1 A2 F1 and F2 use a back up wrench to retain lower nut before tightening upper nut Fig 14 If terminal studs are allowed to turn during up per nut installation internal motor damage can oc cur A Install cable connector and upper nut to motor terminals A1 and A2 While retaining lower nut torque upper nut on terminals A1 and A2 from 85 to 90 in lb 9 6 to 10 2 B Install cable connector and upper nut to motor terminals F1 and F2 While retaining lower nut torque upper nut on terminals F1 and F2 from 55 to 60 in lb 6 2 to 6 8 C Plug motor temperature sensor connector into vehicle wire harness 7 Carefully connect removed battery cable to battery terminals Install lock washers and nuts on battery termi nals Torque nuts from 115 to 125 in lb 13 to 14 1 8 Install cargo box to the rear frame see Cargo Box Installation in Service and Repairs section of Chapter 5 Chassis 9 Check brakes for proper adjustment see Operator s Manual Transaxle and Brakes Rev B Page 4 24 Figure 16 1 Support bracket 3 Transaxle mount plate 2 Carriage screws nuts 85 to 90 in Ib 9 6 to 10 2 N m 55 to 60 in Ib A4 6 2 to 6 8
33. four shoes to maintain equal braking forces A Replace brake shoes if damaged or if lining is worn to 1 16 1 6 mm Also replace shoes if lining is contaminated by oil grease or other fluids NOTE Overheated springs lose their tension and can cause brake linings to wear out prematurely B Inspect brake shoe webbing shoe to shoe springs and auto adjust spring for overheating Over heating is indicated by a slight blue color Inspect brake shoe webbing for deformation Replace parts as necessary C Inspect hold down pins and shoe cups for bends rust and corrosion Replace as necessary Workman e2050 e2065 Page 4 11 Rev C 3 Inspect backing plate surfaces which contact with the brake shoes for grooves that may restrict shoe movement Replace backing plate if grooves can not be removed by light sanding with emery cloth or other suit able abrasive Replace backing plate if cracked warped or excessively rusted 4 Inspect anchor abutment and rivets for deformation Replace entire brake assembly if deformation or exces sive rust is found 5 Replace adjuster screw and shim washers if rusted corroded bent or fatigued 6 Replace brake cables if frayed stretched or kinked Assembly Fig 5 IMPORTANT Brake shoe lining surfaces must be free of grease oil and other foreign matter 1 Apply a light film of lubricant to the following A Surfaces of the shoe web that contact the back ing plate push rod
34. from front of seat base 3 Locate charger interlock switch on rear of receptacle plate Disconnect harness connector from the switch 4 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals Electrical System 5 When the switch plunger is extended there should ap Figure 29 not be continuity between the switch terminals g 1 Receptacle plate 3 Charger receptacle 6 When the switch plunger is depressed there should 2 Screw 4 used 4 Charger interlock switch be continuity between the switch terminals 7 Reconnect harness connector to switch Install re ceptacle plate to front of seat base Figure 30 1 Charger interlock switch 4 Rivet 2 used 2 Switch plate 5 Lock nut 2 used 3 Charger receptacle 6 Socket head screw Workman e2050 e2065 Page 3 19 Electrical System Rev Main and Accessories Contactors Two contactors solenoids are used on the Workman e2050 and e2065 for circuit control The main contactor provides current to the vehicle con troller and is energized when the on off switch is ON The main contactor is located under the controller cover beneath the bed Fig 31 The accessories contactor provides current to the head lights horn and optional electrical accessories The ac cessories contactor is energized when the on off switch is ON The accessories contactor is located beneath the dash panel Testing NOTE
35. pleting the accelerator system calibration procedure evaluate the components in the accelerator system ac celerator switch accelerator potentiometer accelerator pedal circuit wiring and controller Workman e2050 e2065 3 13 Rev Electrical System Rev B Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g disconnect the harness wire connectors from the vehicle on off switch before doing a continuity check on the on off switch When testing electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected On Off Switch The Workman on off switch is located on the dash panel Fig 17 The switch has two 2 positions OFF and ON and three 3 switch terminals Only two of the terminals are used on the Workman 2050 and e2065 The switch terminals are positioned as shown in Figure 18 Testing When testing the on off switch for continuity with a multimeter ohms setting make sure that Ha power to the circuit has been disconnected Figure 17 1 On Off switch When the on off switch is in the OFF position no conti nuity should exist between the common center switch terminal and the switched side terminal In the ON COMMON SWITCHED position continuity should exist between the common TERMINAL S TERMINAL center switch terminal an
36. to the left side of the tower 2 Secure steering gearbox to the tower plate with three 8 cap screws and flange lock nuts Workman e2050 e2065 Page 5 7 3 Insert steering shaft up through the steering column Place dust cover onto the shaft 4 Secure steering column to the mounting plate on the frame with four 4 carriage screws and flange lock nuts NOTE Apply antiseize lubricant to the steering gear box shaft before installing steering shaft knuckle 5 Position knuckle of the lower steering shaft onto the gearbox shaft Secure knuckle to the steering gearbox shaft with cap screw and lock washer 6 Connect both tie rods to the Pitman arm on the steer ing gearbox see Lower Steering Installation in this sec tion NOTE Apply antiseize lubricant to the steering shaft splines before installing the steering wheel 7 Position front tires straight ahead Position steering wheel to the steering shaft so that the leg of the Y formed by the wheel struts is directed towards the oper ator platform 8 Secure steering wheel to shaft with lock washer and nut Torque nut from 13 to 17 ft lb 18 to 23 N m Install steering wheel cover to steering wheel 9 Install front hood to the frame and fenders see Front Hood Installation in this section 10 Reconnect removed battery cable to battery termi nals Install lock washer and nut on battery terminals Torque nuts from 115 to 125 13 to 14 1 11
37. to the vehicle connect the charger cord to the vehicle charger recep tacle before plugging the charger power cord into an outlet After charging the vehicle batteries unplug the charger power cord from the outlet before disconnecting the charger cord from the vehicle charger receptacle 12 1 major repairs are ever needed or assistance is de sired contact an Authorized Toro Distributor 13 To assure optimum performance and continued safety of the machine use genuine Toro replacement parts and accessories Replacement parts and acces sories made by other manufacturers may result in non conformance with safety standards and the warranty may be voided 14 When raising the machine to change tires or to per form other service use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such as a concrete floor Prior to raising the machine re move any attachments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands or solid wood blocks to support the raised machine If the machine is not proper ly supported by blocks or jack stands the machine may move or fall which may result in personal injury see Jacking Instructions in the Operator s Manual and in this Chapter Safety Rev B Jacking and Other Instructions Jacking Vehicle POTENTIAL HAZARD A vehicle that is not properly supported may become unstable WHAT CAN HAPPEN
38. 0 N cm 885 80 N cm 1018 100 133 13 in lb 1500 150 M6 X 1 0 M8 X 1 25 M10 X 1 5 19 2 ft Ib 38 4 ft lb M12 X 1 75 M16 X 2 0 M20 X 2 5 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 66 7 ft lb 166 15 ft lb 325 33 ft lb NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based Workman e2050 e2065 26 3N m 52 5N m 53 5 ft lb 72 7 90 10 92 9 ft lb 125 12 N2m 225 20 N m 229 22 ft lb 310 30 N m 450 37 ft lb 610 50 N m Page 2 5 27 2 ftHb 36 3 N m 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 Product Records and Maintenance Rev B a E a and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque 140 20 inb 73 12 inb Thread Size 1 4 20 UNC 5 16 18UNC 215 35 in Ib 145 20 inb 3 8 16 UNC 1 2 13 UNC 75 15 ft l
39. 1 Clean all metal parts with isopropyl alcohol then clean out and dry grooves and passageways with com pressed air Make sure cylinder bore and component pieces are thoroughly clean 1 Reservoir Dust cover 2 Check cylinder bore pistons and springs for damage 2 SP H wear Replace brake cylinder assembly if 4 Secondary piston assy 10 Retainer washer 2 signs of pitting scoring or cracks are evident cylinder 5 Clevis 11 Primary piston assy x bore 6 nut 12 Cylinder housing 5 Assembly Fig 11 1 Apply a film of clean brake fluid to cylinder bore and piston assemblies 2 Install secondary piston assembly and primary pis ton assembly into cylinder 3 Install retainer washer 4 Install push rod and secure in place with circlip Install lower end of dust cover to housing 5 Push in on push rod so stop pin can be installed to retain secondary piston assembly then install flange seal and reservoir Workman e2050 e2065 Page 4 19 Transaxle and Brakes Rev B Parking Brake Workman 2065 Figure 12 1 Parking brake cover 7 Locknut 13 Cotter pin 2 Operator seat 8 Flat washer 14 Clevis pin 3 Seat base 9 Flange head screw 4 used 15 Parking brake cable 2 used 4 Cable equalizer bracket 10 Flat washer 2 used 16 Parking brake support 5 Parking brake lever 11 Screw 2 used 17 Cable retaining ring 2 used 6 C
40. 1 Make sure vehicle on off switch and all accessories are OFF Raise bed and secure with prop rod Workman e2050 e2065 Page 3 29 2 Make sure the battery supports are clean and re painted if necessary Make sure cables terminals rods and hold down retainers are in good condition IMPORTANT When installing batteries into vehicle do not lift batteries using battery terminals as lift points battery damage may occur 3 Using case loops on battery tops as lifting points set batteries on the battery supports with battery posts properly orientated Fig 45 Make sure that battery rods are positioned to allow installation of retainers 4 Install two 2 battery retainers and nuts to secure batteries to vehicle Fig 44 Torque nuts from 115 to 125 13 to 14 1 5 Install all but one of the battery cables used to con nect battery pack including the positive red cable and negative black cable from vehicle Figures 43 and 45 Make sure that cables are connected to correct battery terminal noting battery polarity Install lock washer and nut on each battery terminal Torque nuts from 115 to 125 13 to 14 1 N m to secure cables 6 Connect final battery cable to battery terminals Install lock washer and nut on battery terminals Torque nuts from 115 to 125 inb 13 to 14 1 7 Apply Toro battery terminal protector see Special Tools to all battery posts and cable connectors to re du
41. 1 Park vehicle on a level surface turn on off switch OFF and remove key from the on off switch 2 Depress brake pedal lightly 10 to 15 pound input force until resistance is achieved Check the gap be tween the brake lever and the brake lever stop to deter mine the distance the brake equalizer needs to be adjusted Fig 2 3 Remove the cotter pin and clevis pin that secure the brake rod clevis to the brake lever 4 Disconnect the spring from the hole near the end of the brake rod 5 Press the brake pedal down fully to raise the brake lever away from the brake rod clevis 6 Thread the brake rod in or out of the brake equalizer as needed to remove the gap identified in Step 2 Do not overtighten or brakes will drag and wear prematurely 7 Reinstall the spring into the hole in the brake rod NOTE Use a pry bar placed between the accelerator pivot shaft and the brake equalizer to aid in installation of the clevis pin that secures the brake rod clevis to the brake lever 8 Connect the brake rod clevis to the brake lever using the clevis pin and cotter pin removed previously 9 Verify that brake pedal travel is from 1 to 1 1 2 25 4 to 38 1 mm with a 75 to 100 pound 34 to 45 4 kg input force to the brake pedal 1 Clevis pin cotter pin 5 Brake equalizer 2 Brake lever 6 Spring 3 Brake rod clevis 7 Brake cable 4 Brake rod 8 Accelerator pedal shaft Figure 2 1 Brake lever 4 Brake rod clevi
42. 1 s INDICATOR p gt d s CHARGERNOT 222 45 O E GE 4589 GE 4589 3 LIGHT SWITCH FPE NIE 275 1 BK 2 Pts DC ESCENA EE Fi 355A m BK i BU W FORWARD REVERSE 212245 7 OR 148 VDC INPUT 123456 1 2 NO JE PROGRAMMER FT ACCELERATOR PEDAL SWITCH PK 5 CONTACTOR B PEDAL PUSHED IN ACCELERATOR PEDAL B4 SOLENOID Y OPTIONS t S E RR TAS ENERGIZED 7 70 BEAR LOW SPEED SWITCH v cL 4 HILOW 4 Q IN OFF HI POSITION 5 CHARGER VIOIEK Mie F1 ies 48V BATT ARRAY 6 HIGH TEMP LOW BATTERY 6V x8 BK o BU W lt lt T MOTOR TEMP SENSOR ALARN OPERE pps 180 C W BK FIELD F1 ATARMATURE 8 MAIN CONTACTOR DIAGNOSTIC LED e DRIVE MOTOR e Q DIAGNOSTIC LIGHT L 10 ACCELERATOR FIELD F2 A2 ARMATURE L BACKUP ALARM cw 6 NG 11 PROGRAMMING T ACCELERATOR POT 10 GA BK p 12 a L Meas cole e 12 12 VDC OUTPUT 100 mA F w 13 4GA 1 14 MILLIPAK s SEVCON wW NG 15 CONTROLLER Qe MARET T Workman e2050 e2065
43. 15 8 4 Ensure the brushes are pushed out of the way 5 While supporting the of the bearing in commutator end head carefully press the armature into the end head and bearing assembly Fig 62 6 Position brushes in brush holders and carefully re lease the brush springs allowing the brushes to contact the commutator Make sure brush shunts do not inter fere with spring movement 7 Repair or replace the headband if damaged Install the headband on the motor 8 Make sure that lower nuts are properly tightened on traction motor terminals Fig 63 and 64 Lower nuts on F1 and F2 terminals should be torqued from 50 to 60 in Ib 5 7 to 6 8 Lower nuts on 1 and A2 terminals should be torqued from 110 to 140 in4b 12 4 to 15 8 N m PRESS FIXTURE MUST PRESS AGAINST OUTER RACE BEARING __ END HEAD MUST BE HELD STATIONARY 1 Terminal 2 Lower nut 3 Flat washer 1 2 terminal 2 F2 terminal Workman 2050 2065 Page 3 41 E va p A ARMATURE _ ASSEMBLY BEARING AND RETAINING RING INSTALLED IN END HEAD PRESS FIXTURE i HOLD R RACE y STATIONARY Figure 63 4 Insulating washer 5 Motor housing Figure 64 3 F1 terminal 4 A1 terminal Electrical System Rev B T 2 System Battery Charger Figure 65 1 Upper case 5 Control board 9 DC cordset 2 Transformer 6 Relay 10
44. 23 64 0 359375 9 128 55 64 0 859375 21 828 38 03750 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 23 416 716 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 12 05000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 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 Pounds Sq In Bar 0 069 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 Subract 32 2
45. 6 8 P2L L HEADLIGHT 25 HEADLIGHT J34 REV ALARM 25 REV ALARM P23 HI LOW SPEED SW PT CHARGER HOOK UP PT DIAGNOSTIC J24 iE HORN 123 Jr FUSE 2 c8 P3 FOR REV SW HEADLIGHT SWITCH gt Pn BOX LIFT ACTUATOR LIFT ACTUATOR P22 HEADLIGHT SECOND POLE n Jn HORN SW Jm OPTIONS 48 VOC P20 BOX LIFT SW ITCH Pio LIFT Sw ITCH J ACCESSORY SOL CONTACTS J6 ACCESSORY SOL COIL 5 m 8 TERM SEVCON CHG INDICATOR J9 Be TERM MAIN SOL J ACCESSORY SOL CONTACTS ACCEL POT P5 ACCELERATOR ta 3 Workman e2065 Electrical Harness Drawing 125 PROGRAMMING P1 SEVCON MOTOR R Page 6 9 Rev B J332 IGN SW J33 FOR REV SW P03 z ACCELERATOR Pos HI LOW SPEED SW 23 DIAGNOSTIC LED ACCEL POT Pos ACC Y REAR Pos HEAD LIGHT SECOND POLE Pee
46. ATIC Electrical Schematic 3 ELECTRICAL CIRCUIT DRAWINGS On Off Switch Turned On 4 Run Circuit 5 Battery Charging 6 ELECTRICAL HARNESS DRAWINGS Electrical Harness Drawing Workman e2050 7 Electrical Harness Wiring Diagram Workman 2050522 8 Electrical Harness Drawing Workman e2065 9 Electrical Harness Wiring Diagram Workman 62065 5 tos dts baute 10 Diagrams 5 Workman 2050 Page 6 1 Electrical Diagrams This page is intentionally blank Electrical Diagrams 6 2 Workman 2050 10 BU PK FUSE IGNITION SWITCH ioi OFF RUN d d F2 10A ACCESSORIES CONTACTOR HORN SOLENOID ee ios w E Bk ee HORN SWITCH BATT CHG SO gt RW R HEADLIGHTS 24V Y Y uet 2 ote INTERLOCK STATE OF CHARGE FL2 T ocn OR GN CHARGER INDICATOR yy es 522 Iu SWITCH
47. BK o 12V BN c1 12 12 VDC OUTPUT 100 mA F2 w 4GA E Ng 1 M1 NG 14 MILLIPAK GY SEVCON Bo w 15 CONTROLLER BK 16 NG T PROGRAMMING T SPLICE Workman e2050 e2065 Battery Charging Circuit Power Current Control Current Indication Current Page 6 6 Rev B 1 8 MOTOR CONTROLLER J25 PROGRAMMING P15 MOTOR TEMP SENSOR yes pE 15 SEVCON B J21 J35 m REV ALARM HORN SW 22 HORN SW REV ALARM J9 MAIN CONTACTOR B TERM 5 1 m MAIN CONTACTOR COIL se P18 HEAD LIGHT Sw i BATTERY CHARGE INDICATOR Pu L ACCY LIFT ACTUATOR 2 23 p17 HORN OPTIONS FRONT 2 P1 BOX LIFT ACTUATOR H L HEADLIGHT OPTIONS REAR P10 Ns E ACCY LIFT SW P22 d HEAD LIGHT SECOND POLE n FUSE 4 ACCY SQL i FUSE 2 J1 J2 FUSE
48. Decals 1 5 Chapter 2 Product Records and Maintenance Product Records 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 Maintenance 2 7 Chapter 3 Electrical System Electrical Diagrams 3 2 General Information 3 3 Vehicle Operation 3 4 Special Tools 3 5 Troubleshooting 3 8 Adjustments ceri eedem iex 3 11 Component Testing 3 14 Service and Repairs 3 28 LESTER ELECTRICAL TECHNICIAN SERVICE GUIDE Chapter 4 Transaxle and Brakes Specifications Paw naw edis 4 3 Troubleshooting 4 4 eee 4 6 Service and Repairs 4 8 SPICER OFF HIGHWAY COMPONENTS MODEL 12 ELECTRIC MAINTENANCE MANUAL Chapter 5 Chassis Specifications 5 2 Troubleshooting 5 3 Service and Repairs 5 5 Chapter 6 Electrical Diagrams Electrical Schematic 6 3 Electrical Circuit Drawings 6 4 Electrical Harness Drawings 6 7 Workman e2050 e2065 Product Records and Maintenance Electrical
49. ERCUT r MICA r MICA COPPER SEGMENT Ld ose BAD UNDERCUT BAD UNDERCUT CUT TOO WIDE CUT TOO NARROW COPPER SEGMENT Figure 61 Traction Motor Specifications BRUSH LENGTH Maximum 1 300 in 33 mm TENSION Minimum Diame ter for Reslotting Reject Diameter 2 750 in 2 800 in Workman 2050 2065 Assembly Fig 57 NOTE After the motor has been disassembled it is recommended that a new commutator end head bear ing be installed because removed bearing may have been damaged during disassembly Although the bear ing may appear and feel good the bearing could be bri nelled races or balls deformed and may exhibit noise and vibration problems or fail within a relatively short pe riod of service When installing new bearing always press against the race that is absorbing the pressure or bearing damage may occur 1 After servicing the commutator and brushes re as semble the wiring in the commutator end head as origi nally found Ensure the wiring does not contact metal and rotating parts Also make sure that the wiring allows the brushes to move unrestricted in the brush holders 2 Press a new bearing into the commutator end head pressing on the bearing outer race only Fig 62 Secure bearing with retaining ring 3 Position the commutator end head to the frame and field assembly and secure with four 4 bolts Torque bolts from 120 to 140 in lb 13 6 to
50. ES 180 C W BK 1 7 BACKUP ALARM LABMRTURE T amp MAIN CONTACTOR 1 DIAGNOSTIC LED 3 DAVEMOTOR E Que doque we QOIAGNOSTIC LIGHT lt lt 10 ACCELERATOR FIELD F2 A2 ARMATURE E BACKUP ALARM cw 11 PROGRAMMING T HORN ACCELERATOR POT 10GA BK Q Att 5 TP we 12 12 VDC OUTPUT 100 mA F2 w MEE 14 MILLIPAK L lt GY SEVCON B 15 CONTROLLER BK 16 T E PROGRAMMING 1 T L f L 2 1 Workman e2050 e2065 On Off Switch Turned On Power Current Control Current Indication Current Page6 4 Rev B F3 10A BU PK IGNITION SWITCH OFF RUN 1 F2 10A c d ACCESSORIES B CONTACTOR HORN SOLENOID ENERGIZED IN RUN i os L HORN SWITCH CHG E ML erum cp Uc ia de ras curet R HEADLIGHTS 24V i d anm INTERLOCK 8 STATE OF CHARGE i e OR y GN ANS i CHARGER
51. Excessive steering play Front wheel lug nuts are loose Front wheel bearings are loose or worn Steering linkage is loose or worn Tie rod ends are loose or worn Steering gear is incorrectly adjusted Front end shimmies Front wheel lug nuts are loose Front wheel bearings are loose or worn Front wheel alignment toe in is incorrect Steering linkage is loose or worn Tie rod ends are loose or worn Rubber insert in A arm is worn Vehicle is unstable or wanders Tire pressure is low or uneven between tires Wheel lug nuts are loose Front wheel bearings are loose Front wheel alignment toe in is incorrect Steering column bushings are worn Rubber insert in A arm is worn Steering gear is incorrectly adjusted Workman e2050 e2065 Page 5 3 Chassis Rev B Suspension and Steering continued Problem Possible Cause Steering is hard Tire pressure is low or uneven between tires Front wheel alignment toe in is incorrect Steering linkage is binding or damaged Steering gear is damaged or worn Vehicle pulls to one side when not Tire pressure is low or uneven between tires braking Front wheel alignment toe in is incorrect Steering or suspension component may be bent Chassis Rev B Page5 4 Workman e2050 e2065 Service and Repairs Check Tire Pressure The tire pressure range for front and rear tires is 8 to 22 PSI 0 55 to 1 52 bar The tire pressure needed is deter mined by the pay
52. Model 12 Electric Maintenance Manual at the end of this chapter 5 If necessary remove brake assembly as follows A Remove cotter and clevis pin securing the brake cable bracket to the brake actuator lever Fig 4 B On Workman e2065 clean hydraulic brake line area of rear brake cylinder to prevent contamina tion Loosen and disconnect hydraulic brake line from wheel cylinder Plug brake line and position it away from wheel cylinder C Remove four 4 cap screws and nuts securing the brake assembly to the transaxle Remove brake assembly from the transaxle Workman e2050 e2065 Installation Fig 3 IMPORTANT On Workman e2050 vehicles the brake actuator levers must be positioned below the trans axle mount On Workman e2065 vehicles the levers should be positioned above the transaxle mount When positioned correctly the brake actuator lev ers will point toward the rear of the vehicle Fig 4 1 If brake assembly was removed from axle position brake assembly to the transaxle A Secure brake assembly to the transaxle with four 4 cap screws and nuts Torque screws from 15 to 19 ft Ib 20 to 26 B On Workman e2065 position hydraulic brake line to wheel cylinder Connect brake line to wheel cylinder C Secure brake cable bracket to the brake actuator lever with clevis pin and cotter pin Fig 4 2 Install axle shaft into transaxle see the Spicer Off Highway Components Model 12 Electr
53. Multiply by 5 9 Product Records and Maintenance Rev B Page 2 2 Workman 2050 2065 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 spe cified in this 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 this Ser vice 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 hard ness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 5 Grade 1 Inch Series Bolts and Screws Figure 1 Workman e2050 e2065 2 3 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 en gagement etc The standard method of verifying torque shall be per formed by marking
54. Operator s Manual and Chapter 1 Safety 2 Chock wheels not being jacked up Jack front wheel off the ground and place blocks beneath the frame 3 Loosen and remove five 5 lug nuts that secure wheel to machine Remove wheel from vehicle 4 Remove wheel hub from spindle A Carefully remove dust cap from the wheel to pre vent damage to the cap B Remove cap screw and two 2 washers that se cure the wheel hub to the spindle Slide wheel hub from the spindle shaft 5 If necessary remove bearings from both sides of the wheel hub Fig 4 Discard removed bearings Retrieve spacer from wheel hub Clean the spacer and the inside of the wheel hub Installation Fig 3 1 If bearings were removed from wheel hub position spacer in wheel hub and press new bearings into the hub until the bearing retaining rings seat against hub Fig 4 2 Install wheel hub to spindle A Apply antiseize lubricant to spindle shaft B Slide wheel hub onto spindle shaft with the wheel studs facing out NOTE Apply Loctite 4242 or equivalent to the threads of the cap screw C Place large washer and then small washer onto the cap screw Thread cap screw with washers into the spindle shaft D Torque cap screw from 135 to 165 ft lb 183 to 224 Workman e2050 e2065 Page 5 11 3 Position wheel to studs in wheel hub and secure with five 5 lug nuts Torque lug nuts from 45 to 65 ft lb 61 to 88 4 L
55. Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less that is due to the internal resistance of the meter and test leads Subtract this value from the measured value of the component you are testing 1 Make sure on off switch is turned OFF Open the bat tery circuit by removing one of the battery cables see Opening Battery Circuit in the General Information sec tion of this chapter and Fig 32 2 Locate contactor that is to be tested Disconnect all vehicle harness electrical connections from contactor Note wire connector locations on contactor for reas sembly purposes 3 Using jumper wires apply 48 VDC directly across the contactor coil posts Fig 33 The contactor should click With the contactor coil energized resistance across the main contact posts should be less than 1 ohm 4 Remove voltage from contactor coil posts The con tactor should click With the contactor coil not energized resistance across the main contact posts should be infi nite ohms 5 Measure resistance across the contactor coil posts Fig 33 A For the main contactor the resistance should be approximately 126 ohms B For the accessories contactor the resistance should be approximately 200 ohms Electrical System Rev B Page 3 20 Figure 31 1 Main contactor 4 Fuse F1 2 Cable to contro
56. System S o 38 Gc cm Electrical Diagrams This page is intentionally blank Workman e2050 e2065 Chapter 1 TORO Safety Table of Contents SAFETY INSTRUCTIONS 2 JACKING AND OTHER INSTRUCTIONS 4 Before Operating 2 Jacking Vehicle 4 While Operating 2 Towing 4 Maintenance and Service 3 Transporting 4 SAFETY AND INSTRUCTION DECALS 5 Workman e2050 e2065 Page 1 1 Safety Rev B Safety Instructions The Workman e2050 and e2065 are designed and tested to offer safe service when operated and main tained properly Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine these factors are also de pendent upon the awareness concern and proper train ing of the personnel involved in the operation transport maintenance and storage of the machine Improper use or maintenance of the machine can result in injury or death To reduce the potential for injury or death comply with the following safety instructions Before Operating 1 Read and understand the contents of the Operator s Manual before starting and operating the machine Be come familiar with the controls and know how to stop the machine qu
57. TIAL HAZARD Battery electrolyte contains sulfuric acid which is a deadly poison and it causes severe burns WHAT CAN HAPPEN If you carelessly drink electrolyte you could die or if it gets onto your skin you will be burned HOW TO AVOID THE HAZARD Do not drink electrolyte and avoid contact with skin eyes or clothing Wear safety glasses to shield your eyes and rubber gloves to protect your hands Fill the battery where clean water is always available for flushing the skin Follow all instructions and comply with all safety messages on the electrolyte container 1 Check for cracks in battery case caused by overly tight or loose hold down retainer Replace any battery that is cracked and or leaking 2 Check battery terminal posts for corrosion Use a ter minal brush to clean corrosion from the battery terminal posts IMPORTANT Before cleaning the battery make sure the filler caps are on tightly Electrical System Rev B Page 3 30 3 Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap overcharging loose terminal post or overfilling 4 Check the battery case for dirt and oil Clean the bat tery with a solution of baking soda and water then rinse battery with clean water 5 Check that the battery cover seal is not broken away Replace the battery if the seal is broken or leaking IMPORTANT Make sure the area around the battery filler cap
58. The minimum commutator diameter is 2 750 70 mm If the commutator diameter falls below this diame ter after turning the armature must be replaced 4 After the commutator is turned undercut the mica to a uniform depth of 0 040 1 0 mm Be careful to only cut the mica and not increase the slot width Fig 61 When using compressed air for cleaning mo tor components follow all safety instructions including wearing eye and respiratory protec tion 5 After undercutting use No 00 sandpaper to lightly remove any burrs left from the undercutting operation Clean commutator with dry oil free compressed air and recheck commutator runout Armature Testing Before an armature is reassembled into the motor the following tests should be performed NOTE Armature is wave wound and can be short cir cuit tested in the following manner 1 Check for grounded circuits by placing one test lead of a dielectric tester on the commutator and the other lead at the armature shaft If the test light comes on the armature is grounded 2 Check for short circuits by placing the armature on a growler Use a long flat piece of metal such as a hack saw blade to locate any shorted windings If armature is found to be shorted grounded or other wise damaged replace the traction motor Electrical System Rev B Page 3 40 MICA COPPER SEGMENT m qp PETS 040 2 1 0 mm GOOD UND
59. Workman e2050 e2065 Page 5 17 4 Lower machine to ground Remove chocks from wheels 5 Adjust front ride height see Operator s Manual 6 Make sure that travel limiting bolt and lock nut are installed and tightened Tighten lock nut only enough to snug travel limiting bolt Do not deform frame plate by overtightening lock nut 7 Make sure that centering bolts are torqued from 240 to 290 ft lb 325 to 393 8 Check front wheel toe in see Operator s Manual Adjust toe in if necessary Figure 8 3 A arm LH shown 4 Ride height adj bolt 1 Travel limiting bolt 2 Centering bolt Figure 9 1 Front A arm LH shown Chassis Rev B Pivot Yoke Removal Fig 7 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from the on off switch 2 Open the battery circuit by carefully removing one of the battery cables see Opening Battery Circuit in the General Information section of Chapter 3 Electrical System 3 Remove cargo bed from the rear frame see Cargo Bed Removal in this section 4 Remove seat base from the front frame see Seat Base Removal in this section Make sure all tires are chocked to prevent the machine from moving Before removing the pivot yoke make sure front and rear frames are supported with jack stands Support both the front and back of each frame 5 Remove four 4 cap screws and flat washers secu
60. 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 Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 Product Records and Maintenance Rev B 7 o gt ao E a and Maintenance Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series SAE Grade 8 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts SAE Grade 5 Bolts Screws Studs amp Sems with Regular Height Nuts Grade 1 5 amp 8 with Thin Height Nuts SAE Grade 1 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts Thread Size 6 32 UNC 147 23 6 40 UNF 8 32 UNC 282 30 8 36 UNF 10 24 UNC 339 56 10 32 UNF 1 4 20 UNC 48 7 599 79 1 4 28 UNF 65 10 734 113 5 16 18 UNC 115 15 105 17 1186 169 5 16 24 UNF 138 17 128 17 1446 192 3 8 16 UNC 16 2 3 8 24 UNF 7 16 14 UNC 27 3 7 16 20 UNF t 104 9 115 11 120 10 163 14 430 45 583 61 600 60 813 81 475 45 644 61 660 60 895 81 on the fastener size the aluminum or base material strength length of thread engagement etc 2943 1 2 13 UNC 30 3 1 2 20 UNF 3243
61. acking up the machine review and follow Jacking Instructions in Operator s Manual and Chapter 1 Safety 2 Chock wheels not being jacked up Jack front wheel off the ground and place blocks beneath the frame 3 Remove front wheel assembly as follows A Remove dust cap carefully from the wheel to pre vent damage to the cap B Remove cap screw and two 2 washers that se cure the wheel assembly to the spindle Slide wheel assembly from the spindle shaft 4 Remove spindle as follows A Remove cotter pin and slotted hex nut that secure tie rod ball joint to the spindle Separate ball joint from the spindle B If necessary remove tie rod from Pitman arm C Remove lock nut and cap screw king pin secur ing the spindle to the A arm Separate spindle from the A arm Locate and retrieve thrust washer item 13 Workman e2050 e2065 Page 5 13 Installation Fig 5 1 Install spindle as follows A Position king pin sleeve into the pivot hub of the A arm Spacer must extend through the bottom of the hub B Place thrust washer onto the bottom of the king pin sleeve Then position spindle over the hub king pin sleeve and thrust washer NOTE Make sure cap screw king pin is inserted down through the spindle and A arm hub C Secure spindle to A arm hub with cap screw king pin and lock nut Torque lock nut from 75 to 100 ft lb 102 to 136 N m D If tie rod was removed from Pitman arm inser
62. arking brake lever from slot and dust cover in backing plate 5 necessary remove two 2 washer head screws that secure wheel cylinder to backing plate Remove wheel cylinder from backing plate 6 If necessary remove bolts and washers to allow ad juster levers to be separated from backing plate Locate and remove belleville washers from between adjuster levers and backing plate Transaxle and Brakes Rev B Page 4 12 Workman e2050 e2065 Inspection Fig 6 1 Inspect brake drums IMPORTANT Brake drum machining is not recom mended Replace brake drums as a set to maintain equal braking forces A Clean drums with denatured alcohol Check braking surface diameter in at least three places If the diameter exceeds 6 320 16 05 cm replace both brake drums B Replace drums that are cracked deeply grooved tapered significantly out of round scored heat spotted or excessively rusted C Minor scoring can be removed with sandpaper 2 Inspect brake shoe linings IMPORTANT Replace brake shoes as a set all four shoes to maintain equal braking forces A Replace brake shoes if damaged or if lining is worn to 1 16 1 6 mm Replace if lining is contami nated by oil grease or other fluids NOTE Overheated springs lose their tension and can cause brake linings to wear out prematurely B Inspect brake shoe webbing upper and lower springs and shoe hold down springs for overheat ing Overheating is ind
63. asher 3 Screw 3 per striker plate 14 Flat washer 25 Push nut 4 Tailgate channel 15 Flange head screw 2 per bracket 26 Latch pin 2 used 5 RH latch rod 16 Pivot bracket 2 used 27 Lock nut 2 used 6 RH latch bracket 17 Flange head screw 6 used 28 Carriage screw 2 used 7 Grip knob 18 Box brace 3 used 29 Rear frame 8 Tailgate 19 Flange head screw 5 per brace 30 RH pivot bracket 9 LH latch rod 20 LH pivot bracket 31 Flange head screw 4 used 10 Screw 2 per bracket 21 Flange head screw 2 per bracket 32 Tension spring 11 LH latch bracket 22 Flange head screw 2 used 33 Latch rod Removal Fig 16 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from the on off switch 2 Remove two 2 flange head screws item 21 that secure RH and LH pivot brackets items 30 and 20 to the rear frame 3 Release latch rod item 33 from the latch pins item 26 Remove cargo bed from the frame Disassemble cargo bed as necessary using Figure 16 as a guide Chassis Rev B Page 5 24 Installation Fig 16 1 Reassemble cargo bed using Figure 16 as a guide 2 Position cargo bed to the frame locking the latch rod item 33 to the latch pins item 26 3 Secure both pivot brackets items 30 and 20 to the rear frame with flange head screws item 21 Workman e2050 e2065 Chapter 6 TORO Electrical Diagrams Table of Contents ELECTRICAL SCHEM
64. b 50 10 ft lb 35 10 ft lb 18 3 ft Ib 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 1 4 20 UNC 85 15 inb 5 16 18 UNC 110 20 inb 3 8 16 UNC 200 100 in Ib No 10 24 UNC 38 7 in lb Conversion Factors in lb X 11 2985 ft lb X 1 3558 Product Records and Maintenance Rev B Page 2 6 Wheel Bolts and Lug Nuts Thread Size Recommended Torque 88 14 7 16 20 UNF 65 10 ftHb Grade 5 1 2 20 UNF 80 10 ftHb f 108 14 Grade 5 M12 X 1 25 80 10 ftHb 108 14 Class 8 8 M12 X 1 5 80 10 ftHb f 108 14 Class 8 8 For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Thread Threads per Inch Size Type A Type B 1 2 1 1 Baseline Torque 16 71 8 11 i 85 1 Hole size material strength material thickness amp finish must be considered when determining specific torque values All torque values are based on non lubricated fasteners X 0 08851 in Ib N m X 0 7376 ft lb Workman e2050 e2065 Maintenance Maintenance procedures and recommended service in tervals for the Workman 2050 and 2065 are covered in the Operator s Manual Refer to that publication when performing regular vehicle mai
65. before removing the caps Workman e2050 e2065 Page 3 31 A Remove battery filler caps Do not add water prior to testing specific gravity of battery electrolyte If electrolyte level is low add distilled water and charge battery see Operator s Manual before per forming specific gravity test B Measure the specific gravity of each cell with a hydrometer Fill and drain the hydrometer two to four times before drawing a sample At the same time take the temperature of the cell C Have enough electrolyte in the hydrometer to completely support the hydrometer float Record the hydrometer reading and return the electrolyte to the battery cell D Repeat test for remaining battery cells E Temperature correct each cell reading For each 10 F 5 5 C above 80 F 26 7 C add 0 004 to the specific gravity reading For each 10 F 5 5 C below 80 F 26 7 C subtract 0 004 from the specific grav ity reading Example Cell Temperature 100 F Cell Specific Gravity Reading 1 245 ADD 20 above 80 F 0 008 Correction to 80 F 1 253 F The specific gravity of all battery cells should be 1 277 007 If low cell readings exist see Fig 47 charge battery see Operator s Manual and take specific gravity readings again G If specific gravity of any cells remain low after complete charging battery should be replaced Level Gravity Voltage 7 2 Figure 47 Electrical System Rev 5
66. ce corrosion after connections are made Make sure that terminal boots are positioned over all connections 8 Lower bed Figure 44 1 Negative cable to vehicle 3 Flange nut 2 Positive cable to vehicle 4 Battery retainer Figure 45 Electrical System Rev B 5 System Charging When the vehicle is not in use it is recommended to keep the batteries charged by connecting the battery charger that is included with the vehicle The Workman e2050 e2065 charger is designed to automatically charge the batteries fully without overcharging Indica tor lights green and red and an ammeter on the char ger give information about the charging operation Make sure to have the battery cell plates covered with electrolyte before charging the batteries Fig 46 Peri odically at least every 50 operating hours check elec trolyte level in the batteries and add distilled water to ensure proper charging and the best battery perfor mance and life Colder temperatures will increase the time needed to fully charge the batteries NEVER attempt to charge fro zen batteries Also if temperatures below freezing are expected do not add water to battery after charging as added water could freeze and damage battery For additional battery charging information see your Operator s Manual and the Battery Charger Operating Instructions Inspection and Maintenance POTEN
67. could short against metal ve hicle parts and cause sparks HOW TO AVOID THE HAZARD When removing or installing the batteries do not allow the battery terminals to short against metal parts of the vehicle Do not allow metal tools or metal vehicle parts to short between the battery terminals or battery cables Always keep the battery retainers in place to protect and secure the batteries IMPORTANT Be careful not to damage terminal posts or cable connectors when removing the bat tery cables 1 Position vehicle on a level surface set parking brake turn On Off switch OFF and remove key 2 Raise bed and secure with prop rod 3 Open the battery circuit by carefully removing one of the battery cables see Opening Battery Circuit in the General Information section of this chapter 4 Once initial cable has been removed from vehicle disconnect and remove remaining battery cables from all battery terminals 5 Remove flange nuts item 11 and battery retainers item 10 used to secure batteries to vehicle Fig 44 6 Make sure that all battery filler caps are on tightly IMPORTANT When removing batteries from ve hicle do not lift batteries using battery terminals as lift points battery damage may occur 7 Using case loops on battery tops as lifting points re move batteries from vehicle Installation Fig 43 IMPORTANT To prevent possible electrical prob lems install only fully charged batteries
68. cylinder 2 screw 3 Brake pedal Removal Fig 10 1 Remove front hood from machine 2 Remove cotter pin from the clevis pin that connects master cylinder to brake pedal 3 Clean hydraulic brake line area of master cylinder to prevent contamination Remove both brake lines from master cylinder Cap ends of brake lines and position them away from master cylinder 4 Remove flange head nuts from cap screws that se cure master cylinder to pedal frame 5 Pull master cylinder from machine Transaxle and Brakes Rev B Page 4 18 6 Flange head nut 7 Pedal frame Installation Fig 10 1 Position master cylinder to pedal frame and secure with cap screws and flange nuts 2 Remove plugs from brake lines Install brake lines to master cylinder 3 Connect master cylinder to brake pedal with clevis pin and cotter pin 4 Install front hood to machine 5 Bleed brakes see Bleed Brake System in this chap ter Check brake operation Workman e2050 e2065 Brake Master Cylinder Service Workman e2065 Disassembly Fig 11 1 Remove reservoir and flange seal Push in on the push rod so the stop pin can be removed 2 Disconnect lower end of the dust cover from the housing 3 Push in on the push rod and remove circlip then re move push rod with dust cover and clevis Remove re tainer washer 4 Remove primary piston assembly and secondary piston assembly from cylinder housing Inspection
69. d motor housing for support and as a lifting point for motor removal 7 Remove six 6 socket head screws item 1 and flat washers item 2 that secure motor to transaxle 8 Slide motor away from transaxle to disengage motor shaft from transaxle input shaft Carefully lift motor from vehicle Take care to not damage thermal switch while motor is removed 9 Locate and retrieve rubber damper from motor shaft internal spline 10 If needed remove two 2 roll pins from motor shaft Installation Fig 51 1 If removed install two 2 roll pins into motor shaft Workman e2050 e2065 Page 3 35 2 Make sure that rubber damper is installed into the motor shaft internal spline with the damper flat side to ward the motor Fig 52 85 to 90 in Ib 9 6 to 10 2 N m 55 to 60 in Ib le a 6 2 to 6 8 N m 55 to 60 in Ib 6 2 to 6 8 Figure 52 3 Rubber damper 4 Transaxle input shaft 1 Thermal switch 2 Motor shaft spline Figure 53 1 Loosening tightening wrench upper nut 2 Retaining wrench lower nut Figure 54 2 Jamnut 1 Eyebolt Electrical System Rev B T i System 3 Apply antiseize lubricant or axle grease to the splines of the transaxle and motor shafts Apply grease to lip of seal in transaxle bore To prevent motor damage and personal injury make sure that traction motor is w
70. d the switched side termi nal SWITCH NOT USED Figure 18 Electrical System Rev B Page 3 14 Workman e2050 e2065 Battery Discharge Indicator and Hour Meter Gauge The combination battery discharge indicator and hour meter gauge is located on the dash panel Fig 19 The battery indicator identifies state of charge of the bat tery pack The battery indicator reads full 10 bars when the battery pack is fully charged approximately 51 volts As battery pack voltage decreases with vehicle use fewer battery indicator bars are shown When the battery indicator reaches 2 bars a warning light illuminates and a battery icon flashes on the gauge face to identify that battery charge level is extremely low Figure 19 At this point the batteries should be charged 1 Battery discharge indicator and hour meter If the battery indicator reaches 1 bar the warning light begins flashing and the vehicle will go into an energy saving mode vehicle speed will be reduced to 3 MPH At this point the batteries should be charged to prevent serious battery damage Electrical System The hour meter registers operating time of the vehicle Whenever the vehicle is in motion the hour meter in creases one tenth every 6 minutes If the vehicle re mains stationary for 30 seconds even if the on off Switch is ON the hour meter quits increasing BACK OF T
71. e Spe o Figure 39 a Termina 4 Terminal 4 cial Tools to prevent corrosion of connection terminals 2 Terminal 2 5 Switch plunger Apply gel fully to both harness connector and switch ter 3 Terminal 3 6 Mounting tab minal area plug harness connector into switch to distrib ute gel unplug harness connector reapply gel to both surfaces and replug harness connector into switch 6 If switch replacement is needed see Accelerator Switch Adjustment procedure in the Adjustments sec tion of this chapter Electrical System Rev B Page 3 24 Workman e2050 e2065 Accelerator Potentiometer The accelerator potentiometer is attached to the pedal frame under the dash Fig 40 This potentiometer is used as one of the inputs for the vehicle controller to command vehicle speed The accelerator pedal posi tions the accelerator potentiometer lever When the op erator presses or releases the accelerator pedal the potentiometer resistance changes This resistance change is used by the controller to determine current flow to the traction motor If the accelerator potentiometer is out of adjustment the diagnostic light on the dash will flash six 6 times Addi tionally if vehicle movement is erratic and jerky calibra tion of the accelerator system should be performed See Accelerator Potentiometer Adjustment and Accelerator System Calibration in the Adjustments section of this chapter Before suspecting a faulty pot
72. e two 2 flange nuts and carriage screws that secure transaxle mount plate item 5 to support bracket item 4 Fig 16 10 Remove four 4 flange head screws and flange nuts securing the transaxle to the rear frame 11 Carefully lower transaxle and motor assembly from the rear of the vehicle 12 11 necessary remove traction motor from transaxle see Traction Motor Removal in Service and Repairs section of Chapter 3 Electrical System Figure 14 1 Loosening tightening wrench upper nut 2 Retaining wrench lower nut Figure 15 3 Brake cable bracket 4 Brake actuator lever 1 Cotter pin 2 Clevis pin Transaxle and Brakes Rev B S x 21 Ls Installation Fig 13 1 If removed install traction motor to transaxle see Traction Motor Installation in Service and Repairs sec tion of Chapter 3 Electrical System 2 Position transaxle and motor assembly to the rear frame Loosely install all fasteners used to secure trans axle to vehicle Tighten fasteners in the following order A Tighten four 4 flange head screws and flange nuts that secure transaxle to the rear frame B Tighten two 2 flange nuts and carriage screws that secure transaxle mount plate item 5 to support bracket item 4 3 Install brake cables to brake actuator levers with cle vis pins and cotter pins 4 Position wheel assemblies to the vehicle with valve stems facing out Secure
73. ect 12 VDC source to the light terminals Figure 25 4 Light should illuminate Remove voltage source from the light and reconnect wire harness Replace status light if needed Workman e2050 e2065 Page 3 17 Electrical System Rev B Supervisor Speed Limit Switch Workman 2050 The supervisor speed limit switch is open in Off position key vertical and closed in On position key rotated clockwise The speed limit switch is one of several in puts for the vehicle controller and allows the speed of the vehicle to be limited Test the switch by disconnecting the wiring and connect ing a continuity tester across the two switch terminals Rotate key to On position there should be an indication of continuity Rotate key to Off position there should be no continuity Figure 26 Supervisor Speed Limit Switch Workman e2065 The supervisor speed limit switch is open in Off position key vertical and closed in On position key rotated clockwise The speed limit switch is one of several in puts for the vehicle controller and allows the speed of the vehicle to be limited Test the switch by disconnecting the wiring and connect ing a continuity tester across switch terminals A and D Fig 27 Rotate key to On position there should be an indication of continuity Rotate key to Off position there should be no continuity Audio Alarm Reverse The audio alarm sounds when the forward reverse Switch is placed in the reve
74. ed for one hour at 300 F 148 C to remove any cleaning residue Workman e2050 e2065 Page 3 39 3 Itis also recommended that the field be coated with PD George 1000 70 or RanBar 535 55 varnish for proper insulation protection Both recommended var nishes are Class H water soluble varnishes A similar air dry varnish may also be used providing it has a Class H rating 4 Screws securing the pole pieces to the frame should be torqued from 250 to 300 28 3 to 33 9 Fig 60 ure 58 3 Arbor press Motor housing Puller 1 Spring scale 2 Brush spring 3 Paper Figure 60 2 Pole piece screw 1 Brush screw Electrical System Rev B T 9 2 System Commutator Service 1 Chuck armature on the commutator end bearing journal and support the drive end of armature using the live center of the shaft With the armature supported on both ends measure the commutator runout and the bar to bar differences with a dial gauge Total indicated run out should not exceed 0 003 0 08 mm and not more than 0 0005 0 013 mm between any two bars If the readings fall outside this limit the commutator must be turned and re undercut 2 If the commutator must be turned use only high quality cutting tools with a controlled cutting rate Re move only enough copper to bring total indicated runout and bar to bar height differences into specification 3
75. ehicle movement is erratic or jerky Battery Charger Operation Light Status Green light on battery charger illuminated not flashing Green light on battery charger flashing Red light on battery charger flashing Workman e2050 e2065 Page Possible Causes Wiring to the traction motor components e g main contactor controller traction motor loose corroded or damaged see Electrical Schematic in Chapter 6 Electrical Diagrams Battery cables are loose corroded or damaged Controller is overheated Traction motor is overheated Traction motor is faulty Brake or transaxle problem see Chapter 4 Transaxle and Brakes Supervisor speed limit switch in slow position Tire pressure is low see Chapter 5 Chassis Brakes improperly adjusted see Chapter 4 Transaxle and Brakes Battery charge is extremely low Controller is overheated Traction motor is overheated Collar on throttle is loose Accelerator potentiometer is improperly adjusted Accelerator system is out of adjustment Batteries is fully charged Vehicle ready to operate Slow flash once per second Batteries being charged batteries less than 8096 charged Continue charging Rapid flash four times per second Batteries being charged batteries more than 8096 charged Continue charging Rapid flash Charger timer shutoff has occurred after 20 hours of charging Slow flash No current to charger Check AC outlet
76. ell sup ported as it is installed Motor weighs approxi mately 62 pounds 28 1 kg 4 Carefully lower motor into vehicle Align motor shaft with transaxle input shaft and slide motor to transaxle Take care to not damage thermal switch while installing motor 5 Align mounting holes of motor transaxle and trans axle mount plate Secure motor to transaxle with six 6 socket head screws item 1 and flat washers item 2 IMPORTANT When connecting wires to motor ter minals A1 A2 F1 and F2 use a wrench to retain lower nut while tightening upper nut Fig 53 If ter minal studs are allowed to turn during upper nut installation internal motor damage can occur 6 Connect wires to traction motor Fig 52 A Make sure that fasteners and cable connectors are properly positioned on motor terminals Fig 56 B Install correct cable connector and nut to motor terminals A1 and A2 While retaining lower nut torque upper nut on terminals A1 and A2 from 85 to 90 in lb 9 6 to 10 2 C Install correct wire connector and nut to motor ter minals F1 and F2 While retaining lower nut torque upper nut on terminals F1 and F2 from 55 to 60 inb 6 2 to 6 8 D Plug motor temperature sensor connector into vehicle wire harness 7T Position fan to traction motor and secure with socket head screw and washer Install plastic plug in hole in rear frame 8 Carefully connect removed battery cable to battery termina
77. embly 5 Secure brake cables to rear of machine A Secure each R clamp to rear frame with screw and flange nut B Secure each brake cable to frame with retaining ring C Secure each brake cable end to brake lever with clevis pin and cotter pin 6 Check parking brake operation and adjust if neces sary Transaxle and Brakes Rev B 75 S o 2 55 7 c n gt Transaxle C 115 to 125 in Ib ge 13 to 14 1 N m Socket head screw 6 used Flange nut Carriage screw 5 used Support bracket Transaxle mount plate Rubber damper Traction motor Fan POO SO Transaxle and Brakes Rev B Figure 13 Roll pin 2 used Washer Socket head screw Lug nut 5 used per wheel Wheel assembly Brake drum Transaxle Flange head screw 4 used Page 4 22 45 to 65 ft Ib 61 to 88 Cotter pin Clevis pin Brake cable Transaxle vent hose Flat washer 6 used Negative battery cable Positive battery cable Workman e2050 e2065 Removal Fig 13 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from switch 2 Remove cargo bed from vehicle see Cargo Bed Re moval in Service and Repairs section of Chapter 5 Chassis 3 Open the battery circuit by carefully removing one of the battery cables see Opening Battery Circuit in the General Information section of Chapter 3 Elec
78. emoved battery cable to battery terminals Install lock washer and nut on battery termi nals Torque nuts from 115 to 125 in lb 13 to 14 1 10 Lower bed Figure 50 1 Brush holder side view 3 Worn brush 2 Normal brush 4 Brush shunt wire Workman e2050 e2065 Page 3 33 Electrical System Rev B 9 System Traction Motor 115to125inIb x 45 13 to 14 1 pee Figure 51 8 Traction motor 9 Fan Socket head screw 6 used Flat washer 6 used Flange nut Support bracket Carriage screw Transaxle mount plate Rubber damper 11 Washer Removal Fig 51 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from switch 2 Remove cargo bed from vehicle see Cargo Bed Re moval in Service and Repairs section of Chapter 5 Chassis 3 Open the battery circuit by carefully removing one of the battery cables see Opening Battery Circuit in the General Information section of this chapter Electrical System Rev B 10 Roll pin 2 used 12 Socket head screw 13 Plastic cap fits in rear frame 19 Negative battery cable Page 3 34 14 Cable terminal boot 15 Hex nut 16 Lock washer 17 Positive battery cable 18 Cable terminal boot NOTE Label all electrical leads for reassembly pur poses IMPORTANT When removing wires from motor ter minals A1 A2 F1 and F2 use a
79. entiometer follow adjust ment procedures for the accelerator switch accelerator potentiometer and acceleration system calibration found in the Adjustments section of this chapter 1 Potentiometer 2 Accelerator pedal Workman e2050 e2065 Page 3 25 Figure 40 3 Collar 4 Roll pin Electrical System Rev B E System Controller The Workman controller is secured to the rear frame un der the controller cover beneath the bed Fig 41 The controller uses inputs from several vehicle switches on off forward reverse accelerator pedal supervisor charger interlock motor temperature accelerator po tentiometer to accurately control vehicle speed vehicle NOTE If the controller LED and vehicle status light are flashing attempt to reset the controller by turning the On Off switch to OFF waiting a few seconds and then turning the switch to ON If LED and status light continue flashing proceed with fault code identification and nec essary action direction forward and reverse and regenerative brak ing An internal thermal sensor prevents overheating of the controller Cable connections for the controller are as follows Terminal Negative battery cable and wire harness ground Terminal B Positive cable from main contac tor post and wire harness fusible link FL3 Terminal M1 Cable to traction motor armature A2 post Terminal M2 Cable to traction motor armatu
80. eview and follow Jacking Instructions in Operator s Manual and Chapter 1 Safety 2 Chock wheels not being jacked up Jack front wheel off the ground and place blocks beneath the frame 3 Remove front wheel and spindle from A arm see Lower Steering Removal in this section 4 Remove lock nut item 6 and travel limiting bolt item 9 from the frame NOTE To aid reassembly note hole location of ride height adjustment bolt in A arm Fig 9 5 Remove flange nut item 5 and ride height adjust ment bolt item 1 from the adjustment pattern of the A arm and frame 6 Remove two centering bolts item 8 and lock wash ers item 7 securing the A arm to the the frame Lower A arm from the frame A arm Installation Fig 7 1 Position A arm to the frame Secure A arm to the frame with two 2 centering bolts item 8 and lock washers item 7 Do not tighten bolts 2 Install spindle and front wheel to the see Lower Steering Installation in this section NOTE If A arm is being replaced look for number be tween 200 and 400 written next to the serial tag on the bottom of the replacement A arm This number should be used to identify the location of the ride height adjust ment bolt Fig 9 Number from 200 to 220 use hole 4 Number from 225 to 285 use hole 3 Number from 290 to 400 use hole 2 3 Install ride height adjustment bolt item 1 and flange nut item 5 into correct hole location
81. ff System inoperable Check for low battery voltage faulty fuse s loose battery cable connections damaged battery cables and or faulty main contactor If batteries cables and other electrical components are in good condition controller replacement may be necessary Electrical System Rev B Page 3 26 Workman e2050 e2065 1 Flash System inoperable Turn on off switch OFF wait several seconds and turn on off switch ON If controller does not reset correctly controller replacement may be necessary 2 Flashes The accelerator pedal was Turn on off switch OFF release accelerator pedal and depressed when on off turn on off switch to ON Switch was turned ON If controller does not reset correctly accelerator switch adjustment may be necessary or switch may be faulty 3 Flashes System inoperable Turn on off switch OFF wait several seconds and turn on off switch ON If controller does not reset check battery pack voltage and all battery cable connections Also check main contactor wire and cable connections and main contactor NOTE If main contactor audibly clicks when on off switch is turned ON problem is most likely a faulty wire or cable connection Controller replacement may be necessary 4 Flashes Main contactor malfunction Turn on off switch OFF wait several seconds and turn on off switch ON If controller does not reset inspect main contactor see Main and Accessories Contactors in this section Check main
82. for effective results WATER ION Figure 5 Workman e2050 e2065 Page3 5 Electrical System Rev B Battery Watering Dispenser Use the battery watering dispenser when adding dis tilled water to vehicle batteries Obtain watering dis penser locally Figure 6 Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte Obtain hydrometer locally Figure 7 Battery Lift Strap Use the battery lift strap to remove and install batteries from the vehicle Lift strap allows use of case loops on battery tops as safe battery lifting points Obtain battery lift strap locally Figure 8 Electrical System Rev B Page3 6 Workman 2050 2065 36 48 Volt Battery Discharge Unit The 36 48 Volt Battery Discharge Unit TOR4106 is rec ommended for quick and accurate load testing for the batteries on the Workman e2050 and e2065 This tool is used to determine the capacity of the Workman bat tery pack and also for finding faulty battery or batteries in the battery pack Order the 36 48 Volt Battery Discharge Unit TOR4106 from your Toro Distributor Figure 9 System 2 gt o Workman 2050 2065 Page 3 7 Rev D Electrical System Rev B Troubleshooting Remove all jewelry especially rings and watches before doing any electrical trouble shooting or testing Disconnect a battery cable from the battery pack to open the battery circuit unless a
83. from backing plate slide parking brake le ver into slot and dust cover in backing plate 5 Position brake shoes to backing plate Make sure that each shoe is properly positioned at anchor block parking brake lever wheel cylinder and pin on adjuster lever Secure shoes to backing plate with shoe hold down cups and springs Be careful when installing springs to brake shoes The springs are under heavy load and may cause personal injury 6 Secure brake shoes with upper and lower springs Transaxle and Brakes Rev B 2 x 2 6 o KU x LS a Hydraulic Brake System Workman 2065 O ONO OT BON Brake caliper LH Brake caliper RH Brake rotor 2 used Front brake tube Front brake hose Carriage screw Rear brake tube Carriage screw Rear brake hose bracket Cap screw Thread forming screw 6 used Clip Tee fitting Figure 7 Rear brake tube RH Rear brake tube LH Insulated clip 5 used Cap screw 2 used Flange nut 2 used Clevis pin Cotter pin Master cylinder Union fitting Rear brake tube Rear brake hose Hose bracket 2 used When performing service work on the Workman e2065 hydraulic brake system make sure to thoroughly clean components before disassembly Use Figure 7 as a guide for removal and installation of hydraulic brake components Transaxle and Brakes Rev B Page 4 14 Tube clamp 2 used
84. he back of the gauge is shown in Figure 20 A wire har GAUGE ness connector plugs into the gauge Terminals 1 2 and 5 are not used on the Workman 2050 2065 See Figure 20 Chapter 6 Electrical Diagrams for schematic and wire harness information If the battery discharge indicator or the hour meter prove to be inaccurate the gauge should be replaced Workman e2050 e2065 Page 3 15 Electrical System Rev B Vehicle Direction Forward Reverse and Headlight Switches The vehicle direction forward reverse switch Fig 21 and headlight switch Fig 22 are located on the control panel These two switches have identical logic The vehicle direction switch is one of several inputs for the vehicle controller and allows the direction forward reverse of the vehicle to be changed by the operator The headlight switch allows the headlights to be turned on and off NOTE The headlight system on the Workman e2050 and e2065 consists of two 2 24 volt lamps connected in series If one lamp is burned out or disconnected nei ther lamp will illuminate a a gt Figure 21 Testing 1 Direction switch The switch terminals for these switches are marked as shown in Figure 23 The circuitry of the switch is shown in the chart below With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each switch position Verify con
85. ic Maintenance Manual at the end of this chapter 3 Slide brake drum onto wheel hub making sure that hole in drum aligns with hole in wheel hub on axle 4 Position wheel assembly to the vehicle with valve stem facing out and secure with five 5 lug nuts Torque lug nuts in a criss cross pattern from 45 to 65 ft lb 61 to 88 5 Lower vehicle to ground After servicing the brakes always check the brakes in a wide open level area that is free of other persons and obstructions 6 Check and adjust brakes see Operator s Manual Workman e2050 e2065 4 9 Burnish Brake Shoes To provide maximum brake performance after rear brake shoes are replaced burnish new brake shoe lin ings IMPORTANT To prevent brake overheating do not drive vehicle with the brakes applied IMPORTANT When burnishing brake shoes do not allow the brakes to lock up Also allow brakes to cool between stops 1 Drive vehicle while making 6 to 7 normal stops at about 200 ft 60 m intervals while traveling at 10 to 15 mph 16 to 24 KPH 2 Make several normal stops with the vehicle going in the reverse direction This will self adjust the clearance between the brake shoes and drum Workman e2050 Shown Y Figure 4 1 Cotter pin 3 Brake cable bracket 2 Clevis pin 4 Brake actuator lever Transaxle and Brakes Rev B S x 21 gt Brake Service Workman 2050
86. icated by a slight blue color In spect brake shoe webbing for deformation Replace parts as necessary C Inspect hold down pins on adjuster levers for bends rust and corrosion Replace as necessary 3 Inspect backing plate surfaces which contact with the brake shoes for grooves that may restrict shoe movement Replace plate if grooves can not be re moved by light sanding with emery cloth or other suit able abrasive Replace plate if cracked warped or excessively rusted 4 Inspect adjuster levers for deformation Replace lev ers if deformation or excessive rust is found 5 Replace parking brake cables if frayed stretched or kinked Workman e2050 e2065 Page 4 13 Assembly Fig 6 IMPORTANT Brake shoe lining surfaces must be free of grease oil and other foreign matter 1 Apply a light film of lubricant to the following A Ledges on which the brake shoes rest B Pin surfaces on adjuster levers C Anchor block surface that contacts shoe webs D Both surfaces of belleville washers that are posi tioned between adjuster levers and backing plate 2 If removed position lubricated belleville washer be tween lever adjuster and backing plate Secure adjuster to backing plate with washer and bolt Torque bolt from 110 to 120 inb 12 4 to 13 6 3 If removed secure wheel cylinder to backing plate with two 2 washer head screws Torque screws from 110 to 120 inb 12 4 to 13 6 4 If removed
87. ickly A replacement Operator s Manual is available on the Internet at www Toro com While Operating The Workman e2050 and e2065 are off highway vehicles only They are not designed equipped or manufactured for use on public streets roads or highways 1 Siton the operator seat when starting and operating the vehicle 2 Before starting the vehicle A Make sure that the battery charger is discon nected from the vehicle charger receptacle B Engage the parking brake C Make sure accelerator pedal is not depressed D Check position of forward reverse switch and Hi Low speed switch Safety Rev B Page1 2 Rev D To reduce the potential for injury or death comply with the following safety instructions 2 Keep all shields safety devices and decals in place If ashield safety device or decal is defective illegible or damaged repair or replace it before operating the ma chine Also tighten any loose nuts bolts or screws to en sure machine is in safe operating condition 3 Before getting off the operator seat A Stop vehicle turn on off switch OFF and remove key from switch B Set parking brake 4 f vehicle is parked on incline chock or block the wheels after getting off the vehicle Workman e2050 e2065 Maintenance and Service 1 Before servicing or making adjustments to the ve hicle stop vehicle turn on off switch to OFF engage parking brake and remove key from the on off switch
88. ies provide current for a 48 volt DC high torque trac tion motor the vehicle controller and vehicle accesso ries headlights horn various optional accessories The batteries are discharged as the vehicle is used so charging the batteries after using the vehicle is neces sary A battery discharge indicator gauge on the dash provides the operator with information on battery charge level Demands on the vehicle during use speed pay load incline use battery condition age charge level ambient temperature and vehicle condition will all put constraints on how long a vehicle can be used before the batteries are discharged An automatic 115 VAC 230 VAC on international mod els battery charger is included with the vehicle An inter lock switch on the vehicle charger receptacle prevents the vehicle from operating when the charger cord is plugged into the vehicle The electric traction motor directly drives a double re duction transaxle with differential Operator inputs for forward reverse supervisor switch position high or low speed and accelerator pedal position are used by the controller to determine voltage to the traction motor The traction motor is cooled with an external fan Addi tionally the motor is protected from overheating by a thermal switch in the motor housing If unsafe motor temperature is sensed by the switch the controller is signaled to limit vehicle speed and torque until the motor temperature reduces
89. igure 6 1 Wheel assembly 14 Seal 27 Ball joint RH thread 2 Lug nut 5 used per wheel 15 Brake rotor 28 Jam nut RH thread 3 Dustcap 16 Socket head screw 4 used per rotor 29 Tie rod tube 4 Cotter pin 17 Lock nut 30 Pitman arm 5 Nutretainer 18 LH spindle 31 Ball joint LH thread 6 Jamnut 19 Cap screw 32 Grease fitting 7 Tab washer 20 Brake hose bracket 33 Jam nut LH thread 8 Bearing cone 21 Bushing 2 used per A arm 34 A arm RH 9 Bearing cup 22 Thrust washer 35 A arm LH 10 Wheel hub 23 RH spindle 36 Grease fitting 11 Wheel stud 5 used per hub 24 Castle nut 37 Brake caliper LH shown 12 Bearing cup 25 Cotter pin 38 Lock washer 2 used per caliper 13 Bearing cone 26 Kingpin sleeve 39 Cap screw 2 used per caliper NOTE Both tie rod assemblies consist of the following parts ball joints 27 and 31 jam nuts 28 and 33 tie rod tube 29 and grease fittings 32 and 36 Removal Fig 6 Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition 2 Chock wheels not being jacked up Jack front wheel off the ground and place blocks beneath the frame Chassis Rev B Page 5 14 Workman e2050 e2065 3 Remove lug nuts and pull wheel assembly from ma chine 4 Remove brake caliper from spindle see Front Brake Calipers in the Service and Repairs sectio
90. in this Figure 16 Se section 1 Controller 3 Ground post B 3 2 Gray controller lead 4 Controller LED og 3 Check accelerator potentiometer adjustment and tZ adjust if necessary see Accelerator Potentiometer Ad justment in this section 4 Using a jumper wire connect gray controller lead to ground post on controller Fig 16 NOTE During calibration the vehicle status light on the dash should flash the same as the controller LED 5 Turn On Off switch ON The alarm should sound and the controller LED should flash six 6 times 6 Slowly depress accelerator pedal until the alarm mo mentarily stops and hold pedal in position This should take a very small movement of the pedal Once alarm re sumes release accelerator pedal completely 7 Depress and hold accelerator pedal fully Alarm will momentarily stop while controller calibration occurs Hold pedal fully depressed until alarm resumes and then release pedal 8 If calibration process was successful alarm will chirp and diagnostic light on the dash will be lit continuous not flashing If alarm continues to sound or if diagnostic light is flashing turn On Off switch OFF and repeat steps 5 6 and 7 9 Turn On Off switch OFF and remove key Disconnect jumper wire from gray controller lead and controller ground post 10 Install controller cover and lower bed 11 If vehicle operation continues to be erratic after com
91. ion and key is removed from switch Workman e2050 e2065 Safety and Instruction Decals There are several safety and instruction decals attached to your Workman vehicle If any decal becomes illegible or damaged install a new decal Part numbers are listed in the Parts Catalog Order replacement decals from your Authorized Toro Distributor Workman e2050 e2065 Page 1 5 Safety Rev B This page is intentionally blank Safety Rev B Page 1 6 Workman 2050 2065 Chapter 2 TORO Product Records and Maintenance Table of Contents 28 PRODUCT RECORDS 1 Standard Torque for Dry Zinc Plated and EQUIVALENTS AND CONVERSIONS 2 Steel Fasteners Metric Fasteners 5 9 5 Decimal and Millimeter Equivalents 2 Other Torque Specifications 6 E U S to Metric Conversions 2 Conversion Factors 6 TORQUE SPECIFICATIONS 3 MAINTENANCE ds Fastener Identification 3 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 4 Product Records Insert Operator s Manual and Parts Catalog for your Workman vehicle at the end of this chapter Additionally if any optional equipment or accessories have been installed to your Workman insert the Installation In structions Operator s Manuals a
92. irs Battery Service 115 to 125 in Ib x 13 to 14 1 N m 115 to 125 in lb gt 5 13 to 14 1 N m 12 Figure 43 Battery 8 used Battery rod 2 used Negative cable to vehicle Lock washer 2 used per battery The batteries the heart of the Workman electrical system With regular and proper service battery life can be extended Additionally battery and electrical compo nent failure can be prevented Workman e2050 Battery Specifications Trojan model T 105 Battery 6 Volt Deep Cycle Weight 62 lbs 28 kg Capacity 140 minutes 56 25 amps discharge Electrical System Rev B Hex nut 2 used per battery Cable terminal boot Battery cable 6 used Positive cable to vehicle 3 28 Rev D 9 Cable terminal boot 10 Battery retainer 2 used 11 Flange nut 2 used 12 Battery cable Workman e2065 Battery Specifications Trojan model T 145 Battery 6 Volt Deep Cycle Weight 72 Ibs 33 kg Capacity 210 minutes 56 25 amps discharge NOTE Trojan model T 145 batteries can be used in the Workman e2050 These batteries have a higher ca pacity than the standard Workman e2050 batteries and therefore have a longer run time Workman e2050 e2065 Removal Fig 43 POTENTIAL HAZARD The battery terminals metal tools and metal ve hicle parts could short together WHAT CAN HAPPEN Sparks can cause the battery gasses to explode Damaged cables
93. ke sure cap screw 19 is inserted down through the spindle and A arm hub C Install brake hose bracket 20 onto cap screw 19 Secure spindle to A arm hub with cap screw 19 and lock nut Torque lock nut from 75 to 100 ftHb 102 to 136 Workman e2050 e2065 Page 5 15 D Insert tie rod ball joints down through the spindle and up through the Pitman arm Secure with castle nuts E Torque castle nuts from 20 to 25 ft lb 27 to 34 N m to secure ball joint while aligning castle nut slot with hole in ball joint stud If necessary to align holes castle nut torque may be slightly more than specifi cation Install cotter pin 2 Assemble wheel hub A If bearing cups were removed from the wheel hub press inner and outer cups into the hub until they seat against the hub shoulder B Pack both bearings with grease Install inner bearing into the cup on inboard side of the wheel hub IMPORTANT The lip seal must be pressed in so it is flush with the end of the hub The lip of the seal must be toward the bearing C Apply grease to the inside of the new lip seal and press it into the wheel hub D If brake rotor was removed apply Loctite 242 or equivalent to socket head screws and install brake rotor to hub Make sure that the brake rotor bore chamfer is assembled toward the wheel hub 3 Slide wheel hub assembly onto spindle Install outer bearing tab washer and jam nut onto spindle 4 While rotating the
94. lerator pedal released check that the distance between the head of the accelerator switch stop cap screw and the body of the switch is 5 8 inch 1 6 cm Fig 12 celerator switch stop cap screw position Fig 11 6 After adjustment make sure that switch plunger is not bottomed out when accelerator pedal is released 7 After adjustment to switch stop cap screw make sure that the switch does not open when the parking brake is engaged Readjust switch stop cap screw if re quired 8 Calibrate accelerator system after adjusting acceler ator switch see Accelerator System Calibration in this section 1 Workman e2050 e2065 Page 3 11 Accelerator pedal 5 If distance is incorrect loosen lock nut and adjust ac 2 switch Plate Figure 10 4 Screw 2 used 5 Switch stop cap screw 6 Lock nut Figure 11 1 Accelerator switch 2 Switch stop cap screw 3 Accelerator stop cap screw 5 8 inch 1 6 cm Switch stop cap screw Figure 12 2 Accelerator switch Electrical System Rev B T 9 System Accelerator Potentiometer Adjustment The accelerator potentiometer is used as one of the in puts for the vehicle controller and is attached to the ped al frame under the dash Fig 13 A collar with roll pin on the accelerator pedal shaft positions the accelerator po tentiometer lever If the accelerator pote
95. ller B 5 Positive battery cable 3 Wire harness connector 6 Isolator Figure 32 1 Negative cable to vehicle 2 Positive cable to vehicle Figure 33 3 Main contact posts 4 Contactor coil posts 1 Main contactor 2 Accessories contactor Workman e2050 e2065 6 Replace contactor if necessary 7 Reconnect electrical connections to contactor If main contactor connections were removed use Figure 34 as a guide for reattaching cable and wire harness connections 8 Reconnect battery cable that was removed from bat tery pack Figure 34 1 Main contactor 5 Wire harness connector 2 Cable to controller 6 Fuse F1 S 3 Lock nut 7 Positive battery cable T2 4 Flat washer 8 Isolator 9 o 72 Workman 2050 2065 Page 3 21 Electrical System Rev There are three 3 fuses the Workman electrical sys tem Two 2 of the fuses are located beneath the steering column Fig 35 These fuses supply power to the fol lowing The upper 10 ampere fuse F2 supplies power to the on off switch and switched circuits The lower 10 ampere fuse F3 supplies power to op tional accessories The third fuse F1 is located under the controller cover beneath the bed Fig 36 This fuse is rated at 355 am peres continuous and allows current flow between the batteries and the vehicle If this fuse has failed vehicle operatio
96. load carried The lower the air pressure the less the compaction and tire marks are minimized Lower pressure should not be used for heavy payloads at higher speeds Inspect Tires and Wheels Operating accidents such as hitting curbs can damage a tire or rim and also disrupt wheel alignment so inspect wheel condition tire and rim and wheel alignment toe in after any accident Check wheels to ensure they are mounted securely Torque wheel lug nuts front and rear from 45 to 65 ft lb 61 to 88 On Workman 2050 vehicles the front wheel cap screws should be torqued from 135 to 165 ft Ib 183 to 224 Higher pressures should be used for heavier payloads at higher speeds Do not exceed the maximum tire pres sure If desired tires can be moved from one position of the vehicle to another to extend tread life e g front tires to rear and rear tires to front All tires on the Workman e2050 and e2065 are the same size Workman e2050 e2065 Page 5 5 Chassis Rev B Upper Steering Antiseize lubricant Nut Lock washer Steering wheel Flange lock nut Steering gearbox Cap screw grord ov Chassis Rev B Antiseize lubricant Figure 1 7 Lock washer 8 Steering shaft 9 Cap screw 3 used 10 Upper steering bushing 11 Carriage bolt 4 used 5 6 12 13 14 15 16 13 to 17 ft lb 18 to 23 N m Steering column Dust cover Collar Pitman arm Steering wheel
97. ls Install lock washers and nuts on battery termi nals Torque nuts from 115 to 125 in lb 13 to 14 1 9 Install cargo box to the rear frame see Cargo Box Installation in Service and Repairs section of Chapter 5 Chassis Electrical System Rev B Page 3 36 Figure 55 3 Transaxle mount plate 1 Transaxle 2 Screw washer 6 used Figure 56 1 Upper nut 4 Flat washer 2 Cable connector 5 Insulating washer 3 Lower nut 6 Motor housing Workman e2050 e2065 System 5 This page is intentionally blank Workman e2050 e2065 3 37 Electrical System Rev Traction Motor Service 120 to 140 in Ib 13 6 to 15 8 18 to 22 in lb 2 to 2 5 N m Figure 57 Frame and field assembly Armature Brush lead 2 used Cap screw 2 used per brush lead Cap screw 4 used Headband 0 Bolt 4 used grs o NS Disassembly Fig 57 1 Unlatch and slide headband from traction motor 2 Pull back the brush springs and latch them in the open position on the spring holders Slide brushes from the brush holders 3 Use an arbor press or a bearing puller to remove the armature from the commutator end head and frame and field assembly Fig 58 4 Remove four 4 bolts that secure the commutator end head to the frame and field assembly Remove com mutator end head from frame and field assembly Electrical System Rev B Cap scre
98. n of Chapter 4 Transaxle and Brakes Position caliper away from wheel hub and spindle 5 Carefully pry dust cap from wheel hub 6 Remove cotter pin and nut retainer from spindle 7 Remove jam nut that secures wheel hub to spindle Slide wheel hub with bearings and rotor from spindle 8 Disassemble the wheel hub A Pull the seal out of the wheel hub B Remove bearings from both sides of the wheel hub Clean bearings in solvent Make sure bearings are in good operating condition Clean the inside of the wheel hub Check the bearing cups for wear pit ting or other noticeable damage Replace worn or damaged parts C If necessary remove four 4 socket head screws and brake rotor from wheel hub 9 Remove spindle A Remove cotter pin and castle nut securing tie rod ball joint to the spindle Separate ball joint from the spindle Remove tie rod from Pitman arm if neces sary B Remove lock nut and cap screw 19 securing the spindle to the A arm Separate spindle from A arm C Locate and remove thrust washer from bottom of kingpin sleeve A arm Remove kingpin sleeve from A arm if necessary Installation Fig 6 1 Install spindle as follows A Position king pin sleeve into the pivot hub of the Sleeve must extend through the bottom of the hub B Place thrust washer onto the bottom of the king pin sleeve Then position spindle over the hub king pin sleeve and thrust washer NOTE Ma
99. n will not occur Testing When testing fuses for continuity with a multime ter ohms setting make sure that fuse is re moved from circuit IMPORTANT Before removing fuse F1 355 Amp for testing open the battery circuit by removing one of the battery cables see Opening Battery Circuit in the General Information section of this chapter Make sure on off switch is turned OFF Remove fuse to check continuity The test meter should read less than 1 ohm Figure 35 1 Fuse F2 2 Fuse F3 1 Controller 3 Main contactor 2 Fuse F1 Electrical System Rev B Page 3 22 Workman e2050 e2065 Fusible Links The wiring harness for the Workman includes three 3 fusible links for circuit protection Fig 37 Two fusible links attach to the same main contactor post as the main fuse One of these fusible links FL2 is used for the switched power circuit The other fusible link FL1 protects the charger circuit The third fusible link FL3 is attached to the controller B terminal This link provides protection for the charge indicator hour meter gauge If any of these fusible links should fail the affected circuit will not function See Chapter 6 Electrical Diagrams for schematic and wire harness information 1 Main contactor 4 Fusible links FL1 amp FL2 2 Main fuse contactor post 5 Fusible link FL3 5 p o 9 3 Switched contactor post System Workman e2050 e2065 Page 3
100. nd 4 4 Workman 2050 2065 Brakes continued Problem Possible Cause Brakes drag Parking brake is applied Brakes are incorrectly adjusted Workman e2050 Rear shoe to shoe spring s is are weak or broken Brake pedal is binding Brake cable is binding Workman e2050 Brake linings are saturated Rear brake drums are bent or out of round Front brake calipers or rotors are damaged Workman e2065 Brake pedal is hard to push Incorrect brake lining material Brake pedal linkage is binding Brake cable is binding Workman e2050 Wheels lock up when braking Brake linings are contaminated Brakes Brake linings are loose or damaged Wheel or transaxle bearings damaged Rear brake shoe to shoe springs are weak Rear brake drums are grooved in the contact face with brake shoes Brakes fade Brake drums or rotors are overheated Brake linings are saturated Vehicle surges at slow speeds and Brake drums or rotors are bent or out of round chatters at fast speeds Rear brakes do not self adjust Adjuster bolt is seized Adjuster lever does not engage star wheel Workman e2050 e2065 4 5 Transaxle and Brakes Rev Adjustments Adjust Brakes Workman e2050 The recommended brake pedal travel is from 1 to 1 1 2 25 4 to 38 1 mm with a 75 to 100 pound 34 to 45 4 kg input force to the brake pedal Adjustment Procedure Figures 1 and 2
101. nd Parts Catalogs for those options at the end of this chapter Workman e2050 e2065 Page 2 1 Product Records and Maintenance Rev B 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 17 82 0 53125 13 494 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 09375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 18 01250 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 14 02500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 82 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 7 938 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
102. nsaxle Transaxle Fluid Capacity 2 quarts 1 9 liters Transaxle Fluid 10W 30 Motor xe S 5 S cam Workman e2050 e2065 Page 4 3 Transaxle and Brakes Rev B Troubleshooting Brakes Problem Brake pedal goes to the floor Brake pedal is spongy Brakes pull to either side Brakes squeal Transaxle and Brakes Rev B Possible Cause Brakes are incorrectly adjusted Workman e2050 Brake cable is loose or broken Workman e2050 Rear brake shoes are excessively worn Front brake pads are excessively worn Workman e2065 Brake fluid level low Workman e2065 Brake fluid leak at hose caliper or wheel cylinder Workman e2065 Brake master cylinder faulty Workman e2065 Rear brake drums are excessively worn or cracked Rear brake shoes are not burnished Brake cable is loose or broken Workman e2050 Brakes are incorrectly adjusted Workman e2050 Air in brake lines Workman e2065 Tire pressure is incorrect or uneven between tires Brake linings are contaminated Front wheel alignment toe in is incorrect Brake cable is binding loose or broken Workman e2050 Brake shoes are distorted Tires on same axle are unmatched Brake lining is glazed or saturated Rear shoe to shoe spring s is are weak or broken Brake shoes are distorted Anchor plate is bent Workman e2050 Brake drums and shoes are dusty Rear brake drums are scored or out of rou
103. ntenance a E 5 a and Maintenance Workman e2050 e2065 Page 2 7 Product Records and Maintenance Rev B This page is intentionally blank Product Records and Maintenance Rev B Page 2 8 Workman 2050 2065 Chapter 3 TORO Electrical System Table of Contents ELECTRICAL DIAGRAMS 2 GENERAL INFORMATION 3 Opening Battery Circuit 3 VEHICLE OPERATION 4 SPECIAL TOOLS 5 TROUBLESHOOTING 8 General Run Problems 8 Battery Charger Operation 9 Battery Charger Problems 10 ADJUSTMENTS 11 Accelerator Switch Adjustment 11 Accelerator Potentiometer Adjustment 12 Accelerator System Calibration 13 COMPONENT TESTING 14 On Off 14 Battery Discharge Indicator and Hour Meter Gauge 15 Vehicle Direction Forward Reverse and Headlight Switches 16 Vehicle Status Light 17 Supervisor Speed Limit Switch Workman e2050 18 Supervisor Speed Limit Switch Workman e2065 18 Audio Alarm 18 Charger Interlock Switch 19 Main and Accessories Contactors
104. ntiometer is out of adjustment the diagnostic light on the dash will flash six 6 times Addi tionally if vehicle movement is erratic and jerky poten tiometer adjustment and calibration of the accelerator system should be performed Adjustment 1 Position vehicle on a level surface turn On Off switch OFF and remove key 2 Make sure that accelerator potentiometer is securely attached to the pedal frame of the machine 3 Check accelerator switch adjustment and adjust if necessary see Accelerator Switch Adjustment in this section 4 Check movement of the accelerator potentiometer lever A With the accelerator pedal released the roll pin on the throttle position collar should keep the poten tiometer lever from 0 050 to 0 100 1 3 to 2 5 mm from the lower stop on the potentiometer body Fig ure 14 B With the accelerator pedal fully depressed the in put lever of the potentiometer should not contact the upper stop on the potentiometer body Figure 15 5 If potentiometer lever movement is incorrect adjust location of collar on accelerator pedal shaft A Loosen two 2 set screws that secure throttle position collar to throttle pedal shaft and reposition collar to allow correct potentiometer movement Make sure that there is clearance between roll pin and side of potentiometer lever to prevent binding B Remove set screws one at a time from collar and apply Loctite 242 or equivalent to set screw thread
105. o the small bearing in the steer ing housing 6 Fill steering housing with number 2 general purpose grease Make sure all gear teeth on the sector and pin ion gears are covered with grease 7 Place gasket and steering housing cover onto the housing Secure cover to housing with four 4 hex washer head screws Torque screws from 90 to 110 in Ib 10 2 to 12 4 IMPORTANT Flange head screw with patch lock item 9 should be replaced whenever it is removed 8 Secure flange head screw with patch lock item 9 and step washer item 8 to the Pitman arm Make sure to position step washer as in Figure 2 Torque screw from 27 to 33 ft lb 37 to 45 9 Secure cap screw item 13 and flat washer item 12 to the pinion gear shaft Torque cap screw from 175 to 225 in lb 19 8 to 25 4 Chassis Rev B Front Wheels Workman 2050 Antiseize Lubricant 135 to 165 ft lb 183 to 224 61 to 88 c 45 to 65 ft lb Figure 3 1 Spindle LH shown 5 Spacer 9 Large flat washer 2 Bearing with retaining ring 6 Tire wheel assembly 10 Cap screw 3 Wheel stud 5 per wheel 7 Lug nut 5 per wheel 11 Dust cap 4 Wheel hub 8 Flat washer Chassis Rev B Page 5 10 Workman 2050 2065 Removal Fig 3 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from the on off Switch Before jacking up the machine review and follow Jacking Instructions in
106. ote alignment marks on Pitman arm shaft and sector gear If marks are not visible matchmark shaft and gear before disassembly Their position is critical during assembly 6 Separate Pitman arm item 19 from the sector gear item 4 and steering housing Remove Pitman arm from the housing 7 Inspect bearings Bearings must spin smoothly and be free of damage Press bearings and spacer out of housing if necessary NOTE If seals are removed note orientation of seal lips for installation purposes 8 Inspect seals Seals must be free of rips and tears Replace seals if necessary Workman e2050 e2065 Page 5 9 Assembly Fig 2 IMPORTANT Always replace ball bearings as a set 1 If ball bearings were removed A Press new bearing into housing from the inside first B Turn housing over Insert spacer and press new bearing into housing 2 If seals items and 18 were removed press new seals into housing Install seals with seal lips up 3 Place flat washer onto shaft of the Pitman arm Insert shaft into steering housing IMPORTANT The position of the Pitman arm and sector gear is critical during assembly If either or both of these parts is replaced make sure their alignment matches the alignment of the original gear and Pitman arm 4 Position sector gear onto the spline of the Pitman arm shaft while aligning marks IMPORTANT Make sure sector gear is centered to the pinion gear 5 Insert pinion gear int
107. ower machine to ground Remove chocks from wheels Figure 4 1 Wheel hub 4 Spacer 2 Bearing 5 Wheel stud 3 Retaining ring Chassis Rev B Lower Steering Workman 2050 P 17 201025 ft lb 27 to 34 N m Antiseize Lubricant 135 to 165 ft lb 183 to 224 N m 20 to 25 ft lb 27 to 34 N m Loctite 242 N 00 75 to 100 ft lb 102 to 136 d Figure 5 1 Pitman arm 9 Dustcap 17 Slotted hex nut 2 used per tie rod 2 Grease fitting 10 Lock nut 18 Cotter pin 2 used per tie rod 3 Cap screw king pin 11 A arm LH 19 Ball joint RH thread 4 Spindle LH 12 A arm RH 20 Jam nut RH thread 5 Front wheel assembly 13 Thrust washer 21 Tie rod 6 Flat washer 14 Bushing 22 Jam nut LH thread 7 Large flat washer 15 Kingpin sleeve 23 Ball joint LH thread 8 screw 16 Spindle RH 24 Grease fitting NOTE Both tie rod assemblies consist of two ball joints items 19 and 23 with jam nuts two slotted hex nuts item 17 two cotter pins item 18 and tie rod item 21 Chassis Rev B Page 5 12 Workman e2050 e2065 Removal Fig 5 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from the on off Switch Before j
108. r ing the pivot yoke to the rear frame Fig 10 6 Remove cap screw and hardened washer securing the pivot yoke to the front frame tab Support pivot yoke while removing it from the front frame to prevent dropping and causing serious injury and damage to the machine 7 Remove four flange head screws and flanged lock nuts securing the pivot yoke to the front frame Remove pivot yoke from the machine Pivot Yoke Installation Fig 7 Support pivot yoke while installing it to the front frame to prevent dropping and causing serious injury and damage to the machine 1 Position pivot yoke to the front frame so the diamond pattern faces up Fig 10 Secure yoke to front frame with four flange head screws and flanged lock nuts Tighten lower two fasteners first then tighten upper two fasteners Chassis Rev B Page 5 18 2 Secure pivot yoke to the front frame tab with cap screw and hardened washer Torque cap screw from 240 to 290 ft lb 325 to 393 3 Secure pivot yoke to the rear frame with four cap screws and flat washers 4 Install seat base to the front frame see Seat Base Installation in this section 5 Install cargo bed to the rear frame see Cargo Bed Installation in this section 6 Reconnect removed battery cable to battery termi nals Install lock washer and nut on battery terminals Torque nuts from 115 to 125 inb 13 to 14 1 1 Pivot yoke 4 2 Cap screw amp flat washe
109. r 5 Front frame 6 Flange lock nut 3 Rear frame Diamond pattern Workman e2050 e2065 This page is intentionally blank Workman e2050 e2065 Page 5 19 Chassis Rev B Seat Base ONO ONE ON Seat Seat bracket Rubber receptacle Rivet Cap screw 4 used per seat Screw Holding post Seat base Chassis Rev B Figure 11 Seat base tray Flange head screw 8 used Flat washer 4 used Front frame Screw 4 used Floor mat Charger receptacle plate Page 5 20 Charger receptacle Switch plate Charger interlock switch Pop rivet 2 used Lock nut 2 used Charger wire harness Socket head screw 2 used Workman 2050 2065 Removal Fig 11 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from the on off switch 2 Open the battery circuit by carefully removing one of the battery cables see Opening Battery Circuit in the General Information section of Chapter 3 Electrical System 3 Remove seats from seat base 4 Remove four 4 screws item 12 that secure recep tacle plate to front of seat base Unplug charger wire har ness from vehicle wire harness and remove receptacle plate assembly from vehicle 5 On Workman e2065 remove parking brake assem bly from seat base Fig 13 see Parking Brake Work man e2065 in the Service and Repairs section of Chapter 4 Transaxle and Brakes 6
110. r types of battery load testers can also be used to test the Workman batteries Many locally available bat tery load testers do not however have any adjustment on the load that is put on the battery Results received from using load testers should follow the recommenda tions of the load tester manufacturer 2 If the Lester Battery Discharge Unit or other load tester is not available an alternate battery test can be done using a multimeter to perform a voltage test of each battery Use the following procedure A For accurate voltage testing allow batteries to re main idle no charging no discharging for at least 6 hours and preferably 24 hours B Open the battery circuit by carefully removing one of the battery cables see Opening Battery Cir cuit in the General Information section of this chap ter Then disconnect both cables from battery to be tested C Measure the battery voltage with the multimeter Record battery voltage The measured voltage will determine battery state of charge D If voltage readings below 7096 charged see Fig 47 exist charge battery see Operator s Manual and take voltage measurements again If voltage re mains low after charging consider battery replace ment 3 A third option for battery testing is to perform a specif ic gravity test of the battery electrolyte using a hydrome ter Use the following procedure IMPORTANT Make sure the area around the battery fill caps is clean
111. re A1 post Terminal F1 Cable to traction motor field F1 post Terminal F2 Cable to traction motor field F2 post Figure 41 When installing cables to controller torque screws at 1 Controller 3 Wire harness connector terminals B M1 and M2 from 85 to 90 in b 9 6 to 2 Controller LED 10 2 and torque screws at terminals F1 and F2 from 55 to 60 inh 6 2 to 6 8 Fig 42 Apply Toro battery terminal protector see Special Tools to control ler connections after tightening terminal screws If wire harness connector is removed from controller both harness connector and controller socket should be filled with dielectric gel to prevent corrosion of connec tion terminals and potential controller damage Apply gel fully to both harness connector and controller sock et plug harness connector into controller to distribute gel unplug harness connector reapply gel to both sur faces and plug harness connector into controller 85 90 in Ib 9 6 to 10 2 A LED exists on the controller to identify normal opera tion or faults that will prevent the vehicle from operating N correctly The vehicle status light on the dash panel dis 55 to 60 in Ib plays the same information as the LED on the controller 6 2 to 6 8 N m See chart below for light pattern fault codes identified by Figure 42 the controller LED and vehicle status light Light Pattern Cause Necessary Action flashing Always o
112. rse position The alarm is lo cated under the controller cover beneath the bed Testing IMPORTANT Make sure to observe polarity on the alarm terminals when testing Damage to the alarm may result from an improper connection NOTE The audio alarm is a 12 volt DC component Do not test the alarm using jumper wires from the vehicle battery pack 48 VDC 1 Make sure on off switch is turned OFF Remove key from switch Raise bed and remove controller cover 2 Disconnect wire harness connectors from alarm Fig 28 Using jumper wires correctly connect 12VDC source to the alarm terminals noting polarity shown on alarm decal Electrical System Rev B Page 3 18 Figure 27 3 Alarm should sound Remove voltage source from the alarm Reconnect alarm to the circuit or replace alarm if needed 2 Audio alarm 1 Controller Workman e2050 e2065 Charger Interlock Switch The charger interlock switch is located behind the char ger receptacle plate on the front of the seat base Fig 29 When the battery charger is plugged into the char ger receptacle the interlock switch closes and provides an input to the vehicle controller to inhibit vehicle opera tion NOTE The vehicle should not operate if the char ger plug is connected to the charger receptacle 1 Make sure vehicle On Off switch is OFF Remove key from switch 2 Remove receptacle plate
113. s 2 Brake lever stop 5 Brake equalizer 3 Clevis pin cotter pin Transaxle and Brakes Rev B Page 4 6 Workman e2050 e2065 Workman 2050 2065 This page is intentionally blank 4 7 Transaxle and Brakes Rev 6 o 5 8 55 c n gt Service and Repairs Rear Wheels and Brakes 45 to 65 ft Ib 61 to 88 15 to 19 ft lb 20 to 26 N m Figure 3 Lug nut 5 used per wheel Wheel assembly Brake drum Axle shaft Wheel stud 5 used per wheel Cotter pin SUP ONS Removal Fig 3 1 Park vehicle on a level surface turn on off switch OFF and remove key from the on off switch Before jacking up the vehicle review and follow Jacking Instructions in Operator s Manual and Chapter 1 Safety 2 Chock wheels not being jacked up Lift rear wheel off the ground using a jack and place jack stand or blocks beneath the rear frame to support vehicle NOTE To remove brake drum it may be necessary to loosen brake cable adjustment or remove brake cable from brake actuator lever 3 Remove five 5 lug nuts wheel assembly and brake drum from the wheel hub Transaxle and Brakes Rev B Flange head screw 4 used per brake Brake assembly RH shown Nut 4 used per brake Page 4 8 10 Clevis pin 11 Brake cable RH shown 12 Retaining ring 13 Transaxle 4 Remove the axle shaft from the transaxle see the Spicer Off Highway Components
114. s Install and tighten set screws to secure col lar to accelerator pedal shaft C Recheck potentiometer lever movement 6 Calibrate accelerator system after any accelerator potentiometer adjustment see Accelerator System Cal ibration in this section Electrical System Rev B Page 3 12 Figure 13 1 Potentiometer 2 Accelerator pedal 3 Throttle position collar 4 Roll pin 5 Setscrew 2 used Figure 14 1 Potentiometer lever accelerator pedal released 2 Potentiometer lower stop 3 Gap of 0 050 to 0 100 1 3 to 2 5 mm Figure 15 1 Potentiometer lever accelerator pedal fully depressed 2 Potentiometer upper stop 3 Nolever contact with stop Workman e2050 e2065 Accelerator System Calibration The accelerator system on the Workman e2050 and e2065 includes the accelerator pedal assembly the ac celerator potentiometer the accelerator switch and the controller If any of these components are adjusted re moved or replaced the following calibration procedure should be performed Additionally if vehicle movement is erratic and jerky or if the diagnostic light on the dash is flashing six 6 times calibration of the accelerator system should be performed 1 Position vehicle on a level surface turn On Off switch OFF and remove key Raise bed and secure with prop rod Remove controller cover 2 Check accelerator switch adjustment and adjust if necessary see Accelerator Switch Adjustment
115. s is clean before opening the caps IMPORTANT Do not add acid to the battery Use only distilled water to adjust the electrolyte level 6 Check the electrolyte level in each cell If the level is below the tops of the plates in any cell add just enough distilled water to the cell to cover the plates Replace filler caps and charge the battery see Operator s Manu al After charging check electrolyte level in all cells and add distilled water until the level is 1 8 3 mm below the bottom of the fill well Fig 46 1 8 inch 3 IN Figure 46 3 Electrolyte level 4 Battery terminal 1 Battery plates 2 Filler cap Workman e2050 e2065 Testing When testing batteries in the Workman 2050 and 2065 it is important to test all batteries Proper perfor mance of the vehicle depends on all batteries being in good condition Testing will determine if one or more of the batteries needs to be replaced 1 The preferred testing procedure is to use the Lester Electrical 36 48 Volt Battery Discharge Unit Model 17770 This instrument puts a known discharge load 56 25 Amps on the battery pack until the battery pack reaches 42 volts A timer incorporated into the discharg er measures the time needed to reach that voltage level Battery capacity and remaining life can be determined from the test results Refer to Discharge Unit Operating Instructions for further information Othe
116. t tie rod ball joint up through Pitman arm and secure with slotted hex nut E Insert tie rod ball joint down through the spindle Secure with slotted hex nut F Torque slotted hex nut s from 20 to 25 ftHb 27 to 34 N m to secure ball joint to spindle and Pitman arm if installed If necessary tighten nut to allow cotter pin to be inserted Install cotter pin to secure assembly 2 Install front wheel assembly A Place antiseize lubricant on spindle shaft B Slide wheel assembly onto spindle shaft with the valve stem facing out NOTE Apply Loctite 4242 or equivalent to the threads of the cap screw C Place large washer and then small washer onto the cap screw Thread cap screw with washers into the spindle shaft D Torque cap screw from 135 to 165 ft lb 183 to 224 3 Lower machine to ground Remove chocks from wheels 4 Align steering and toe in see Operator s Manual 5 Lubricate tie rod ball joints and king pin see Opera tor s Manual Chassis Rev B Front Wheels and Lower Steering Workman 2065 See text for Loctite 242 Enc 16 57 tightening 20 to 25 ft lb f procedure 27 to 34 N m RIGHT FRONT m 45 to 55 ft Ib _ 61 to 74 N m 34 35 m 23 28 45 to 55 ft lb gt E ru 61 to 74 27 25 a 45 to 65 ft Ib 24 9 20 to 25 ft lb md AT T ATS 61 to 88 27 to 34 N m 75 to 100 ft Ib 102 to 136 F
117. test procedure requires battery voltage General Run Problems NOTE Check vehicle status light on dash panel and controller LED for possible faults whenever diagnosing vehicle problems see Controller in the Component Testing section of this chapter Main contactor clicks but vehicle will not operate Nothing happens when on off switch is turned to ON Electrical System Rev B Page For effective troubleshooting and repairs there must be a good understanding of the electrical circuits and com ponents used on this vehicle see Electrical Schematic in Chapter 6 If the vehicle has any switches by passed they must be reconnected for proper vehicle operation troubleshoot ing and safety Possible Causes Battery charge is low Battery cables are loose corroded or damaged Cable connection s at controller is are loose or corroded Cable connection s at traction motor is are loose or corroded Traction motor is faulty Controller is faulty Battery charge is extremely low Battery cables are loose corroded or damaged Cable connection s at controller is are loose or corroded 10 ampere fuse F2 to the on off switch is loose or blown Fusible link FL2 is faulty Main fuse F1 is loose or blown The on off switch or circuit wiring is faulty Controller is faulty 3 8 Workman 2050 2065 General Run Problems Continued Traction motor stops during operation Vehicle runs slowly V
118. timeter can test electrical components and cir cuits for current resistance or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it NOTE Workman e2050 and e2065 vehicles use a 48 volt DC electrical system If multimeter is not of the auto range type make sure to properly set multimeter range before performing any voltage test Figure 3 5 p System Battery Terminal Protector Battery Terminal Protector Toro Part No 107 0392 is an aerosol spray that should be used on all battery and controller terminals to reduce corrosion problems Apply terminal protector after cable has been secured to termi nal Figure 4 Dielectric Gel Dielectric gel Toro Part No 107 0342 should be used to prevent corrosion of connection terminals To ensure complete coating of terminals liberally apply gel to both component and wire harness connector plug connector DOW CORNING 111 to component unplug connector reapply gel to both SILICONE COMPOUND surfaces and reconnect harness connector to compo NOTE MAY mme nent Connectors should be thoroughly packed with gel DE EYE CONTACT FLUSH IMMEDIATELY WITH
119. tinuity between switch terminals SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS Figure 22 ONT REVERSE Figure 23 Electrical System Rev B Page 3 16 Workman 2050 2065 Vehicle Status Light The vehicle status light is located on the control panel Fig 24 During normal operation the status light should be continuously illuminated A vehicle electrical problem will be identified by a flashing status light The vehicle status light and LED on the vehicle control ler should have the same condition off illuminated or flashing If the vehicle status light does not illuminate when the on off switch is turned ON check the LED on the vehicle controller to make sure it is illuminated If the controller LED is illuminated and the vehicle status light is not illuminated check the vehicle status light and cir cuit wiring See Controller in this section and your Operators Manual for information on a flashing vehicle status light 1 Vehicle status light Testing System T 2 1 Make sure on off switch is turned OFF Remove key from switch 2 Disconnect wire harness from vehicle status light NOTE The vehicle status light is a 12 volt DC compo nent Do not test the light using jumper wires from the vehicle battery pack 48 VDC 3 The terminals for the light are marked as shown in Figure 25 Correctly conn
120. to a normal level Electrical System Rev B Page 3 4 The vehicle controller is a sealed electronic logic device that uses inputs from several vehicle components to control motor speed and direction These inputs include several switches on off forward reverse accelerator supervisor charger a motor temperature sensor an accelerator pedal potentiometer and the vehicle contac tor solenoid The controller also provides regenerative braking to assist in slowing the vehicle The controller has fault detection capabilities to help identify system problems Battery current is available to the controller whenever the on off switch is ON which energizes the main contactor A high current fuse protects this high current circuit The Workman controller also provides a roll off warning in instances when the vehicle begins to move roll away after being stopped On an incline and with the on off switch in the ON position if the vehicle starts moving the alarm will sound warning the operator that the ve hicle is moving When the vehicle goes into this roll off mode regenerative braking will limit vehicle speed Vehicle accessories include headlights horn and op tional electrical equipment The accessories contactor solenoid on the vehicle provides battery current to these components when the on off switch is ON Fuses provide circuit protection for these accessories Workman e2050 e2065 Special Tools Multimeter The mul
121. trical System NOTE Label all electrical leads for reassembly pur poses IMPORTANT When removing cables from traction motor terminals A1 A2 F1 and F2 use a wrench to retain lower nut before loosening upper nut Fig 14 If terminal studs are allowed to turn during up per nut removal internal motor damage can occur 4 Disconnect cables from traction motor A While retaining lower nut remove upper nut and cable connector from motor terminals A1 A2 F1 and F2 B Unplug motor temperature sensor from vehicle wire harness C Position disconnected cables away from motor Before jacking up the vehicle review and follow Jacking Instructions in Operator s Manual and in Chapter 1 Safety 5 Jack up rear of vehicle enough to remove rear wheels A Chock the front and rear of both front tires to pre vent the vehicle from moving B Support both sides of the rear frame with jack stands positioned just in front of the axle tubes This will allow the transaxle to be removed from the rear of the vehicle 6 Remove rear wheels from vehicle 7 Remove cotter pins and clevis pins that secure brake cables to brake actuator levers Fig 15 Position brake cables away from transaxle assembly 8 Attach hoist or chain fall to the transaxle and motor assembly Make sure lifting device is attached so it can hold the full weight of the transaxle and motor Workman e2050 e2065 Page 4 23 9 Loosen and remov
122. urved washer 12 Cap screw Transaxle and Brakes Rev B Page 4 20 Workman e2050 e2065 Disassembly Fig 12 1 Park machine on a level surface stop engine and re move key from the ignition switch Chock wheels to pre vent the machine from moving 2 Disconnect both brake cables from rear of machine A Remove cotter pin and clevis pin that secures each brake cable end to brake lever B Remove retaining ring that secures each brake cable to frame C Remove screw and flange nut that secure each R clamp to rear frame 3 Note routing of brake cables for assembly purposes 4 Remove parking brake cover from seat base 5 Remove four 4 flange head screws that secure parking brake support to seat base 6 Carefully remove parking brake support and brake cables from machine Take care to not damage brake cables while removing them from seat base opening 7 Remove brake cables from parking brake support and cable equalizer bracket using Figure 12 as a guide Workman e2050 e2065 Page 4 21 Assembly Fig 12 1 Secure brake cables to parking brake support and cable equalizer bracket using Figure 12 as a guide 2 Route brake cables through seat base opening tak ing care to not damage cables Position parking brake support to seat base 3 Secure parking brake support to seat base with four 4 flange head screws 4 Position brake cables to rear brake assemblies using cable routing noted during disass
123. vehicle Installation Fig 14 1 Position hood to the vehicle NOTE Do not tighten fasteners securing the hood until all fasteners are in place 2 Install fasteners removed during hood removal A Two 2 flange head screws item 2 that fasten hood to the dash B Two 2 flange head screws item 2 and flange nuts item 4 that fasten hood to the top of each fend er C Flange head screw item 10 two flat washers item 9 and flange nut item 4 that fasten hood to each fender front D Two flange head screws item 11 that fasten cen ter lower hood to the front frame support 3 Tighten all fasteners securing the hood 4 Secure bumper to vehicle with two 2 cap screws item 8 and flat washers item 7 5 Connect wire harness connectors to headlight termi nals with screws 6 Reconnect removed battery cable to battery termi nals Install lock washer and nut on battery terminals Torque nuts from 115 to 125 13 to 14 1 gt Coo Figure 15 1 Negative cable to vehicle 2 Positive cable to vehicle Workman e2050 e2065 Page 5 23 Chassis Rev B Cargo Bed 35to55in lb 3 4 to 6 2 N m 12 13 35 to 55 in Ib 4 to 6 2 100 to 200 in Ib 11 3 to 22 6 N m Figure 16 1 Cargo bed 12 Screw 2 per bracket 23 Prop rod bracket 2 Striker plate 2 used 13 Spring 24 Flat w
124. w 8 used Brush 8 used High temperature sensor Page 3 38 11 Commutator end head 12 Bearing 13 Retaining ring 14 Brush spring 8 used 15 Brush box 5 Remove the retaining ring and press bearing from the commutator end head Discard the bearing When using compressed air for cleaning motor components follow all safety instructions in cluding wearing eye and respiratory protection 6 Carefully blow out any accumulated carbon dust and dirt from the commutator end head and the frame and field assembly using clean oil free compressed air Workman e2050 e2065 Brush Service 1 Check the brush springs for correct alignment on the back of the brush A brush spring that does not apply equal pressure on the center of the brush will cause the brush to wear unevenly Check for correct clearance and freedom of brush movement in the holder 2 Replace brushes that are worn to a length of 0 620 16 mm Also replace brushes if they show signs of un even wear or show signs of overheating such as discol ored brush shunts and brush springs 3 Brushes should always be replaced in complete sets of eight Use identical replacement parts do not substi tute brush grades as the brushes are matched to the motor type and application to provide the best service Substituting brushes of the wrong grade can cause pre mature commutator failure and excessive brush wear Remove old brushes and replace with identical replace
125. wheel by hand tighten the jam nut from 75 to 100 in Ib 8 5 to 11 3 to set the bearings Then loosen the nut until the hub has end play 5 While rotating the wheel by hand re tighten the jam nut from 15 to 20 in Ib 1 7 to 2 3 6 Position nut retainer over jam nut and install cotter pin through spindle shaft hole Install dust cap to hub 7 Install brake caliper to spindle see Front Brake Cali pers in the Service and Repairs section of Chapter 4 Transaxle and Brakes 8 Install wheel assembly with valve stem facing out Torque lug nuts from 45 to 65 ft lb 61 to 88 9 Lower machine to ground 10 Align steering and toe in see Operator s Manual 11 Lubricate tie rod ball joints and king pin Chassis Rev B and Frame Pivot Yoke 240 to 290 ft lb 325 to 393 N m 240 to 290 ft lb 325 to 393 N m Chassis Rev B Page 5 16 Figure 7 1 Ride height adjustment bolt 7 Lock washer 13 Pivot yoke 2 Bushing 8 Centering bolt 2 used per A arm 14 Rear frame 3 Grease fitting 9 Travel limiting bolt 15 Flat washer 4 used 4 A arm LH 10 A arm RH 16 Cap screw 4 used 5 Flange nut 11 Flange head screw 4 used 17 Hardened washer 6 Locknut 12 Flange nut 4 used Workman e2050 e2065 A arm Removal Fig 7 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from the on off switch Before jacking up the machine r
126. wrench to retain lower nut while loosening upper nut Fig 53 If ter minal studs are allowed to turn during upper nut re moval internal motor damage can occur Workman e2050 e2065 4 Disconnect wires from traction motor Fig 52 A While retaining lower nut remove upper nut and wire connector from motor terminals A1 A2 F1 and F2 B Unplug motor temperature sensor from vehicle wire harness Note location of cable tie that secures temperature sensor wires to vehicle C Position disconnected wires away from motor 5 Remove plastic plug from rear frame to allow access to socket head screw that retains fan to traction motor Remove screw and washer and then remove fan from motor To prevent motor damage and personal injury make sure that traction motor is well supported as it is removed Motor weighs approximately 62 pounds 28 1 kg 6 Support traction motor to prevent it from falling Two suggestions for traction motor support are as follows IMPORTANT Damage to traction motor field coils will result if eyebolt is threaded into motor housing to far A Remove silver flange head screw from top of mo tor and carefully install a 3 8 16 eyebolt into motor Fig 54 Thread eyebolt into motor approximately four 4 turns taking care to not bottom eyebolt into internal field coils Secure eyebolt with jam nut Use eyebolt for support and as a lifting point for motor re moval B Use lifting strap wrapped aroun

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