Form No.
Revision History Revision Date -- 2016 A 02/2018 Added revision history. B 10/2020 Added Electrical-Lithium chapter, updated chassis and electrical drawings. © THE TORO COMPANY 2020 Description Initial Issue This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content.
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
Part Number 16228SL (Rev. B) Service Manual WorkmanR GTX Electric & Lithium 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 GTX Electric vehicle. REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’s Manual and Parts Catalog for your machine into Chapter 2 of this service manual.
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Chapter 2 -- Product Records and Maintenance Chapter 5 -- Chassis Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 -2 -2 -2 -- 1 1 2 3 Chapter 3A -- Electrical System General Information . . . . . . . . . . . . . . . . . . . . . . 3A -- 2 Vehicle Operation . . . . . . . . . . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Supervisor’s Responsibilities . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING AND OTHER INSTRUCTIONS . . . . . . . . Jacking Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Towing Vehicle . . . . . . .
Safety Instructions The Workman GTX Electric is designed and tested to offer safe service when operated and maintained properly. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training 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.
While Operating 3. Before getting off the operator seat: A. Stop vehicle, turn key switch to OFF and remove key from switch. 2. Before starting the vehicle: A. Make sure that the AC power supply cord (extension cord) is disconnected from the vehicle onboard charger receptacle. B. Apply the parking brake. 4. If vehicle is parked on incline, chock or block the wheels after getting off the vehicle. B. Engage the parking brake. C. Make sure accelerator pedal is not depressed. D.
Jacking and Other Instructions Jacking Vehicle DANGER POTENTIAL HAZARD • A vehicle that is not properly supported may become unstable. WHAT CAN HAPPEN • 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. • Make sure key switch is OFF and key is removed from the switch before getting off the vehicle.
Safety and Instruction Decals Workman GTX Electric Page 1 − 5 Safety 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.
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Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in 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 Service Manual.
Standard Torque 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) in−lb in−lb N−cm 10 + 2 13 + 2 147 + 23 # 6 − 32 UNC # 6 − 40 UNF # 8 − 32 UNC 13 + 2 25 + 5 # 10 − 24 UNC 30 + 5 SAE Grade 8 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in−lb N−cm in−lb N−cm 15 + 2 169 + 23 23 + 3 262 + 34
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in−lb 644 + 68 N−cm 78 + 8 in−lb 881 + 90 N−cm M6 X 1.0 96 + 10 in−lb 1085 + 113 N−cm 133 + 14 in−lb 1503 + 158 N−cm M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 28 + 3 ft−lb 38 + 4 N−m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Recommended Torque Recommended Torque** Thread Size Square Head Hex Socket 1/4 − 20 UNC 140 + 20 in−lb 73 + 12 in−lb 5/16 − 18 UNC 215 + 35 in−lb 145 + 20 in−lb 3/8 − 16 UNC 35 + 10 ft−lb 18 + 3 ft−lb 1/2 − 13 UNC 75 + 15 ft−lb 50 + 10 ft−lb 7/16 − 20 UNF Grade 5 65 + 10 ft−lb 88 + 14 N−m 1/2 − 20 UNF Grade 5 80 + 10 ft−lb 108 + 14 N−m M12 X 1.25 Class 8.
Chapter 3A Electrical System GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear Frame Panel Cover . . . . . . . . . . . . . . . . . . . . . 2 Opening Battery Circuit . . . . . . . . . . . . . . . . . . . . . . 3 VEHICLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information The Workman GTX Electric uses a 48 VDC electrical system that is an isolated circuit. The vehicle frame is not used for any ground connections. The vehicle controller monitors operator and vehicle inputs to determine voltage to the traction motor. If a problem exists that will prevent normal vehicle operation, an LED on the controller and the status indicator light on the dash panel will flash a fault code to assist in identifying the problem.
Opening Battery Circuit Battery pack cable routing is shown in Figure 2. Before working on the vehicle electrical system, remove battery conductors as follows (Fig. 2): 1. Park vehicle on a level surface, turn key switch to OFF, engage the parking brake and remove key from the key switch. Make sure that the vehicle battery charger is not connected to an electrical outlet. 3.
Vehicle Operation The Workman GTX Electric electrical system uses a 48 volt battery pack, an electric traction motor, a vehicle controller and numerous other electrical components to allow vehicle operation. Eight, 6 volt, advanced deep cycle batteries that are connected in series provide current for a 48V, brushless, high torque, AC inductive traction motor, the vehicle controller and vehicle accessories.
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The multimeter can test electrical components and circuits for current, resistance or voltage. NOTE: Workman GTX Electric 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.
Hand Pump Hose Assembly Use the hand pump hose assembly when adding distilled water to vehicle batteries through the single port fill system. The hand pump hose coupler attaches to the fill port coupler on the Workman vehicle. 30 inch Tube 30 inch Tube Toro Part Number: 131--8522 Coupler Hand Pump Figure 6 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.
36/48 Volt Battery Discharge Unit The 36/48 Volt Battery Discharge Unit is recommended for quick and accurate load testing for the batteries on a Workman GTX Electric vehicle. This tool is used to determine the capacity of the Workman battery pack and also for finding a faulty battery (or batteries) in the battery pack.
Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Before working on the vehicle electrical system, open the battery circuit by disconnecting the conductors between the battery pack and vehicle components (see Opening Battery Circuit in the General Information section of this chapter). Connect the battery circuit if a test procedure requires battery voltage.
General Run Problems (Continued) Problem Possible Causes Nothing happens when key switch is turned to ON. Battery charge is extremely low (check battery discharge indicator on dash). Battery cables are loose, corroded or damaged. Cable connection(s) at main contactor is/are loose or corroded. 10 ampere fuse to the key switch is loose or faulty. Cable connection(s) at controller is/are loose or corroded.
General Run Problems (Continued) Problem Possible Causes Vehicle runs slowly. The supervision speed limit switch is in the slow position. Tire pressure is low (see Check Tire Pressure in the Service and Repairs section of Chapter 5 -- Chassis). The parking brake is improperly adjusted (see Adjust Parking Brake in the Adjustments section of Chapter 5 -- Chassis). Brakes are worn or faulty (see Brakes in the Troubleshooting section of Chapter 5 -- Chassis).
Battery Charger Problems NOTE: Check battery charger diagnostic LED for possible faults whenever diagnosing on--board battery charger problems (see On--board Battery Charger in the Component Testing section of this chapter). Problem Possible Causes Battery charger does not turn on. AC outlet (electrical supply for charger) circuit breaker or fuse is tripped or blown. AC outlet (electrical supply for charger) is faulty. AC power supply cord (extension cord) is faulty.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. disconnect the harness wire connectors from the vehicle key switch before doing a continuity check on the key switch). CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.
Fuses The Workman fuse block is located under the seat assembly (Fig. 11). All fuse block fuses are rated at 80 VDC. 2 The fuse location in the fuse block is shown in Figure 12. The fuses protect circuits as follows: The front 10 amp (80 VDC) fuse protects the power supply to the key switch and all switched circuits. The battery charge indicator is also protected by the front fuse. The third fuse position is used to protect the optional horn circuit.
Battery Discharge Indicator The battery discharge indicator identifies the battery pack state of charge and is located on the dash panel (Fig. 14). 1 2 The discharge indicator reads full (10 indicator bars) after the battery pack has been fully charged (approximately 51 volts). As battery pack voltage decreases with vehicle use, fewer battery indicator bars are shown on the indicator.
Light Switch The light switch allows the headlights to be turned ON and OFF. This rocker switch is located on the dash panel (Fig. 17). 1 2 NOTE: The Workman GTX Electric headlight circuit is a 12 VDC circuit. Testing 1. Park vehicle on a level surface, turn key switch to OFF, engage the parking brake and remove key from the key switch. 2. Raise hood to allow access to wire harness connections for switches mounted in dash. 1. Dash panel 2. Light switch 4.
Direction Selector Switch The direction selector switch allows the direction (forward/neutral/reverse) of the vehicle to be changed by the operator and is one of several inputs for the vehicle controller. The direction selector switch is located on the dash panel (Fig. 19). 2 1 NOTE: Direction selector switch terminals 1, 2 and 3 are used on all Workman GTX Electric vehicles to change the direction of the vehicle.
Status Indicator Light 1 2 The status indicator and LED on the vehicle controller should have the same condition (off, illuminated or flashing). If the status indicator does not illuminate when the key 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 status indicator light is not illuminated, check the status indicator light and circuit wiring.
Supervision Speed Limit Switch The supervision speed limit switch allows the maximum speed of the vehicle to be set to either performance (16 mph/26 kph) or economy (12 mph/19 kph). The speed limit switch is one of several inputs for the vehicle controller and is located under the seat assembly (Fig. 23). The supervision speed limit switch is open in the performance position (key vertical) and closed in the economy position (key rotated clockwise).
Parking Brake Switch The parking brake switch is used as an input for the vehicle controller to identify when the parking brake is applied. The parking brake switch is attached to the parking brake mount behind the dash (Fig. 25). 8. If the brake switch tests correctly and a circuit problem still exists, check wire harness for problems (see electrical schematic and wire harness drawing in Chapter 6 -- Electrical Drawings).
USB Charge Port The USB charge port can be used to charge or power electrical devices that use a USB port. The charge port has a 5 VDC output and is mounted to the dash (Fig. 27). 2 1 If the vehicle wire harness is to be disconnected from the charge port, note the wire harness connections at the charge port for assembly purposes.
Main Contactor (48 VDC) The main contactor provides provides current to the 48 VDC system circuits (e.g. controller, traction motor) and is energized by the controller when the key switch is ON. The main contactor is mounted to the controller bracket beneath the cargo bed (Fig. 29). 9. Connect the conductors between the battery pack and vehicle components (see Opening Battery Circuit in the General Information section of this chapter).
Accelerator Pedal The accelerator pedal is attached to the foot board under the dash (Fig. 31). This pedal is used as one of the inputs for the vehicle controller to determine vehicle speed. The electronic control incorporated in the accelerator pedal is a non--contact, rotary hall effect sensor that varies output voltage based on the pedal position. When the operator presses or releases the accelerator pedal, the voltage from the pedal sensor changes.
Traction Motor If a traction motor component is faulty, there should likely be a fault code displayed on the controller LED and the status indicator light. Before disconnecting electrical connections on the motor, check for existing fault codes that suggest a problem with the motor. See Controller in this section for additional information regarding faults.
On--board Battery Charger The Workman GTX Electric on--board battery charger is attached to the left side of the vehicle under the operator seat. 1 Power input to the charger is provided at the charging receptacle by an AC power supply cord. A four (4) wire output cable with three (3) connectors is used to connect the charger to the vehicle electrical system. The connectors include battery positive (red wire), battery negative (black and white wires) and charging lock out (green wire).
LED Pattern Cause Necessary Action Amber LED is flashing Reduced--power mode: Low AC voltage or high internal charger temperature. Make sure that electrical outlet is providing adequate voltage for charger. Remove operator seat assembly to allow additional cooling air to on--board battery charger. Also, make sure that charger cooling fins are clean. Red LED is flashing Internal charger error (fault) or battery pack problem.
Controller The Workman controller is secured to the rear frame beneath the cargo box (Fig. 36). The controller uses inputs from several vehicle components to accurately control vehicle speed, direction (forward and reverse) and regenerative braking. Controller inputs include key switch, direction selector switch (forward/reverse), accelerator pedal, supervision speed limit switch, traction motor thermistor (temperature), traction motor encoder (speed sensor) and battery charger lockout.
Light Pattern Cause Necessary Action Always on (not flashing) System functioning normally. None required. Always off System inoperable. No electrical power to the controller. Check for low battery voltage, faulty fuse(s), loose battery cable connections, damaged battery cables and/or faulty main contactor. 1 Flash The controller has failed. If necessary, contact your Authorized Toro Distributor for assistance. System inoperable. Turn key switch OFF, wait several seconds and turn key switch ON.
Light Pattern Cause Necessary Action 6 Flashes The accelerator pedal is pressed while starting the machine. Release the accelerator pedal, turn the key switch to the OFF position, wait several seconds, turn the key switch to the ON position and check for normal vehicle operation. Accelerator pedal operation is abnormal. If controller does not reset correctly, check accelerator pedal operation (see Accelerator Pedal in this section).
Light Pattern Cause Necessary Action 12 Flashes A controller configuration fault occurred. Turn the key switch to the OFF position, wait several seconds, turn the key switch to the ON position, and check for normal vehicle operation. If this fault continues to occur, contact your Authorized Toro Distributor for assistance.
Diode Assembly A diode assembly is included in the Workman GTX Electric wire harness. This diode is used for for circuit logic to allow key switch current to the controller. The diode plugs into the wire harness near the controller and main contactor. 4 1 2 The diode assembly can be identified by a black color and a diode symbol on the end of the diode assembly body (Fig. 38). Refer to the wire harness drawings in Chapter 6 -- Electrical Drawings for additional information on diode assembly location.
Reverse Audio Alarm (If Equipped) The reverse alarm sounds when the direction switch (forward/reverse) is placed in the reverse position. The alarm is located under the seat assembly attached to the rear frame panel near the fuse block (Fig. 39). Testing IMPORTANT: Make sure to observe polarity on the alarm terminals when testing. Damage to the alarm may result from an improper connection. 2 1.
Service and Repairs Battery Service 95 to 105 in--lb (10.8 to 11.8 N--m) 6 7 2 8 1 2 5 3 9 RIGHT FRONT 4 Figure 41 1. Battery (8 used) 2. Hex nut (2 used per battery) 3. Battery cable with boots (6 used) 4. Battery cable with boots 5. Watering hose assembly 6. Flange nut (2 used) The batteries are the heart of the Workman electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented.
Battery Removal (Fig. 41) CAUTION POTENTIAL HAZARD: The battery terminals, metal tools and metal vehicle parts could short together. WHAT CAN HAPPEN: Sparks can cause battery gasses to explode. Damaged cables could short against metal vehicle 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.
Battery Inspection and Maintenance CAUTION To prevent battery damage and personal injury, make sure that batteries are well supported as they are installed into vehicle. Each battery weighs approximately 66 pounds (30 kg). IMPORTANT: Make sure that batteries are installed with the positive terminals toward the outside of the vehicle and the negative terminals toward the center of the vehicle (Fig. 42). 4.
When testing batteries in the Workman GTX Electric, it is important to periodically test all batteries. Proper performance 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.
Battery Charging Battery Storage When the vehicle is not in use, it is recommended to keep the batteries charged by connecting the on--board battery charger to an appropriate electrical outlet. The Workman GTX charger is designed to automatically charge the batteries fully without overcharging. An indicator LED on the charger provides information during the charging operation. If the vehicle will be stored for any period of time, use the on--board battery charger to fully charge batteries.
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Traction Motor 12 11 8 90 to 110 in--lb (10.2 to 12.4 N--m) 7 13 6 5 9 4 3 10 1 2 Antiseize Lubricant RIGHT FRONT Figure 44 1. 2. 3. 4. 5. Swing arm Transaxle assembly Traction motor Motor thermistor connector Motor encoder connector Electrical System 6. 7. 8. 9. Cable (motor W to controller M1) Cable (motor V to controller M2) Cable (motor U to controller M3) Flange head screw (6 used) Page 3A -- 38 10. 11. 12. 13.
Removal (Fig. 44) 1. Park vehicle on a level surface, turn key switch to OFF, engage the parking brake and remove key from the key switch. 2. To allow easier access to traction motor, remove cargo bed from vehicle (see Cargo Bed in the Service and Repairs section of Chapter 5 -- Chassis). 3. Make sure that vehicle battery charger IS NOT connected to electrical outlet.
Installation (Fig. 44) 1. If isolator and wire cables were removed from cable bracket (item 10), insert cables into isolator. Secure isolator and cables to bracket with isolator bracket and washer head screw. Torque screw from 90 to 110 in--lb (10.2 to 12.4 N--m). 2. Apply antiseize lubricant to the splines of the transaxle and traction motor shafts. CAUTION To prevent motor damage and personal injury, make sure that traction motor is well supported as it is installed.
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Traction Motor Service 25 to 33 in--lb (2.8 to 3.8 N--m) 13 72 to 88 in--lb (8 to 10 N--m) 11 12 9 6 14 8 25 to 33 in--lb (2.8 to 3.8 N--m) 4 5 3 10 7 1 16 71 to 97 in--lb (8 to 11 N--m) 15 2 Figure 47 1. 2. 3. 4. 5. 6. Torx head screw Encoder (speed sensor) Drive end bracket Armature assembly Wave washer Retaining ring 7. 8. 9. 10. 11.
6. Remove four (4) socket head screws and lock washers that secure drive and rear end brackets to stator assembly. Remove end brackets from stator. 1 NOTE: After the traction motor has been disassembled, it is recommended that a new rear end bracket bearing be installed. Although the bearing may appear and feel in good condition, the bearing could be ”brinelled” (races or balls deformed).
4. Secure drive and rear end brackets to stator assembly with four (4) socket head screws and lock washers. Tighten screws in two (2) stages using the sequence shown in Figure 51. Final torque on screws should be from 71 to 97 in--lb (8 to 11 N--m). Screw Tightening Sequence 1 3 5. Install connection plate assembly (item 12) to stator: A. Place connection plate assembly onto stator so that three (3) terminal screws fit through plate. B. Secure connection plate assembly to stator with two (2) torx screws.
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Controller 4 3 5 90 to 110 in--lb (10.2 to 12.4 N--m) 7 6 1 2 8 RIGHT FRONT Figure 52 1. Controller 2. Washer head screw (4 used) 3. Washer head screw 4. Isolator retainer 5. Isolator 6. Controller bracket Removal (Fig. 52) 1. Park vehicle on a level surface, turn key switch to OFF, engage the parking brake and remove key from the key switch. 2. Raise cargo bed and support with prop rod to allow access to controller. 3.
5. Support controller to prevent it from falling. 6. Remove four (4) washer head screws that secure controller to controller bracket. Carefully remove controller from vehicle. 2 6 7 Torque All Cable Cap Screws From 89 to 106 in--lb (10 to 12 N--m) 1 7. If necessary, remove washer head screw (item 3) that secures isolator retainer, isolator and controller cables to controller bracket. Separate isolator and controller cables from bracket. Installation (Fig. 52) 2.
On--board Battery Charger 16 15 2 3 12 1 4 5 8 7 9 14 6 10 13 11 RIGHT FRONT Figure 55 1. 2. 3. 4. 5. 6. On--board battery charger Heat shrink tube Cord set Lock nut (2 used) Screw (2 used) AC power cord 7. 8. 9. 10. 11. LED holder Charger function decal LH seat base side Screw (4 used) Charger bracket 12. 13. 14. 15. 16.
A. Remove positive charger connection (red charger wire) from right, rear battery positive (+) terminal. B. Remove negative charger connection (black and white charger wires) from left, rear battery negative (--) terminal. C. Unplug charger lock out connection (green charger wire) from vehicle wire harness connector (yellow harness wire). D. Remove two (2) screws and lock nuts that secure cord set receptacle to charger bracket. Separate receptacle from bracket. E.
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Chapter 3B Electrical System -- Lithium Table of Contents Workman GTX Electric Lithium SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . Caring for the Lithium--Ion Batteries . . . . . . . . . Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . Battery Storage . . . . . .
General Information The Workman GTX Electric Lithium uses a 48 VDC electrical system that is an isolated circuit. The vehicle frame is not used for any ground connections. The vehicle controller monitors operator and vehicle inputs to determine voltage to the traction motor. If a problem exists that will prevent normal vehicle operation.
Opening Battery Circuit WARNING 2 1 Battery terminals, battery cables, or metal tools could short against metal components causing sparks. Sparks can cause the battery damage and high heat, resulting in personal injury. -- When removing or installing the batteries, do not allow the battery terminals or battery cables to touch any metal parts of the machine. -- Do not allow metal tools to short between the battery terminals or battery cables and metal parts of the machine.
After working on the vehicle electrical system, attach battery conductors as follows (Fig. 2): 5. Lower and secure cargo bed. 1. Make sure that key is removed from the key switch. 2. If installed, remove the rubber hose on the positive (+) cable. Install the positive (+) cable onto the positive terminal on the left, rear battery. Secure conductors to battery with flange nut and torque tighten the nut from 72 to 88 in--lb (8 to 10 N--m); refer to Fig. 4. 3.
Electrical System Operation The Workman GTX Electric electrical system uses a 48 volt battery pack, an electric traction motor, a vehicle controller and numerous other electrical components to allow vehicle operation. The battery pack is composed of four 48 VDC lithium-ion batteries that are connected in parallel provide current for a 48V, brushless, high torque, AC inductive traction motor, the vehicle controller and vehicle accessories.
T: Display The display is a LCD device located on the dash. The display provides the operating status, various diagnostics, and other information about the machine. Power for the display is available when the key switch is in the ON position. A 2 Amps fuse protects the all of the key switched circuits. The display communicates with the other machine controllers on a Controller Area Network (CAN) bus system.
Figure 11 1. Active fault indicator When the direction switch is operated, the direction position appears on the display (Fig. 9). 2. Fault code An active fault code appears on the display when there is an issue with the machine (Fig. 11). Figure 10 1. Vehicle speed The vehicle speed appears on the display when you are driving the machine (Fig. 10). Workman GTX Electric Lithium Page 3B -- 7 Electrical System Electrical System Figure 9 1.
CAN bus Communications The machine controllers communicate with each other on a Controller Area Network (CAN) bus system. Using this network allows full integration of all the different electrical components of the machine, allowing them to operate together as one. The CAN bus system reduces the number of electrical components and connections used on the machine and allows the number of wires in the wire harness to be significantly reduced.
SC1: Lithium--Ion Battery Controller The machine uses a Lithium–ion battery controller or Battery Management System (BMS) to manage the lithium--ion batteries. Each of the four lithium--ion batteries communicates with the BMS through a sub--net via the battery interface harness. The battery interface harness includes a 4--pin connector at each of the batteries and a 9--pin connector at the BMS.
SC2: Traction Controller The SC2: traction controller is secured to the seat base rear panel (Fig. 14). The controller uses inputs from several vehicle components to accurately control vehicle speed, direction (forward and reverse) and regenerative braking. Controller inputs include key switch, direction selector switch (forward/reverse), accelerator pedal, mode switch, traction motor thermistor (temperature), traction motor encoder (speed sensor) and parking brake.
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The multimeter can test electrical components and circuits for current, resistance or voltage. NOTE: Workman GTX Electric 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.
Lithium--Ion Battery Shipping Kit Use the original packing or the battery shipping kit and a certified carrier to ship one of the lithium--ion batteries. The kit includes the appropriate carton, packing, labels, and instructions necessary to confirm to current lithium-ion battery shipping regulations in the USA. Note: Outside of the USA, contact the appropriate government agency in your country for detailed regulations on shipping the lithium--ion batteries.
Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Before working on the vehicle electrical system, open the battery circuit by disconnecting the conductors between the battery pack and vehicle components (see Opening Battery Circuit in the General Information section of this chapter). Connect the battery circuit if a test procedure requires battery voltage.
Machine Faults Machine faults are generated by the machine controllers to identify an electrical system malfunction (fault) that occurs during machine operation. The fault IDs conform to SAE J2012 standards. When a fault occurs, the bi--color LED on the display panel will flash red and a code for the active fault will appear along the bottom of the display screen. If more than one fault is active, their codes will scroll across the bottom of the display screen one--by--one.
Fault Title Controll er(s) Affected Fault Condition / Circuit Description Additional Notes Service Actions P0A3C Traction Motor SC2 Controller -High Temp Warning The measured FET temperature exceeds the design limit. When the overtemp region is entered, motor current is limited on a linear basis until the absolute over temp value is reached. FET temperature exceeds 75 ºC (Sevcon). 1) Reduce ground speed.
Fault ID Fault Title Controll er(s) Affected Fault Condition / Circuit Description Additional Notes Service Actions SC1 A battery is supplying too much current for too long. This can either be because of too much power draw or a battery cell imbalance. Discharge current is greater than 130A for 30s OR greater than 178.75A for 6s. 1) Reduce power draw. SC1 A battery voltage was measured to be lower than the allowed threshold but is still recoverable.
Fault ID Fault Title Controll er(s) Affected P1511 Traction Motor SC2 Controller -High Temp Shutdown Fault Condition / Circuit Description Additional Notes Service Actions The controller temperature was measured to be greater than the temperature shutdown threshold. The controller temperature exceeds 85 ºC (Sevcon). 1) Reduce ground speed NOTE: Coasting downhill or towing with batteries at full charge can cause this fault to occur.
Fault ID Fault Title Controll er(s) Affected Fault Condition / Circuit Description Additional Notes Service Actions P1A02 Battery Charging-Low Temp Shutdown SC1 A battery temperature was measured to be less than the allowed threshold and will not charge. One or more of the batteries temp is less than --10 ºC. Let the machine warm up before operating. P1A11 SC1 A battery voltage was measured to be higher than the allowed threshold while the battery charger was connected.
Fault ID Fault Title Controll er(s) Affected Fault Condition / Circuit Description Additional Notes Service Actions B1107 Transmission Lever Switch Broken SC2 Both TRANMISSION_FW D and TRANMISSION_RE V inputs are active at the same time. Traction is disabled. 1) Check the switch. There could be a short in the switch. CAN Bus T Communicatio n Fault -Traction Motor 1 Primary controller Traction is disabled. never established communication or lost communication with Traction Motor 1 controller.
General Run Problems NOTE: Check the display on dash panel for possible faults whenever diagnosing vehicle electrical circuit problems. Problem Possible Causes Main contactor clicks, but vehicle will not operate. Battery charge is low (check battery discharge indicator on dash). Battery cables are loose, corroded or damaged. Cable connection(s) at main contactor is/are loose or corroded. Cable connection(s) at controller is/are loose or corroded.
Problem Possible Causes Traction motor stops during operation. Battery charge is extremely low (check display on dash). Wiring to the traction motor components (e.g. main contactor, controller, traction motor) is loose, corroded or damaged (refer to Electrical Schematic in Chapter 6 -- Electrical Diagrams). Battery cables are loose, corroded or damaged. Traction motor is overheated (check display on dash for possible fault). Traction motor is faulty (check display on dash for possible fault).
Battery Charger Problems Problem Possible Causes Battery charger does not turn on. AC outlet (electrical supply for charger) circuit breaker or fuse is tripped or blown. AC outlet (electrical supply for charger) is faulty. AC power supply cord (extension cord) is faulty. Vehicle wiring is loose or damaged (see electrical schematic in Chapter 6 -- Electrical Diagrams). Vehicle charger receptacle or circuit wiring is damaged. Battery charger is faulty.
Possible Cause Corrective Action Code E--0--2--4 Charger failed to initialize Disconnect the charger AC input and battery connections for 30 seconds, then reconnect the charger. Code E--0--2--5 Low AC voltage oscillation error The charger requires an AC power source that provides stable AC power between 85 -- 270 VAC at 45--65 Hz. Confirm the AC power supply capacity and verify AC input cable gauge. Code E--0--3--7 Re--programming failed Software upgrade failure or script operation failure.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. disconnect the harness wire connectors from the vehicle key switch before doing a continuity check on the key switch). Always check the item being tested and the harness connector for damage or corrosion and clean or repair as necessary.
Fuse Testing 3 CAUTION 4 1 5 2 89 to 106 in--lb (10 to 12 N--m) IMPORTANT: Before removing fuse from controller (425 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 key switch is turned OFF. Remove fuse to check continuity. The test meter should read less than 1 ohm if a fuse is functional. Replace the fuse if faulty.
CAN bus The machine controllers communicate with each other on a Controller Area Network (CAN) bus system. Using this network allows full integration of all the different electrical components of the machine, allowing them to operate together as one. The CAN bus system reduces the number of electrical components and connections used on the machine and allows the number of wires in the wire harness to be significantly reduced.
T: Display ANALOG IN OUTPUT POWER GROUND DIGITAL IN CAN BUS OUTPUT The display communicates with the other machine controllers on a Controller Area Network (CAN) bus system. 2 A 16 pin wire harness connector is attached to the display. The connection terminal function for the display and the wire harness connector pins are shown Fig . Check the display module and the harness connector for damage or corrosion and clean or repair if necessary.
SC1: Lithium--Ion Battery Controller (BMS) The machine uses a Lithium–ion battery controller or Battery Management System (BMS) to manage the lithium--ion batteries. Each of the eight lithium--ion batteries communicates with the BMS through a sub--net via the battery interface harness. The battery interface harness includes a 4--pin connector at each of the batteries and a 9--pin connector at the BMS.
SC2: Traction Controller 1 A fuse that is rated at 425 amperes continuous is attached to the controller and protects the 48VDC vehicle power supply circuit. If this fuse has failed, vehicle operation will not occur.
Cause Necessary Action Always on (not flashing) System functioning normally. None required. Always off System inoperable. Check for low battery voltage, faulty fuse(s), loose battery cable connections, damaged battery cables and/or faulty main contactor. Light Pattern Fault Code No electrical power to the controller. If batteries, cables and other electrical Status indicator light on dash components are in good condition, controller is faulty. replacement may be needed.
Light Pattern 5 Flashes P0A44 Cause Necessary Action Exceeded the maximum motor speed. Turn key switch OFF, wait several seconds and turn key switch ON. If controller does not reset correctly, inspect traction motor encoder (speed sensor) (see Traction Motor in this section). 6 Flashes P0226 P156C The accelerator pedal is pressed while starting the machine.
Light Pattern 11 Flashes P0A44 P1520 Cause Necessary Action A motor encoder (speed sensor) fault occurred. Turn the key switch to the OFF position, wait several seconds, turn the key switch to the ON position, and check for normal vehicle operation. Exceeded the maximum motor speed. If this fault continues to occur, inspect traction motor encoder (speed sensor) (see Traction Motor in this section).
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Key Switch The Workman GTX Electric Lithium key switch has two (3) positions -- OFF, RUN and START. The START position is not used on this machine. The key switch is located on the dash. The key switch is used to energize the SC1: Battery Controller, SC2: Traction Controller and T: Display. NOTE: The Workman GTX Electric key switch circuit is a 48 VDC circuit.
Light Switch The light switch allows the headlights to be turned ON and OFF. This rocker switch is located on the dash panel (Fig. 31). NOTE: The Workman GTX Electric headlight circuit is a 12 VDC circuit. 1 2 Testing 1. Park vehicle on a level surface, turn key switch to OFF, engage the parking brake and remove key from the key switch. 2. Raise hood to allow access to wire harness connections for switches mounted in dash. 1. Dash panel 2. Light switch 4.
Direction Selector Switch The direction selector switch allows the direction (forward/neutral/reverse) of the vehicle to be changed by the operator and is one of several inputs for the vehicle controller. The direction selector switch is located on the dash panel (Fig. 33). 2 1 NOTE: Direction selector switch terminals 1, 2 and 3 are used on all Workman GTX Electric vehicles to change the direction of the vehicle.
Supervision Speed Limit Switch The supervision speed limit switch allows the maximum speed of the vehicle to be set to e ither performance (16 mph/26 kph) or economy (12 mph/19 kph). The speed limit switch is one of several inputs for the vehicle controller and is located under the seat assembly (Fig. 35). The supervision speed limit switch is open in the performance position (key vertical) and closed in the economy position (key rotated clockwise). 6.
Parking Brake Switch The parking brake switch is used as an input for the vehicle controller to identify when the parking brake is applied. The parking brake switch is attached to the parking brake mount behind the dash (Fig. 37). 8. If the brake switch tests correctly and a circuit problem still exists, check wire harness for problems (see electrical schematic and wire harness drawing in Chapter 6 -- Electrical Drawings).
USB Charge Port The USB charge port can be used to charge or power electrical devices that use a USB port. The charge port has a 5 VDC output and is mounted to the dash (Fig. 39). If the vehicle wire harness is to be disconnected from the charge port, note the wire harness connections at the charge port for assembly purposes.
Main Contactor (48 VDC) The main contactor provides provides current to the 48 VDC system circuits (e.g. controller, traction motor) and is energized by the controller when the key switch is ON. The main contactor is mounted to the controller bracket under the operator seat. (Fig. 41). 9. Connect the conductors between the battery pack and vehicle components (see Opening Battery Circuit in the General Information section of this chapter).
Accelerator Pedal 1 If the accelerator pedal is thought to be faulty, consider the following before replacing the pedal: 1. Make sure that the accelerator pedal moves smoothly through its entire range of motion. 2 Figure 43 1. Dash panel 2. Accelerator pedal 2. Check the vehicle controller for any existing faults that indicate a problem with the accelerator pedal (see Controller in this section of this chapter). 3.
Traction Motor The traction motor stator winding, thermistor (temperature) and encoder (speed sensor) can be tested with the motor attached to the transaxle. Test connection points for the traction motor are shown in Fig. 45. If a traction motor component is faulty, there should likely be a fault code displayed on the display. Before disconnecting electrical connections on the motor, check for existing fault codes that suggest a problem with the motor.
On--board Battery Charger The Workman GTX Electric on--board battery charger is attached to the right side of the vehicle under the operator seat. 1 Power input to the charger is provided at the charging receptacle by an AC power supply cord. If the plug does not fit into the wall receptacle, other grounded plug types are available; contact an authorized Toro distributor. Do not change the charger or the power--supply--cord plug in any way. The battery pack charging operation is fully automated.
Diode Assembly A diode assembly is included in the Workman GTX Electric wire harness. This diode is used for for circuit logic to allow key switch current to the controller. The diode plugs into the wire harness near the vehicle fuses next to the on--board battery charger. 4 1 2 The diode assembly can be identified by a black color and a diode symbol on the end of the diode assembly body (Fig. 48).
CAN bus Terminator Resistor System communication between various electrical components on the Workman GTX Electric Lithium machines is accomplished on a CAN bus communications network. Two specially designed, twisted wires form the CAN bus. These wires provide the data pathways between the components on the network. The engineering term for these cables are CAN High and CAN Low. The CAN bus wires are red/white (CAN High) and black/ white (CAN Low).
Reverse Audio Alarm (If Equipped) The reverse alarm sounds when the direction switch (forward/reverse) is placed in the reverse position. The alarm is located under the seat assembly attached to the rear frame panel below the supervision speed limit switch (Fig. 51). Testing IMPORTANT: Make sure to observe polarity on the alarm terminals when testing. Damage to the alarm may result from an improper connection. 1 IMPORTANT: The audio alarm is a 12 volt DC component.
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Service and Repairs Battery Service 18 90 to 110 in--lb (10 to 12.4 N--m) 72 to 88 in--lb (8 to 10 N--m) 15 16 45 to 55 in--lb (5 to 6.2 N--m) 1 17 2 3 27 to 33 ft--lb (36.5 to 44.5 N--m) 5 6 7 90 to 110 in--lb (10 to 12.4 N--m) 4 9 5 6 7 19 8 72 to 88 in--lb (8 to 10 N--m) 10 11 14 12 13 27 to 33 ft--lb (36.5 to 44.5 N--m) 1. 2. 3. 4. 5. 6. 7.
Battery Removal (Fig. 53) 1 2 WARNING IMPORTANT: To prevent accidentally shorting a disconnected battery cable across other components or tools, insulate the battery cable terminal with a 76 mm (3 inch) length of 1.27 mm (0.5 in) internal diameter rubber hose immediately after disconnecting the cable; refer to Fig. 54. 1. Park vehicle on a level surface, turn key switch to OFF, engage the parking brake and remove key from the key switch. 2. Raise cargo bed and support with prop rod.
4. Install the battery assembly onto the machine frame using the figure 53. Torque tighten the battery pack flange nuts (3 and 13) from 27 to 33 ft--lb (36.5 to 44.5 N--m). 5. Using the labels that attached during the removal, connect the battery interface cable, positive (+) battery cable and negative (--) battery cable onto the battery pack. 6. Tighten the battery cable fasteners from 72 to 88 in-lb (8 to 10 N--m), then apply battery terminal protector Toro Part No.
When the vehicle is not in use, it is recommended to keep the batteries charged by connecting the on--board battery charger to an appropriate electrical outlet. The Workman GTX charger is designed to automatically charge the batteries fully without overcharging. For additional battery charging information, see your Operator’s Manual and the Battery Charger Operating Instructions. Refer to Battery Charger Error and Fault Codes in this manual for battery charger troubleshooting information.
Traction Motor 12 11 8 90 to 110 in--lb (10.2 to 12.4 N--m) 7 13 6 5 9 4 3 10 1 2 Antiseize Lubricant RIGHT FRONT Figure 55 1. 2. 3. 4. 5. Swing arm Transaxle assembly Traction motor Motor thermistor connector Motor encoder connector Electrical System 6. 7. 8. 9. Cable (motor W to controller M1) Cable (motor V to controller M2) Cable (motor U to controller M3) Flange head screw (6 used) Page 3B -- 52 10. 11. 12. 13.
Removal (Fig. 55) 1. Park vehicle on a level surface, turn key switch to OFF, engage the parking brake and remove key from the key switch. 2. To allow easier access to traction motor, remove cargo bed from vehicle (see Cargo Bed in the Service and Repairs section of Chapter 5 -- Chassis). 3. Make sure that vehicle battery charger IS NOT connected to electrical outlet.
Installation (Fig. 55) 1. If isolator and wire cables were removed from cable bracket (item 10), insert cables into isolator. Secure isolator and cables to bracket with isolator bracket and washer head screw. Torque screw from 90 to 110 in--lb (10.2 to 12.4 N--m). 2. Apply antiseize lubricant to the splines of the transaxle and traction motor shafts. CAUTION To prevent motor damage and personal injury, make sure that traction motor is well supported as it is installed.
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Traction Motor Service 25 to 33 in--lb (2.8 to 3.8 N--m) 13 72 to 88 in--lb (8 to 10 N--m) 11 12 9 6 14 8 25 to 33 in--lb (2.8 to 3.8 N--m) 4 5 3 10 7 1 16 71 to 97 in--lb (8 to 11 N--m) 15 2 Figure 58 1. 2. 3. 4. 5. 6. Torx head screw Encoder (speed sensor) Drive end bracket Armature assembly Wave washer Retaining ring 7. 8. 9. 10. 11.
6. Remove four (4) socket head screws and lock washers that secure drive and rear end brackets to stator assembly. Remove end brackets from stator. 1 NOTE: After the traction motor has been disassembled, it is recommended that a new rear end bracket bearing be installed. Although the bearing may appear and feel in good condition, the bearing could be ”brinelled” (races or balls deformed).
4. Secure drive and rear end brackets to stator assembly with four (4) socket head screws and lock washers. Tighten screws in two (2) stages using the sequence shown in Figure 62. Final torque on screws should be from 71 to 97 in--lb (8 to 11 N--m). Screw Tightening Sequence 1 3 5. Install connection plate assembly (item 12) to stator: A. Place connection plate assembly onto stator so that three (3) terminal screws fit through plate. B. Secure connection plate assembly to stator with two (2) torx screws.
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SC2: Traction Controller 90 to 110 in--lb (10 to 12.4 N--m) 13 14 16 1 15 2 4 72 to 88 in--lb 12 (8 to 10 N--m) 72 to 88 in--lb (8 to 10 N--m) 4 9 8 11 3 6 45 to 55 in--lb (5 to 6.2 N--m) 7 10 5 4 45 to 55 in--lb (5 to 6.2 N--m) 72 to 88 in--lb (8 to 10 N--m) Figure 63 1. 2. 3. 4. 5. 6. Contactor Controller bracket Battery (+) positive cable Flange nut (4 used) Battery (+) positive cable SC1: battery controller 7. 8. 9. 10. 11.
5. Disconnect electrical conductors from SC2: traction controller and position them away from controller: 3 4 1 5 A. Remove cap screw, lock washer, flat washer and cable connector from controller terminals B+, B--, M1, M2 and M3 (Fig. 64). 2 B. Carefully unplug wire harness connector from controller. 7 6 C. Position cables and wire harness connector away from controller. 6. Support traction controller to prevent it from falling. Installation (Fig. 63) 1.
SC1: Lithium--Ion Battery Controller (BMS) 90 to 110 in--lb (10 to 12.4 N--m) 13 14 16 1 15 2 4 17 72 to 88 in--lb 12 (8 to 10 N--m) 72 to 88 in--lb (8 to 10 N--m) 4 9 8 11 3 6 45 to 55 in--lb (5 to 6.2 N--m) 7 10 5 4 45 to 55 in--lb (5 to 6.2 N--m) 72 to 88 in--lb (8 to 10 N--m) Figure 66 1. 2. 3. 4. 5. 6. Contactor Controller bracket Battery (+) positive cable Flange nut (4 used) Battery (+) positive cable SC1: battery controller 7. 8. 9. 10. 11. 12.
5. Disconnect electrical conductors from SC1: lithium-ion battery controller and position them away from controller: A. Remove nut, lock washer, flat washer and cable connector from battery controller terminals negative, B--, B+ and positive terminal. (Fig. 67). B. Carefully unplug the COM and M--S wire harness connector from battery controller. IMPORTANT: Do not open the lithium--Ion battery controller. There are no serviceable parts on or in the controller.
On--board Battery Charger 90 to 110 in--lb (10 to 12.4 N--m) 2 1 3 18 to 22 in--lb (2 to 2.5 N--m) 10 4 11 9 6 36 to 44 in--lb (4 to 5 N--m) 7 5 45 to 55 in--lb (5 to 6.2 N--m) 12 8 13 14 Figure 69 1. 2. 3. 4. 5. On--board battery charger Flange head bolt (4 used) Power supply cord Charger bracket Charger interface wire harness 6. 7. 8. 9. 10. Nut Nut Machine wire harness Nut (2 used) AC input 11. Screw (6 used) 12. Bolt (2 used) 13. Charger outlet bracket 14.
5. Disconnect charger electrical conductors from vehicle connections: B. Connect the charger interface wire harness (item 5) to the machine wire harness (item 8). A. Unplug the power supply cord (item 3) from the battery charger (item 1). C. Plug--in the power supply cord (item 3) to the battery charger (item 1). B. Disconnect the charger interface wire harness (item 5) from the machine wire harness (item 8). 4.
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Chapter 4 Transaxle Table of Contents 2 2 3 4 4 8 Transaxle GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . Transaxle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . Transaxle Assembly Service . . . . . . . . . . . . . . . . . .
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman GTX Electric vehicle. Refer to the Operator’s Manual for additional information when servicing the machine.
Specifications Item Description Transaxle Transaxle Fluid Capacity Transaxle Fluid Transaxle 0.7 quarts (0.
Service and Repairs Transaxle Assembly 10 5 11 90 to 110 in--lb (10.2 to 12.4 N--m) 3 9 6 12 4 8 77 to 95 ft--lb (105 to 128 N--m) 2 7 15 13 16 13 RIGHT FRONT 14 17 1 Antiseize Lubricant 14 v Figure 1 1. 2. 3. 4. 5. 6. Transaxle assembly Traction motor Cable (motor W to controller M1) Cable (motor V to controller M2) Cable (motor U to controller M3) Motor speed sensor connector Transaxle 7. 8. 9. 10. 11. 12.
CAUTION CAUTION The drive motor and transaxle may be hot. To avoid possible burns, allow all drive components to cool before working on the transaxle. Transaxle Removal (Fig. 1) To prevent personal injury, make sure that transaxle is properly supported as it is removed from the vehicle. Transaxle weighs approximately 130 pounds (59 kg). 1. Park vehicle on a level surface, turn key switch to OFF, engage the parking brake and remove key from the key switch. 8.
3. Install both rear wheel hubs and wheels to the vehicle (see Rear Wheel and Hubs in the Service and Repairs section of Chapter 5 -- Chassis). Make sure that fasteners for wheel hubs, brake calipers and wheels are properly torqued during assembly. 4. Lower vehicle to ground. 5. Apply antiseize lubricant to the splines of the transaxle and motor shafts. 6. Install traction motor to transaxle (see Traction Motor in the Service and Repairs section of Chapter 3 -- Electrical System). 7.
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Transaxle Assembly Service Apply Rapid--Curing Anaerobic Adhesive 24 10 5 6 11 8 4 7 29 6 5 9 28 19 Apply Rapid--Curing Anaerobic Adhesive 10 26 27 11 26 25 15 2 6 12 13 5 16 23 1 13 17 3 14 20 18 55 to 63 ft--lb (75 to 85 N--m) 15 3 2 Apply Silicone Sealant 25 21 26 27 22 35 to 45 ft--lb (47 to 61 N--m) 26 16 to 24 ft--lb (22 to 33 N--m) 15 to 20 ft--lb (20 to 27 N--m) Figure 3 1. Transaxle housing assembly (includes bearing caps) 2. Bearing cap (2 used) 3.
4. Remove the intermediate shaft and gear assembly. Disassembly (Fig. 3) A. Punch or drill a small hole in the center of each end cap plug (item 10). Insert a suitable sheet metal screw into the hole until the the cap plug is driven from the housing bore. CAUTION The transaxle assembly is a precision assembly, and any repair or replacement of parts must be done with great care in a clean environment. Handle all components (especially gears) with extreme care. B.
Assembly (Fig. 3) 1. Assemble and install the input shaft. A. Press the inner and outer bearings (items 7 and 8) onto input shaft until seated against bearing shoulders. B. Apply a light coat of oil to a new O--ring (item 6) and install into input bearing bore of housing. C. Install input shaft assembly in housing. Bearings should slide easily into housing. Use a soft mallet to tap the input shaft assembly into position if necessary. D. Install retaining ring (item 5). E.
E. Install the outer snap ring. F. Repeat procedure for opposite side. 5. Fill the transaxle with 0.7 quarts (0.66 liters) of new SAE 10W--30 motor oil. Transaxle D. Apply light oil or grease to the inner lip of the oil seal and insert the shaft and bearing assembly into the axle housing. Align the axle shaft splines with those in the differential assembly and drive the axle shaft and bearing assembly into the axle housing.
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Chapter 5 Chassis Table of Contents Front Brake Caliper Service . . . . . . . . . . . . . . . . . Rear Brake Calipers . . . . . . . . . . . . . . . . . . . . . . . . Rear Brake Caliper Service . . . . . . . . . . . . . . . . . . Parking Brake Cables and Lever Assembly . . . . Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . Brake Master Cylinder Service . . . . . . . . . . . . . . . Bleed Brake System . . . . . . . . . . . . . . . . . . . . . . . . Steering Assembly . . . . . . . . . . . .
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman GTX Electric vehicle. Refer to the Operator’s Manual for additional information when servicing the machine. Thread Forming Fasteners Numerous thread forming fasteners are used to secure Workman GTX frame components.
Specifications Item Description Front and Rear Tires Pressure Range 205/65 -- 10 24 to 30 PSI (165 to 207 kPa) Wheel Lug Nut Torque (all wheels) 75 to 95 ft--lb (102 to 128 N--m) Front Wheel Toe--In 0 + 0.
Special Tools Order special tools from your Toro Distributor. Spanner Wrench Use spanner wrench to rotate collar on front suspension strut and rear shock absorber. Collar rotation may be necessary to accommodate installed accessories or heavier vehicle loads. Make sure that vehicle is jacked up off the ground to allow spring to be at full extension before using spanner wrench.
Tools for Frame Extension Kit Use this tool kit (shown in Fig. 4) when installing or servicing the vehicle frame extension kit. 3 When the front and rear frame components are separated to install or service the frame extension kit, the rear frame of the machine can be supported with the legs included in this tool kit. The legs attach to the rear frame with two (2) flange head screws and nuts for each leg (Fig. 5). 4 2 1 Toro Part Number: TOR6040 1 Figure 4 3. Flange nut (4 used) 4.
Troubleshooting Suspension and Steering Problem Possible Cause Front end is noisy. Front wheel lug nuts are loose. Front suspension struts are loose or worn. Front wheel bearings are loose or worn. Front end components (e.g. tie--rod, spindle, A--arm) are loose or worn. Steering rack assembly is damaged or worn. Rear end is noisy. Rear wheel lug nuts are loose. Rear suspension shocks are loose or worn. Rear wheel bearings are loose or worn. Rear end components (e.g.
Suspension and Steering (continued) Problem Possible Cause Front end shimmies. Front wheel lug nuts are loose. Front wheel alignment (toe--in) is incorrect. Front wheel bearings are loose or worn. Tie rod ends are loose or worn. Steering shaft bearings or joints are loose or worn. Bushings in spindle or A--arm are loose or worn. Steering is hard. Tire pressure is low or uneven between tires. Steering components are binding or damaged. Front wheel alignment (toe--in) is incorrect.
Brakes (continued) Problem Possible Cause Brakes pull to either side. Tire pressure is incorrect or uneven between tires. Brake pads are worn or contaminated. Front wheel alignment (toe--in) is incorrect. Brake rotors are bent or damaged. Tires on same axle are unmatched. Brakes squeal. Brake pads are worn or contaminated. Brake components are dirty. Brake rotors are scored or bent. Brakes drag. Parking brake is applied or incorrectly adjusted. Brake pedal is binding. Parking brake cable is binding.
Adjustments Adjust Parking Brake Checking Parking Brake (Fig. 6) 8. Adjust other rear wheel using steps 4 to 7 above. 1. Apply parking brake with brake lever on dash. 9. Check parking brake adjustment as described in Checking Parking Brake on this page. Make additional parking brake adjustments if necessary. 2. There should be tension felt when applying the parking brake within 4½” to 6½” (11.4 to 16.
Adjust Front Wheel Toe--in 1. Adjust tire pressures from 24 to 30 PSI (165 to 207 kPa) before checking front wheel toe--in. 2. Either have an operator on the vehicle operator’s seat or add weight to the driver’s seat equal to the average operator who will run the vehicle. The operator or weight must remain on the seat for the duration of the front wheel toe--in adjustment procedure. 1 2 3.
Service and Repairs Check Tire Pressure The tire pressure range for front and rear tires is 24 to 30 PSI (165 to 207 kPa). The air pressure needed is determined by the payload carried. Lower air pressure will provide less compaction, a smoother ride and fewer tire marks. Lower pressure should not be used for heavy payloads at higher speeds. Higher pressures should be used for heavier payloads at higher speeds. Do not exceed the maximum tire pressure.
Front Wheels and Hubs Lifted suspension models 18 14 18 17 See text for tightening procedure 12 2 14 5 4 10 6 8 9 7 35 to 40 ft−lb (48 to 54 N−m) Medium Strength Thread Locker RIGHT 3 1 75 to 95 ft−lb (102 to 128 N−m) 16 15 13 9 to 11 ft−lb (13 to 14 N−m) 12 11 2 FRONT 1 Figure 10 1. 2. 3. 4. 5. 6. Front wheel assembly Lug nut (4 per wheel) Front brake caliper (LH shown) Socket head screw (2 per caliper) Front brake line Banjo bolt and washers 7. 8. 9. 10. 11. 12.
6. Remove the cotter pin, retainer, jam nut and tab washer. Slide the front wheel hub from the spindle shaft. 7. Pull the seal out of the wheel hub. Discard seal. 8. Remove the bearing cones from both sides of the wheel hub. Clean the bearings in solvent. Make sure the bearings are in good operating condition. Clean the inside of the wheel hub. Check the bearing cups for wear, pitting or other damage. Replace worn or damaged parts. 9.
Rear Wheels and Hubs 13 17 Lifted suspension models 1 12 220 to 240 ft−lb (299 to 325 N−m) 11 35 to 40 ft−lb (48 to 54 N−m) Medium Strength Thread Locker 9 4 10 2 5 8 3 13 6 7 75 to 95 ft−lb (102 to 128 N−m) 1 17 12 14 16 Antiseize Lubricant 15 RIGHT 11 9 to 11 ft−lb (13 to 14 N−m) 10 2 FRONT 220 to 240 ft−lb (299 to 325 N−m) Figure 12 1. 2. 3. 4. 5. 6.
4. Install the wheel hub to the transaxle shaft: 1. Park vehicle on a level surface, turn key switch OFF and remove key from the key switch. Do not apply parking brake. A. Install hardened spacer, wheel hub and then thrust washer onto the transaxle shaft. B. Secure wheel hub assembly with slotted hex nut. Torque slotted hex nut from 220 to 240 ft--lb (299 to 325 N--m). Make sure that slot in nut aligns with hole in transaxle shaft to allow installation of cotter pin.
Front Brake Calipers RIGHT 9 to 11 ft--lb (13 to 14 N--m) 4 FRONT 5 6 7 8 10 2 3 9 54 to 66 in--lb (6.1 to 7.4 N--m) 11 35 to 40 ft--lb (48 to 54 N--m) Medium Strength Threadlocker 1 108 to 132 in--lb (12.3 to 14.9 N--m) Figure 13 1. 2. 3. 4. LH brake caliper RH brake caliper Socket head screw (2 per caliper) Wheel hub assembly (2 used) 5. 6. 7. 8. Brake rotor (2 used) Socket head screw (4 per rotor) Spindle (RH shown) Front brake line 4. Disconnect brake line from front caliper (Fig.
7. Inspect front brake rotor for wear or damage. Minimum brake rotor thickness is 0.154” (3.9 mm). If brake rotors need to be removed from vehicle, refer to Front Wheels and Hubs in this section. 8. Bleed brakes (see Bleed Brake System in this section). CAUTION Assembly (Fig. 13) 1. Make sure that brake rotor is properly secured to wheel hub (see Front Wheels and Hubs in this section). 2. Slide brake caliper onto brake rotor. Make sure that rotor is between brake pads.
Front Brake Caliper Service 9 White Lithium Grease 4 27 to 33 ft--lb (37 to 44 N--m) 3 8 7 6 1 5 BAF--12 Assembly Lube 2 Figure 15 1. Bolt (2 used) 2. Caliper body 3. O--ring (4 used) Chassis 4. Caliper bracket 5. Square seal (2 used) 6. Dust seal (used) Page 5 -- 18 7. Piston (2 used) 8. Brake pad (2 used) 9.
Disassembly (Fig. 15) Assembly (Fig. 15) 1. Remove two (2) bolts that secure brake caliper body to the caliper anvil. 1. If caliper body was disassembled, install components in caliper body: 2. Remove caliper anvil and then slide brake pads from pins on caliper bracket. A. Apply hydraulic brake cylinder assembly lube (BAF--12 or equivalent) to square seals, dust seals and piston before installation. 3. Slide caliper body assembly from caliper bracket. 4.
Rear Brake Calipers 108 to 132 in--lb (12.3 to 14.9 N--m) 35 to 40 ft--lb (48 to 54 N--m) Medium Strength Threadlocker 2 4 54 to 66 in--lb (6.1 to 7.4 N--m) 5 10 1 9 3 8 16 17 15 7 6 RIGHT 12 9 to 11 ft--lb (13 to 14 N--m) FRONT 220 to 240 ft--lb (299 to 325 N--m) 11 14 13 Figure 16 1. 2. 3. 4. 5. 6. LH rear brake caliper assembly RH rear brake caliper assembly Transaxle assembly Rear swing arm Socket head screw (2 per caliper) Parking brake cable (2 used) 7. 8. 9. 10. 11. 12.
5. Disconnect brake line from rear brake caliper: A. Clean brake line area of brake caliper to prevent contamination of brake system. C. Rotate brake lever on caliper toward front of vehicle and hold lever in place. Then, insert cable into caliper bracket and slowly release brake lever to align cable conduit with caliper bracket. B. Remove banjo bolt that secures brake line fitting to caliper. 5. Install rear wheel assembly (see Rear Wheels and Hubs in this section). C.
Rear Brake Caliper Service 2 1 30 to 35 ft--lb (41 to 47 N--m) 3 5 4 108 to 132 in--lb (12.3 to 14.9 N--m) Figure 18 1. Brake caliper assembly (LH shown) 2. Caliper slide pin (2 used) 3. Anti--rattle spring (2 used) 4. Brake pad assembly 5. Bleed screw NOTE: Replacement parts for the rear caliper assembly are limited to the brake pad assembly and bleed screw. If any other caliper components are damaged or worn, replace the caliper assembly.
Disassembly (Fig. 18) 1. Remove two (2) caliper slide pins that secure brake pads to the caliper assembly. 2 2. Slide brake pads with attached anti--rattle springs from caliper. 3. Remove anti--rattle springs from brake pads. 4. Clean caliper components with brake cleaner. 3 Inspection 1. Check brake pads for uneven wear that might indicate binding in the caliper assembly. Replace the brake pads if the friction material is worn to less than 1/16” (1.6 mm).
Parking Brake Cables and Lever Assembly FRONT RIGHT 15 14 200 to 230 in--lb (23 to 25 N--m) 13 18 2 17 3 6 7 10 8 5 11 16 5 4 12 1 9 Figure 20 1. 2. 3. 4. 5. 6. Parking brake lever Clevis pin Flat washer Spring washer Hair pin (2 used) Parking brake link 7. 8. 9. 10. 11. 12. Clevis pin Cable equalizer bracket Button head screw (2 used) Flange nut (2 used) Parking brake mount Parking brake cable (2 used) 13. 14. 15. 16. 17. 18.
1. Park vehicle on a level surface, turn key switch OFF and remove key from the key switch. Chock wheels to prevent the vehicle from moving. 3. Secure brake cables to parking brake lever assembly: A. Insert both brake cable ends through parking brake mount and then through jam nuts. 2. Disconnect both parking brake cables from rear brake calipers (Fig. 21): B. Insert both cable ends into cable equalizer bracket. A. Make sure that parking brake is released. C.
Brake Master Cylinder RIGHT FRONT 7 3 2 4 1 5 9 8 6 75 to 85 in--lb (8.5 to 9.6 N--m) Figure 22 1. Master cylinder 2. Hair pin 3. Clevis pin Chassis 4. Brake pedal 5. Pedal mount 6. Flange nut (2 used) Page 5 -- 26 7. Flange head screw (2 used) 8. Front brake line 9.
Removal (Fig. 22) 1 1. Park vehicle on a level surface, turn key switch OFF, apply parking brake and remove key from the key switch. 2. Raise front hood to gain access to master cylinder. 3. Remove hair pin from the clevis pin that connects master cylinder to brake pedal. IMPORTANT: To prevent contamination of the brake system, make sure to clean master cylinder components before disassembly. 4. Clean hydraulic brake line area of master cylinder to prevent contamination.
Brake Master Cylinder Service Disassembly (Fig. 24) 1. Thoroughly clean outside of master cylinder before disassembly. 2. Remove reservoir and flange seal. Push in on the push rod so the stop pin can be removed. 1 2 12 3 3. Disconnect lower end of the dust cover from the housing. 4. Push in on the push rod and remove circlip, then remove push rod with dust cover and clevis. Remove retainer washer. 4 11 5. Remove primary piston assembly and secondary piston assembly from cylinder housing.
Bleed Brake System IMPORTANT: To prevent contamination of the brake system, make sure to clean components before disassembly. 1. Park vehicle on a level surface, turn key switch OFF, apply parking brake and remove key from the key switch. 2 2. Connect a suitable transparent hose to bleeder valve on front or rear brake caliper. Submerge other end of hose in a glass container partially filled with clean brake fluid. 1 54 to 66 in--lb (6.1 to 7.4 N--m) 3.
Steering Assembly 11 FRONT 16 to 20 ft--lb (21.5 to 27 N--m) 13 12 14 7 3 RIGHT 2 10 3 4 9 5 6 1 8 16 15 16 to 20 ft--lb (21.5 to 27 N--m) 45 to 55 ft--lb (61 to 75 N--m) Figure 27 1. 2. 3. 4. 5. 6. Steering rack assembly Steering column Bearing (2 used) Steering shaft Lock washer Cap screw 7. 8. 9. 10. 11. Dust cover Washer head screw (4 used) Carriage bolt (4 used) Flange nut (4 used) Steering wheel Disassembly (Fig. 27) 1.
8. Lift up on steering column assembly, slide lower steering shaft joint from the steering rack assembly input shaft and remove steering column from vehicle. 5. Secure lower steering shaft joint to the steering rack input shaft with cap screw and lock washer. Torque screw from 16 to 20 ft--lb (21.5 to 27 N--m). 9. Remove dust cover from the steering shaft. Replace cover if damaged. 6. Place dust cover onto the steering shaft. A.
Steering Rack Assembly Service 6 5 4 45 to 50 ft--lb (61 to 75 N--m) 7 2 8 3 Medium Strength Thread Locker 1 34 to 42 ft--lb (47 to 57 N--m) Figure 28 1. Tie rod end (2 used) 2. Jam nut (2 used) 3. Tie rod track (2 used) 4. Bellows clamp (2 used) 5. Bellows (2 used) 6. Bellows clamp (2 used) 7. Input shaft seal 8. Steering rack assembly NOTE: Check parts catalog to identify individual components that are available for the steering rack assembly on your Workman GTX vehicle.
Disassembly (Fig. 28) 1. For assembly purposes, measure the distance from shoulder on the tie rod track to the location of the tie rod end (Fig. 29). This will help to adjust front wheel toe--in during assembly of steering rack. 2. Loosen jam nut that secures tie rod end to tie rod track. Remove tie rod end and jam nut from end of tie rod track. 3. Remove clamps that secure bellows to the tie rod track and steering rack housing. Remove bellows from steering rack assembly. 4.
Front Suspension 200 to 230 in--lb (23 to 25 N--m) 200 to 230 in--lb (23 to 25 N--m) 22 80 to 90 ft--lb (109 to 122 N--m) 23 17 18 45 to 55 ft--lb (61 to 75 N--m) 23 27 to 33 ft--lb (37 to 44 N--m) 45 to 55 ft--lb (61 to 75 N--m) 24 27 to 33 ft--lb (37 to 44 N--m) 13 25 14 20 9 14 26 27 19 16 21 7 FRONT 4 14 15 RIGHT 2 8 45 to 55 ft--lb (61 to 75 N--m) 12 27 to 33 ft--lb (37 to 44 N--m) 6 10 11 Grade 8 5 Grade 5 3 1 Figure 31 1. 2. 3. 4. 5. 6. 7. 8. 9.
4. Remove front wheel assembly and wheel hub from vehicle (see Front Wheels and Hubs in this section). 5. Remove spindle assembly from vehicle: A. Remove cotter pin and slotted hex nut securing steering rack tie rod ball joint stud to the spindle. Separate ball joint from the spindle. 2. If suspension strut assembly was removed from vehicle, position the top of the strut assembly to the front frame and secure with flange head screw and lock nut. Torque screw from 80 to 90 ft--lb (109 to 122 N--m). 3.
Rear Suspension 12 5 Lifted suspension models 7 4 27 to 33 ft−lb (37 to 44 N−m) 6 77 to 95 ft− lb (104 to 128 N--m) 27 to 33 ft−lb (37 to 44 N−m) 1 2 13 16 6 6 15 9 5 6 7 9 77 to 95 ft−lb (104 to 128 N−m) 17 3 27 to 33 ft−lb (37 to 44 N−m) 11 10 11 8 7 5 14 4 7 RIGHT 4 9 77 to 95 ft−lb (104 to 128 N−m) 77 to 95 ft− lb (104 to 128 N−m) 6 77 to 95 ft−lb (104 to 128 N−m) 18 FRONT 7 5 Figure 33 1. 2. 3. 4. 5. 6.
3. Chock front wheels. Use a jack to raise rear wheels off the ground. Support vehicle with appropriate jack stands beneath the rear frame. 2. Install rear shock absorber(s) if it was removed (Fig. 34): A. Position shock absorber(s) to rear frame and swing arm brackets. 4. Support transaxle from below to prevent the transaxle and swing arm from moving during rear suspension disassembly. CAUTION B. Secure shock absorber(s) to vehicle with flange head screws and lock nuts.
Swing Arm Mount Assembly 140 to 160 ft--lb (190 to 216 N--m) RIGHT FRONT 4 3 27 to 33 ft--lb (37 to 44 N--m) 5 9 1 6 2 7 8 10 Figure 36 1. 2. 3. 4. Front frame Swing arm Cap screw Upper plate Chassis 5. Isolator (upper portion) 6. Isolator (lower portion) 7. Snubbing washer Page 5 -- 38 8. Rear suspension mount 9. Cap screw (2 used) 10.
Removal (Fig. 36) Installation (Fig. 36) 1. Park vehicle on a level surface, turn key switch OFF and remove key from the key switch. Make sure to apply parking brake 1. If rear suspension mount was removed, position mount to front frame and secure with two (2) cap screws, washers and flange nuts. Torque cap screws from 27 to 33 ft--lb (37 to 44 N--m). 2. Raise and support cargo bed with prop rod. 3. Chock the front and rear of both front tires to prevent the vehicle from moving.
Seat Base 8 18 to 22 in--lb (2.1 to 2.4 N--m) 40 to 45 in--lb (4.6 to 5.0 N--m) 20 1 90 to 110 in--lb (10.2 to 12.4 N--m) 18 16 21 17 7 40 to 45 in--lb (4.6 to 5.0 N--m) 14 15 19 12 4 6 13 16 16 6 10 11 18 to 22 in--lb (2.1 to 2.4 N--m) 5 23 16 15 22 2 12 9 3 17 12 RIGHT 17 90 to 110 in--lb (10.2 to 12.4 N--m) FRONT Figure 37 1. 2. 3. 4. 5. 6. 7. 8.
Disassembly (Fig. 37) 1. Park vehicle on a level surface, turn key switch OFF, apply parking brake and remove key from the key switch. 18 to 22 in--lb (2.1 to 2.4 N--m) 1 2 2. Remove seat base assembly with attached seats from vehicle. 6 3. If left hand seat base side is to be removed from vehicle (Fig. 38): A. Remove onboard battery charger from vehicle (see Onboard Battery Charger in the Service and Repairs section of Chapter 3 -- Electrical System). 3 4 B.
Dash 40 to 45 in--lb (4.6 to 5.0 N--m) 90 to 100 in--lb (10.2 to 11.3 N--m) 13 2 15 12 13 2 16 9 13 5 1 3 10 40 to 45 in--lb (4.6 to 5.0 N--m) 14 5 4 6 11 40 to 45 in--lb (4.6 to 5.0 N--m) 18 to 22 in--lb (2.1 to 2.4 N--m) 8 FRONT 7 RIGHT Figure 40 1. 2. 3. 4. 5. 6. Dash Washer head screw (10 used) Foot board Screw (2 used) Washer head screw (10 used) Foot board cover Chassis 7. 8. 9. 10. 11.
Removal (Fig. 40) Installation (Fig. 40) 1. Park vehicle on a level surface, turn key switch OFF, apply parking brake and remove key from the key switch. NOTE: Do not fully tighten fasteners securing dash until all fasteners are in place. 2. Raise hood to allow access to wire harness connections to switches mounted in dash. 3. Disconnect wire harness connectors from all switches and power ports on dash. 4. Remove ten (10) washer head screws that secure dash to vehicle. 5.
Front Fenders, Hood and Bumper 7 7 to 13 in--lb (0.8 to 1.4 N--m) 20 10 19 18 11 8 9 13 18 to 22 in--lb (2.1 to 2.4 N--m) 4 18 to 22 in--lb (2.1 to 2.4 N--m) 3 2 21 1 22 40 to 45 in--lb (4.6 to 5.0 N--m) 17 14 5 RIGHT 200 to 230 in--lb (23 to 25 N--m) 6 12 15 FRONT 16 25 24 40 to 45 in--lb (4.6 to 5.0 N--m) 23 Figure 41 1. 2. 3. 4. 5. 6. 7. 8. 9.
Removal (Fig. 41) Installation (Fig. 41) 1. Park vehicle on a level surface, turn key switch OFF, apply parking brake and remove key from the key switch. NOTE: Do not fully tighten fasteners securing body components until all fasteners are in place. 1. Install removed body components using Figure 41 as a guide. During assembly, use fastener torque specifications that are identified in Figure 41. Chassis 2. Remove front fenders, hood or front bumper using Figure 41 as a guide.
Cargo Bed 2 RIGHT FRONT 5 6 12 3 133 to 147 in--lb (15 to 16 N--m) 10 4 8 9 11 3 7 1 8 140 to 170 in--lb (16 to 19 N--m) 4 27 to 33 ft--lb (37 to 44 N--m) Figure 42 1. 2. 3. 4. Cap screw (2 used) Cargo bed assembly Flange head screw Bed latch striker (2 used) Chassis 5. 6. 7. 8. Prop rod RH cargo bed support LH cargo bed support Flange head screw (6 used) Page 5 -- 46 9. 10. 11. 12.
Disassembly 1. Park vehicle on a level surface, turn key switch OFF, apply parking brake and remove key from the key switch. 90 to 110 in--lb (10.2 to 12.4 N--m) 4 3 6 9 2. Make sure that cargo bed is empty. 3. If necessary, remove cargo bed from vehicle (Fig. 42): 133 to 147 in--lb (15 to 16 N--m) 10 A. Raise cargo bed and support bed so that prop rod assembly can be removed from bottom of bed. 8 11 14 B.
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Chapter 6 Electrical Drawings Table of Contents Electrical Drawings ELECTRICAL DRAWING DESIGNATIONS . . . . . . . 2 ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . 3 Workman GTX Electric (Serial number below 403448000) . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Workman GTX Electric (Serial number above 403448001) . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Workman GTX Lithium . . . . . . . . . . . . . . . . . . . . . . .
Electrical Drawing Designations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BK BLACK BN BROWN BU BLUE GN GREEN GY GRAY OR ORANGE PK PINK R or RD RED T TAN VIO VIOLET W or WH WHITE Y or YE YELLOW Numerous harness wires used on Workman GTX Electric vehicles include a line with an alternate color.
6 5 4 3 2 1 122--0525 REV.
122--1474 Rev.
122--1662 Rev.
6 5 4 3 2 1 122--0525 REV.
6 5 4 3 2 1 122--0525 REV.
6 5 4 3 2 1 122--0525 REV.
6 5 4 3 2 1 122--0524 REV.
6 5 4 3 2 (B--) 1 122--0524 REV.
122--1475 Rev.
122--1475 Rev.
122--1663 Rev.
122--1663 Rev.
6 5 4 3 2 1 122--0839 REV.
6 5 4 3 2 1 122--0730 REV.
6 5 4 3 2 1 122--0818 REV.
6 5 4 3 2 1 122--0785 REV.
6 5 4 3 2 1 122--3995 REV.
6 5 4 3 2 1 122--0894 REV.
122--1027 Rev.
122--1918 Rev.
