Part No. 04127SL (Rev. D) Service Manual WorkmanR e2050 & e2065 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 e2050 and e2065. REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine.
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Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 2 Jacking and Other Instructions . . . . . . . . . . . . . . . 1 – 4 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 5 Chapter 2 – Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . Workman e2050/e2065 2 2 2 3 JACKING AND OTHER INSTRUCTIONS . . . . . . . . Jacking Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Towing Vehicle . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions The Workman e2050 and e2065 are 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.
1. Before servicing or making adjustments to the vehicle, stop vehicle, turn on/off switch to OFF, engage parking brake and remove key from the on/off switch. 10.Never use an open flame to check level or leakage of battery electrolyte. 3. Do not use open pans of flammable cleaning fluids for cleaning parts. 11. When connecting the battery charger to the vehicle, connect the charger cord to the vehicle charger receptacle before plugging the charger power cord into an outlet.
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 On/Off switch is OFF and key is removed from the switch before getting off the vehicle.
Safety and Instruction Decals Workman e2050/e2065 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. Safety (Rev.
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Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) . . . . . . . . . . . . . .
Equivalents and Conversions 0.09375 Product Records and Maintenance (Rev.
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 # 6 – 32 UNC 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 – 40 UNF # 8 – 32 UNC 13 + 2 25 + 5 282 + 30 # 8 – 36 UNF # 10 – 24 UNC 18 + 2 30 + 5 339 + 56 # 10 – 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SA
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) 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 + 5 in–lb 640 + 60 N–cm 78 + 7 in–lb 885 + 80 N–cm M6 X 1.0 96 + 9 in–lb 1018 + 100 N–cm 133 + 13 in–lb 1500 + 150 N–cm M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 27 + 2 ft–lb 36 + 3 N–m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size 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 Recommended Torque** 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.
Maintenance Product Records and Maintenance Maintenance procedures and recommended service intervals for the Workman e2050 and e2065 are covered in the Operator’s Manual. Refer to that publication when performing regular vehicle maintenance. Workman e2050/e2065 Page 2 – 7 Product Records and Maintenance (Rev.
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Chapter 3 Electrical System ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Opening Battery Circuit . . . . . . . . . . . . . . . . . . . . . . 3 VEHICLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 8 General Run Problems . . . . . . . . . . . . . . . . . . . . . .
Electrical Diagrams The electrical schematic, circuit drawings and wire harness drawings for the Workman e2050 and e2065 are located in Chapter 6 – Electrical Diagrams. Electrical System (Rev.
General Information The Workman e2050 and e2065 use a 48 volt DC electrical system that is an isolated circuit. The vehicle frame is not used for any ground connections. After performing any repair on electrical components on the vehicle, make sure that wiring is routed and secured so as to prevent abrasion or contact with moving parts. The vehicle controller monitors operator and vehicle inputs to determine voltage to the traction motor.
Vehicle Operation The Workman e2050 and e2065 electrical system use a 48 volt battery pack, an electric traction motor, a vehicle controller and numerous other electrical components to allow vehicle operation. Eight, 6 volt, deep cycle batteries that are connected in series provide current for a 48 volt DC, high torque traction motor, the vehicle controller and vehicle accessories (headlights, horn, various optional accessories).
Special Tools Multimeter The multimeter can test electrical components and circuits for current, resistance or voltage. NOTE: Workman e2050 and e2065 vehicles use a 48 volt, DC electrical system. If multimeter is not of the auto–range type, make sure to properly set multimeter range before performing any voltage test. Figure 3 Battery Terminal Protector Battery Terminal Protector (Toro Part No.
Battery Watering Dispenser Use the battery watering dispenser when adding distilled water to vehicle batteries. Obtain watering dispenser locally. Figure 6 Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte. Obtain hydrometer locally. Figure 7 Battery Lift Strap Use the battery lift strap to remove and install batteries from the vehicle. Lift strap allows use of case loops on battery tops as safe battery lifting points. Obtain battery lift strap locally.
36/48 Volt Battery Discharge Unit The 36/48 Volt Battery Discharge Unit (TOR4106) is recommended 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 battery pack and also for finding faulty battery or batteries in the battery pack. Order the 36/48 Volt Battery Discharge Unit (TOR4106) from your Toro Distributor. Electrical System Figure 9 Workman e2050/e2065 Page 3 -- 7 Rev. D Electrical System (Rev.
Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect a battery cable from the battery pack to open the battery circuit unless a test procedure requires battery voltage. For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on this vehicle (see Electrical Schematic in Chapter 6).
General Run Problems (Continued) Problem Possible Causes Traction 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 cables are loose, corroded or damaged. Controller is overheated. Traction motor is overheated. Brake or transaxle problem (see Chapter 4 – Transaxle and Brakes). Vehicle runs slowly.
Battery Charger Problems Problem Possible Causes Battery charger does not turn on. AC outlet fuse/circuit breaker blown. AC outlet is faulty. Vehicle wiring is loose or damaged (see electrical schematic in Chapter 6 – Electrical Diagrams). Fusible link FL1 is damaged. Vehicle charger interlock switch or circuit wiring faulty. Vehicle charger receptacle or circuit wiring damaged. Battery charger is faulty. Battery charger does not turn off. Battery charger is faulty.
Adjustments Accelerator Switch Adjustment 1. Position vehicle on a level surface, turn On/Off switch OFF and remove key. Apply parking brake. 3 2 1 2. Make sure that at complete brake pedal travel, the park detent and pawl are fully engaged. If needed, adjust the accelerator pedal stop cap screw to allow full engagement (Fig. 11). 6 5 3. Disengage the parking brake. 5. If distance is incorrect, loosen lock nut and adjust accelerator switch stop cap screw position (Fig. 11). 4 Figure 10 1.
Accelerator Potentiometer Adjustment The accelerator potentiometer is used as one of the inputs for the vehicle controller and is attached to the pedal frame under the dash (Fig. 13). A collar with roll pin on the accelerator pedal shaft positions the accelerator potentiometer lever. 1 4 5 If the accelerator potentiometer is out of adjustment, the diagnostic light on the dash will flash six (6) times.
Accelerator System Calibration The accelerator system on the Workman e2050 and e2065 includes the accelerator pedal assembly, the accelerator potentiometer, the accelerator switch and the controller. If any of these components are adjusted, removed or replaced, the following calibration procedure should be performed. Additionally, if vehicle movement is erratic and jerky or if the diagnostic light on the dash is flashing six (6) times, calibration of the accelerator system should be performed. 1 4 2.
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 on/off switch before doing a continuity check on the on/off switch). CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected. On/Off Switch The Workman on/off switch is located on the dash panel (Fig. 17).
Battery Discharge Indicator and Hour Meter Gauge The combination battery discharge indicator and hour meter gauge is located on the dash panel (Fig. 19). 1 The battery indicator identifies state of charge of the battery pack. The battery indicator reads full (10 bars) when the battery pack is fully charged (approximately 51 volts). As battery pack voltage decreases with vehicle use, fewer battery indicator bars are shown. Figure 19 1.
Vehicle Direction (Forward/Reverse) and Headlight Switches The vehicle direction (forward/reverse) switch (Fig. 21) and headlight switch (Fig. 22) are located on the control panel. These two switches have identical logic. The vehicle direction switch is one of several inputs for the vehicle controller and allows the direction (forward/ reverse) of the vehicle to be changed by the operator. The headlight switch allows the headlights to be turned on and off.
Vehicle Status Light The vehicle status light is located on the control panel (Fig. 24). During normal operation, the status light should be continuously illuminated. A vehicle electrical problem will be identified by a flashing status light. See Controller (in this section) and your Operator’s Manual for information on a flashing vehicle status light. 1 Figure 24 1. Vehicle status light Testing 1. Make sure on/off switch is turned OFF. Remove key from switch. 1B (–) 2.
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 inputs for the vehicle controller and allows the speed of the vehicle to be limited. Test the switch by disconnecting the wiring and connecting a continuity tester across the two switch terminals. Rotate key to On position: there should be an indication of continuity.
Charger Interlock Switch The charger interlock switch is located behind the charger receptacle plate on the front of the seat base (Fig. 29). When the battery charger is plugged into the charger receptacle, the interlock switch closes and provides an input to the vehicle controller to inhibit vehicle operation. NOTE: The vehicle should not operate if the charger plug is connected to the charger receptacle. 1. Make sure vehicle On/Off switch is OFF. Remove key from switch. 2.
Main and Accessories Contactors Two contactors (solenoids) are used on the Workman e2050 and e2065 for circuit control. 5 4 1 The main contactor provides current to the vehicle controller and is energized when the on/off switch is ON. The main contactor is located under the controller cover beneath the bed (Fig. 31). 2 The accessories contactor provides current to the headlights, horn and optional electrical accessories. The accessories contactor is energized when the on/off switch is ON.
6. Replace contactor if necessary. 3 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. 5 4 4 6 8. Reconnect battery cable that was removed from battery pack. 3 2 7 1 8 1. 2. 3. 4. Workman e2050/e2065 Page 3 – 21 Main contactor Cable to controller B+ Lock nut Flat washer 5. 6. 7. 8. Wire harness connector Fuse (F1) Positive battery cable Isolator Electrical System (Rev.
Fuses There are three (3) fuses in the Workman electrical system. Two (2) of the fuses are located beneath the steering column (Fig. 35). These fuses supply power to the following: 1 The upper 10 ampere fuse (F2) supplies power to the on/off switch and switched circuits. The lower 10 ampere fuse (F3) supplies power to optional accessories. The third fuse (F1) is located under the controller cover beneath the bed (Fig. 36).
Fusible Links The wiring harness for the Workman includes three (3) fusible links for circuit protection (Fig. 37). 1 Two fusible links attach to the same main contactor post as the main fuse. One of these fusible links (FL2) is used for the switched power circuit. The other fusible link (FL1) protects the charger circuit. The third fusible link (FL3) is attached to the controller B+ terminal. This link provides protection for the charge indicator/hour meter gauge. 3 2 4 5 Figure 37 1.
Accelerator Switch The accelerator switch is a four terminal, two circuit switch that is located on the control pedal frame (Fig. 38). The Workman 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 circuit (input) for the controller to allow traction motor operation. When the accelerator pedal is released, the switch provides an open circuit (no input) for the controller to prevent traction motor operation.
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 positions the accelerator potentiometer lever. When the operator presses or releases the accelerator pedal, the potentiometer resistance changes. This resistance change is used by the controller to determine current flow to the traction motor.
Controller The Workman controller is secured to the rear frame under 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 potentiometer) to accurately control vehicle speed, vehicle direction (forward and reverse) and regenerative braking. An internal thermal sensor prevents overheating of the controller.
1 Flash System inoperable. Turn on/off switch OFF, wait several seconds and turn on/off switch ON. If controller does not reset correctly, controller replacement may be necessary. 2 Flashes The accelerator pedal was depressed when on/off switch was turned ON. Turn on/off switch OFF, release accelerator pedal and turn on/off switch to ON. System inoperable. Turn on/off switch OFF, wait several seconds and turn on/off switch ON.
Service and Repairs Battery Service 115 to 125 in--lb (13 to 14.1 N--m) 9 115 to 125 in lb (13 to 14.1 N--m) 11 5 12 10 4 1 8 6 7 5 4 3 RIGHT 2 FRONT Figure 43 1. 2. 3. 4. Battery (8 used) Battery rod (2 used) Negative cable to vehicle Lock washer (2 used per battery) 5. 6. 7. 8. Hex nut (2 used per battery) Cable terminal boot Battery cable (6 used) Positive cable to vehicle 9. 10. 11. 12.
2. Make sure the battery supports are clean and repainted if necessary. Make sure cables, terminals, rods and hold down retainers are in good condition. WARNING POTENTIAL HAZARD: The battery terminals, metal tools and metal vehicle parts could short together. WHAT CAN HAPPEN: Sparks can cause the battery gasses to explode. Damaged cables could short against metal vehicle parts and cause sparks.
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. Indicator lights (green and red) and an ammeter on the charger give information about the charging operation. Make sure to have the battery cell plates covered with electrolyte before charging the batteries (Fig. 46).
A. Remove battery filler caps. Do not add water prior to testing specific gravity of battery electrolyte. If electrolyte level is low, add distilled water and charge battery (see Operator’s Manual) before performing specific gravity test. Testing When testing batteries in the Workman e2050 and e2065, it is important to 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. 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 remain connected to vehicle during storage to prevent battery discharge and potential battery damage. Electrical System (Rev. B) If the vehicle will be stored for more than 30 days and the battery charger cannot be used for some reason, charge the batteries fully. Either store batteries on a shelf or in the vehicle.
Traction Motor Brushes The traction motor in the Workman e2050/e2065 uses eight (8) brushes. Traction motor brushes should be inspected every 500 hours of operation or annually. 4 2 3 Inspection 1. Make sure that on/off switch is OFF. Raise and latch bed to allow access to traction motor. 2. Open the battery circuit by carefully removing one of the battery cables (see Opening Battery Circuit in the General Information section of this chapter). 3.
Traction Motor 14 115 to 125 in lb (13 to 14.1 N–m) 15 16 18 3 17 4 5 6 15 7 5 8 16 9 10 1 19 11 12 2 13 RIGHT FRONT Figure 51 1. 2. 3. 4. 5. 6. 7. Socket head screw (6 used) Flat washer (6 used) Flange nut Support bracket Carriage screw Transaxle mount plate Rubber damper 8. 9. 10. 11. 12. 13. Traction motor Fan Roll pin (2 used) Washer Socket head screw Plastic cap (fits in rear frame) Removal (Fig. 51) 1.
4. Disconnect wires from traction motor (Fig. 52): A. While retaining lower nut, remove upper nut and wire connector from motor terminals A1, A2, F1 and F2. B. Unplug motor temperature sensor from vehicle wire harness. Note location of cable tie that secures temperature sensor wires to vehicle. 2. Make sure that rubber damper is installed into the motor shaft internal spline with the damper flat side toward the motor (Fig. 52). 85 to 90 in–lb (9.6 to 10.2 N–m) 55 to 60 in–lb (6.2 to 6.8 N–m) 2 C.
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. 3 CAUTION 1 To prevent motor damage and personal injury, make sure that traction motor is well supported as it is installed. Motor weighs approximately 62 pounds (28.1 kg). 2 4. Carefully lower motor into vehicle. Align motor shaft with transaxle input shaft and slide motor to transaxle. Take care to not damage thermal switch while installing motor. Figure 55 1.
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Traction Motor Service 15 14 120 to 140 in–lb (13.6 to 15.8 N–m) 11 13 1 12 3 10 2 5 4 6 7 18 to 22 in–lb (2 to 2.5 N–m) 8 9 Figure 57 1. 2. 3. 4. 5. Frame and field assembly Armature Brush lead (2 used) Cap screw (2 used per brush lead) Cap screw (4 used) 6. 7. 8. 9. 10. Cap screw (8 used) Brush (8 used) High temperature sensor Headband Bolt (4 used) Disassembly (Fig. 57) 1. Unlatch and slide headband from traction motor. 4.
1. Check the brush springs for correct alignment on the back of the brush. A brush spring that does not apply equal pressure on the center of the brush will cause the brush to wear unevenly. Check for correct clearance and freedom of brush movement in the holder. 2. Replace brushes that are worn to a length of 0.620” (16 mm). Also, replace brushes if they show signs of uneven wear or show signs of overheating, such as discolored brush shunts and brush springs. 3.
Commutator Service MICA 1. Chuck armature on the commutator end–bearing journal and support the drive end of armature using the ”live” center of the shaft. With the armature supported on both ends, measure the commutator runout and the bar to bar differences with a dial gauge. Total indicated runout should not exceed 0.003” (0.08 mm) and not more than 0.0005” (0.013 mm) between any two bars. If the readings fall outside this limit, the commutator must be turned and re–undercut. COPPER SEGMENT .040” (1.
Assembly (Fig. 57) PRESS FIXTURE MUST HOLD INNER RACE STATIONARY END HEAD MUST BE HELD STATIONARY Figure 62 1 2 2. Press a new bearing into the commutator end head, pressing on the bearing outer race only (Fig. 62). Secure bearing with retaining ring. 4. Ensure the brushes are pushed out of the way. BEARING AND RETAINING RING INSTALLED IN END HEAD BEARING 1. After servicing the commutator and brushes, re–assemble the wiring in the commutator end head as originally found.
Battery Charger 1 2 12 3 11 10 4 9 5 8 7 6 Figure 65 1. 2. 3. 4. Upper case Transformer Lower case SCR assembly 5. 6. 7. 8. Control board Relay Circuit breaker AC cordset 9. 10. 11. 12. DC cordset Ammeter Fuse Diode assembly For service of the battery charger, see the Lester Electrical Technician Service Guide at the end of this chapter. Electrical System (Rev.
Chapter 4 Transaxle and Brakes Table of Contents Workman e2050/e2065 Page 4 – 1 Transaxle and Brakes SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Adjust Brakes (Workman e2050) . . . . . . . . . . . . . . 6 SERVICE AND REPAIRS . . . . . . . . . . . . . .
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Specifications Item Description Transaxle Transaxle Fluid Capacity Transaxle Fluid Transaxle and Brakes 2 quarts (1.9 liters) 10W–30 Motor Oil Workman e2050/e2065 Page 4 – 3 Transaxle and Brakes (Rev.
Troubleshooting Brakes ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
Brakes (continued) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Adjustments Adjust Brakes (Workman e2050) The recommended brake pedal travel is from 1” to 1 1/2” (25.4 to 38.1 mm) with a 75 to 100 pound (34 to 45.4 kg) input force to the brake pedal. 1 Adjustment Procedure (Figures 1 and 2) 2 1. Park vehicle on a level surface, turn on/off switch OFF and remove key from the on/off switch. 3 4 2. Depress brake pedal lightly (10 to 15 pound input force) until resistance is achieved.
Transaxle and Brakes This page is intentionally blank. Workman e2050/e2065 Page 4 – 7 Transaxle and Brakes (Rev.
Service and Repairs Rear Wheels and Brakes 45 to 65 ft–lb (61 to 88 N–m) 15 to 19 ft–lb (20 to 26 N–m) 5 4 2 3 6 7 1 8 13 12 9 RIGHT 10 11 FRONT Figure 3 1. 2. 3. 4. 5. Lug nut (5 used per wheel) Wheel assembly Brake drum Axle shaft Wheel stud (5 used per wheel) 6. 7. 8. 9. Flange head screw (4 used per brake) Brake assembly (RH shown) Nut (4 used per brake) Cotter pin Removal (Fig. 3) 1. Park vehicle on a level surface, turn on/off switch OFF and remove key from the on/off switch. 10. 11.
Installation (Fig. 3) Burnish Brake Shoes IMPORTANT:On Workman e2050 vehicles, the brake actuator levers must be positioned below the transaxle mount. On Workman e2065 vehicles, the levers should be positioned above the transaxle mount. When positioned correctly, the brake actuator levers will point toward the rear of the vehicle (Fig. 4). To provide maximum brake performance after rear brake shoes are replaced, burnish new brake shoe linings. 1.
Brake Service (Workman e2050) 19 6 1 4 7 7 7 2 2 1 9 9 6 ROTATION TO EXPAND BRAKE SHOES 18 6 12 9 5 3 17 17 11 7 16 15 7 10 14 3 5 7 7 8 13 8 1 Figure 5 1. 2. 3. 4. 5. 6. 7. Backing plate Hold down pin Bottom shoe–to–shoe spring Top shoe–to–shoe spring Auto adjust spring Shoe cup (spring loaded) Brake shoe Transaxle and Brakes (Rev. B) 8. Actuator lever 9. Adjusting screw 10. PTFE coated washer 11. Push rod 12. Shim washer 13. Protective boot Page 4 – 10 (Rev. C) 14. 15. 16.
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. Inspect backing plate surfaces which contact with the brake shoes for grooves that may restrict shoe movement. Replace backing plate if grooves can not be removed by light sanding with emery cloth or other suitable abrasive. Replace backing plate if cracked, warped or excessively rusted. 4.
Rear Brake Service (Workman e2065) 110 to 120 in–lb (12.4 to 13.6 N–m) 6 110 to 120 in–lb (12.4 to 13.6 N–m) 3 8 2 9 11 10 7 11 5 10 12 1 13 8 7 110 to 120 in–lb (12.4 to 13.6 N–m) 4 3 12 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. Brake backing plate Washer head screw Brake shoe Lower spring Wheel cylinder Parking brake lever (LH shown) Belleville washer Adjuster lever Dust cover 10. 11. 12. 13. Flat washer Bolt Shoe hold down cup and spring Upper spring 4.
Inspection (Fig. 6) Assembly (Fig. 6) 1. Inspect brake drums. IMPORTANT:Brake shoe lining surfaces must be free of grease, oil and other foreign matter. A. Clean drums with denatured alcohol. Check braking surface diameter in at least three places. If the diameter exceeds 6.320” (16.05 cm), replace both brake drums. B. Replace drums that are cracked, deeply grooved, tapered, significantly out–of–round, scored, heat spotted or excessively rusted. C. Minor scoring can be removed with sandpaper. 2.
Hydraulic Brake System (Workman e2065) 14 13 35 34 33 36 7 4 12 24 19 2 5 11 21 10 26 18 6 17 16 11 9 32 20 8 15 23 27 25 32 32 22 31 30 28 Loctite #242 29 3 RIGHT FRONT 37 1 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Brake caliper (LH) Brake caliper (RH) Brake rotor (2 used) Front brake tube Front brake hose Carriage screw Rear brake tube Carriage screw Rear brake hose bracket Cap screw Thread forming screw (6 used) Clip Tee fitting 14. 15. 16. 17. 18. 19. 20. 21.
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. 5. Repeat steps 1 to 4 for other brake cylinders and calipers. CAUTION 2. Have a helper pump brake pedal several times, then hold pedal down firmly. 3. With pedal firmly depressed, open bleeder valve until pedal fades to floor. Close bleeder valve before releasing pedal. 6.
Front Brake Calipers (Workman e2065) 10 2 To rear brakes 9 Loctite #242 8 13 7 45 to 65 ft–lb (61 to 88 N–m) 6 3 5 4 RIGHT 1 12 FRONT 11 Figure 8 1. 2. 3. 4. 5. LH brake caliper RH brake caliper Lock washer (2 per caliper used) Cap screw (2 per caliper used) Wheel hub assembly Transaxle and Brakes (Rev. B) 6. 7. 8. 9. Brake rotor Socket head screw (4 per rotor used) Spindle (LH shown) A–arm (LH shown) Page 4 – 16 10. 11. 12. 13.
Removal (Fig. 8) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. 3. Align caliper mounting holes with spindle. Secure caliper with two (2) cap screws and lock washers. 4. Install brake hose to caliper. 5. Install front wheel assembly. Torque lug nuts from 45 to 65 ft–lb (61 to 88 N–m). Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety. 6. Lower machine to ground. 7.
Brake Master Cylinder (Workman e2065) 1 4 2 5 3 6 7 RIGHT FRONT Figure 10 1. Master cylinder 2. Cap screw 3. Brake pedal 4. Clevis pin 5. Cotter pin 6. Flange head nut 7. Pedal frame Removal (Fig. 10) Installation (Fig. 10) 1. Remove front hood from machine. 1. Position master cylinder to pedal frame and secure with cap screws and flange nuts. 2. Remove cotter pin from the clevis pin that connects master cylinder to brake pedal. 3.
Brake Master Cylinder Service (Workman e2065) Disassembly (Fig. 11) 1 1. Remove reservoir and flange seal. Push in on the push rod so the stop pin can be removed. 2 12 3 2. Disconnect lower end of the dust cover from the housing. 3. Push in on the push rod and remove circlip, then remove push rod with dust cover and clevis. Remove retainer washer. 4 11 4. Remove primary piston assembly and secondary piston assembly from cylinder housing. Inspection 2.
Parking Brake (Workman e2065) 11 10 8 2 1 9 7 6 17 16 5 14 4 12 3 15 13 RIGHT FRONT Figure 12 1. 2. 3. 4. 5. 6. Parking brake cover Operator seat Seat base Cable equalizer bracket Parking brake lever Curved washer Transaxle and Brakes (Rev. B) 7. 8. 9. 10. 11. 12. Lock nut Flat washer Flange head screw (4 used) Flat washer (2 used) Screw (2 used) Cap screw Page 4 – 20 13. 14. 15. 16. 17.
Disassembly (Fig. 12) Assembly (Fig. 12) 1. Park machine on a level surface, stop engine and remove key from the ignition switch. Chock wheels to prevent the machine from moving. 1. Secure brake cables to parking brake support and cable equalizer bracket using Figure 12 as a guide. A. Remove cotter pin and clevis pin that secures each brake cable end to brake lever. B. Remove retaining ring that secures each brake cable to frame. C. Remove screw and flange nut that secure each R–clamp to rear frame. 3.
Transaxle 23 115 to 125 in–lb (13 to 14.1 N–m) 2 3 4 5 3 6 22 7 8 1 9 10 11 21 16 15 14 13 45 to 65 ft–lb (61 to 88 N–m) 20 2 17 19 12 18 v Figure 13 1. 2. 3. 4. 5. 6. 7. 8. Socket head screw (6 used) Flange nut Carriage screw (5 used) Support bracket Transaxle mount plate Rubber damper Traction motor Fan Transaxle and Brakes (Rev. B) 9. 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 13) 1. Park vehicle on a level surface, turn on/off switch OFF, set parking brake and remove key from switch. 2. Remove cargo bed from vehicle (see Cargo Bed Removal in Service and Repairs section of Chapter 5 – Chassis). 3. Open the battery circuit by carefully removing one of the battery cables (see Opening Battery Circuit in the General Information section of Chapter 3 – Electrical System). 9.
Installation (Fig. 13) 1. If removed, install traction motor to transaxle (see Traction Motor Installation in Service and Repairs section of Chapter 3 – Electrical System). 1 3 2 2. Position transaxle and motor assembly to the rear frame. Loosely install all fasteners used to secure transaxle to vehicle. Tighten fasteners in the following order: A. Tighten four (4) flange head screws and flange nuts that secure transaxle to the rear frame. B.
Transaxle and Brakes This page is intentionally blank. Workman e2050/e2065 Page 4 – 25 Transaxle and Brakes (Rev.
Transaxle Service 1 6 87 4 5 7 9 8 30 28 89 34 7 29 35 27 12 10 32 3 11 28 31 30 27 26 21 23 24 29 30 31 23 33 22 25 13 15 13 30 16 25 32 15 14 16 3 20 18 2 19 17 Figure 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Oil seal Wheel stud (5 used per side) Axle shaft Ball bearing Input shaft Ball bearing O–ring Retaining ring Endcap plug Ball bearing Vent elbow Transaxle housing 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Chapter 5 Chassis Table of Contents Chassis SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3 Suspension and Steering . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5 Check Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inspect Tires and Wheels . . . . . . . . . . . . . . . . . . . . 5 Upper Steering . . . . . . . . . . . . . . . . . . .
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 rear) Chassis (Rev.
Troubleshooting Suspension and Steering ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Suspension and Steering (continued) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Problem Possible Cause Steering
Service and Repairs Check Tire Pressure The tire pressure range for front and rear tires is 8 to 22 PSI (0.55 to 1.52 bar). The tire pressure needed is determined by the payload carried. Higher pressures should be used for heavier payloads at higher speeds. Do not exceed the maximum tire pressure. The lower the air pressure, the less the compaction and tire marks are minimized. Lower pressure should not be used for heavy payloads at higher speeds.
Upper Steering 1 13 Antiseize lubricant 10 2 16 3 13 to 17 ft–lb (18 to 23 N–m) 11 10 12 14 4 9 8 7 6 Antiseize lubricant 4 5 15 Figure 1 1. 2. 3. 4. 5. 6. Nut Lock washer Steering wheel Flange lock nut Steering gearbox Cap screw Chassis (Rev. B) 7. 8. 9. 10. 11. Lock washer Steering shaft Cap screw (3 used) Upper steering bushing Carriage bolt (4 used) Page 5 – 6 12. 13. 14. 15. 16.
1. Park vehicle on a level surface, turn on/off switch OFF, set parking brake and remove key from the switch. 2. Open the battery circuit by carefully removing one of the battery cables (see Opening Battery Circuit in the General Information section of Chapter 3 – Electrical System). 3. Remove front hood to gain access to the steering mechanism (see Front Hood Removal in this section). 4. Remove steering wheel cover carefully from the steering wheel.
Steering Gearbox 27 to 33 ft–lb (37 to 45 N–m) 9 90 to 110 in–lb (10.2 to 12.4 N–m) 8 18 3 6 2 17 15 10 16 7 14 6 1 11 5 10 175 to 225 in–lb (19.8 to 25.4 N–m) 12 4 19 13 Note alignment marks Figure 2 1. 2. 3. 4. 5. 6. 7. Gasket Hex washer head screw (4 used) Seal Sector gear Flat washer Ball bearing Output shaft spacer Chassis (Rev. B) 8. 9. 10. 11. 12. 13. Stepped washer Flange head screw with patch lock Ball bearing Input shaft spacer Flat washer Cap screw Page 5 – 8 14. 15. 16.
Disassembly (Fig. 2) Assembly (Fig. 2) IMPORTANT:Do not reuse flange head screw with patch lock (item 9) after it has been removed. IMPORTANT:Always replace ball bearings as a set. 1. If ball bearings were removed: A. Press new bearing into housing from the inside first. 2. Remove cap screw (item 13) and flat washer (item 12) from pinion gear shaft. B. Turn housing over. Insert spacer and press new bearing into housing. 3.
Front Wheels (Workman e2050) Antiseize Lubricant 1 6 2 4 135 to 165 ft–lb (183 to 224 N–m) 2 Loctite #242 3 5 8 9 10 RIGHT 45 to 65 ft–lb (61 to 88 N–m) FRONT 11 7 Figure 3 1. 2. 3. 4. Spindle (LH shown) Bearing (with retaining ring) Wheel stud (5 per wheel) Wheel hub Chassis (Rev. B) 5. 6. 7. 8. Spacer Tire/wheel assembly Lug nut (5 per wheel) Flat washer Page 5 – 10 9. Large flat washer 10. Cap screw 11.
Removal (Fig. 3) 1. Park vehicle on a level surface, turn on/off switch OFF, set parking brake and remove key from the on/off switch. 3. Position wheel to studs in wheel hub and secure with five (5) lug nuts. Torque lug nuts from 45 to 65 ft–lb (61 to 88 N–m). 4. Lower machine to ground. Remove chocks from wheels. WARNING 1 Before jacking up the machine, review and follow Jacking Instructions in Operator’s Manual and Chapter 1 – Safety. 3 2 2. Chock wheels not being jacked up.
Lower Steering (Workman e2050) 19 20 17 21 22 18 20 to 25 ft–lb (27 to 34 N–m) 1 23 24 14 17 Antiseize Lubricant 16 2 15 20 to 25 ft–lb (27 to 34 N–m) 3 14 13 5 4 12 135 to 165 ft–lb (183 to 224 N–m) Loctite #242 11 2 6 RIGHT 10 7 75 to 100 ft–lb (102 to 136 N–m) 8 FRONT 9 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. Pitman arm Grease fitting Cap screw (king pin) Spindle (LH) Front wheel assembly Flat washer Large flat washer Cap screw 9. 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 5) Installation (Fig. 5) 1. Park vehicle on a level surface, turn on/off switch OFF, set parking brake and remove key from the on/off switch. 1. Install spindle as follows: A. Position king pin sleeve into the pivot hub of the A–arm. Spacer must extend through the bottom of the hub. WARNING NOTE: Make sure cap screw (king pin) is inserted down through the spindle and A–arm hub. 2. Chock wheels not being jacked up. Jack front wheel off the ground and place blocks beneath the frame. C.
Front Wheels and Lower Steering (Workman e2065) Loctite #242 16 14 20 to 25 ft–lb (27 to 34 N–m) RIGHT See text for tightening procedure 13 12 10 1 8 24 FRONT 6 3 30 15 25 11 9 45 to 55 ft–lb (61 to 74 N–m) 31 36 7 5 33 29 26 32 19 34 35 23 45 to 55 ft–lb (61 to 74 N–m) 2 20 28 27 18 25 24 20 to 25 ft–lb (27 to 34 N–m) 39 45 to 65 ft–lb (61 to 88 N–m) 38 21 22 4 17 37 75 to 100 ft–lb (102 to 136 N–m) Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
D. Insert tie rod ball joints down through the spindle and up through the Pitman arm. Secure with castle nuts. 3. Remove lug nuts and pull wheel assembly from machine. 4. Remove brake caliper from spindle (see Front Brake Calipers in the Service and Repairs section of Chapter 4 – Transaxle and Brakes). Position caliper away from wheel hub and spindle. E. Torque castle nuts from 20 to 25 ft–lb (27 to 34 N–m) to secure ball joint while aligning castle nut slot with hole in ball joint stud.
A–arm and Frame Pivot Yoke RIGHT 14 FRONT 13 12 11 15 8 2 16 17 240 to 290 ft–lb (325 to 393 N–m) 2 10 2 9 8 7 240 to 290 ft–lb (325 to 393 N–m) 6 5 1 4 3 2 Figure 7 1. 2. 3. 4. 5. 6. Ride height adjustment bolt Bushing Grease fitting A–arm (LH) Flange nut Lock nut Chassis (Rev. B) 7. 8. 9. 10. 11. 12. Lock washer Centering bolt (2 used per A–arm) Travel limiting bolt A–arm (RH) Flange head screw (4 used) Flange nut (4 used) Page 5 – 16 13. 14. 15. 16. 17.
A–arm Removal (Fig. 7) 1. Park vehicle on a level surface, turn on/off switch OFF, set parking brake and remove key from the on/off switch. WARNING Before jacking up the machine, review and follow Jacking Instructions in Operator’s Manual and Chapter 1 – Safety. 2. Chock wheels not being jacked up. Jack front wheel off the ground and place blocks beneath the frame. 4. Lower machine to ground. Remove chocks from wheels. 5. Adjust front ride height (see Operator’s Manual). 6.
Pivot Yoke Removal (Fig. 7) 1. Park vehicle on a level surface, turn on/off switch OFF, set parking brake and remove key from the on/off switch. 2. Open the battery circuit by carefully removing one of the battery cables (see Opening Battery Circuit in the General Information section of Chapter 3 – Electrical System). 3. Remove cargo bed from the rear frame (see Cargo Bed Removal in this section). 4. Remove seat base from the front frame (see Seat Base Removal in this section). 2.
Chassis This page is intentionally blank. Workman e2050/e2065 Page 5 – 19 Chassis (Rev.
Seat Base 1 2 3 4 18 17 5 6 16 15 7 14 8 13 22 12 21 20 19 9 RIGHT 10 11 FRONT 10 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. Seat Seat bracket Rubber receptacle Rivet Cap screw (4 used per seat) Screw Holding post Seat base Chassis (Rev. B) 9. 10. 11. 12. 13. 14. 15. Seat base tray Flange head screw (8 used) Flat washer (4 used) Front frame Screw (4 used) Floor mat Charger receptacle plate Page 5 – 20 16. 17. 18. 19. 20. 21. 22.
Removal (Fig. 11) 1 1. Park vehicle on a level surface, turn on/off switch OFF, set parking brake and remove key from the on/off switch. 2. Open the battery circuit by carefully removing one of the battery cables (see Opening Battery Circuit in the General Information section of Chapter 3 – Electrical System). 2 A 3. Remove seats from seat base. 4. Remove four (4) screws (item 12) that secure receptacle plate to front of seat base.
Front Hood 3 1 2 2 12 4 11 13 9 4 10 9 RIGHT 5 6 7 FRONT 8 Figure 14 1. 2. 3. 4. 5. Hood Flange head screw (6 used) Dash Flange nut (6 used) Fender (LH shown) Chassis (Rev. B) 6. 7. 8. 9. Bumper Flat washer (2 used) Cap screw (2 used) Flat washer (4 used) Page 5 – 22 10. 11. 12. 13.
Removal (Fig. 14) 1. Park vehicle on a level surface, turn on/off switch OFF, set parking brake and remove key from the on/off switch. 2. Open the battery circuit by carefully removing one of the battery cables (see Opening Battery Circuit in the General Information section of Chapter 3 – Electrical System). 5. Connect wire harness connectors to headlight terminals with screws. 6. Reconnect removed battery cable to battery terminals. Install lock washer and nut on battery terminals.
Cargo Bed 35 to 55 in–lb (4 to 6.2 N–m) 3 2 5 6 4 7 8 10 9 1 11 12 13 17 14 35 to 55 in–lb (4 to 6.2 N–m) 15 15 16 100 to 200 in–lb (11.3 to 22.6 N–m) 33 32 RIGHT 31 18 30 19 20 21 22 23 29 24 FRONT 26 27 28 25 Figure 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Cargo bed Striker plate (2 used) Screw (3 per striker plate) Tailgate channel RH latch rod RH latch bracket Grip knob Tailgate LH latch rod Screw (2 per bracket) LH latch bracket 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Chapter 6 Electrical Diagrams Table of Contents Electrical Diagrams ELECTRICAL SCHEMATIC Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL CIRCUIT DRAWINGS On/Off Switch Turned On . . . . . . . . . . . . . . . . . . . . 4 Run Circuit (Forward) . . . . . . . . . . . . . . . . . . . . . . . . 5 Battery Charging Circuit . . . . . . . . . . . . . . . . . . . . . . 6 ELECTRICAL HARNESS DRAWINGS Electrical Harness Drawing: Workman e2050 . . .
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F3 IGNITION–SWITCH OFF RUN FUSE HOLDERS F2 W 10 A R ACCESSORIES CONTACTOR (SOLENOID) HORN BK HORN SWITCH 10 A PK BU OR BATT. CHG.
F3 BU IGNITION–SWITCH OFF RUN FUSE HOLDERS F2 (IN RUN) BK HORN SWITCH 10 A R ACCESSORIES CONTACTOR (SOLENOID) (ENERGIZED) HORN W 10 A PK OR BATT. CHG.
F3 BU IGNITION–SWITCH OFF RUN FUSE HOLDERS F2 (IN RUN) BK HORN SWITCH 10 A R ACCESSORIES CONTACTOR (SOLENOID) (ENERGIZED) HORN W 10 A PK OR BATT. CHG.
F3 BU IGNITION–SWITCH OFF RUN FUSE HOLDERS F2 (OFF) BK HORN SWITCH 10 A R ACCESSORIES CONTACTOR (SOLENOID) (NOT ENERGIZED) HORN W 10 A PK OR BATT. CHG.
Workman e2050 Electrical Harness Drawing Page 6 – 7
FUSIBLE LINK RED RED ORANGE PINK RED/WHITE ORANGE ORANGE FUSIBLE LINK RED ORANGE WHITE BLUE RED/WHITE BLACK BLUE/WHITE BLUE BLACK BLACK BLACK BROWN WHITE/BLACK BLUE/WHITE YELLOW ORANGE PINK BLACK BLUE YELLOW VIOLET/BLACK BLUE/WHITE BLACK WHITE BROWN BLACK BLACK GREEN BLACK TAN TAN TAN GRAY BLACK BLACK BLUE BLACK BLUE RED/WHITE BLUE YELLOW/BLACK BLACK RED BLACK RED/BLACK YELLOW FUSIBLE LINK BLACK ORANGE GREEN BLACK ORANGE BLUE ORANGE BLUE Workman e2050 Elect
Workman e2065 Electrical Harness Drawing Page 6 – 9 Rev.
ORANGE ORANGE WHITE RED/WHITE BLACK FUSIBLE LINK RED RED ORANGE PINK FUSIBLE LINK RED ORANGE WHITE RED/WHITE BLUE BLACK BLUE/WHITE BLUE BLACK BLACK BLACK BROWN WHITE/BLACK BLUE/WHITE YELLOW ORANGE BLACK PINK BLUE YELLOW VIOLET/BLACK BLACK BLUE/WHITE WHITE BROWN BLACK BLACK BLACK GREEN BLACK TAN TAN TAN GRAY BLACK BLACK BLUE BLACK RED/WHITE BLUE BLUE YELLOW/BLACK BLACK RED BLACK RED/BLACK ORANGE GREEN YELLOW ORANGE BLUE BLACK ORANGE FUSIBLE LINK BLUE Wor