Toro e2065 manual

Part No. 04127S L (Rev . D) Service Manual W orkman R e2050 & e2065 Preface The pur pose of this public ation is to pr ovide t he service technic ian with inf orm ation f or t roubles hooting, test ing and repair of maj or syst ems and co mponents on the Workman e2050 and e2065. REFE R TO THE O PERA TOR’S MANUAL F OR OPE R- A TI NG , MAI NTE [...]

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Workman e2050/e2065 T able Of Contents Chapter 1 – Safety Safety Instructions 1 – 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Jacking and Other Instructions 1 – 4 . . . . . . . . . . . . . . . Safety and Instruction Decals 1 – 5 . . . . . . . . . . . . . . . . Chapter 2 – Product Records and Maintenance Product Records 2 – 1 .[...]

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Workman e2050/e2065 Page 1 – 1 Safety (Rev . B) Chapter 1 Safety T able of Contents SAFETY INSTRUCTIONS 2 . . . . . . . . . . . . . . . . . . . . . . Before Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service 3 . . . . . . . . . . . .[...]

Rev . D W orkman e2050/e2065 Page 1 - - 2 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- penden[...]

Workman e2050/e2065 Page 1 – 3 Safety (Rev . B) 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. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and screws tight. 3. Do not use ope[...]

Workman e2050/e2065 Page 1 – 4 Safety (Rev . B) Jacking and Other Instructions Jacking V ehicle DANGER POTENTIAL HAZARD • A vehicle that is not properly supported may become unstable. WHA T CAN HAPPEN • The vehicle may move or fall. Personal injury or damage to the machine may result. HOW TO A VOID THE HAZARD • Make sure vehicle is parked o[...]

Workman e2050/e2065 Page 1 – 5 Safety (Rev . B) Safety and Instruction Decals There are several safety and instruction decals attached to your W orkman 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 T oro Distributor . Safety[...]

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Workman e2050/e2065 Page 2 – 1 Product Records and Maintenance (Rev . B) Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . EQUIV ALENTS AND CONVERSIONS 2 . . . . . . . . . . . Decimal and Millimeter Equivalents 2 . . . . . . . . . . . . U.S. to Metric Conversions 2 . .[...]

0.09375 Workman e2050/e2065 Page 2 – 2 Product Records and Maintenance (Rev . B) Equivalents and Conversions[...]

Workman e2050/e2065 Page 2 – 3 Product Records and Maintenance (Rev . B) T orque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by T oro, either the recommended torque or a torque that is unique to the application is clearly identified and spe- cified in this Service [...]

Workman e2050/e2065 Page 2 – 4 Product Records and Maintenance (Rev . B) Standard T orque for Dry , Zinc Plated and Steel Fasteners (Inch Series) Thread Size Grade 1, 5, & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE Grade 5 Bolts, Screws, Studs & Sems[...]

Workman e2050/e2065 Page 2 – 5 Product Records and Maintenance (Rev . B) Standard T orque for Dry , Zinc Plated and Steel Fasteners (Metric Fasteners) Thread Size Class 8.8 Bolts, Screws and Studs with Regular Height Nuts Class 10.9 Bolts, Screws and Studs with Regular Height Nuts Thread Size Regular Height Nuts (Class 8 or Stronger Nuts) Regular[...]

Workman e2050/e2065 Page 2 – 6 Product Records and Maintenance (Rev . B) Other T orque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended T orque Thread Size Square Head Hex Socket 1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb 5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb 3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb 1/2 ?[...]

Workman e2050/e2065 Page 2 – 7 Product Records and Maintenance (Rev . B) Maintenance Maintenance procedures and recommended service in- tervals for the Workman e2050 and e2065 are covered in the Operator ’s Manual. Refer to that publication when performing regular vehicle maintenance. Product Records and Maintenance[...]

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Workman e2050/e2065 Page 3 – 1 Electrical System (Rev . B) Chapter 3 Electrical System T able of Contents ELECTRICAL DIAGRAMS 2 . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMA TION 3 . . . . . . . . . . . . . . . . . . . . . Opening Battery Circuit 3 . . . . . . . . . . . . . . . . . . . . . . VEHICLE OPERA TION 4 . . . . . . . . . . . [...]

Workman e2050/e2065 Page 3 – 2 Electrical System (Rev . B) Electrical Diagrams The electrical schematic, circuit drawings and wire har- ness drawings for the Workman e2050 and e2065 are located in Chapter 6 – Electrical Diagrams.[...]

Workman e2050/e2065 Page 3 – 3 Electrical System (Rev . B) General Information The W orkman 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 . I f a pro[...]

Workman e2050/e2065 Page 3 – 4 Electrical System (Rev . B) V ehicle Operation The Workman e2050 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 series provide [...]

Workman e2050/e2065 Page 3 – 5 Electrical System (Rev . B) Special T ools Multimeter The multimeter can test electrical components and cir- cuits for current, resistance or voltage. NOTE: T oro recommends the use of a DIGIT AL V olt– Ohm–Amp multimeter when testing electrical circuits. Th e high impedance (internal resistance) of a digital me[...]

Workman e2050/e2065 Page 3 – 6 Electrical System (Rev . B) Battery W atering 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[...]

Rev . D Workman e2050/e2065 Page 3 - - 7 Electrical System (Rev . B) 36/48 V olt Battery Discharge Unit The 36/48 V olt 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[...]

Workman e2050/e2065 Page 3 – 8 Electrical System (Rev . B) T roubleshooting CAUTION 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 test procedure requires battery voltage. For e ffective troubleshooti[...]

Workman e2050/e2065 Page 3 – 9 Electrical System (Rev . B) General Run Problems (Continued) Problem Possible Causes T raction motor stops during operation. 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 [...]

Workman e2050/e2065 Page 3 – 10 Electrical System (Rev . B) Battery Charger Problems Problem Possible Causes Battery charger does not turn on. AC outlet fuse/circuit breaker blown. AC outlet is faulty . V ehicle wiring is loose or damaged (see electrical schematic in Chapter 6 – Electrical Diagrams). Fusible link FL1 is damaged. V ehicle charge[...]

Workman e2050/e2065 Page 3 – 1 1 Electrical System (Rev . B) Adjustments Accelerator Switch Adjustment 1. Position vehicle on a level surface, turn On/Of f 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 ca[...]

Workman e2050/e2065 Page 3 – 12 Electrical System (Rev . B) Accelerator Potentiometer Adjustment The accelerator potentiometer is used as one of the in- puts for the vehicle controller and is attached t o the ped- al frame under the dash (Fig. 13). A collar with roll pin on the accelerator pedal shaft positions the accelerator po- tentiometer lev[...]

Rev . A Workman e2050/e2065 Page 3 – 13 Electrical System (Rev . B) 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 followi[...]

Workman e2050/e2065 Page 3 – 14 Electrical System (Rev . B) Component T esting 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). CAUTION When testi[...]

Workman e2050/e2065 Page 3 – 15 Electrical System (Rev . B) Battery Discharge Indicator and Hour Meter Gauge The combination battery discharge indicator and hour meter gauge is located on the dash panel (Fig. 19). Th e battery indicator identifies state of charge of the bat- tery pack. The battery indicator reads full (10 bars) when the battery p[...]

Workman e2050/e2065 Page 3 – 16 Electrical System (Rev . B) V ehicle 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 veh[...]

Workman e2050/e2065 Page 3 – 17 Electrical System (Rev . B) V ehicle 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 vehi[...]

Workman e2050/e2065 Page 3 – 18 Electrical System (Rev . B) Supervisor Speed Limit Switch (Workman e2050) 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[...]

Workman e2050/e2065 Page 3 – 19 Electrical System (Rev . B) 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 t[...]

Workman e2050/e2065 Page 3 – 20 Electrical System (Rev . B) Main and Accessories Contactors T wo 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[...]

Workman e2050/e2065 Page 3 – 21 Electrical System (Rev . B) 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. 1. Main contact[...]

Workman e2050/e2065 Page 3 – 22 Electrical System (Rev . B) Fuses There are three (3) fuses in the W orkman electrical sys- tem. T wo (2) of the fuses are located beneath the steering column (Fig. 35). These fuses supply power to the fol- lowing: Th e upper 10 ampere fuse (F2) supplies power to the on/off switch and switched circuits. Th e lower [...]

Workman e2050/e2065 Page 3 – 23 Electrical System (Rev . B) Fusible Links The wiring harness for the Workman includes three (3) fusible links for circuit protection (Fig. 37). T wo 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 [...]

Workman e2050/e2065 Page 3 – 24 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). The W orkman e2050 and e2065 use only one of the switch circuits (terminals 3 and 4). When the accelerator pedal is depressed, the switch allows a closed[...]

Workman e2050/e2065 Page 3 – 25 Electrical System (Rev . B) 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 . Wh[...]

Workman e2050/e2065 Page 3 – 26 Electrical System (Rev . B) Controller Th e W orkman 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 p[...]

Workman e2050/e2065 Page 3 – 27 Electrical System (Rev . B) 1 Flash System inoperable. T urn 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 depressed when on/off switch was turned ON. T urn on/off switch OFF [...]

Rev . D Workman e2050/e2065 Page 3 - - 28 Electrical System (Rev . B) Service and Repairs Battery Service 1. Battery (8 used) 2. Battery rod (2 used) 3. Negative cable to vehicle 4. Lock washer (2 used per battery) 5. Hex nut (2 used per battery) 6. Cable terminal boot 7. Battery cable (6 used) 8. Positive cable to vehicle 9. Cable terminal boot 10[...]

Workman e2050/e2065 Page 3 – 29 Electrical System (Rev . B) Removal (Fig. 43) W ARNING POTENTIAL HAZARD: The battery terminals, metal tools and metal ve- hicle parts could short together . WHA T CAN HAPPEN: Sparks can cause the battery gasses to explode. Damaged cables could short against metal ve- hicle parts and cause sparks. HOW TO A VOID THE [...]

Workman e2050/e2065 Page 3 – 30 Electrical System (Rev . B) 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 ([...]

Workman e2050/e2065 Page 3 – 31 Electrical System (Rev . B) T esting When testing batteries in the Workman e2050 and e2065, it i s important to test all batteries. Proper perfor- mance of the vehicle depends on all batteries being in good condition. T esting will determine if one (or more) of the batteries needs to be replaced. 1. The preferred t[...]

Workman e2050/e2065 Page 3 – 32 Electrical System (Rev . B) 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 da[...]

Workman e2050/e2065 Page 3 – 33 Electrical System (Rev . B) T raction Motor Brushes The traction motor in the Workman e2050/e2065 uses eight (8) brushes. T raction motor brushes should be in- spected every 500 hours of operation or annually . Inspection 1. Make sure that on/of f switch is OFF . Raise and latch bed to allow access to traction moto[...]

Workman e2050/e2065 Page 3 – 34 Electrical System (Rev . B) T raction Motor 1. Socket head screw (6 used) 2. Flat washer (6 used) 3. Flange nut 4. Support bracket 5. Carriage screw 6. T ransaxle mount plate 7. Rubber damper 8. T raction motor 9. Fan 10. Roll pin (2 used) 1 1. Washer 12. Socket head screw 13. Plastic cap (fits in rear frame) 14. C[...]

Workman e2050/e2065 Page 3 – 35 Electrical System (Rev . B) 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 v[...]

Workman e2050/e2065 Page 3 – 36 Electrical System (Rev . B) 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. CAUTION T o prevent motor damage and personal injury , make sure that traction motor is well sup- ported as it is installed. Motor weighs approxi- [...]

Workman e2050/e2065 Page 3 – 37 Electrical System (Rev . B) This page is intentionally blank. Electrical System[...]

Workman e2050/e2065 Page 3 – 38 Electrical System (Rev . B) T raction Motor Service 1. Frame and field assembly 2. Armature 3. Brush lead (2 used) 4. Cap screw (2 used per brush lead) 5. Cap screw (4 used) 6. Cap screw (8 used) 7. Brush (8 used) 8. High temperature sensor 9. Headband 10. Bolt (4 used) 1 1. Commutator end head 12. Bearing 13. Reta[...]

Workman e2050/e2065 Page 3 – 39 Electrical System (Rev . B) 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. Repla[...]

Workman e2050/e2065 Page 3 – 40 Electrical System (Rev . B) 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. T otal in[...]

Workman e2050/e2065 Page 3 – 41 Electrical System (Rev . B) 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- in g may appear and feel good, the bearing could be ”bri- nelled[...]

Workman e2050/e2065 Page 3 – 42 Electrical System (Rev . B) Battery Charger 1. Upper case 2. T ransformer 3. Lower case 4. SCR assembly 5. Control board 6. Relay 7. Circuit breaker 8. AC cordset 9. DC cordset 10. Ammeter 1 1. Fuse 12. Diode assembly Figure 65 3 4 5 8 6 7 9 1 2 10 11 12 Fo r service of the battery charger , see the Lester Electri-[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 1 Chapter 4 T ransaxle and Brakes T able of Contents SPECIFICA TIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 4 . . . . . . . . . . . . . . . . . . . . . . . . . Brakes 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMEN[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 2 This page is intentionally blank.[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 3 Specifications Item Description T ransaxle T ransaxle Fluid Capacity 2 quarts (1.9 liters) T ransaxle Fluid 10W–30 Motor Oil T ransaxle and Brakes[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 4 T roubleshooting Brakes Problem Possible Cause Brake pedal goes to the floor . 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 lev[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 5 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 [...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 6 Adjustments Adjust Brakes (Workman e2050) Th e 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) 1. Park vehicle on a level surface, turn on/of f switc[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 7 This page is intentionally blank. T ransaxle and Brakes[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 8 Service and Repairs Rear Wheels and Brakes Figure 3 1. Lug nut (5 used per wheel) 2. Wheel assembly 3. Brake drum 4. Axle shaft 5. Wheel stud (5 used per wheel) 6. Flange head screw (4 used per brake) 7. Brake assembly (RH shown) 8. Nut (4 used per brake) 9. Cotter pin 10. Clevis pin [...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 9 Installation (Fig. 3) IMPORT ANT : On W orkman 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 p[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 1 0 (Rev. C) Brake Service (Workman e2050) Figure 5 1. Backing plate 2. Hold down pin 3. Bottom shoe–to–shoe spring 4. T op shoe–to–shoe spring 5. Auto adjust spring 6. Shoe cup (spring loaded) 7. Brake shoe 8. Actuator lever 9. Adjusting screw 10. PTFE coated washer 1 1. Push r[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 1 1 (Rev. C) 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. IMPORT ANT : B[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 12 Rear Brake Service (Workman e2065) 1. Brake backing plate 2. W asher head screw 3. Brake shoe 4. Lower spring 5. Wheel cylinder 6. Parking brake lever (LH shown) 7. Belleville washer 8. Adjuster lever 9. Dust cover 10. Flat washer 1 1. Bolt 12. Shoe hold down cup and spring 13. Upper[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 13 Inspection (Fig. 6) 1. Inspect brake drums. IMPORT ANT : 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[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 14 Hydraulic Brake System (Workman e2065) 1. Brake caliper (LH) 2. Brake caliper (RH) 3. Brake rotor (2 used) 4. Front brake tube 5. Front brake hose 6. Carriage screw 7. Rear brake tube 8. Carriage screw 9. Rear brake hose bracket 10. Cap screw 1 1. Thread forming screw (6 used) 12. Cl[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 15 Bleed Brake System (Workman e2065) 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 f[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 16 Front Brake Calipers (Workman e2065) 1. LH brake caliper 2. RH brake caliper 3. Lock washer (2 per caliper used) 4. Cap screw (2 per caliper used) 5. Wheel hub assembly 6. Brake rotor 7. Socket head screw (4 per rotor used) 8. Spindle (LH shown) 9. A–arm (LH shown) 10. Brake master[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 17 Removal (Fig. 8) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. W ARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety . 2. Chock whee ls not being jacked up. Jack front wheel[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 18 Brake Master Cylinder (Workman e2065) 1. Master cylinder 2. Cap screw 3. Brake pedal 4. Clevis pin 5. Cotter pin 6. Flange head nut 7. Pedal frame Figure 10 7 3 5 6 2 1 4 FRONT RIGHT Removal (Fig. 10) 1. Remove front hood from machine. 2. Remove cotter pin from the clevis pin that co[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 19 Brake Master Cylinder Service (Workman e2065) Disassembly (Fig. 1 1) 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 p[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 20 Parking Brake (Workman e2065) 1. Parking brake cover 2. Operator seat 3. Seat base 4. Cable equalizer bracket 5. Parking brake lever 6. Curved washer 7. Lock nut 8. Flat washer 9. Flange head screw (4 used) 10. Flat washer (2 used) 1 1. Screw (2 used) 12. Cap screw 13. Cotter pin 14.[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 21 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 [...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 22 T ransaxle 1. Socket head screw (6 used) 2. Flange nut 3. Carriage screw (5 used) 4. Support bracket 5. T ransaxle mount plate 6. Rubber damper 7. T raction motor 8. Fan 9. Roll pin (2 used) 10. W asher 1 1. Socket head screw 12. Lug nut (5 used per wheel) 13. Wheel assembly 14. Brak[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 23 Removal (Fig. 13) 1. Park vehicle on a level surface, turn on/of f 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 [...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 24 Installation (Fig. 13) 1. If removed, install traction motor to transaxle (see T raction 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 t[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 25 This page is intentionally blank. T ransaxle and Brakes[...]

Workman e2050/e2065 T ransaxle and Brakes (Rev . B) Page 4 – 26 T ransaxle Service 1. Oil seal 2. Wheel stud (5 used per side) 3. Axle shaft 4. Ball bearing 5. Input shaft 6. Ball bearing 7. O–ring 8. Retaining ring 9. Endcap plug 10. Ball bearing 1 1. Vent elbow 12. T ransaxle housing 13. Bearing 14. Cap screw (4 used) 15. Bearing cap 16. Bear[...]

Workman e2050/e2065 Page 5 – 1 Chassis (Rev . B) Chapter 5 Chassis T able of Contents SPECIFICA TIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 3 . . . . . . . . . . . . . . . . . . . . . . . . . Suspension and Steering 3 . . . . . . . . . . . . . . . . . . . . SER VICE AND REP AIRS 5 . . . . . . . . . . . . . . . [...]

Workman e2050/e2065 Page 5 – 2 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 N–m) Wheel lug nut torque (front and r[...]

Workman e2050/e2065 Page 5 – 3 Chassis (Rev . B) T roubleshooting 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. T ransaxle problem (see Cha[...]

Workman e2050/e2065 Page 5 – 4 Chassis (Rev . B) Suspension and Steering (continued) Problem Possible Cause Steering is hard. T ire 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. V ehicle pulls to one side when not braking. T ire pre[...]

Workman e2050/e2065 Page 5 – 5 Chassis (Rev . B) Service and Repairs Check Tire Pressure The tire pressure range for front and rear tires is 8 to 22 PS I (0.55 to 1.52 bar). The tire pressure needed is deter- mined by the payload carried. The lower the air pressure, the less the compaction and tire marks are minimized. Lower pressure should not b[...]

Workman e2050/e2065 Page 5 – 6 Chassis (Rev . B) Upper Steering 1. Nut 2. Lock washer 3. Steering wheel 4. Flange lock nut 5. Steering gearbox 6. Cap screw 7. Lock washer 8. Steering shaft 9. Cap screw (3 used) 10. Upper steering bushing 1 1. Carriage bolt (4 used) 12. Steering column 13. Dust cover 14. Collar 15. Pitman arm 16. Steering wheel co[...]

Workman e2050/e2065 Page 5 – 7 Chassis (Rev . B) Removal (Fig. 1) 1. Park vehicle on a level surface, turn on/of f switch OF F , 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 S[...]

Workman e2050/e2065 Page 5 – 8 Chassis (Rev . B) Steering Gearbox 1. Gasket 2. Hex washer head screw (4 used) 3. Seal 4. Sector gear 5. Flat washer 6. Ball bearing 7. Output shaft spacer 8. Stepped washer 9. Flange head screw with patch lock 10. Ball bearing 1 1. Input shaft spacer 12. Flat washer 13. Cap screw 14. Grease fitting 15. Steering hou[...]

Workman e2050/e2065 Page 5 – 9 Chassis (Rev . B) Disassembly (Fig. 2) IMPORT ANT : 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) [...]

Workman e2050/e2065 Page 5 – 10 Chassis (Rev . B) Front Wheels (Workman e2050) 1. Spindle (LH shown) 2. Bearing (with retaining ring) 3. Wheel stud (5 per wheel) 4. Wheel hub 5. Spacer 6. Tire/wheel assembly 7. Lug nut (5 per wheel) 8. Flat washer 9. Large flat washer 10. Cap screw 1 1. Dust cap Figure 3 7 4 3 2 2 1 6 5 8 9 10 11 FRONT RIGHT Anti[...]

Workman e2050/e2065 Page 5 – 1 1 Chassis (Rev . B) Removal (Fig. 3) 1. Park vehicle on a level surface, turn on/of f switch OFF , set parking brake and remove key from the on/off switch. W ARNING Before jacking up the machine, review and follow Jacking Instructions in Operator ’ s Manual and Chapter 1 – Safety . 2. Chock whee ls not being jac[...]

Workman e2050/e2065 Page 5 – 12 Chassis (Rev . B) Lower Steering (Workman e2050) 1. Pitman arm 2. Grease fitting 3. Cap screw (king pin) 4. Spindle (LH) 5. Front wheel assembly 6. Flat washer 7. Large flat washer 8. Cap screw 9. Dust cap 10. Lock nut 1 1. A–arm (LH) 12. A–arm (RH) 13. Thrust washer 14. Bushing 15. Kingpin sleeve 16. Spindle ([...]

Workman e2050/e2065 Page 5 – 13 Chassis (Rev . B) Removal (Fig. 5) 1. Park vehicle on a level surface, turn on/of f switch OFF , set parking brake and remove key from the on/off switch. W ARNING Before jacking up the machine, review and follow Jacking Instructions in Operator ’ s Manual and Chapter 1 – Safety . 2. Chock whee ls not being jack[...]

Workman e2050/e2065 Page 5 – 14 Chassis (Rev . B) Front Wheels and Lower Steering (Workman e2065) 1. Wheel assembly 2. Lug nut (5 used per wheel) 3. Dust cap 4. Cotter pin 5. Nut retainer 6. Jam nut 7. T ab washer 8. Bearing cone 9. Bearing cup 10. Wheel hub 1 1. Wheel stud (5 used per hub) 12. Bearing cup 13. Bearing cone 14. Seal 15. Brake roto[...]

Workman e2050/e2065 Page 5 – 15 Chassis (Rev . B) 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 section of Chapter 4 – T ransaxle and Brakes). Position caliper away from wheel hub and spindle. 5. Carefully pry dust cap from wheel hub. 6. Remov[...]

Workman e2050/e2065 Page 5 – 16 Chassis (Rev . B) A–arm and Frame Pivot Y oke 1. Ride height adjustment bolt 2. Bushing 3. Grease fitting 4. A–arm (LH) 5. Flange nut 6. Lock nut 7. Lock washer 8. Centering bolt (2 used per A–arm) 9. T ravel limiting bolt 10. A–arm (RH) 1 1. Flange head screw (4 used) 12. Flange nut (4 used) 13. Pivot yoke[...]

Workman e2050/e2065 Page 5 – 17 Chassis (Rev . B) A–arm Removal (Fig. 7) 1. Park vehicle on a level surface, turn on/of f switch OFF , set parking brake and remove key from the on/off switch. W ARNING Before jacking up the machine, review and follow Jacking Instructions in Operator ’ s Manual and Chapter 1 – Safety . 2. Chock whee ls not be[...]

Workman e2050/e2065 Page 5 – 18 Chassis (Rev . B) Pivot Y oke Removal (Fig. 7) 1. Park vehicle on a level surface, turn on/of f 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[...]

Workman e2050/e2065 Page 5 – 19 Chassis (Rev . B) This page is intentionally blank. Chassis[...]

Workman e2050/e2065 Page 5 – 20 Chassis (Rev . B) Seat Base 1. Seat 2. Seat bracket 3. Rubber receptacle 4. Rivet 5. Cap screw (4 used per seat) 6. Screw 7. Holding post 8. Seat base 9. Seat base tray 10. Flange head screw (8 used) 1 1. Flat washer (4 used) 12. Front frame 13. Screw (4 used) 14. Floor mat 15. Charger receptacle plate 16. Charger [...]

Workman e2050/e2065 Page 5 – 21 Chassis (Rev . B) Removal (Fig. 1 1) 1. Park vehicle on a level surface, turn on/of f 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 – Ele[...]

Workman e2050/e2065 Page 5 – 22 Chassis (Rev . B) Front Hood 1. Hood 2. Flange head screw (6 used) 3. Dash 4. Flange nut (6 used) 5. Fender (LH shown) 6. Bumper 7. Flat washer (2 used) 8. Cap screw (2 used) 9. Flat washer (4 used) 10. Flange head screw (2 used) 1 1. Flange head screw (2 used) 12. Headlight mount (2 used) 13. Headlight (2 used) Fi[...]

Workman e2050/e2065 Page 5 – 23 Chassis (Rev . B) Removal (Fig. 14) 1. Park vehicle on a level surface, turn on/of f 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 – Elec[...]

Workman e2050/e2065 Page 5 – 24 Chassis (Rev . B) Cargo Bed 1. Cargo bed 2. Striker plate (2 used) 3. Screw (3 per striker plate) 4. T ailgate channel 5. RH latch rod 6. RH latch bracket 7. Grip knob 8. T ailgate 9. LH latch rod 10. Screw (2 per bracket) 1 1. LH latch bracket 12. Screw (2 per bracket) 13. Spring 14. Flat washer 15. Flange head sc[...]

Rev . B Workman e2050 Electrical Diagrams Page 6 – 1 Chapter 6 Electrical Diagrams T able of Contents ELECTRICAL SCHEMA TIC Electrical Schematic 3 . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL CIRCUIT DRA WINGS On/Off Switch T urned On 4 . . . . . . . . . . . . . . . . . . . . Run Circuit (Forward) 5 . . . . . . . . . . . . . . . .[...]

Workman e2050 Electrical Diagrams Page 6 – 2 This page is intentionally blank.[...]

Rev . B Page 6 – 3 Electrical Schematic W orkman e2050/e2065 Contactors shown de–energized RUN 15 14 M1 M2 FL3 BU B BK BK BK 4 Y W 16 13 12 45 F2 F1 FL1 FL2 F1 FRONT HORN SWITCH W HORN SWITCH HOOK UP R (PEDAL NOT PUSHED IN) (+) 4 HR ENABLE 3 SETUP + 2 SENSE A 1 CW 7 FET OUT 8 (–) 6 IGN + 5 SENSE B T VIO/BK Y PK OR NC NC NC OR R/W OFF 1 1 PROG[...]

Rev . B Page 6 – 4 RUN 15 14 M1 M2 FL3 BU B BK BK BK 4 Y W 16 13 12 45 F2 F1 FL1 FL2 F1 FRONT HORN SWITCH W HORN SWITCH HOOK UP R (PEDAL NOT PUSHED IN) CW T VIO/BK Y PK OR NC NC NC OR R/W OFF 1 1 PROGRAMMING 9 DIAGNOSTIC LIGHT 8 MAIN CONT ACTOR 5 CHARGER 2 FOR/REV F3 10 A SEVCON B+ 10 GA R A1 ARMA TURE MAIN 48V BA TT ARRA Y A OPTIONS LIGHT SWITCH[...]

Rev . B Page 6 – 5 RUN 15 14 M1 M2 FL3 BU B BK BK BK 4 Y W 16 13 12 45 F2 F1 FL1 FL2 F1 FRONT HORN SWITCH W HORN SWITCH HOOK UP R (PEDAL PUSHED IN) CW T VIO/BK Y PK OR NC NC NC OR R/W OFF 1 1 PROGRAMMING 9 DIAGNOSTIC LIGHT 8 MAIN CONT ACTOR 5 CHARGER 2 FOR/REV F3 10 A SEVCON B+ 10 GA R A1 ARMA TURE MAIN 48V BA TT ARRA Y A OPTIONS LIGHT SWITCH OR [...]

Rev . B Page 6 – 6 RUN 15 14 M1 M2 FL3 BU B BK BK BK 4 Y W 16 13 12 45 F2 F1 FL1 FL2 F1 FRONT HORN SWITCH W HORN SWITCH HOOK UP R (PEDAL NOT PUSHED IN) CW T VIO/BK Y PK OR NC NC NC OR R/W OFF 1 1 PROGRAMMING 9 DIAGNOSTIC LIGHT 8 MAIN CONT ACTOR 5 CHARGER 2 FOR/REV F3 10 A SEVCON B+ 10 GA R A1 ARMA TURE MAIN 48V BA TT ARRA Y A OPTIONS LIGHT SWITCH[...]

Page 6 – 7 Electrical Harness Drawing W orkman e2050[...]

Page 6 – 8 Electrical Harness W orkman e2050 Wiring Diagram ORANGE RED/WHITE WHITE PINK RED BLACK ORANGE BLUE ORANGE ORANGE BROWN BLACK BLACK BLACK BLACK BLACK GREEN BLACK TA N TA N BLACK BLUE BLUE BLUE ORANGE BLUE ORANGE BLACK ORANGE GREEN FUSIBLE LINK BLACK BLACK YELLOW BLUE BLACK BLACK YELLOW/BLACK BLACK BLACK RED/BLACK TA N RED/WHITE GRA Y BR[...]

Rev . B Page 6 – 9 Electrical Harness Drawing W orkman e2065[...]

Rev . B Page 6 – 10 Electrical Harness W orkman e2065 Wiring Diagram ORANGE RED/WHITE PINK ORANGE BLUE ORANGE ORANGE BLACK BLACK BLACK BROWN BLACK BLUE RED/WHITE PINK BLUE/WHITE YELLOW BLUE YELLOW RED RED RED VIOLET/BLACK BLUE/WHITE ORANGE WHITE/BLACK BLUE/WHITE WHITE FUSIBLE LINK FUSIBLE LINK WHITE RED YELLOW/BLACK BLACK BLACK RED/BLACK TA N RED[...]