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.
This safety symbol means DANGER, WARNING
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
REFER TO THE OPERATOR’S MANUAL FOR OPER-
ATING, MAINTENANCE AND ADJUSTMENT IN-
STRUCTIONS. Space is provided in Chapter 2 of this
book to insert the Operator’s Manuals and Parts Cata-
logs for your machine. Replacement Operator’s Manu-
als are available on the Internet at www.toro.com.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
The Toro Company reserves the right to change product
specifications or this publication without notice.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
E The Toro Company - 2004, 2006, 2007, 2011
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Table Of Contents
Chapter 1 – Safety
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 – 2
Jacking and Other Instructions . . . . . . . . . . . . . . . 1 – 4
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 – 5
Chapter 2 – Product Records and Maintenance
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 1
Equivalents and Conversions . . . . . . . . . . . . . . . . 2 – 2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 – 3
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 – 7
Chapter 3 – Electrical System
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 – 3
Vehicle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 8
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 – 11
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 3 – 14
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 3 – 28
LESTER ELECTRICAL TECHNICIAN
SERVICE GUIDE
Chapter 4 – Transaxle and Brakes
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 6
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 4 – 8
SPICER OFF–HIGHWAY COMPONENTS MODEL
12 (ELECTRIC) MAINTENANCE MANUAL
Chapter 5 – Chassis
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 – 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 5 – 5
Chapter 6 – Electrical Diagrams
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 6 – 3
Electrical Circuit Drawings . . . . . . . . . . . . . . . . . . . 6 – 4
Electrical Harness Drawings . . . . . . . . . . . . . . . . . 6 – 7
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Chapter 1
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3
JACKING AND OTHER INSTRUCTIONS . . . . . . . . 4
Jacking Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Towing Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transporting Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 5
Workman e2050/e2065
Page 1 – 1
Safety (Rev. B)
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Safety Instructions
The Workman e2050 and e2065 are designed and
tested to offer safe service when operated and main-
tained properly. Although hazard control and accident
prevention are partially dependent upon the design and
configuration of the machine, these factors are also de-
pendent upon the awareness, concern and proper train-
ing of the personnel involved in the operation, transport,
maintenance and storage of the machine. Improper use
or maintenance of the machine can result in injury or
death. To reduce the potential for injury or death, comply
with the following safety instructions.
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
Before Operating
1. Read and understand the contents of the Operator’s
Manual before starting and operating the machine. Be-
come familiar with the controls and know how to stop the
machine quickly. A replacement Operator’s Manual is
available on the Internet at www.Toro.com.
2. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is defective, illegible or
damaged, repair or replace it before operating the ma-
chine. Also tighten any loose nuts, bolts or screws to en-
sure machine is in safe operating condition.
While Operating
3. Before getting off the operator seat:
WARNING
A. Stop vehicle, turn on/off switch OFF and remove
key from switch.
The Workman e2050 and e2065 are off--highway
vehicles only. They are not designed, equipped
or manufactured for use on public streets, roads
or highways.
B. Set parking brake.
4. If vehicle is parked on incline, chock or block the
wheels after getting off the vehicle.
1. Sit on the operator seat when starting and operating
the vehicle.
2. Before starting the vehicle:
A. Make sure that the battery charger is discon-
nected from the vehicle charger receptacle.
B. Engage the parking brake.
C. Make sure accelerator pedal is not depressed.
D. Check position of forward/reverse switch and Hi/
Low speed switch.
Rev. D
Safety (Rev. B)
Page 1 -- 2
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Maintenance and Service
1. Before servicing or making adjustments to the ve-
hicle, stop vehicle, turn on/off switch to OFF, engage
parking brake and remove key from the on/off switch.
10.Never use an open flame to check level or leakage
of battery electrolyte.
11.When connecting the battery charger to the vehicle,
connect the charger cord to the vehicle charger recep-
tacle before plugging the charger power cord into an
outlet. After charging the vehicle batteries, unplug the
charger power cord from the outlet before disconnecting
the charger cord from the vehicle charger receptacle.
2. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
3. Do not use open pans of flammable cleaning fluids
for cleaning parts.
4. Keep battery area free of excessive grease, grass,
leaves and dirt.
12.If major repairs are ever needed or assistance is de-
sired, contact an Authorized Toro Distributor.
5. Disconnect batteries before servicing the machine.
Carefully remove one of the battery cables from the bat-
tery pack as the first step in any repair. Once a battery
cable has been removed, the electrical system on the
vehicle can be safely worked on. Take care during re-
pairs, however, to not allow tools or vehicle components
to complete the battery circuit that was opened with the
cable removal. Reattach the removed cable to the bat-
tery pack as the last step in any repair.
13.To assure optimum performance and continued
safety of the machine, use genuine Toro replacement
parts and accessories. Replacement parts and acces-
sories made by other manufacturers may result in non-
conformance with safety standards and the warranty
may be voided.
14.When raising the machine to change tires or to per-
form other service, use correct blocks, hoists and jacks.
Make sure machine is parked on a solid level surface
such as a concrete floor. Prior to raising the machine, re-
move any attachments that may interfere with the safe
and proper raising of the machine. Always chock or
block wheels. Use jack stands or solid wood blocks to
support the raised machine. If the machine is not proper-
ly supported by blocks or jack stands, the machine may
move or fall, which may result in personal injury (see
Jacking Instructions in the Operator’s Manual and in this
Chapter).
6. When using metal, uninsulated tools around batter-
ies, do not allow tools to contact both positive and nega-
tive battery terminals simultaneously.
7. Remove jewelry and watches before servicing elec-
trical components of the vehicle.
8. Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect your
face, eyes and clothing when working with batteries.
9. Battery gases can explode. Keep cigarettes, sparks
and flames away from the batteries. Always service,
store and charge the vehicle batteries in a well ventilated
area.
Workman e2050/e2065
Page 1 – 3
Safety (Rev. B)
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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
2
1
• 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.
Figure 1
1. Front frame
2. Towing tongue
• Before raising the vehicle, remove any
attachments that may interfere with the safe
and proper raising of the vehicle.
• Always chock or block wheels to prevent
the vehicle from rolling.
• Make sure proper hoists, solid wooden
blocks and jack stands are used to raise
and support the vehicle.
1
1
2
Jacking Locations
Figure 2
1. Jack front of the vehicle on the front of the frame be-
hind the towing tongue (Fig. 1).
1. Axle tube
2. Transaxle case
2. Jack rear of the vehicle under each rear axle tube. Do
not jack vehicle below the transaxle case (Fig. 2).
Towing Vehicle
IMPORTANT: Frequent or long distance towing of
the Workman e2050/e2065 is not recommended.
IMPORTANT: If vehicle is towed, make sure that on/
off switch is in the OFF position and key is removed
from switch.
In case of emergency, the vehicle can be towed for a
short distance. See Operator’s Manual for towing in-
formation.
Transporting Vehicle
When moving the vehicle long distances, use a trailer or
flatbed truck. Make sure vehicle is secured to the trailer
properly. See Operator’s Manual for transport informa-
tion.
Safety (Rev. B)
Page 1 – 4
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Safety and Instruction Decals
There are several safety and instruction decals attached
to your Workman vehicle. If any decal becomes illegible
or damaged, install a new decal. Part numbers are listed
in the Parts Catalog. Order replacement decals from
your Authorized Toro Distributor.
Workman e2050/e2065
Page 1 – 5
Safety (Rev. B)
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Safety (Rev. B)
Page 1 – 6
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Chapter 2
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2
Decimal and Millimeter Equivalents . . . . . . . . . . . . 2
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 3
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . 3
Standard Torque for Dry, Zinc Plated and
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric Fasteners) . . . . . . . . . . 5
Other Torque Specifications . . . . . . . . . . . . . . . . . . 6
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . 6
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Steel Fasteners (Inch Series) . . . . . . . . . . . . . . . 4
Product Records
Insert Operator’s Manual and Parts Catalog for your
Workman vehicle at the end of this chapter. Additionally,
if any optional equipment or accessories have been
installed to your Workman, insert the Installation In-
structions, Operator’s Manuals and Parts Catalogs for
those options at the end of this chapter.
Workman e2050/e2065
Page 2 – 1
Product Records and Maintenance (Rev. B)
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Equivalents and Conversions
0.09375
Product Records and Maintenance (Rev. B)
Page 2 – 2
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Torque Specifications
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
is unique to the application is clearly identified and spe-
cified in this Service Manual.
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread en-
gagement, etc.
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Ser-
vice Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (Loctite), degree of lubrication on the
fastener, presence of a prevailing torque feature, hard-
ness of the surface underneath the fastener’s head or
similar condition which affects the installation.
The standard method of verifying torque shall be per-
formed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Fastener Identification
Grade 1
Grade 5
Grade 8
Class 8.8
Class 10.9
Inch Series Bolts and Screws
Figure 1
Metric Bolts and Screws
Figure 2
Workman e2050/e2065
Page 2 – 3
Product Records and Maintenance (Rev. B)
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Grade 1, 5, &
8 with Thin
SAE Grade 1 Bolts, Screws, Studs &
Sems with Regular Height Nuts
SAE Grade 5 Bolts, Screws, Studs &
Sems with Regular Height Nuts
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
Thread Size
Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
(SAE J995 Grade 2 or Stronger Nuts)
(SAE J995 Grade 5 or Stronger Nuts)
in–lb
in–lb
N–cm
in–lb
15 + 2
N–cm
170 + 20
190 + 20
330 + 30
350 + 30
475 + 45
540 + 45
1125 + 100
1300 + 100
2250 + 280
2540 + 280
N–m
in–lb
23 + 2
N–cm
260 + 20
280 + 20
460 + 45
485 + 45
675 + 70
765 + 70
1580 + 170
1800 + 170
3390 + 340
3670 + 340
N–m
# 6 – 32 UNC
# 6 – 40 UNF
# 8 – 32 UNC
# 8 – 36 UNF
# 10 – 24 UNC
# 10 – 32 UNF
1/4 – 20 UNC
1/4 – 28 UNF
5/16 – 18 UNC
5/16 – 24 UNF
10 + 2
13 + 2
147 + 23
17 + 2
25 + 2
29 + 3
41 + 4
13 + 2
18 + 2
25 + 5
30 + 5
282 + 30
339 + 56
31 + 3
43 + 4
42 + 4
60 + 6
48 + 4
68 + 6
48 + 7
53 + 7
53 + 7
65 + 10
105 + 17
128 + 17
ft–lb
599 + 79
734 + 113
1186 + 169
1446 + 192
N–m
100 + 10
115 + 10
200 + 25
225 + 25
ft–lb
140 + 15
160 + 15
300 + 30
325 + 30
ft–lb
115 + 15
138 + 17
ft–lb
3/8 – 16 UNC
3/8 – 24 UNF
7/16 – 14 UNC
7/16 – 20 UNF
1/2 – 13 UNC
1/2 – 20 UNF
5/8 – 11 UNC
5/8 – 18 UNF
3/4 – 10 UNC
3/4 – 16 UNF
7/8 – 9 UNC
16 + 2
16 + 2
22 + 3
30 + 3
41 + 4
43 + 4
58 + 5
17 + 2
18 + 2
24 + 3
35 + 3
47 + 4
50 + 4
68 + 5
27 + 3
27 + 3
37 + 4
50 + 5
68 + 7
70 + 7
95 + 9
29 + 3
29 + 3
39 + 4
55 + 5
75 + 7
77 + 7
104 + 9
30 + 3
48 + 7
65 + 9
75 + 8
102 + 11
115 + 11
203 + 20
230 + 20
359 + 34
407 + 34
583 + 61
644 + 61
105 + 10
120 + 10
210 + 20
240 + 20
375 + 35
420 + 35
600 + 60
660 + 60
142 + 14
163 + 14
285 + 27
325 + 27
508 + 47
569 + 47
813 + 81
895 + 81
32 + 3
53 + 7
72 + 9
85 + 8
65 + 10
75 + 10
93 + 12
115 + 15
140 + 20
155 + 25
88 + 12
95 + 15
140 + 20
165 + 25
225 + 25
260 + 30
119 + 16
129 + 20
190 + 27
224 + 34
305 + 34
353 + 41
150 + 15
170 + 15
265 + 25
300 + 25
430 + 45
475 + 45
7/8 – 14 UNF
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite or thread sealant such as Loctite.
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the mini-
mum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
Product Records and Maintenance (Rev. B)
Page 2 – 4
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws and Studs with
Regular Height Nuts
Class 10.9 Bolts, Screws and Studs with
Thread Size
Regular Height Nuts
(Class 8 or Stronger Nuts)
(Class 10 or Stronger Nuts)
M5 X 0.8
M6 X 1.0
57 + 5 in–lb
96 + 9 in–lb
19 + 2 ft–lb
38 + 4 ft–lb
66 + 7 ft–lb
166 + 15 ft–lb
325 + 33 ft–lb
640 + 60 N–cm
1018 + 100 N–cm
26 + 3 N–m
78 + 7 in–lb
885 + 80 N–cm
1500 + 150 N–cm
36 + 3 N–m
133 + 13 in–lb
27 + 2 ft–lb
M8 X 1.25
M10 X 1.5
M12 X 1.75
M16 X 2.0
M20 X 2.5
52 + 5 N–m
53 + 5 ft–lb
72 + 7 N–m
90 + 10 N–m
225 + 20 N–m
440 + 45 N–m
92 + 9 ft–lb
125 + 12 N–m
310 + 30 N–m
610 + 50 N–m
229 + 22 ft–lb
450 + 37 ft–lb
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite or thread sealant such as Loctite.
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately + 10% of the
nominal torque value.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
Workman e2050/e2065
Page 2 – 5
Product Records and Maintenance (Rev. B)
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Other Torque Specifications
SAE Grade 8 Steel Set Screws
Wheel Bolts and Lug Nuts
Recommended Torque
Thread Size
Thread Size
Recommended Torque**
65 + 10 ft–lb 88 + 14 N–m
Square Head
140 + 20 in–lb
215 + 35 in–lb
35 + 10 ft–lb
75 + 15 ft–lb
Hex Socket
73 + 12 in–lb
145 + 20 in–lb
18 + 3 ft–lb
7/16 – 20 UNF
Grade 5
1/4 – 20 UNC
5/16 – 18 UNC
3/8 – 16 UNC
1/2 – 13 UNC
1/2 – 20 UNF
Grade 5
80 + 10 ft–lb 108 + 14 N–m
80 + 10 ft–lb 108 + 14 N–m
80 + 10 ft–lb 108 + 14 N–m
M12 X 1.25
Class 8.8
50 + 10 ft–lb
M12 X 1.5
Class 8.8
** For steel wheels and non–lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Threads per Inch
Size
Baseline Torque*
Thread Size
Baseline Torque*
20 + 5 in–lb
Type A Type B
No. 6 – 32 UNC
No. 8 – 32 UNC
No. 10 – 24 UNC
1/4 – 20 UNC
No. 6
No. 8
18
15
12
11
20
18
16
14
20 + 5 in–lb
30 + 5 in–lb
38 + 7 in–lb
85 + 15 in–lb
30 + 5 in–lb
38 + 7 in–lb
No. 10
No. 12
85 + 15 in–lb
110 + 20 in–lb
200 + 100 in–lb
5/16 – 18 UNC
3/8 – 16 UNC
* Hole size, material strength, material thickness & finish
must be considered when determining specific torque
values. All torque values are based on non–lubricated
fasteners.
Conversion Factors
in–lb X 11.2985 = N–cm
N–cm X 0.08851 = in–lb
ft–lb X 1.3558 = N–m
N–m X 0.7376 = ft–lb
Product Records and Maintenance (Rev. B)
Page 2 – 6
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Maintenance
Maintenance procedures and recommended service in-
tervals for the Workman e2050 and e2065 are covered
in the Operator’s Manual. Refer to that publication when
performing regular vehicle maintenance.
Workman e2050/e2065
Page 2 – 7
Product Records and Maintenance (Rev. B)
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Chapter 3
Electrical System
Table of Contents
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Opening Battery Circuit . . . . . . . . . . . . . . . . . . . . . . 3
VEHICLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Run Problems . . . . . . . . . . . . . . . . . . . . . . 8
Battery Charger Operation . . . . . . . . . . . . . . . . . . . 9
Battery Charger Problems . . . . . . . . . . . . . . . . . . . 10
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Accelerator Switch Adjustment . . . . . . . . . . . . . . . . 11
Accelerator Potentiometer Adjustment . . . . . . . . 12
Accelerator System Calibration . . . . . . . . . . . . . . 13
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 14
On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Battery Discharge Indicator and Hour
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 28
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Battery Specifications . . . . . . . . . . . . . . . . . . . . . 28
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Inspection and Maintenance . . . . . . . . . . . . . . . 30
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Traction Motor Brushes . . . . . . . . . . . . . . . . . . . . . 33
Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Traction Motor Service . . . . . . . . . . . . . . . . . . . . . . 38
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
LESTER ELECTRICAL TECHNICIAN
SERVICE GUIDE
Meter Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Vehicle Direction (Forward/Reverse) and
Headlight Switches . . . . . . . . . . . . . . . . . . . . . . . 16
Vehicle Status Light . . . . . . . . . . . . . . . . . . . . . . . . 17
Supervisor Speed Limit Switch (Workman e2050)18
Supervisor Speed Limit Switch (Workman e2065)18
Audio Alarm (Reverse) . . . . . . . . . . . . . . . . . . . . . . 18
Charger Interlock Switch . . . . . . . . . . . . . . . . . . . . 19
Main and Accessories Contactors . . . . . . . . . . . . 20
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fusible Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Accelerator Switch . . . . . . . . . . . . . . . . . . . . . . . . . 24
Accelerator Potentiometer . . . . . . . . . . . . . . . . . . . 25
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 1
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Electrical Diagrams
The electrical schematic, circuit drawings and wire har-
ness drawings for the Workman e2050 and e2065 are
located in Chapter 6 – Electrical Diagrams.
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 2
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General Information
The Workman e2050 and e2065 use a 48 volt DC elec-
trical system that is an isolated circuit. The vehicle frame
is not used for any ground connections.
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 in-
puts to determine voltage to the traction motor. If a prob-
lem exists that will prevent normal vehicle operation, an
LED on the controller and the vehicle status light on the
dash panel will flash a fault code to assist in identifying
the problem.
Opening Battery Circuit
To prevent allowing a current path through tools used
during vehicle electrical circuit repairs, remove one of
the battery cables from the battery pack as the first step
in any repair (Fig. 1). Once a cable has been removed,
the electrical system on the vehicle can be safely
worked on. Take care during repairs, however, to not al-
low tools or vehicle components to complete the battery
circuit that was opened with the cable removal.
Reattach the removed cable to the battery pack as the
last step in any repair. Secure cable on each battery ter-
minal with lock washer and nut. Torque nuts from 115 to
125 in–lb (13 to 14.1 N–m).
Battery pack cable routing is shown in Figure 2.
Figure 1
1
2
Figure 2
1. Negative cable to vehicle
2. Positive cable to vehicle
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 3
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Vehicle Operation
The Workman e2050 and e2065 electrical system use
a 48 volt battery pack, an electric traction motor, a ve-
hicle controller and numerous other electrical compo-
nents to allow vehicle operation.
The vehicle controller is a sealed electronic logic device
that uses inputs from several vehicle components to
control motor speed and direction. These inputs include
several switches (on/off, forward/reverse, accelerator,
supervisor, charger), a motor temperature sensor, an
accelerator pedal potentiometer and the vehicle contac-
tor (solenoid). The controller also provides regenerative
braking to assist in slowing the vehicle. The controller
has fault detection capabilities to help identify system
problems. Battery current is available to the controller
whenever the on/off switch is ON which energizes the
main contactor. A high current fuse protects this high
current circuit.
Eight, 6 volt, deep cycle batteries that are connected in
series provide current for a 48 volt DC, high torque trac-
tion motor, the vehicle controller and vehicle accesso-
ries (headlights, horn, various optional accessories).
The batteries are discharged as the vehicle is used so
charging the batteries after using the vehicle is neces-
sary. A battery discharge indicator gauge on the dash
provides the operator with information on battery charge
level. Demands on the vehicle during use (speed, pay-
load, incline use), battery condition (age, charge level),
ambient temperature and vehicle condition will all put
constraints on how long a vehicle can be used before the
batteries are discharged.
The Workman controller also provides a roll off warning
in instances when the vehicle begins to move (roll away)
after being stopped. On an incline and with the on/off
switch in the ON position, if the vehicle starts moving,
the alarm will sound warning the operator that the ve-
hicle is moving. When the vehicle goes into this roll–off
mode, regenerative braking will limit vehicle speed.
An automatic, 115 VAC (230 VAC on international mod-
els) battery charger is included with the vehicle. An inter-
lock switch on the vehicle charger receptacle prevents
the vehicle from operating when the charger cord is
plugged into the vehicle.
Vehicle accessories include headlights, horn and op-
tional electrical equipment. The accessories contactor
(solenoid) on the vehicle provides battery current to
these components when the on/off switch is ON. Fuses
provide circuit protection for these accessories.
The electric traction motor directly drives a double re-
duction transaxle with differential. Operator inputs for
forward/reverse, supervisor switch position (high or low
speed) and accelerator pedal position are used by the
controller to determine voltage to the traction motor.
The traction motor is cooled with an external fan. Addi-
tionally, the motor is protected from overheating by a
thermal switch in the motor housing. If unsafe motor
temperature is sensed by the switch, the controller is
signaled to limit vehicle speed and torque until the motor
temperature reduces to a normal level.
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 4
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Special Tools
Multimeter
The multimeter can test electrical components and cir-
cuits for current, resistance or voltage.
NOTE: Toro recommends the use of a DIGITAL Volt–
Ohm–Amp multimeter when testing electrical circuits.
The high impedance (internal resistance) of a digital me-
ter in the voltage mode will make sure that excess cur-
rent is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
NOTE: Workman e2050 and e2065 vehicles use a 48
volt, DC electrical system. If multimeter is not of the
auto–range type, make sure to properly set multimeter
range before performing any voltage test.
Figure 3
Battery Terminal Protector
Battery Terminal Protector (Toro Part No. 107–0392) is
an aerosol spray that should be used on all battery and
controller terminals to reduce corrosion problems. Apply
terminal protector after cable has been secured to termi-
nal.
Figure 4
Dielectric Gel
Dielectric gel (Toro Part No. 107–0342) should be used
to prevent corrosion of connection terminals. To ensure
complete coating of terminals, liberally apply gel to both
component and wire harness connector, plug connector
to component, unplug connector, reapply gel to both
surfaces and reconnect harness connector to compo-
nent. Connectors should be thoroughly packed with gel
for effective results.
Figure 5
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 5
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Battery Watering Dispenser
Use the battery watering dispenser when adding dis-
tilled water to vehicle batteries. Obtain watering dis-
penser locally.
Figure 6
Battery Hydrometer
Use the battery hydrometer when measuring specific
gravity of battery electrolyte. Obtain hydrometer locally.
Figure 7
Battery Lift Strap
Use the battery lift strap to remove and install batteries
from the vehicle. Lift strap allows use of case loops on
battery tops as safe battery lifting points. Obtain battery
lift strap locally.
Figure 8
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 6
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36/48 Volt Battery Discharge Unit
The36/48VoltBatteryDischargeUnit(TOR4106) isrec-
ommended for quick and accurate load testing for the
batteries on the Workman e2050 and e2065. This tool
is used to determine the capacity of the Workman bat-
tery pack and also for finding faulty battery or batteries
in the battery pack.
Order the 36/48 Volt Battery Discharge Unit (TOR4106)
from your Toro Distributor.
Figure 9
Workman e2050/e2065
Electrical System (Rev. B)
Rev. D
Page 3 -- 7
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Troubleshooting
CAUTION
For effective troubleshooting and repairs, there must be
a good understanding of the electrical circuits and com-
ponents used on this vehicle (see Electrical Schematic
in Chapter 6).
Remove all jewelry, especially rings and
watches, before doing any electrical trouble-
shooting or testing. Disconnect a battery cable
from the battery pack to open the battery circuit
unless a test procedure requires battery voltage.
If the vehicle has any switches by–passed, they must be
reconnected for proper vehicle operation, troubleshoot-
ing and safety.
General Run Problems
NOTE: Check vehicle status light on dash panel and
controller LED for possible faults whenever diagnosing
vehicle problems (see Controller in the Component
Testing section of this chapter).
Problem
Possible Causes
Main contactor clicks, but vehicle will not operate.
Battery charge is low.
Battery cables are loose, corroded or damaged.
Cable connection(s) at controller is/are loose or
corroded.
Cable connection(s) at traction motor is/are loose or
corroded.
Traction motor is faulty.
Controller is faulty.
Nothing happens when on/off switch is turned to ON.
Battery charge is extremely low.
Battery cables are loose, corroded or damaged.
Cable connection(s) at controller is/are loose or
corroded.
10 ampere fuse (F2) to the on/off switch is loose or
blown.
Fusible link FL2 is faulty.
Main fuse (F1) is loose or blown.
The on/off switch or circuit wiring is faulty.
Controller is faulty.
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 8
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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.
Traction motor is faulty.
Brake or transaxle problem (see Chapter 4 – Transaxle
and Brakes).
Vehicle runs slowly.
Supervisor speed limit switch in slow position.
Tire pressure is low (see Chapter 5 – Chassis).
Brakes improperly adjusted (see Chapter 4 –
Transaxle and Brakes).
Battery charge is extremely low.
Controller is overheated.
Traction motor is overheated.
Vehicle movement is erratic or jerky.
Collar on throttle is loose.
Accelerator potentiometer is improperly adjusted.
Accelerator system is out of adjustment.
Battery Charger Operation
Light Status
Indicates
Green light on battery charger illuminated (not
flashing).
Batteries is fully charged. Vehicle ready to operate.
Green light on battery charger flashing.
Red light on battery charger flashing.
Slow flash (once per second): Batteries being charged
(batteries less than 80% charged). Continue charging.
Rapid flash (four times per second): Batteries being
charged (batteries more than 80% charged). Continue
charging.
Rapid flash: Charger timer shutoff has occurred after
20 hours of charging.
Slow flash: No current to charger. Check AC outlet.
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 9
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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 fuse blows.
Battery charger is faulty.
NOTE: Charging new batteries or charging batteries in
cold temperatures may require extended charge time
to achieve full charge.
Vehicle battery polarity is reversed (vehicle battery
cables incorrectly attached).
Vehicle charger receptacle polarity is reversed.
Battery charger is faulty.
The AC outlet circuit breaker or fuse blows when using Overloaded AC circuit.
the battery charger.
Battery charger is faulty.
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 10
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Adjustments
Accelerator Switch Adjustment
1. Position vehicle on a level surface, turn On/Off
switch OFF and remove key. Apply parking brake.
2
3
1
2. Make sure that at complete brake pedal travel, the
park detent and pawl are fully engaged. If needed, ad-
just the accelerator pedal stop cap screw to allow full en-
gagement (Fig. 11).
6
5
3. Disengage the parking brake.
4. With the accelerator pedal released, check that the
distance between the head of the accelerator switch
stop cap screw and the body of the switch is 5/8 inch (1.6
cm) (Fig. 12).
4
Figure 10
1. Accelerator pedal
2. Accelerator switch
3. Plate
4. Screw (2 used)
5. Switch stop cap screw
6. Lock nut
5. If distance is incorrect, loosen lock nut and adjust ac-
celerator switch stop cap screw position (Fig. 11).
6. After adjustment, make sure that switch plunger is
not bottomed out when accelerator pedal is released.
2
3
7. After adjustment to switch stop cap screw, make
sure that the switch does not open when the parking
brake is engaged. Readjust switch stop cap screw if re-
quired.
1
8. Calibrate accelerator system after adjusting acceler-
ator switch (see Accelerator System Calibration in this
section).
Figure 11
1. Accelerator switch
2. Switch stop cap screw
3. Accelerator stop cap screw
5/8 inch
(1.6 cm)
2
1
Figure 12
1. Switch stop cap screw
2. Accelerator switch
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 11
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Accelerator Potentiometer Adjustment
The accelerator potentiometer is used as one of the in-
puts for the vehicle controller and is attached to the ped-
al frame under the dash (Fig. 13). A collar with roll pin on
the accelerator pedal shaft positions the accelerator po-
tentiometer lever.
1
4
5
If the accelerator potentiometer is out of adjustment, the
diagnostic light on the dash will flash six (6) times. Addi-
tionally, if vehicle movement is erratic and jerky, poten-
tiometer adjustment and calibration of the accelerator
system should be performed.
3
2
Adjustment
1. Position vehicle on a level surface, turn On/Off
switch OFF and remove key.
Figure 13
2. Make sure that accelerator potentiometer is securely
attached to the pedal frame of the machine.
1. Potentiometer
4. Roll pin
5. Set screw (2 used)
2. Accelerator pedal
3. Throttle position collar
3. Check accelerator switch adjustment and adjust if
necessary (see Accelerator Switch Adjustment in this
section).
4. Check movement of the accelerator potentiometer
lever:
1
A. With the accelerator pedal released, the roll pin
on the throttle position collar should keep the poten-
tiometer lever from 0.050” to 0.100” (1.3 to 2.5 mm)
from the lower stop on the potentiometer body (Fig-
ure 14).
2
3
B. With the accelerator pedal fully depressed, the in-
put lever of the potentiometer should not contact the
upper stop on the potentiometer body (Figure 15).
Figure 14
1. Potentiometer lever (accelerator pedal released)
2. Potentiometer lower stop
3. Gap of 0.050” to 0.100” (1.3 to 2.5 mm)
5. If potentiometer lever movement is incorrect, adjust
location of collar on accelerator pedal shaft:
3
A. Loosen two (2) set screws that secure throttle
position collar to throttle pedal shaft and reposition
collar to allow correct potentiometer movement.
Make sure that there is clearance between roll pin
and side of potentiometer lever to prevent binding.
1
2
B. Remove set screws one at a time from collar and
apply Loctite #242 (or equivalent) to set screw
threads. Install and tighten set screws to secure col-
lar to accelerator pedal shaft.
C. Recheck potentiometer lever movement.
Figure 15
1. Potentiometer lever (accelerator pedal fully depressed)
6. Calibrate accelerator system after any accelerator
potentiometer adjustment (see Accelerator System Cal-
ibration in this section).
2. Potentiometer upper stop
3. No lever contact with stop
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 12
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Accelerator System Calibration
The accelerator system on the Workman e2050 and
e2065 includes the accelerator pedal assembly, the ac-
celerator potentiometer, the accelerator switch and the
controller. If any of these components are adjusted, re-
moved or replaced, the following calibration procedure
should be performed. Additionally, if vehicle movement
is erratic and jerky or if the diagnostic light on the dash
is flashing six (6) times, calibration of the accelerator
system should be performed.
1
4
1. Position vehicle on a level surface, turn On/Off
switch OFF and remove key. Raise bed and secure with
prop rod. Remove controller cover.
2
3
2. Check accelerator switch adjustment and adjust if
necessary (see Accelerator Switch Adjustment in this
section).
Figure 16
1. Controller
2. Gray controller lead
3. Ground post (B–)
4. Controller LED
3. Check accelerator potentiometer adjustment and
adjust if necessary (see Accelerator Potentiometer Ad-
justment in this section).
4. Using a jumper wire, connect gray controller lead to
ground post (B–) on controller (Fig. 16).
NOTE: During calibration, the vehicle status light on the
dash should flash the same as the controller LED.
5. Turn On/Off switch ON. The alarm should sound and
the controller LED should flash six (6) times.
6. Slowly depress accelerator pedal until the alarm mo-
mentarily stops and hold pedal in position. This should
take a very small movement of the pedal. Once alarm re-
sumes, release accelerator pedal completely.
7. Depress and hold accelerator pedal fully. Alarm will
momentarily stop while controller calibration occurs.
Hold pedal fully depressed until alarm resumes and then
release pedal.
8. If calibration process was successful, alarm will chirp
and diagnostic light on the dash will be lit continuous (not
flashing). If alarm continues to sound or if diagnostic
light is flashing, turn On/Off switch OFF and repeat steps
5, 6 and 7.
9. Turn On/Off switch OFF and remove key. Disconnect
jumper wire from gray controller lead and controller
ground post (B–).
10.Install controller cover and lower bed.
11.If vehicle operation continues to be erratic after com-
pleting the accelerator system calibration procedure,
evaluate the components in the accelerator system: ac-
celerator switch, accelerator potentiometer, accelerator
pedal, circuit wiring and controller.
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 13
Rev. A
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Component Testing
For accurate resistance and/or continuity checks, elec-
trically disconnect the component being tested from the
circuit (e.g. disconnect the harness wire connectors
from the vehicle on/off switch before doing a continuity
check on the on/off switch).
CAUTION
When testing electrical components for continu-
ity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.
On/Off Switch
The Workman on/off switch is located on the dash panel
(Fig. 17). The switch has two (2) positions (OFF and ON)
and three (3) switch terminals. Only two of the terminals
are used on the Workman e2050 and e2065. The switch
terminals are positioned as shown in Figure 18.
Testing
1
CAUTION
When testing the on/off switch for continuity
with a multimeter (ohms setting), make sure that
power to the circuit has been disconnected.
Figure 17
1. On/Off switch
When the on/off switch is in the OFF position, no conti-
nuity should exist between the common (center) switch
terminal and the switched (side) terminal. In the ON
position, continuity should exist between the common
(center) switch terminal and the switched (side) termi-
nal.
SWITCHED
TERMINAL
COMMON
TERMINAL
BACK OF
SWITCH
NOT USED
Figure 18
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 14
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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 bat-
tery pack. The battery indicator reads full (10 bars) when
the battery pack is fully charged (approximately 51
volts). As battery pack voltage decreases with vehicle
use, fewer battery indicator bars are shown.
When the battery indicator reaches 2 bars, a warning
light illuminates and a battery icon flashes on the gauge
face to identify that battery charge level is extremely low.
At this point, the batteries should be charged.
Figure 19
1. Battery discharge indicator and hour meter
If the battery indicator reaches 1 bar, the warning light
begins flashing and the vehicle will go into an energy
saving mode: vehicle speed will be reduced to 3 MPH.
At this point, the batteries should be charged to prevent
serious battery damage.
8
4
5
1
The hour meter registers operating time of the vehicle.
Whenever the vehicle is in motion, the hour meter in-
creases one tenth every 6 minutes. If the vehicle re-
mains stationary for 30 seconds (even if the on/off
switch is ON), the hour meter quits increasing.
BACK OF
GAUGE
The back of the gauge is shown in Figure 20. A wire har-
ness connector plugs into the gauge. Terminals 1, 2 and
5 are not used on the Workman e2050/e2065. See
Chapter 6 – Electrical Diagrams for schematic and wire
harness information.
Figure 20
If the battery discharge indicator or the hour meter prove
to be inaccurate, the gauge should be replaced.
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 15
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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.
1
NOTE: The headlight system on the Workman e2050
and e2065 consists of two (2) 24 volt lamps connected
in series. If one lamp is burned out or disconnected, nei-
ther lamp will illuminate.
Figure 21
1. Direction switch
Testing
The switch terminals for these switches are marked as
shown in Figure 23. The circuitry of the switch is shown
in the chart below. With the use of a multimeter (ohms
setting), the switch functions may be tested to determine
whether continuity exists between the various terminals
for each switch position. Verify continuity between
switch terminals.
1
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
Figure 22
1. Headlight switch
OFF / FORWARD
ON / REVERSE
1 + 2
2 + 3
4 + 5
5 + 6
4
5
6
1
2
3
Figure 23
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 16
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Vehicle Status Light
The vehicle status light is located on the control panel
(Fig. 24). During normal operation, the status light
should be continuously illuminated. A vehicle electrical
problem will be identified by a flashing status light.
The vehicle status light and LED on the vehicle control-
ler should have the same condition (off, illuminated or
flashing). If the vehicle status light does not illuminate
when the on/off switch is turned ON, check the LED on
the vehicle controller to make sure it is illuminated. If the
controller LED is illuminated and the vehicle status light
is not illuminated, check the vehicle status light and cir-
cuit wiring.
1
Figure 24
1. Vehicle status light
See Controller (in this section) and your Operator’s
Manual for information on a flashing vehicle status light.
Testing
1. Make sure on/off switch is turned OFF. Remove key
from switch.
1B (–)
2. Disconnect wire harness from vehicle status light.
NOTE: The vehicle status light is a 12 volt DC compo-
nent. Do not test the light using jumper wires from the
vehicle battery pack (48 VDC).
1A (+)
3. The terminals for the light are marked as shown in
Figure 25. Correctly connect 12 VDC source to the light
terminals.
Figure 25
4. Light should illuminate. Remove voltage source from
the light and reconnect wire harness. Replace status
light if needed.
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 17
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Supervisor Speed Limit Switch (Workman e2050)
The supervisor speed limit switch is open in Off position
(key vertical) and closed in On position (key rotated
clockwise). The speed limit switch is one of several in-
puts for the vehicle controller and allows the speed of the
vehicle to be limited.
Test the switch by disconnecting the wiring and connect-
ing a continuity tester across the two switch terminals.
Rotate key to On position: there should be an indication
of continuity. Rotate key to Off position: there should be
no continuity.
Figure 26
Supervisor Speed Limit Switch (Workman e2065)
The supervisor speed limit switch is open in Off position
(key vertical) and closed in On position (key rotated
clockwise). The speed limit switch is one of several in-
puts for the vehicle controller and allows the speed of the
vehicle to be limited.
OFF
B&C
45o
ON
A&D
B&C
Test the switch by disconnecting the wiring and connect-
ing a continuity tester across switch terminals A and D
(Fig. 27). Rotate key to On position: there should be an
indication of continuity. Rotate key to Off position: there
should be no continuity.
Figure 27
Audio Alarm (Reverse)
The audio alarm sounds when the forward/reverse
switch is placed in the reverse position. The alarm is lo-
cated under the controller cover beneath the bed.
3. Alarm should sound. Remove voltage source from
the alarm. Reconnect alarm to the circuit or replace
alarm if needed.
Testing
2
IMPORTANT: Make sure to observe polarity on the
alarm terminals when testing. Damage to the alarm
may result from an improper connection.
NOTE: The audio alarm is a 12 volt DC component. Do
not test the alarm using jumper wires from the vehicle
battery pack (48 VDC).
1. Make sure on/off switch is turned OFF. Remove key
from switch. Raise bed and remove controller cover.
2. Disconnect wire harness connectors from alarm
(Fig. 28). Using jumper wires, correctly connect 12VDC
source to the alarm terminals noting polarity shown on
alarm decal.
1
Figure 28
1. Controller
2. Audio alarm
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 18
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Charger Interlock Switch
The charger interlock switch is located behind the char-
ger receptacle plate on the front of the seat base (Fig.
29). When the battery charger is plugged into the char-
ger receptacle, the interlock switch closes and provides
an input to the vehicle controller to inhibit vehicle opera-
tion.
NOTE: The vehicle should not operate if the char-
ger plug is connected to the charger receptacle.
1. Make sure vehicle On/Off switch is OFF. Remove
key from switch.
2. Remove receptacle plate from front of seat base.
3. Locate charger interlock switch on rear of receptacle
plate. Disconnect harness connector from the switch.
4
1
4. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector termi-
nals.
2
3
5. When the switch plunger is extended there should
not be continuity between the switch terminals.
Figure 29
1. Receptacle plate
2. Screw (4 used)
3. Charger receptacle
4. Charger interlock switch
6. When the switch plunger is depressed, there should
be continuity between the switch terminals.
1
7. Reconnect harness connector to switch. Install re-
ceptacle plate to front of seat base.
2
3
4
5
6
Figure 30
1. Charger interlock switch
2. Switch plate
3. Charger receptacle
4. Rivet (2 used)
5. Lock nut (2 used)
6. Socket head screw
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 19
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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 con-
troller and is energized when the on/off switch is ON.
The main contactor is located under the controller cover
beneath the bed (Fig. 31).
2
The accessories contactor provides current to the head-
lights, horn and optional electrical accessories. The ac-
cessories contactor is energized when the on/off switch
is ON. The accessories contactor is located beneath the
dash panel.
3
6
Testing
Figure 31
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less) that is due to the internal resistance of
the meter and test leads. Subtract this value from the
measured value of the component you are testing.
1. Main contactor
4. Fuse (F1)
5. Positive battery cable
6. Isolator
2. Cable to controller B+
3. Wire harness connector
1
1. Make sure on/off switch is turned OFF. Open the bat-
tery circuit by removing one of the battery cables (see
Opening Battery Circuit in the General Information sec-
tion of this chapter and Fig. 32).
2
2. Locate contactor that is to be tested. Disconnect all
vehicle harness electrical connections from contactor.
Note wire connector locations on contactor for reas-
sembly purposes.
3. Using jumper wires, apply 48 VDC directly across the
contactor coil posts (Fig. 33). The contactor should click.
With the contactor coil energized, resistance across the
main contact posts should be less than 1 ohm.
Figure 32
1. Negative cable to vehicle
2. Positive cable to vehicle
4
4. Remove voltage from contactor coil posts. The con-
tactor should click. With the contactor coil not energized,
resistance across the main contact posts should be infi-
nite ohms.
4
3
2
5. Measure resistance across the contactor coil posts
(Fig. 33):
3
3
A. For the main contactor, the resistance should be
approximately 126 ohms.
B. For the accessories contactor, the resistance
should be approximately 200 ohms.
4
4
1
3
Figure 33
1. Main contactor
3. Main contact posts
4. Contactor coil posts
2. Accessories contactor
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 20
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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
3
2
8. Reconnect battery cable that was removed from bat-
tery pack.
7
1
8
Figure 34
1. Main contactor
5. Wire harness connector
6. Fuse (F1)
7. Positive battery cable
8. Isolator
2. Cable to controller B+
3. Lock nut
4. Flat washer
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 21
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Fuses
There are three (3) fuses in the Workman electrical sys-
tem.
Two (2) of the fuses are located beneath the steering
column (Fig. 35). These fuses supply power to the fol-
lowing:
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 op-
tional accessories.
2
The third fuse (F1) is located under the controller cover
beneath the bed (Fig. 36). This fuse is rated at 355 am-
peres continuous and allows current flow between the
batteries and the vehicle. If this fuse has failed, vehicle
operation will not occur.
Figure 35
1. Fuse (F2)
2. Fuse (F3)
1
Testing
2
CAUTION
When testing fuses for continuity with a multime-
ter (ohms setting), make sure that fuse is re-
moved from circuit.
IMPORTANT: Before removing fuse F1 (355 Amp)
for testing, open the battery circuit by removing one
of the battery cables (see Opening Battery Circuit in
the General Information section of this chapter).
3
Figure 36
Make sure on/off switch is turned OFF. Remove fuse to
check continuity. The test meter should read less than
1 ohm.
1. Controller
2. Fuse (F1)
3. Main contactor
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 22
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Fusible Links
The wiring harness for the Workman includes three (3)
fusible links for circuit protection (Fig. 37).
3
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.
2
4
5
If any of these fusible links should fail, the affected circuit
will not function. See Chapter 6 – Electrical Diagrams for
schematic and wire harness information.
Figure 37
1. Main contactor
4. Fusible links FL1 & FL2
2. Main fuse contactor post
3. Switched contactor post
5. Fusible link FL3
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 23
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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 (in-
put) for the controller to allow traction motor operation.
When the accelerator pedal is released, the switch pro-
vides an open circuit (no input) for the controller to pre-
vent traction motor operation.
2
3
1
6
5
Testing
1. Park vehicle on a level surface, turn On/Off switch
OFF and remove key from switch.
4
2. Locate accelerator switch on pedal frame under
dashboard of vehicle.
Figure 38
1. Accelerator pedal
2. Accelerator switch
3. Plate
4. Screw (2 used)
5. Stop cap screw
6. Lock nut
3. Unplug wiring harness connector from accelerator
switch.
1
2
4. With the use of a multimeter (ohms setting), the
switch functions may be tested to determine whether
continuity exists between the switch terminals for both
switch positions. Verify continuity between switch termi-
nals using the following table:
6
END VIEW
3
4
PLUNGER
POSITION
NO
CONTINUITY CONTINUITY
5
IN
1 and 2
3 and 4
3 and 4
1 and 2
SIDE VIEW
OUT
6
5. When reconnecting wiring harness connector to
switch after testing, harness connector and switch ter-
minal area should be filled with dielectric gel (see Spe-
cial Tools) to prevent corrosion of connection terminals.
Apply gel fully to both harness connector and switch ter-
minal area, plug harness connector into switch to distrib-
ute gel, unplug harness connector, reapply gel to both
surfaces and replug harness connector into switch.
Figure 39
1. Terminal 1
2. Terminal 2
3. Terminal 3
4. Terminal 4
5. Switch plunger
6. Mounting tab
6. If switch replacement is needed, see Accelerator
Switch Adjustment procedure in the Adjustments sec-
tion of this chapter.
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 24
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Accelerator Potentiometer
The accelerator potentiometer is attached to the pedal
frame under the dash (Fig. 40). This potentiometer is
used as one of the inputs for the vehicle controller to
command vehicle speed. The accelerator pedal posi-
tions the accelerator potentiometer lever. When the op-
erator presses or releases the accelerator pedal, the
potentiometer resistance changes. This resistance
change is used by the controller to determine current
flow to the traction motor.
1
4
3
If the accelerator potentiometer is out of adjustment, the
diagnostic light on the dash will flash six (6) times. Addi-
tionally, if vehicle movement is erratic and jerky, calibra-
tion of the accelerator system should be performed. See
Accelerator Potentiometer Adjustment and Accelerator
System Calibration in the Adjustments section of this
chapter.
2
Figure 40
1. Potentiometer
2. Accelerator pedal
3. Collar
4. Roll pin
Before suspecting a faulty potentiometer, follow adjust-
ment procedures for the accelerator switch, accelerator
potentiometer and acceleration system calibration
found in the Adjustments section of this chapter.
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 25
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Controller
The Workman controller is secured to the rear frame un-
der the controller cover beneath the bed (Fig. 41). The
controller uses inputs from several vehicle switches (on/
off, forward/reverse, accelerator pedal, supervisor,
charger interlock, motor temperature, accelerator po-
tentiometer) to accurately control vehicle speed, vehicle
direction (forward and reverse) and regenerative brak-
ing. An internal thermal sensor prevents overheating of
the controller.
NOTE: If the controller LED and vehicle status light are
flashing, attempt to reset the controller by turning the
On/Off switch to OFF, waiting a few seconds and then
turning the switch to ON. If LED and status light continue
flashing, proceed with fault code identification and nec-
essary action.
3
1
Cable connections for the controller are as follows:
Terminal B–: Negative (–) battery cable and wire
harness ground.
Terminal B+: Positive (+) cable from main contac-
tor post and wire harness fusible link (FL3).
Terminal M1: Cable to traction motor armature A2
post.
2
Terminal M2: Cable to traction motor armature A1
post.
Terminal F1: Cable to traction motor field F1 post.
Terminal F2: Cable to traction motor field F2 post.
Figure 41
1. Controller
3. Wire harness connector
When installing cables to controller, torque screws at
terminals B–, B+, M1 and M2 from 85 to 90 in–lb (9.6 to
10.2 N–m) and torque screws at terminals F1 and F2
from 55 to 60 in–lb (6.2 to 6.8 N–m) (Fig. 42). Apply Toro
battery terminal protector (see Special Tools) to control-
ler connections after tightening terminal screws.
2. Controller LED
UP
M 2
M 1
If wire harness connector is removed from controller,
both harness connector and controller socket should be
filled with dielectric gel to prevent corrosion of connec-
tion terminals and potential controller damage. Apply
gel fully to both harness connector and controller sock-
et, plug harness connector into controller to distribute
gel, unplug harness connector, reapply gel to both sur-
faces and plug harness connector into controller.
85 to 90 in–lb
(9.6 to 10.2 N–m)
B +
B –
F 2
F 1
A LED exists on the controller to identify normal opera-
tion or faults that will prevent the vehicle from operating
correctly. The vehicle status light on the dash panel dis-
plays the same information as the LED on the controller.
See chart below for light pattern fault codes identified by
the controller LED and vehicle status light.
55 to 60 in–lb
(6.2 to 6.8 N–m)
Figure 42
Light Pattern
Cause
Necessary Action
Always on (not
flashing)
System functioning correctly. None
Always off
System inoperable.
Check for low battery voltage, faulty fuse(s), loose
battery cable connections, damaged battery cables
and/or faulty main contactor.
If batteries, cables and other electrical components are
in good condition, controller replacement may be
necessary.
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 26
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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.
If controller does not reset correctly, accelerator switch
adjustment may be necessary or switch may be faulty.
3 Flashes
System inoperable.
Turn on/off switch OFF, wait several seconds and turn
on/off switch ON. If controller does not reset, check
battery pack voltage and all battery cable connections.
Also check main contactor wire and cable connections
and main contactor. NOTE: If main contactor audibly
clicks when on/off switch is turned ON, problem is most
likely a faulty wire or cable connection.
Controller replacement may be necessary.
4 Flashes
5 Flashes
Main contactor malfunction. Turn on/off switch OFF, wait several seconds and turn
on/off switch ON. If controller does not reset, inspect
main contactor (see Main and Accessories Contactors in
this section). Check main contactor wire and cable
connections.
If problem continues, contactor replacement may be
necessary.
The charger cord is plugged Turn on/off switch OFF, unplug charger cord from vehicle
into the vehicle charger
receptacle.
and turn on/off switch ON.
If controller does not reset correctly, check charger
interlock switch.
6 Flashes
7 Flashes
Accelerator control
(accelerator switch and
potentiometer) is out of
adjustment.
Adjust accelerator switch and potentiometer (see
Accelerator Switch and Accelerator Potentiometer
adjustment/calibration in the Adjustments section of this
chapter).
Battery voltage is out of
range.
Inspect and test vehicle batteries and battery cable
connections (see Battery Service in the Service and
Repairs section).
8 Flashes
9 Flashes
The controller is overheated. The vehicle will continue to operate but at reduced
power until the controller temperature lowers.
The traction motor is
overheated (battery
Stop vehicle and allow motor to cool before continuing
operation. Traction motor high temperature switch may
discharge indicator displays be faulty.
more than 1 bar).
The battery is nearly
Charge the batteries immediately to prevent battery
damage.
discharged and the vehicle
is in the energy saving mode
(reduced speed and battery
discharge indicator displays
1 bar with red light
illuminated).
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 27
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Service and Repairs
Battery Service
115 to 125 in--lb
(13 to 14.1 N--m)
9
11
10
12
115 to 125 in lb
(13 to 14.1 N--m)
5
4
8
1
6
7
5
4
3
RIGHT
2
FRONT
Figure 43
5. Hex nut (2 used per battery)
6. Cable terminal boot
7. Battery cable (6 used)
8. Positive cable to vehicle
1. Battery (8 used)
9. Cable terminal boot
10. Battery retainer (2 used)
11. Flange nut (2 used)
12. Battery cable
2. Battery rod (2 used)
3. Negative cable to vehicle
4. Lock washer (2 used per battery)
The batteries are the heart of the Workman electrical
system. With regular and proper service, battery life can
be extended. Additionally, battery and electrical compo-
nent failure can be prevented.
Workman e2065 Battery Specifications:
Trojan model T--145 Battery (6 Volt Deep Cycle)
Weight: 72 lbs (33 kg)
Capacity: 210 minutes @ 56.25 amps discharge
NOTE: Trojan model T--145 batteries can be used in
the Workman e2050. These batteries have a higher ca-
pacity than the standard Workman e2050 batteries and
therefore, have a longer run time.
Workman e2050 Battery Specifications:
Trojan model T--105 Battery (6 Volt Deep Cycle)
Weight: 62 lbs (28 kg)
Capacity: 140 minutes @ 56.25 amps discharge
Electrical System (Rev. B)
Workman e2050/e2065
Rev. D
Page 3 -- 28
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Removal (Fig. 43)
2. Make sure the battery supports are clean and re-
painted if necessary. Make sure cables, terminals, rods
and hold down retainers are in good condition.
WARNING
POTENTIAL HAZARD:
The battery terminals, metal tools and metal ve-
hicle parts could short together.
WHAT CAN HAPPEN:
Sparks can cause the battery gasses to explode.
Damaged cables could short against metal ve-
hicle parts and cause sparks.
IMPORTANT: When installing batteries into vehicle,
do not lift batteries using battery terminals as lift
points: battery damage may occur.
3. Using case loops on battery tops as lifting points, set
batteries on the battery supports with battery posts
properly orientated (Fig. 45). Make sure that battery
rods are positioned to allow installation of retainers.
4. Install two (2) battery retainers and nuts to secure
batteries to vehicle (Fig. 44). Torque nuts from 115 to
125 in–lb (13 to 14.1 N–m).
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.
5. Install all but one of the battery cables used to con-
nect battery pack including the positive (red) cable and
negative (black) cable from vehicle (Figures 43 and 45).
Make sure that cables are connected to correct battery
terminal noting battery polarity. Install lock washer and
nut on each battery terminal. Torque nuts from 115 to
125 in–lb (13 to 14.1 N–m) to secure cables.
Do not allow metal tools or metal vehicle parts to
short between the battery terminals or battery
cables.
Always keep the battery retainers in place to
protect and secure the batteries.
IMPORTANT: Be careful not to damage terminal
posts or cable connectors when removing the bat-
tery cables.
6. Connect final battery cable to battery terminals.
Install lock washer and nut on battery terminals. Torque
nuts from 115 to 125 in–lb (13 to 14.1 N–m).
1. Position vehicle on a level surface, set parking
brake, turn On/Off switch OFF and remove key.
7. Apply Toro battery terminal protector (see Special
Tools) to all battery posts and cable connectors to re-
duce corrosion after connections are made. Make sure
that terminal boots are positioned over all connections.
2. Raise bed and secure with prop rod.
3. Open the battery circuit by carefully removing one of
the battery cables (see Opening Battery Circuit in the
General Information section of this chapter).
8. Lower bed.
4. Once initial cable has been removed from vehicle,
disconnect and remove remaining battery cables from
all battery terminals.
1
2
5. Remove flange nuts (item 11) and battery retainers
(item 10) used to secure batteries to vehicle (Fig. 44).
3
6. Make sure that all battery filler caps are on tightly.
4
IMPORTANT: When removing batteries from ve-
hicle, do not lift batteries using battery terminals as
lift points: battery damage may occur.
Figure 44
1. Negative cable to vehicle
2. Positive cable to vehicle
3. Flange nut
4. Battery retainer
7. Using case loops on battery tops as lifting points, re-
move batteries from vehicle.
Installation (Fig. 43)
IMPORTANT: To prevent possible electrical prob-
lems, install only fully charged batteries.
1. Make sure vehicle on/off switch and all accessories
are OFF. Raise bed and secure with prop rod.
Figure 45
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 29
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Charging
3. Check for signs of wetness or leakage on the top of
the battery which might indicate a loose or missing filler
cap, overcharging, loose terminal post or overfilling.
When the vehicle is not in use, it is recommended to
keep the batteries charged by connecting the battery
charger that is included with the vehicle. The Workman
e2050/e2065 charger is designed to automatically
charge the batteries fully without overcharging. Indica-
tor lights (green and red) and an ammeter on the char-
ger give information about the charging operation.
4. Check the battery case for dirt and oil. Clean the bat-
tery with a solution of baking soda and water, then rinse
battery with clean water.
5. Check that the battery cover seal is not broken away.
Replace the battery if the seal is broken or leaking.
Make sure to have the battery cell plates covered with
electrolyte before charging the batteries (Fig. 46). Peri-
odically (at least every 50 operating hours) check elec-
trolyte level in the batteries and add distilled water to
ensure proper charging and the best battery perfor-
mance and life.
IMPORTANT: Make sure the area around the battery
filler caps is clean before opening the caps.
IMPORTANT: Do not add acid to the battery. Use
only distilled water to adjust the electrolyte level.
6. Check the electrolyte level in each cell. If the level is
below the tops of the plates in any cell, add just enough
distilled water to the cell to cover the plates. Replace
filler caps and charge the battery (see Operator’s Manu-
al). After charging, check electrolyte level in all cells and
add distilled water until the level is 1/8” (3 mm) below
the bottom of the fill well (Fig. 46).
Colder temperatures will increase the time needed to
fully charge the batteries. NEVER attempt to charge fro-
zen batteries. Also, if temperatures below freezing are
expected, do not add water to battery after charging as
added water could freeze and damage battery.
For additional battery charging information, see your
Operator’s Manual and the Battery Charger Operating
Instructions.
2
Inspection and Maintenance
4
1/8 inch
(3 mm)
WARNING
3
POTENTIAL HAZARD:
Battery electrolyte contains sulfuric acid which
is a deadly poison and it causes severe burns.
WHAT CAN HAPPEN:
If you carelessly drink electrolyte you could die
or if it gets onto your skin you will be burned.
HOW TO AVOID THE HAZARD:
1
Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and rubber gloves to protect
your hands.
Fill the battery where clean water is always
available for flushing the skin.
Figure 46
1. Battery plates
2. Filler cap
3. Electrolyte level
4. Battery terminal
Follow all instructions and comply with all
safety messages on the electrolyte container.
1. Check for cracks in battery case caused by overly
tight or loose hold–down retainer. Replace any battery
that is cracked and/or leaking.
2. Check battery terminal posts for corrosion. Use a ter-
minal brush to clean corrosion from the battery terminal
posts.
IMPORTANT: Before cleaning the battery, make
sure the filler caps are on tightly.
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 30
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Testing
A. Remove battery filler caps. Do not add water prior
to testing specific gravity of battery electrolyte. If
electrolyte level is low, add distilled water and
charge battery (see Operator’s Manual) before per-
forming specific gravity test.
When testing batteries in the Workman e2050 and
e2065, it is important to test all batteries. Proper perfor-
mance of the vehicle depends on all batteries being in
good condition. Testing will determine if one (or more) of
the batteries needs to be replaced.
B. Measure the specific gravity of each cell with a
hydrometer. Fill and drain the hydrometer two to four
times before drawing a sample. At the same time,
take the temperature of the cell.
1. The preferred testing procedure is to use the Lester
Electrical 36/48 Volt Battery Discharge Unit (Model
17770). This instrument puts a known discharge load
(56.25 Amps) on the battery pack until the battery pack
reaches 42 volts. A timer incorporated into the discharg-
er measures the time needed to reach that voltage level.
Battery capacity and remaining life can be determined
from the test results. Refer to Discharge Unit Operating
Instructions for further information.
C. Have enough electrolyte in the hydrometer to
completely support the hydrometer float. Record the
hydrometer reading and return the electrolyte to the
battery cell.
D. Repeat test for remaining battery cells.
E. Temperature correct each cell reading. For each
10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the
specific gravity reading. For each 10oF (5.5oC) below
80oF (26.7oC) subtract 0.004 from the specific grav-
ity reading.
Other types of battery load testers can also be used to
test the Workman batteries. Many locally available bat-
tery load testers do not, however, have any adjustment
on the load that is put on the battery. Results received
from using load testers should follow the recommenda-
tions of the load tester manufacturer.
Example: Cell Temperature
100oF
Cell Specific Gravity Reading 1.245
2. If the Lester Battery Discharge Unit (or other load
tester) is not available, an alternate battery test can be
done using a multimeter to perform a voltage test of
each battery. Use the following procedure:
ADD (20o above 80oF)
Correction to 80oF
0.008
1.253
F. The specific gravity of all battery cells should be
1.277 + .007. If low cell readings exist (see Fig. 47),
charge battery (see Operator’s Manual) and take
specific gravity readings again.
A. For accurate voltage testing, allow batteries to re-
main idle (no charging, no discharging) for at least 6
hours and preferably 24 hours.
G. If specific gravity of any cells remain low after
complete charging, battery should be replaced.
B. Open the battery circuit by carefully removing
one of the battery cables (see Opening Battery Cir-
cuit in the General Information section of this chap-
ter). Then, disconnect both cables from battery to be
tested.
Battery Charge
Level
Specific
Gravity
Open Circuit
Voltage
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
1.277
1.258
1.238
1.217
1.195
1.172
1.148
1.124
1.098
1.073
6.37
6.31
6.25
6.19
6.12
6.05
5.98
5.91
5.83
5.75
C. Measure the battery voltage with the multimeter.
Record battery voltage. The measured voltage will
determine battery state of charge.
D. If voltage readings below 70% charged (see Fig.
47) exist, charge battery (see Operator’s Manual)
and take voltage measurements again. If voltage re-
mains low after charging, consider battery replace-
ment.
3. A third option for battery testing is to perform a specif-
ic gravity test of the battery electrolyte using a hydrome-
ter. Use the following procedure:
Figure 47
IMPORTANT: Make sure the area around the battery
fill caps is clean before removing the caps.
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 31
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Battery Storage
If the vehicle will be stored for more than 30 days and the
battery charger cannot be used for some reason, charge
the batteries fully. Either store batteries on a shelf or in
the vehicle. Store the batteries in a cool atmosphere to
avoid quick deterioration of the charge in the batteries.
To prevent batteries from freezing, make sure they are
fully charged before storage. During the storage period,
charge the batteries at least once every three (3)
months to prevent battery damage. Before returning the
vehicle to service, make sure to fully charge the batter-
ies.
If the vehicle will be stored for any period of time, check
battery electrolyte level, adjust level if needed and then
connect battery charger to vehicle. Allow charger to re-
main connected to vehicle during storage to prevent bat-
tery discharge and potential battery damage.
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 32
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Traction Motor Brushes
The traction motor in the Workman e2050/e2065 uses
eight (8) brushes. Traction motor brushes should be in-
spected every 500 hours of operation or annually.
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).
1
3. Unlatch headband of traction motor and reposition
headband to allow inspection of a brush at the top of the
motor.
Figure 48
4. If end of brush is even with the brush holder (Figs. 48
and 50), brushes should be removed from motor for in-
spection and measurement (see Traction Motor Service
in this section).
1. Brush
2. Brush holder
3. Brush spring (tensioned)
4. Brush spring (released)
1
5. In most instances, wear of all traction motor brushes
should be similar to wear found on the top brushes. If in-
spection of remaining brushes is needed or if brushes
require replacement, traction motor should be removed
from vehicle (see Traction Motor and Traction Motor
Service in this section).
6. If vehicle is often operated in severely dirty environ-
ments, brush should be removed from motor to allow in-
spection of mating surface of brush (Fig. 49). If brush
surface is rough, pitted, arced or scored, additional
brush and/or motor inspection should be completed
(see Traction Motor and Traction Motor Service in this
section).
2
Figure 49
7. Visually inspect commutator surface of motor arma-
ture. If commutator surface is rough, pitted, arced or
scored, additional motor inspection should be com-
pleted (see Traction Motor and Traction Motor Service
in this section).
1. Removed brush
2. Cap screw
4
2
8. After brush inspection, make sure brush is correctly
installed in brush holder and tensioned by spring. Refit
headband to traction motor and latch headband.
1
1
9. Carefully connect removed battery cable to battery
terminals. Install lock washer and nut on battery termi-
nals. Torque nuts from 115 to 125 in–lb (13 to 14.1 N–m).
4
3
10.Lower bed.
Figure 50
1. Brush holder (side view)
2. Normal brush
3. Worn brush
4. Brush shunt wire
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 33
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Traction Motor
14
115 to 125 in lb
(13 to 14.1 N–m)
15
16
3
17
4
18
5
6
7
5
15
8
9
16
19
10
1
11
12
2
13
RIGHT
FRONT
Figure 51
1. Socket head screw (6 used)
2. Flat washer (6 used)
3. Flange nut
8. Traction motor
9. Fan
14. Cable terminal boot
15. Hex nut
10. Roll pin (2 used)
11. Washer
12. Socket head screw
13. Plastic cap (fits in rear frame)
16. Lock washer
4. Support bracket
17. Positive battery cable
18. Cable terminal boot
19. Negative battery cable
5. Carriage screw
6. Transaxle mount plate
7. Rubber damper
Removal (Fig. 51)
NOTE: Label all electrical leads for reassembly pur-
poses.
1. Park vehicle on a level surface, turn on/off switch
OFF, set parking brake and remove key from switch.
IMPORTANT: When removing wires from motor ter-
minals (A1, A2, F1 and F2), use a wrench to retain
lower nut while loosening upper nut (Fig. 53). If ter-
minal studs are allowed to turn during upper nut re-
moval, internal motor damage can occur.
2. Remove cargo bed from vehicle (see Cargo Bed Re-
moval in Service and Repairs section of Chapter 5 –
Chassis).
3. Open the battery circuit by carefully removing one of
the battery cables (see Opening Battery Circuit in the
General Information section of this chapter).
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 34
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4. Disconnect wires from traction motor (Fig. 52):
2. Make sure that rubber damper is installed into the
motor shaft internal spline with the damper flat side to-
ward the motor (Fig. 52).
A. While retaining lower nut, remove upper nut and
wire connector from motor terminals A1, A2, F1 and
F2.
85 to 90 in–lb
(9.6 to 10.2 N–m)
55 to 60 in–lb
B. Unplug motor temperature sensor from vehicle
wire harness. Note location of cable tie that secures
temperature sensor wires to vehicle.
(6.2 to 6.8 N–m)
2
C. Position disconnected wires away from motor.
5. Remove plastic plug from rear frame to allow access
to socket head screw that retains fan to traction motor.
Remove screw and washer and then remove fan from
motor.
4
3
1
55 to 60 in–lb
(6.2 to 6.8 N–m)
CAUTION
To prevent motor damage and personal injury,
make sure that traction motor is well supported
as it is removed. Motor weighs approximately 62
pounds (28.1 kg).
Figure 52
1. Thermal switch
2. Motor shaft spline
3. Rubber damper
4. Transaxle input shaft
6. Support traction motor to prevent it from falling. Two
suggestions for traction motor support are as follows:
1
IMPORTANT: Damage to traction motor field coils will
result if eyebolt is threaded into motor housing to far.
A. Remove silver flange head screw from top of mo-
tor and carefully install a 3/8 – 16 eyebolt into motor
(Fig. 54). Thread eyebolt into motor approximately
four (4) turns taking care to not bottom eyebolt into
internal field coils. Secure eyebolt with jam nut. Use
eyebolt for support and as a lifting point for motor re-
moval.
2
Figure 53
1. Loosening/tightening wrench (upper nut)
2. Retaining wrench (lower nut)
B. Use lifting strap wrapped around motor housing
for support and as a lifting point for motor removal.
1
7. Remove six (6) socket head screws (item 1) and flat
washers (item 2) that secure motor to transaxle.
8. Slide motor away from transaxle to disengage motor
shaft from transaxle input shaft. Carefully lift motor from
vehicle. Take care to not damage thermal switch while
motor is removed.
9. Locate and retrieve rubber damper from motor shaft
internal spline.
2
10.If needed, remove two (2) roll pins from motor shaft.
Installation (Fig. 51)
Figure 54
1. Eyebolt
2. Jam nut
1. If removed, install two (2) roll pins into motor shaft.
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 35
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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 sup-
ported as it is installed. Motor weighs approxi-
mately 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. Transaxle
3. Transaxle mount plate
2. Screw/washer (6 used)
5. Align mounting holes of motor, transaxle and trans-
axle mount plate. Secure motor to transaxle with six (6)
socket head screws (item 1) and flat washers (item 2).
1
2
IMPORTANT: When connecting wires to motor ter-
minals (A1, A2, F1 and F2), use a wrench to retain
lower nut while tightening upper nut (Fig. 53). If ter-
minal studs are allowed to turn during upper nut
installation, internal motor damage can occur.
4
5
3
6
6. Connect wires to traction motor (Fig. 52):
Figure 56
A. Make sure that fasteners and cable connectors
are properly positioned on motor terminals (Fig. 56).
1. Upper nut
2. Cable connector
3. Lower nut
4. Flat washer
5. Insulating washer
6. Motor housing
B. Install correct cable connector and nut to motor
terminals A1 and A2. While retaining lower nut,
torque upper nut on terminals A1 and A2 from 85 to
90 in–lb (9.6 to 10.2 N–m).
C. Install correct wire connector and nut to motor ter-
minals F1 and F2. While retaining lower nut, torque
upper nut on terminals F1 and F2 from 55 to 60 in–lb
(6.2 to 6.8 N–m).
D. Plug motor temperature sensor connector into
vehicle wire harness.
7. Position fan to traction motor and secure with socket
head screw and washer. Install plastic plug in hole in
rear frame.
8. Carefully connect removed battery cable to battery
terminals. Install lock washers and nuts on battery termi-
nals. Torque nuts from 115 to 125 in–lb (13 to 14.1 N–m).
9. Install cargo box to the rear frame (see Cargo Box
Installation in Service and Repairs section of Chapter 5
– Chassis).
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 36
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Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 37
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Traction Motor Service
1
(1
1
1
9
Figure 57
1. Frame and field assembly
2. Armature
6. Cap screw (8 used)
7. Brush (8 used)
8. High temperature sensor
9. Headband
11. Commutator end head
12. Bearing
13. Retaining ring
14. Brush spring (8 used)
15. Brush box
3. Brush lead (2 used)
4. Cap screw (2 used per brush lead)
5. Cap screw (4 used)
10. Bolt (4 used)
Disassembly (Fig. 57)
5. Remove the retaining ring and press bearing from
the commutator end head. Discard the bearing.
1. Unlatch and slide headband from traction motor.
2. Pull back the brush springs and latch them in the
open position on the spring holders. Slide brushes from
the brush holders.
CAUTION
When using compressed air for cleaning motor
components, follow all safety instructions, in-
cluding wearing eye and respiratory protection.
3. Use an arbor press or a bearing puller to remove the
armature from the commutator end head and frame and
field assembly (Fig. 58).
6. Carefully blow out any accumulated carbon dust and
dirt from the commutator end head and the frame and
field assembly using clean, oil free, compressed air.
4. Remove four (4) bolts that secure the commutator
end head to the frame and field assembly. Remove com-
mutator end head from frame and field assembly.
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 38
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Brush Service
3. It is also recommended that the field be coated with
PD George 1000–70 or RanBar B–535–5S varnish for
proper insulation protection. Both recommended var-
nishes are Class H water–soluble varnishes. A similar
air–dry varnish may also be used providing it has a
Class H rating.
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.
4. Screws securing the pole pieces to the frame should
be torqued from 250 to 300 in–lb (28.3 to 33.9 N–m) (Fig.
60).
2. Replace brushes that are worn to a length of 0.620”
(16 mm). Also, replace brushes if they show signs of un-
even wear or show signs of overheating, such as discol-
ored brush shunts and brush springs.
2
3
3. Brushes should always be replaced in complete sets
of eight. Use identical replacement parts; do not substi-
tute brush grades as the brushes are matched to the
motor type and application to provide the best service.
Substituting brushes of the wrong grade can cause pre-
mature commutator failure and excessive brush wear.
Remove old brushes and replace with identical replace-
ment parts. Hold brush shunts in position and torque
brush screws from 18 to 22 in–lbs (2 to 2.5 N–m) (Fig.
60). Make sure brushes move freely in the holders and
that shunts do not interfere with brush spring movement.
1
Figure 58
1. Motor housing
2. Puller
3. Arbor press
4. Make sure the brush box assembly is tight on the
commutator end head. Replace brush box assemblies
in the commutator end head if they are physically dam-
aged or brush holders are loose on the brush plate.
1
5. Brush springs should be checked for proper tension
using the following procedure (Fig. 59):
2
3
A. Place paper strip between brush face and com-
mutator. Hook spring scale as shown.
B. Pull spring scale on a line directly opposite the
line of force exerted by the brush spring. When the
paper strip begins to move freely, read the spring ten-
sion on the scale. Brush tension for a new brush
should be 65 ounces (1820 grams) and for a worn
brush should be 40 ounces (1120 grams).
Figure 59
1. Spring scale
2. Brush spring
3. Paper
Frame and Field Service
2
2
1. Motors that have been disassembled for servicing
should be given a complete inspection of the frame and
field assembly. If damage to the field coils or frame is
found, replace traction motor. Individual frame and field
components are not available.
1
2. Accumulated carbon dust, grease and other foreign
material can produce a ground path from the field wind-
ing to the frame. The frame and field should be cleaned
with Safety–Kleen 105 washing solvent or equivalent.
After cleaning, the frame and field must be oven–dried
for one hour at 300 F (148 C) to remove any cleaning
residue.
Figure 60
1. Brush screw
2. Pole piece screw
o
o
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 39
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Commutator Service
MICA
COPPER SEGMENT
1. Chuck armature on the commutator end–bearing
journal and support the drive end of armature using the
”live” center of the shaft. With the armature supported on
both ends, measure the commutator runout and the bar
to bar differences with a dial gauge. Total indicated run-
out should not exceed 0.003” (0.08 mm) and not more
than 0.0005” (0.013 mm) between any two bars. If the
readings fall outside this limit, the commutator must be
turned and re–undercut.
.040”
(1.0 mm)
GOOD UNDERCUT
MICA
MICA
COPPER SEGMENT
COPPER SEGMENT
2. If the commutator must be turned, use only high
quality cutting tools with a controlled cutting rate. Re-
move only enough copper to bring total indicated runout
and bar to bar height differences into specification.
BAD UNDERCUT
(CUT TOO WIDE)
BAD UNDERCUT
(CUT TOO NARROW)
3. The minimum commutator diameter is 2.750” (70
mm). If the commutator diameter falls below this diame-
ter after turning, the armature must be replaced.
Figure 61
4. After the commutator is turned, undercut the mica to
a uniform depth of 0.040” (1.0 mm). Be careful to only cut
the mica and not increase the slot width (Fig. 61).
Traction Motor Specifications
BRUSH LENGTH
Maximum
Minimum
1.300 in
0.620 in
33 mm
16 mm
CAUTION
BRUSH SPRING
TENSION
When using compressed air for cleaning mo-
tor components, follow all safety instructions,
including wearing eye and respiratory protec-
tion.
New Brush
Worn Brush
65 ounces
40 ounces
1820 grams
1120 grams
COMMUTATOR
New Diameter
2.920 in
2.800 in
74 mm
71 mm
5. After undercutting, use No. 00 sandpaper to lightly
remove any burrs left from the undercutting operation.
Clean commutator with dry, oil free compressed air and
recheck commutator runout.
Minimum Diame-
ter for Reslotting
Reject Diameter
2.750 in
70 mm
Armature Testing
Before an armature is reassembled into the motor, the
following tests should be performed:
NOTE: Armature is wave wound and can be short cir-
cuit tested in the following manner.
1. Check for grounded circuits by placing one test lead
of a dielectric tester on the commutator and the other
lead at the armature shaft. If the test light comes on, the
armature is grounded.
2. Check for short circuits by placing the armature on a
growler. Use a long, flat piece of metal (such as a hack-
saw blade) to locate any shorted windings.
If armature is found to be shorted, grounded or other-
wise damaged, replace the traction motor.
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 40
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Assembly (Fig. 57)
ARMATURE
ASSEMBLY
PRESS FIXTURE
MUST PRESS
AGAINST
NOTE: After the motor has been disassembled, it is
recommended that a new commutator end head bear-
ing be installed because removed bearing may have
been damaged during disassembly. Although the bear-
ing may appear and feel good, the bearing could be ”bri-
nelled” (races or balls deformed) and may exhibit noise
and vibration problems or fail within a relatively short pe-
riod of service. When installing new bearing, always
press against the race that is absorbing the pressure or
bearing damage may occur.
OUTER RACE
BEARING AND
RETAINING RING
INSTALLED
IN END HEAD
BEARING
PRESS FIXTURE
MUST HOLD
END HEAD
MUST BE HELD
STATIONARY
INNER RACE
STATIONARY
1. After servicing the commutator and brushes, re–as-
semble the wiring in the commutator end head as origi-
nally found. Ensure the wiring does not contact metal
and rotating parts. Also, make sure that the wiring allows
the brushes to move unrestricted in the brush holders.
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.
3
4
5
3. Position the commutator end head to the frame and
field assembly and secure with four (4) bolts. Torque
bolts from 120 to 140 in–lb (13.6 to 15.8 N–m).
Figure 63
1. Terminal
2. Lower nut
3. Flat washer
4. Insulating washer
5. Motor housing
4. Ensure the brushes are pushed out of the way.
5. While supporting the inner–race of the bearing in
commutator end head, carefully press the armature into
the end head and bearing assembly (Fig. 62).
2
6. Position brushes in brush holders and carefully re-
lease the brush springs allowing the brushes to contact
the commutator. Make sure brush shunts do not inter-
fere with spring movement.
1
4
7. Repair or replace the headband if damaged. Install
the headband on the motor.
3
8. Make sure that lower nuts are properly tightened on
traction motor terminals (Fig. 63 and 64). Lower nuts on
F1 and F2 terminals should be torqued from 50 to 60 in–
lb (5.7 to 6.8 N–m). Lower nuts on A1 and A2 terminals
should be torqued from 110 to 140 in–lb (12.4 to 15.8
N–m).
Figure 64
1. A2 terminal
2. F2 terminal
3. F1 terminal
4. A1 terminal
Workman e2050/e2065
Electrical System (Rev. B)
Page 3 – 41
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Battery Charger
1
2
12
3
11
10
4
9
5
7
8
6
Figure 65
1. Upper case
2. Transformer
3. Lower case
4. SCR assembly
5. Control board
6. Relay
9. DC cordset
10. Ammeter
11. Fuse
7. Circuit breaker
8. AC cordset
12. Diode assembly
For service of the battery charger, see the Lester Electri-
cal Technician Service Guide at the end of this chapter.
Electrical System (Rev. B)
Workman e2050/e2065
Page 3 – 42
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Chapter 4
Transaxle and Brakes
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Adjust Brakes (Workman e2050) . . . . . . . . . . . . . . 6
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8
Rear Wheels and Brakes . . . . . . . . . . . . . . . . . . . . . 8
Brake Service (Workman e2050) . . . . . . . . . . . . . 10
Rear Brake Service (Workman e2065) . . . . . . . . 12
Hydraulic Brake System (Workman e2065) . . . . 14
Bleed Brake System (Workman e2065) . . . . . . . 15
Front Brake Calipers (Workman e2065) . . . . . . . 16
Brake Master Cylinder (Workman e2065) . . . . . 18
Brake Master Cylinder Service (Workman e2065)19
Parking Brake (Workman e2065) . . . . . . . . . . . . . 20
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Transaxle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SPICER OFF–HIGHWAY COMPONENTS MODEL
12 (ELECTRIC) MAINTENANCE MANUAL
Workman e2050/e2065
Page 4 – 1
Transaxle and Brakes (Rev. B)
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Page 4 – 2
Workman e2050/e2065
Transaxle and Brakes (Rev. B)
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Specifications
Item
Description
Transaxle
Transaxle Fluid Capacity
Transaxle Fluid
2 quarts (1.9 liters)
10W–30 Motor Oil
Workman e2050/e2065
Page 4 – 3
Transaxle and Brakes (Rev. B)
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Troubleshooting
Brakes
Problem
Possible Cause
Brake pedal goes to the floor.
Brakes are incorrectly adjusted (Workman e2050).
Brake cable is loose or broken (Workman e2050).
Rear brake shoes are excessively worn.
Front brake pads are excessively worn (Workman e2065).
Brake fluid level low (Workman e2065).
Brake fluid leak at hose, caliper or wheel cylinder (Workman
e2065).
Brake master cylinder faulty (Workman e2065).
Rear brake drums are excessively worn or cracked.
Brake pedal is spongy.
Rear brake shoes are not burnished.
Brake cable is loose or broken (Workman e2050).
Brakes are incorrectly adjusted (Workman e2050).
Air in brake lines (Workman e2065).
Brakes pull to either side.
Tire pressure is incorrect or uneven between tires.
Brake linings are contaminated.
Front wheel alignment (toe–in) is incorrect.
Brake cable is binding, loose or broken (Workman e2050).
Brake shoes are distorted.
Tires on same axle are unmatched.
Brake lining is glazed or saturated.
Brakes squeal.
Rear shoe–to–shoe spring(s) is (are) weak or broken.
Brake shoes are distorted.
Anchor plate is bent (Workman e2050).
Brake drums and shoes are dusty.
Rear brake drums are scored or out–of–round.
Page 4 – 4
Workman e2050/e2065
Transaxle and Brakes (Rev. B)
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Brakes (continued)
Problem
Possible Cause
Brakes drag.
Parking brake is applied.
Brakes are incorrectly adjusted (Workman e2050).
Rear shoe–to–shoe spring(s) is (are) weak or broken.
Brake pedal is binding.
Brake cable is binding (Workman e2050).
Brake linings are saturated.
Rear brake drums are bent or out–of–round.
Front brake calipers or rotors are damaged (Workman e2065)
Incorrect brake lining material.
Brake pedal is hard to push.
Wheels lock–up when braking.
Brake pedal linkage is binding.
Brake cable is binding (Workman e2050).
Brake linings are contaminated.
Brake linings are loose or damaged.
Wheel or transaxle bearings are damaged.
Rear brake shoe–to–shoe springs are weak.
Rear brake drums are grooved in the contact face with brake
shoes.
Brakes fade.
Brake drums or rotors are overheated.
Brake linings are saturated.
Vehicle surges at slow speeds and
chatters at fast speeds.
Brake drums or rotors are bent or out–of–round.
Rear brakes do not self adjust.
Adjuster bolt is seized.
Adjuster lever does not engage star wheel.
Workman e2050/e2065
Page 4 – 5
Transaxle and Brakes (Rev. B)
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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. Check the gap be-
tween the brake lever and the brake lever stop to deter-
mine the distance the brake equalizer needs to be
adjusted (Fig 2).
5
7
6
8
3. Remove the cotter pin and clevis pin that secure the
brake rod clevis to the brake lever.
7
4. Disconnect the spring from the hole near the end of
the brake rod.
Figure 1
5. Press the brake pedal down fully to raise the brake
lever away from the brake rod clevis.
1. Clevis pin/cotter pin
2. Brake lever
3. Brake rod clevis
4. Brake rod
5. Brake equalizer
6. Spring
7. Brake cable
8. Accelerator pedal shaft
6. Thread the brake rod in or out of the brake equalizer
as needed to remove the gap identified in Step 2. Do not
overtighten or brakes will drag and wear prematurely.
1
2
3
7. Reinstall the spring into the hole in the brake rod.
NOTE: Use a pry bar placed between the accelerator
pivot shaft and the brake equalizer to aid in installation
of the clevis pin that secures the brake rod clevis to the
brake lever.
4
5
8. Connect the brake rod clevis to the brake lever using
the clevis pin and cotter pin removed previously.
9. Verify that brake pedal travel is from 1” to 1 1/2” (25.4
to 38.1 mm) with a 75 to 100 pound (34 to 45.4 kg) input
force to the brake pedal.
Figure 2
1. Brake lever
2. Brake lever stop
3. Clevis pin/cotter pin
4. Brake rod clevis
5. Brake equalizer
Page 4 – 6
Workman e2050/e2065
Transaxle and Brakes (Rev. B)
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Workman e2050/e2065
Page 4 – 7
Transaxle and Brakes (Rev. B)
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Service and Repairs
Rear Wheels and Brakes
15 to 19 ft–lb
(20 to 26 N–m)
45 to 65 ft–lb
(61 to 88 N–m)
2
6
7
1
8
13
12
9
RIGHT
11
10
FRONT
Figure 3
1. Lug nut (5 used per wheel)
2. Wheel assembly
6. Flange head screw (4 used per brake)
7. Brake assembly (RH shown)
8. Nut (4 used per brake)
9. Cotter pin
10. Clevis pin
11. Brake cable (RH shown)
12. Retaining ring
3. Brake drum
4. Axle shaft
5. Wheel stud (5 used per wheel)
13. Transaxle
Removal (Fig. 3)
4. Remove the axle shaft from the transaxle (see the
Spicer Off–Highway Components Model 12 (Electric)
Maintenance Manual at the end of this chapter).
1. Park vehicle on a level surface, turn on/off switch
OFF and remove key from the on/off switch.
5. If necessary, remove brake assembly as follows:
A. Remove cotter pin and clevis pin securing the
brake cable bracket to the brake actuator lever (Fig.
4).
WARNING
Before jacking up the vehicle, review and follow
Jacking Instructions in Operator’s Manual and
Chapter 1 – Safety.
B. On Workman e2065, clean hydraulic brake line
area of rear brake cylinder to prevent contamina-
tion. Loosen and disconnect hydraulic brake line
from wheel cylinder. Plug brake line and position it
away from wheel cylinder.
2. Chock wheels not being jacked up. Lift rear wheel off
the ground using a jack and place jack stand or blocks
beneath the rear frame to support vehicle.
C. Remove four (4) cap screws and nuts securing
the brake assembly to the transaxle. Remove brake
assembly from the transaxle.
NOTE: To remove brake drum, it may be necessary to
loosen brake cable adjustment or remove brake cable
from brake actuator lever.
3. Remove five (5) lug nuts, wheel assembly and brake
drum from the wheel hub.
Page 4 – 8
Workman e2050/e2065
Transaxle and Brakes (Rev. B)
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Installation (Fig. 3)
Burnish Brake Shoes
IMPORTANT:On Workman e2050 vehicles, the brake
actuator levers must be positioned below the trans-
axle mount. On Workman e2065 vehicles, the levers
should be positioned above the transaxle mount.
When positioned correctly, the brake actuator lev-
ers will point toward the rear of the vehicle (Fig. 4).
To provide maximum brake performance after rear
brake shoes are replaced, burnish new brake shoe lin-
ings.
IMPORTANT:To prevent brake overheating, do not
drive vehicle with the brakes applied.
IMPORTANT:When burnishing brake shoes, do not
allow the brakes to lock up. Also, allow brakes to
cool between stops.
1. If brake assembly was removed from axle, position
brake assembly to the transaxle.
A. Secure brake assembly to the transaxle with four
(4) cap screws and nuts. Torque screws from 15 to 19
ft–lb (20 to 26 N–m).
1. Drive vehicle while making 6 to 7 normal stops at
about 200 ft (60 m) intervals while traveling at 10 to 15
mph (16 to 24 KPH).
B. On Workman e2065, position hydraulic brake
line to wheel cylinder. Connect brake line to wheel
cylinder.
2. Make several normal stops with the vehicle going in
the reverse direction. This will self adjust the clearance
between the brake shoes and drum.
C. Secure brake cable bracket to the brake actuator
lever with clevis pin and cotter pin (Fig. 4).
Workman e2050 Shown
2. Install axle shaft into transaxle (see the Spicer Off–
Highway Components Model 12 (Electric) Maintenance
Manual at the end of this chapter).
3. Slide brake drum onto wheel hub making sure that
hole in drum aligns with hole in wheel hub on axle.
3
4
4. Position wheel assembly to the vehicle with valve
stem facing out and secure with five (5) lug nuts. Torque
lug nuts in a criss–cross pattern from 45 to 65 ft–lb (61
to 88 N–m).
1
2
5. Lower vehicle to ground.
Figure 4
1. Cotter pin
2. Clevis pin
3. Brake cable bracket
4. Brake actuator lever
CAUTION
After servicing the brakes, always check the
brakes in a wide open, level area that is free of
other persons and obstructions.
6. Check and adjust brakes (see Operator’s Manual).
Workman e2050/e2065
Page 4 – 9
Transaxle and Brakes (Rev. B)
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Brake Service (Workman e2050)
19
6
1
4
7
7
2
7
1
2
9
9
6
ROTATION TO
5
EXPAND BRAKE SHOES
3
6
12
11
18
9
17
17
3
7
16
15
5
14
7
7
7
10
8
13
8
1
Figure 5
1. Backing plate
8. Actuator lever
9. Adjusting screw
10. PTFE coated washer
11. Push rod
12. Shim washer
13. Protective boot
14. Pivot pin
15. Wave washer
16. Washer
17. Adjusting lever
18. Retaining clip
19. Anchor abutment
2. Hold down pin
3. Bottom shoe–to–shoe spring
4. Top shoe–to–shoe spring
5. Auto adjust spring
6. Shoe cup (spring loaded)
7. Brake shoe
Page 4 – 10 (Rev. C)
Workman e2050/e2065
Transaxle and Brakes (Rev. B)
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Disassembly (Fig. 5)
3. Inspect backing plate surfaces which contact with
the brake shoes for grooves that may restrict shoe
movement. Replace backing plate if grooves can not be
removed by light sanding with emery cloth or other suit-
able abrasive. Replace backing plate if cracked, warped
or excessively rusted.
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.
4. Inspect anchor abutment and rivets for deformation.
Replace entire brake assembly if deformation or exces-
sive rust is found.
3. Remove brake shoes from backing plate.
Inspection
5. Replace adjuster screw and shim washers if rusted,
corroded, bent or fatigued.
1. Inspect brake drums.
IMPORTANT:Brake drum machining is not recom-
mended. Replace brake drums as a set to maintain
equal braking forces.
6. Replace brake cables if frayed, stretched or kinked.
Assembly (Fig. 5)
A. Clean drums with denatured alcohol. Check
braking surface diameter in at least three places. If
the diameter exceeds 6.320 inches (16.05 cm), re-
place both brake drums.
IMPORTANT:Brake shoe lining surfaces must be
free of grease, oil and other foreign matter.
1. Apply a light film of lubricant to the following:
B. Replace drums that are cracked, deeply grooved,
tapered, significantly out–of–round, scored, exces-
sively rusted or heat spotted.
A. Surfaces of the shoe web that contact the back-
ing plate, push rod and adjusting screw.
B. Six ledges on which the brake shoes rest.
C. Entire surfaces ofPTFE coated washers.
D. Entire surface of pivot pin.
C. Minor scoring can be removed with sandpaper.
2. Inspect brake shoe linings.
IMPORTANT:Replace brake shoes as a set (all four
shoes) to maintain equal braking forces.
E. Slot in push rod that contacts actuator lever.
A. Replace brake shoes if damaged or if lining is
worn to 1/16” (1.6 mm). Also, replace shoes if lining is
contaminated by oil, grease or other fluids.
F. Surfaces of adjusting lever that contact wave
washer, washer and pivot pin.
G. Surfaces of the actuator bracket that contact the
star wheel of the adjusting screw.
NOTE: Overheated springs lose their tension and can
cause brake linings to wear out prematurely.
2. Position brake shoes to backing plate. Secure shoes
to plate with shoe cups and hold down pins.
B. Inspect brake shoe webbing, shoe–to–shoe
springs and auto adjust spring for overheating. Over-
heating is indicated by a slight blue color. Inspect
brake shoe webbing for deformation. Replace parts
as necessary.
3. Secure brake shoes with shoe–to–shoe springs and
auto adjust spring.
C. Inspect hold down pins and shoe cups for bends,
rust and corrosion. Replace as necessary.
Workman e2050/e2065
Page 4 – 11 (Rev. C)
Transaxle and Brakes (Rev. B)
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Rear Brake Service (Workman e2065)
110 to 120 in–lb
(12.4 to 13.6 N–m)
6
2
9
11
110 to 120 in–lb
(12.4 to 13.6 N–m)
10
7
3
8
11
10
5
12
1
13
7
8
110 to 120 in–lb
(12.4 to 13.6 N–m)
4
3
12
Figure 6
1. Brake backing plate
2. Washer head screw
3. Brake shoe
6. Parking brake lever (LH shown)
7. Belleville washer
8. Adjuster lever
10. Flat washer
11. Bolt
12. Shoe hold down cup and spring
13. Upper spring
4. Lower spring
9. Dust cover
5. Wheel cylinder
Disassembly (Fig. 6)
4. If required, slide parking brake lever from slot and
dust cover in backing plate.
5. If necessary, remove two (2) washer head screws
that secure wheel cylinder to backing plate. Remove
wheel cylinder from backing plate.
CAUTION
Be careful when removing springs from brake
shoes. The springs are under heavy load and
may cause personal injury.
6. If necessary, remove bolts and washers to allow ad-
juster levers to be separated from backing plate. Locate
and remove belleville washers from between adjuster
levers and backing plate.
1. Remove upper and lower springs from brake shoes.
2. Remove shoe hold down cups and springs that se-
cure the brake shoes to the backing plate.
3. Remove brake shoes from backing plate.
Page 4 – 12
Workman e2050/e2065
Transaxle and Brakes (Rev. B)
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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.
IMPORTANT:Brake drum machining is not recom-
mended. Replace brake drums as a set to maintain
equal braking forces.
1. Apply a light film of lubricant to the following:
A. Ledges on which the brake shoes rest.
B. Pin surfaces on adjuster levers.
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.
C. Anchor block surface that contacts shoe webs.
D. Both surfaces of belleville washers that are posi-
tioned between adjuster levers and backing plate.
B. Replace drums that are cracked, deeply grooved,
tapered, significantly out–of–round, scored, heat
spotted or excessively rusted.
2. If removed, position lubricated belleville washer be-
tween lever adjuster and backing plate. Secure adjuster
to backing plate with washer and bolt. Torque bolt from
110 to 120 in–lb (12.4 to 13.6 N–m).
C. Minor scoring can be removed with sandpaper.
2. Inspect brake shoe linings.
3. If removed, secure wheel cylinder to backing plate
with two (2) washer head screws. Torque screws from
110 to 120 in–lb (12.4 to 13.6 N–m).
IMPORTANT:Replace brake shoes as a set (all four
shoes) to maintain equal braking forces.
A. Replace brake shoes if damaged or if lining is
worn to 1/16” (1.6 mm). Replace if lining is contami-
nated by oil, grease, or other fluids.
4. If removed from backing plate, slide parking brake le-
ver into slot and dust cover in backing plate.
5. Position brake shoes to backing plate. Make sure
that each shoe is properly positioned at anchor block,
parking brake lever, wheel cylinder and pin on adjuster
lever. Secure shoes to backing plate with shoe hold
down cups and springs.
NOTE: Overheated springs lose their tension, and can
cause brake linings to wear out prematurely.
B. Inspect brake shoe webbing, upper and lower
springs, and shoe hold down springs for overheat-
ing. Overheating is indicated by a slight blue color. In-
spect brake shoe webbing for deformation. Replace
parts as necessary.
CAUTION
Be careful when installing springs to brake
shoes. The springs are under heavy load and
may cause personal injury.
C. Inspect hold down pins on adjuster levers for
bends, rust and corrosion. Replace as necessary.
3. Inspect backing plate surfaces, which contact with
the brake shoes for grooves that may restrict shoe
movement. Replace plate if grooves can not be re-
moved by light sanding with emery cloth or other suit-
able abrasive. Replace plate if cracked, warped or
excessively rusted.
6. Secure brake shoes with upper and lower springs.
4. Inspect adjuster levers for deformation. Replace lev-
ers if deformation or excessive rust is found.
5. Replace parking brake cables if frayed, stretched or
kinked.
Workman e2050/e2065
Page 4 – 13
Transaxle and Brakes (Rev. B)
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Hydraulic Brake System (Workman e2065)
14
35
34
13
33
36
7
4
12
24
19
11
21
2
10
26
16
5
11
17
18
32 20
9
15
6
23
8
27
31
25
30
32
Loctite #242
32
28
22
29
3
RIGHT
FRONT
37
1
Figure 7
1. Brake caliper (LH)
2. Brake caliper (RH)
3. Brake rotor (2 used)
4. Front brake tube
5. Front brake hose
6. Carriage screw
7. Rear brake tube
8. Carriage screw
9. Rear brake hose bracket
10. Cap screw
14. Rear brake tube (RH)
15. Rear brake tube (LH)
16. Insulated clip (5 used)
17. Cap screw (2 used)
18. Flange nut (2 used)
19. Clevis pin
26. Tube clamp (2 used)
27. R–Clamp
28. Cap screw (2 per caliper used)
29. Lock washer (2 per caliper used)
30. Socket head screw (4 per rotor used)
31. Washer head screw (2 used)
32. Lock nut
20. Cotter pin
21. Master cylinder
22. Union fitting
23. Rear brake tube
24. Rear brake hose
25. Hose bracket (2 used)
33. Cap screw
34. Lock nut
35. Rear brake (RH)
11. Thread forming screw (6 used)
12. Clip
13. Tee fitting
36. Rear brake (LH)
37. Wheel hub assembly (2 used)
When performing service work on the Workman e2065
hydraulic brake system, make sure to thoroughly clean
components before disassembly. Use Figure 7 as a
guide for removal and installation of hydraulic brake
components.
Page 4 – 14
Workman e2050/e2065
Transaxle and Brakes (Rev. B)
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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 cali-
pers.
CAUTION
2. Have a helper pump brake pedal several times, then
hold pedal down firmly.
After servicing the brakes, always check the
brakes in a wide open, level area that is free of
other persons and obstructions.
3. With pedal firmly depressed, open bleeder valve un-
til pedal fades to floor. Close bleeder valve before re-
leasing pedal.
6. After bleeding of brakes is completed, test vehicle to
make sure brakes are operating correctly and brake
pedal is solid.
4. Repeat procedure until a continuous flow of brake
fluid, with no air bubbles, is released from bleeder valve.
Make sure fluid level is maintained in brake fluid res-
ervoir at all times.
Workman e2050/e2065
Page 4 – 15
Transaxle and Brakes (Rev. B)
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Front Brake Calipers (Workman e2065)
10
2
To rear
brakes
9
Loctite #242
8
45 to 65 ft–lb
(61 to 88 N–m)
13
7
6
3
5
4
RIGHT
1
12
FRONT
11
Figure 8
1. LH brake caliper
6. Brake rotor
10. Brake master cylinder
11. Wheel assembly
12. Lug nut
2. RH brake caliper
7. Socket head screw (4 per rotor used)
8. Spindle (LH shown)
3. Lock washer (2 per caliper used)
4. Cap screw (2 per caliper used)
5. Wheel hub assembly
9. A–arm (LH shown)
13. Front brake hose
Page 4 – 16
Workman e2050/e2065
Transaxle and Brakes (Rev. B)
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Removal (Fig. 8)
3. Align caliper mounting holes with spindle. Secure
caliper with two (2) cap screws and lock washers.
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
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).
WARNING
6. Lower machine to ground.
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 – Safety.
7. Bleed brakes (see Bleed Brake System in this sec-
tion).
2. Chock wheels not being jacked up. Jack front wheel
off the ground and place blocks beneath the frame.
CAUTION
3. Remove front wheel from machine (see Lower
Steering and Front Wheel Removal).
After servicing the brakes, always check the
brakes in a wide open, level area that is free of
other persons and obstructions.
4. Clean hydraulic brake line area of brake caliper to
prevent contamination. Loosen and disconnect brake
line from caliper. Plug brake line and position it away
from caliper.
8. Check brake operation.
5. Remove two (2) cap screws and lock washers that
secure the brake caliper to the spindle.
3
6. Slide brake caliper from brake rotor and remove cali-
per from machine.
2
7. If necessary, remove brake pads from caliper (Fig.
9):
A. Remove anti–rattle clip from caliper.
B. Remove pins from caliper by prying with a flat
blade screwdriver through loop in pins.
1
C. Slide brake pads from caliper. For assembly pur-
poses, note orientation of inner and outer pads as
the pads are not the same.
Figure 9
1. Brake pad
2. Pin (2 used)
3. Anti–rattle clip
D. Replace the brake pads if the friction material is
worn to less than 1/32” (0.8 mm).
Installation (Fig. 8)
1. If brake pads were removed from caliper, install pads
(Fig. 9):
A. If brake pads are being replaced, it will be neces-
sary to push caliper pistons back into the caliper
bore before installing new pads.
B. Slide brake pads into caliper. Make sure that fric-
tion material on pads is toward brake rotor position.
C. Secure pads into caliper with two (2) pins. Make
sure that pins snap into caliper slots. Install anti–
rattle clip to caliper, pin and brake pads.
2. Slide brake caliper onto brake rotor. Make sure that
rotor is between brake pads.
Workman e2050/e2065
Page 4 – 17
Transaxle and Brakes (Rev. B)
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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.
2. Remove plugs from brake lines. Install brake lines to
master cylinder.
3. Clean hydraulic brake line area of master cylinder to
prevent contamination. Remove both brake lines from
master cylinder. Cap ends of brake lines and position
them away from master cylinder.
3. Connect master cylinder to brake pedal with clevis
pin and cotter pin.
4. Install front hood to machine.
4. Remove flange head nuts from cap screws that se-
cure master cylinder to pedal frame.
5. Bleed brakes (see Bleed Brake System in this chap-
ter). Check brake operation.
5. Pull master cylinder from machine.
Page 4 – 18
Workman e2050/e2065
Transaxle and Brakes (Rev. B)
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Brake Master Cylinder Service (Workman e2065)
Disassembly (Fig. 11)
1
2
1. Remove reservoir and flange seal. Push in on the
push rod so the stop pin can be removed.
12
3
2. Disconnect lower end of the dust cover from the
housing.
3. Push in on the push rod and remove circlip, then re-
move push rod with dust cover and clevis. Remove re-
tainer washer.
4
11
4. Remove primary piston assembly and secondary
piston assembly from cylinder housing.
Inspection
10
9
8
1. Clean all metal parts with isopropyl alcohol, then
clean out and dry grooves and passageways with com-
pressed air. Make sure cylinder bore and component
pieces are thoroughly clean.
7
6
5
Figure 11
1. Reservoir
2. Flange seal
3. Stop pin
4. Secondary piston assy
5. Clevis
6. Jam nut
7. Dust cover
8. Push rod
9. Circlip
10. Retainer washer
11. Primary piston assy
12. Cylinder housing
2. Check cylinder bore, pistons and springs for damage
or excessive wear. Replace brake cylinder assembly if
signs of pitting, scoring or cracks are evident in cylinder
bore.
Assembly (Fig. 11)
1. Apply a film of clean brake fluid to cylinder bore and
piston assemblies.
2. Install secondary piston assembly and primary pis-
ton assembly into cylinder.
3. Install retainer washer.
4. Install push rod and secure in place with circlip.
Install lower end of dust cover to housing.
5. Push in on push rod so stop pin can be installed to
retain secondary piston assembly, then install flange
seal and reservoir.
Workman e2050/e2065
Page 4 – 19
Transaxle and Brakes (Rev. B)
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Parking Brake (Workman e2065)
11
10
1
2
9
8
7
6
17
16
5
4
14
15
13
12
3
RIGHT
FRONT
Figure 12
1. Parking brake cover
2. Operator seat
7. Lock nut
8. Flat washer
13. Cotter pin
14. Clevis pin
3. Seat base
9. Flange head screw (4 used)
10. Flat washer (2 used)
11. Screw (2 used)
15. Parking brake cable (2 used)
16. Parking brake support
17. Cable retaining ring (2 used)
4. Cable equalizer bracket
5. Parking brake lever
6. Curved washer
12. Cap screw
Page 4 – 20
Workman e2050/e2065
Transaxle and Brakes (Rev. B)
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Disassembly (Fig. 12)
Assembly (Fig. 12)
1. Park machine on a level surface, stop engine and re-
move key from the ignition switch. Chock wheels to pre-
vent the machine from moving.
1. Secure brake cables to parking brake support and
cable equalizer bracket using Figure 12 as a guide.
2. Route brake cables through seat base opening tak-
ing care to not damage cables. Position parking brake
support to seat base.
2. Disconnect both brake cables from rear of machine:
A. Remove cotter pin and clevis pin that secures
each brake cable end to brake lever.
3. Secure parking brake support to seat base with four
(4) flange head screws.
B. Remove retaining ring that secures each brake
cable to frame.
4. Position brake cables to rear brake assemblies using
cable routing noted during disassembly.
C. Remove screw and flange nut that secure each
R–clamp to rear frame.
5. Secure brake cables to rear of machine:
3. Note routing of brake cables for assembly purposes.
4. Remove parking brake cover from seat base.
A. Secure each R–clamp to rear frame with screw
and flange nut.
B. Secure each brake cable to frame with retaining
ring.
5. Remove four (4) flange head screws that secure
parking brake support to seat base.
C. Secure each brake cable end to brake lever with
clevis pin and cotter pin.
6. Carefully remove parking brake support and brake
cables from machine. Take care to not damage brake
cables while removing them from seat base opening.
6. Check parking brake operation and adjust if neces-
sary.
7. Remove brake cables from parking brake support
and cable equalizer bracket using Figure 12 as a guide.
Workman e2050/e2065
Page 4 – 21
Transaxle and Brakes (Rev. B)
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Transaxle
23
115 to 125 in–lb
(13 to 14.1 N–m)
2
3
4
6
5
3
7
8
9
22
1
10
11
21
16
15
13
45 to 65 ft–lb
(61 to 88 N–m)
14
20
2
17
18
12
19
v
Figure 13
1. Socket head screw (6 used)
2. Flange nut
9. Roll pin (2 used)
10. Washer
17. Cotter pin
18. Clevis pin
3. Carriage screw (5 used)
4. Support bracket
5. Transaxle mount plate
6. Rubber damper
7. Traction motor
11. Socket head screw
19. Brake cable
12. Lug nut (5 used per wheel)
13. Wheel assembly
14. Brake drum
15. Transaxle
16. Flange head screw (4 used)
20. Transaxle vent hose
21. Flat washer (6 used)
22. Negative battery cable
23. Positive battery cable
8. Fan
Page 4 – 22
Workman e2050/e2065
Transaxle and Brakes (Rev. B)
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Removal (Fig. 13)
9. Loosen and remove two (2) flange nuts and carriage
screws that secure transaxle mount plate (item 5) to
support bracket (item 4) (Fig. 16).
1. Park vehicle on a level surface, turn on/off switch
OFF, set parking brake and remove key from switch.
10.Remove four (4) flange head screws and flange nuts
securing the transaxle to the rear frame.
2. Remove cargo bed from vehicle (see Cargo Bed Re-
moval in Service and Repairs section of Chapter 5 –
Chassis).
11.Carefully lower transaxle and motor assembly from
the rear of the vehicle.
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).
12.If necessary, remove traction motor from transaxle
(see Traction Motor Removal in Service and Repairs
section of Chapter 3 – Electrical System).
NOTE: Label all electrical leads for reassembly pur-
poses.
1
IMPORTANT: When removing cables from traction
motor terminals (A1, A2, F1 and F2), use a wrench to
retain lower nut before loosening upper nut (Fig.
14). If terminal studs are allowed to turn during up-
per nut removal, internal motor damage can occur.
4. Disconnect cables from traction motor:
2
A. While retaining lower nut, remove upper nut and
cable connector from motor terminals A1, A2, F1 and
F2.
Figure 14
1. Loosening/tightening wrench (upper nut)
2. Retaining wrench (lower nut)
B. Unplug motor temperature sensor from vehicle
wire harness.
C. Position disconnected cables away from motor.
WARNING
3
Before jacking up the vehicle, review and follow
Jacking Instructions in Operator’s Manual and in
Chapter 1 – Safety.
4
1
5. Jack up rear of vehicle enough to remove rear
wheels.
2
A. Chock the front and rear of both front tires to pre-
vent the vehicle from moving.
Figure 15
1. Cotter pin
2. Clevis pin
3. Brake cable bracket
4. Brake actuator lever
B. Support both sides of the rear frame with jack-
stands positioned just in front of the axle tubes. This
will allow the transaxle to be removed from the rear of
the vehicle.
6. Remove rear wheels from vehicle.
7. Remove cotter pins and clevis pins that secure brake
cables to brake actuator levers (Fig. 15). Position brake
cables away from transaxle assembly.
8. Attach hoist or chain fall to the transaxle and motor
assembly. Make sure lifting device is attached so it can
hold the full weight of the transaxle and motor.
Workman e2050/e2065
Page 4 – 23
Transaxle and Brakes (Rev. B)
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Installation (Fig. 13)
1. If removed, install traction motor to transaxle (see
Traction Motor Installation in Service and Repairs sec-
tion of Chapter 3 – Electrical System).
1
3
2
2. Position transaxle and motor assembly to the rear
frame. Loosely install all fasteners used to secure trans-
axle to vehicle. Tighten fasteners in the following order:
A. Tighten four (4) flange head screws and flange
nuts that secure transaxle to the rear frame.
B. Tighten two (2) flange nuts and carriage screws
that secure transaxle mount plate (item 5) to support
bracket (item 4).
Figure 16
1. Support bracket
3. Transaxle mount plate
3. Install brake cables to brake actuator levers with cle-
vis pins and cotter pins.
2. Carriage screws/nuts
4. Position wheel assemblies to the vehicle with valve
stems facing out. Secure each wheel with five (5) lug
nuts. Torque lug nuts in a criss–cross pattern from 45 to
65 ft–lb (61 to 88 N–m).
85 to 90 in–lb
(9.6 to 10.2 N–m)
55 to 60 in–lb
(6.2 to 6.8 N–m)
5. Lower vehicle from jackstands.
6. Connect wires to traction motor (Fig. 17):
IMPORTANT: When connecting cables to motor ter-
minals (A1, A2, F1 and F2), use a back–up wrench to
retain lower nut before tightening upper nut (Fig.
14). If terminal studs are allowed to turn during up-
per nut installation, internal motor damage can oc-
cur.
A. Install cable connector and upper nut to motor
terminals A1 and A2. While retaining lower nut,
torque upper nut on terminals A1 and A2 from 85 to
90 in–lb (9.6 to 10.2 N–m).
55 to 60 in–lb
(6.2 to 6.8 N–m)
Figure 17
B. Install cable connector and upper nut to motor
terminals F1 and F2. While retaining lower nut,
torque upper nut on terminals F1 and F2 from 55 to
60 in–lb (6.2 to 6.8 N–m).
C. Plug motor temperature sensor connector into
vehicle wire harness.
7. Carefully connect removed battery cable to battery
terminals. Install lock washers and nuts on battery termi-
nals. Torque nuts from 115 to 125 in–lb (13 to 14.1 N–m).
8. Install cargo box to the rear frame (see Cargo Box
Installation in Service and Repairs section of Chapter 5
– Chassis).
9. Check brakes for proper adjustment (see Operator’s
Manual).
Page 4 – 24
Workman e2050/e2065
Transaxle and Brakes (Rev. B)
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This page is intentionally blank.
Workman e2050/e2065
Page 4 – 25
Transaxle and Brakes (Rev. B)
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Transaxle Service
30
30
29
31
28
27
4
9
8
5
7
34
6
35
7
8
1
12
10
32
7
8
9
3
11
25
33
22
28
13
26
27
32
21
30
23
24
29
15
16
31
30
23
13
25
15
14
16
3
20
18
2
19
17
Figure 18
1. Oil seal
2. Wheel stud (5 used per side)
3. Axle shaft
4. Ball bearing
5. Input shaft
6. Ball bearing
7. O–ring
13. Bearing
14. Cap screw (4 used)
15. Bearing cap
16. Bearing cap bolt (2 used per cap)
17. Plug
18. Cover plate
25. Flange head screw (4 per brake)
26. LH brake assembly
27. Oil seal
28. Retaining ring
29. Bearing retaining ring
30. Retaining ring
31. Ball bearing
32. Lock nut (4 used per brake)
33. Plug
34. Ball bearing
35. RH brake assembly
19. Screw (10 used)
20. Lock nut (4 used)
21. Final drive gear
22. Differential assembly
23. O–ring
8. Retaining ring
9. Endcap plug
10. Ball bearing
11. Vent elbow
12. Transaxle housing
24. Intermediate shaft & gear
NOTE: For service of the transaxle, see the Spicer Off–
Highway Components Model 12 (Electric) Maintenance
Manual at the end of this chapter.
Page 4 – 26
Workman e2050/e2065
Transaxle and Brakes (Rev. B)
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Chapter 5
Chassis
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3
Suspension and Steering . . . . . . . . . . . . . . . . . . . . 3
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5
Check Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspect Tires and Wheels . . . . . . . . . . . . . . . . . . . . 5
Upper Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Steering Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Front Wheels (Workman e2050) . . . . . . . . . . . . . 10
Lower Steering (Workman e2050) . . . . . . . . . . . . 12
Front Wheels and Lower Steering (Workman
e2065) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
A–arm and Frame Pivot Yoke . . . . . . . . . . . . . . . . 16
Seat Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Front Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cargo Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Workman e2050/e2065
Page 5 – 1
Chassis (Rev. B)
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Specifications
Item
Description
8 to 22 PSI (0.55 to 1.52 bar)
8 to 22 PSI (0.55 to 1.52 bar)
135 to 165 ft–lb (183 to 224 N–m)
45 to 65 ft–lb (61 to 88 N–m)
Front tire (22 x 9.5 – 10, 4 ply) pressure
Rear tire (22 x 9.5 – 10, 4 ply) pressure
Front wheel cap screw torque (Workman e2050)
Wheel lug nut torque (front and rear)
Chassis (Rev. B)
Page 5 – 2
Workman e2050/e2065
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Troubleshooting
Suspension and Steering
Problem
Possible Cause
Front end is noisy.
Front wheel lug nuts are loose.
Front wheel bearings are loose or worn.
Front end components are loose or worn.
Steering gear is loose.
Rear end is noisy.
Rear wheel lug nuts are loose.
Transaxle problem (see Chapter 4 – Transaxle and Brakes).
Front wheel lug nuts are loose.
Excessive steering play.
Front wheel bearings are loose or worn.
Steering linkage is loose or worn.
Tie rod ends are loose or worn.
Steering gear is incorrectly adjusted.
Front wheel lug nuts are loose.
Front end shimmies.
Front wheel bearings are loose or worn.
Front wheel alignment (toe–in) is incorrect.
Steering linkage is loose or worn.
Tie rod ends are loose or worn.
Rubber insert in A–arm is worn.
Vehicle is unstable or wanders.
Tire pressure is low or uneven between tires.
Wheel lug nuts are loose.
Front wheel bearings are loose.
Front wheel alignment (toe–in) is incorrect.
Steering column bushings are worn.
Rubber insert in A–arm is worn.
Steering gear is incorrectly adjusted.
Workman e2050/e2065
Page 5 – 3
Chassis (Rev. B)
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Suspension and Steering (continued)
Problem
Possible Cause
Steering is hard.
Tire pressure is low or uneven between tires.
Front wheel alignment (toe–in) is incorrect.
Steering linkage is binding or damaged.
Steering gear is damaged or worn.
Vehicle pulls to one side when not
braking.
Tire pressure is low or uneven between tires.
Front wheel alignment (toe–in) is incorrect.
Steering or suspension component may be bent.
Chassis (Rev. B)
Page 5 – 4
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Service and Repairs
Check Tire Pressure
The tire pressure range for front and rear tires is 8 to 22
PSI (0.55 to 1.52 bar). The tire pressure needed is deter-
mined by the payload carried.
Higher pressures should be used for heavier payloads
at higher speeds. Do not exceed the maximum tire pres-
sure.
The lower the air pressure, the less the compaction and
tire marks are minimized. Lower pressure should not be
used for heavy payloads at higher speeds.
Inspect Tires and Wheels
Operating accidents, such as hitting curbs, can damage
a tire or rim and also disrupt wheel alignment, so inspect
wheel condition (tire and rim) and wheel alignment (toe–
in) after any accident.
If desired, tires can be moved from one position of the
vehicle to another to extend tread life (e.g. front tires to
rear and rear tires to front). All tires on the Workman
e2050 and e2065 are the same size.
Check wheels to ensure they are mounted securely.
Torque wheel lug nuts (front and rear) from 45 to 65 ft-lb
(61 to 88 N–m). On Workman e2050 vehicles, the front
wheel cap screws should be torqued from 135 to 165 ft-
lb (183 to 224 N–m).
Workman e2050/e2065
Page 5 – 5
Chassis (Rev. B)
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Upper Steering
1
2
13
10
16
Antiseize
lubricant
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. Nut
7. Lock washer
12. Steering column
13. Dust cover
2. Lock washer
3. Steering wheel
4. Flange lock nut
5. Steering gearbox
6. Cap screw
8. Steering shaft
9. Cap screw (3 used)
10. Upper steering bushing
11. Carriage bolt (4 used)
14. Collar
15. Pitman arm
16. Steering wheel cover
Chassis (Rev. B)
Page 5 – 6
Workman e2050/e2065
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Removal (Fig. 1)
3. Insert steering shaft up through the steering column.
Place dust cover onto the shaft.
1. Park vehicle on a level surface, turn on/off switch
OFF, set parking brake and remove key from the switch.
4. Secure steering column to the mounting plate on the
frame with four (4) carriage screws and flange lock nuts.
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).
NOTE: Apply antiseize lubricant to the steering gear-
box shaft before installing steering shaft knuckle.
5. Position knuckle of the lower steering shaft onto the
gearbox shaft. Secure knuckle to the steering gearbox
shaft with cap screw and lock washer.
3. Remove front hood to gain access to the steering
mechanism (see Front Hood Removal in this section).
4. Remove steering wheel cover carefully from the
steering wheel. Remove nut and lock washer securing
the steering wheel to the steering shaft. Pull steering
wheel from the shaft.
6. Connect both tie rods to the Pitman arm on the steer-
ing gearbox (see Lower Steering Installation in this sec-
tion).
NOTE: Apply antiseize lubricant to the steering shaft
5. Remove cap screw and lock washer securing the
lower steering shaft knuckle to the steering gearbox
shaft. Pull knuckle from the gearbox shaft.
splines before installing the steering wheel.
7. Position front tires straight ahead. Position steering
wheel to the steering shaft so that the leg of the “Y”
formed by the wheel struts is directed towards the oper-
ator platform.
6. Remove four (4) flange lock nuts and carriage bolts
securing the steering column to the mounting plate on
the frame.
8. Secure steering wheel to shaft with lock washer and
nut. Torque nut from 13 to 17 ft–lb (18 to 23 N–m). Install
steering wheel cover to steering wheel.
7. Remove dust cover from the steering shaft. Replace
cover if damaged. Slide steering shaft out of the steering
column.
9. Install front hood to the frame and fenders (see Front
Hood Installation in this section).
8. Disconnect both tie rods from the Pitman arm on the
steering gearbox (see Lower Steering Removal in this
section).
10.Reconnect removed battery cable to battery termi-
nals. Install lock washer and nut on battery terminals.
Torque nuts from 115 to 125 in–lb (13 to 14.1 N–m).
9. Remove three (3) flange lock nuts and cap screws
securing the steering gearbox to the tower plate on the
front frame. Remove gearbox from the tower plate.
11.Check front wheel alignment and adjust if required
(see Operator’s Manual).
Installation (Fig. 1)
1. Position steering gearbox to the tower plate of the
front frame with the Pitman arm facing down and to the
rear. The gearbox shaft must be to the left side of the
tower.
2. Secure steering gearbox to the tower plate with three
(3) cap screws and flange lock nuts.
Workman e2050/e2065
Page 5 – 7
Chassis (Rev. B)
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Steering Gearbox
27 to 33 ft–lb
(37 to 45 N–m)
9
8
90 to 110 in–lb
(10.2 to 12.4 N–m)
6
3
2
18
15
17
10
16
7
6
14
1
4
11
10
12
5
175 to 225 in–lb
(19.8 to 25.4 N–m)
19
13
Note alignment marks
Figure 2
8. Stepped washer
1. Gasket
14. Grease fitting
2. Hex washer head screw (4 used)
3. Seal
9. Flange head screw with patch lock
10. Ball bearing
11. Input shaft spacer
12. Flat washer
13. Cap screw
15. Steering housing cover
16. Steering housing
17. Pinion gear
4. Sector gear
5. Flat washer
18. Oil seal
6. Ball bearing
19. Pitman arm
7. Output shaft spacer
Chassis (Rev. B)
Page 5 – 8
Workman e2050/e2065
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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:
1. Remove flange head screw with patch lock (item 9)
and stepped washer (item 8) from Pitman arm. Discard
flange head screw.
A. Press new bearing into housing from the inside
first.
B. Turn housing over. Insert spacer and press new
bearing into housing.
2. Remove cap screw (item 13) and flat washer (item
12) from pinion gear shaft.
2. If seals (items 3 and 18) were removed, press new
seals into housing. Install seals with seal lips up.
3. Remove four (4) hex washer head screws (item 2)
securing the housing cover and gasket to the steering
housing. Remove cover and gasket from the housing.
Replace gasket if damaged.
3. Place flat washer onto shaft of the Pitman arm. Insert
shaft into steering housing.
4. Inspect gears. Sector and pinion gear teeth must be
free of damage that prevents them of free movement.
IMPORTANT:The position of the Pitman arm and
sector gear is critical during assembly. If either or
both of these parts is replaced, make sure their
alignment matches the alignment of the original
gear and Pitman arm.
5. Remove pinion gear (item 17) from the housing.
IMPORTANT:Note alignment marks on Pitman arm
shaft and sector gear. If marks are not visible,
matchmark shaft and gear before disassembly.
Their position is critical during assembly.
4. Position sector gear onto the spline of the Pitman
arm shaft while aligning marks.
IMPORTANT:Make sure sector gear is centered to
the pinion gear.
6. Separate Pitman arm (item 19) from the sector gear
(item 4) and steering housing. Remove Pitman arm from
the housing.
5. Insert pinion gear into the small bearing in the steer-
ing housing.
7. Inspect bearings. Bearings must spin smoothly and
be free of damage. Press bearings and spacer out of
housing if necessary.
6. Fill steering housing with number 2 general purpose
grease. Make sure all gear teeth on the sector and pin-
ion gears are covered with grease.
NOTE: If seals are removed, note orientation of seal
lips for installation purposes.
7. Place gasket and steering housing cover onto the
housing. Secure cover to housing with four (4) hex
washer head screws. Torque screws from 90 to 110 in–
lb (10.2 to 12.4 N–m).
8. Inspect seals. Seals must be free of rips and tears.
Replace seals if necessary.
IMPORTANT:Flange head screw with patch lock
(item 9) should be replaced whenever it is removed.
8. Secure flange head screw with patch lock (item 9)
and step washer (item 8) to the Pitman arm. Make sure
to position step washer as in Figure 2. Torque screw
from 27 to 33 ft–lb (37 to 45 N–m).
9. Secure cap screw (item 13) and flat washer (item 12)
to the pinion gear shaft. Torque cap screw from 175 to
225 in–lb (19.8 to 25.4 N–m).
Workman e2050/e2065
Page 5 – 9
Chassis (Rev. B)
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Front Wheels (Workman e2050)
Antiseize
Lubricant
1
6
2
135 to 165 ft–lb
(183 to 224 N–m)
4
2
Loctite #242
3
5
8
10
9
RIGHT
45 to 65 ft–lb
(61 to 88 N–m)
FRONT
11
7
Figure 3
1. Spindle (LH shown)
2. Bearing (with retaining ring)
3. Wheel stud (5 per wheel)
4. Wheel hub
5. Spacer
6. Tire/wheel assembly
9. Large flat washer
10. Cap screw
11. Dust cap
7. Lug nut (5 per wheel)
8. Flat washer
Chassis (Rev. B)
Page 5 – 10
Workman e2050/e2065
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Removal (Fig. 3)
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).
1. Park vehicle on a level surface, turn on/off switch
OFF, set parking brake and remove key from the on/off
switch.
4. Lower machine to ground. Remove chocks from
wheels.
WARNING
1
3
Before jacking up the machine, review and follow
Jacking Instructions in Operator’s Manual and
Chapter 1 – Safety.
2
2. Chock wheels not being jacked up. Jack front wheel
off the ground and place blocks beneath the frame.
3. Loosen and remove five (5) lug nuts that secure
wheel to machine. Remove wheel from vehicle.
2
4. Remove wheel hub from spindle:
4
A. Carefully remove dust cap from the wheel to pre-
vent damage to the cap.
5
3
B. Remove cap screw and two (2) washers that se-
cure the wheel hub to the spindle. Slide wheel hub
from the spindle shaft.
Figure 4
1. Wheel hub
2. Bearing
3. Retaining ring
4. Spacer
5. Wheel stud
5. If necessary, remove bearings from both sides of the
wheel hub (Fig. 4). Discard removed bearings. Retrieve
spacer from wheel hub. Clean the spacer and the inside
of the wheel hub.
Installation (Fig. 3)
1. If bearings were removed from wheel hub, position
spacer in wheel hub and press new bearings into the
hub until the bearing retaining rings seat against hub
(Fig. 4).
2. Install wheel hub to spindle:
A. Apply antiseize lubricant to spindle shaft.
B. Slide wheel hub onto spindle shaft with the wheel
studs facing out.
NOTE: Apply Loctite #242 (or equivalent) to the
threads of the cap screw.
C. Place large washer and then small washer onto
the cap screw. Thread cap screw with washers into
the spindle shaft.
D. Torque cap screw from 135 to 165 ft–lb (183 to
224 N–m).
Workman e2050/e2065
Page 5 – 11
Chassis (Rev. B)
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Lower Steering (Workman e2050)
17
19
20 to 25 ft–lb
(27 to 34 N–m)
20
21
22
23
1
18
24
14
17
Antiseize
Lubricant
16
2
15
14
135 to 165 ft–lb
(183 to 224 N–m)
3
5
20 to 25 ft–lb
4
(27 to 34 N–m)
13
12
Loctite #242
11
2
6
10
7
RIGHT
75 to 100 ft–lb
8
(102 to 136 N–m)
9
FRONT
Figure 5
1. Pitman arm
9. Dust cap
10. Lock nut
17. Slotted hex nut (2 used per tie rod)
18. Cotter pin (2 used per tie rod)
19. Ball joint (RH thread)
20. Jam nut (RH thread)
21. Tie rod
22. Jam nut (LH thread)
23. Ball joint (LH thread)
24. Grease fitting
2. Grease fitting
3. Cap screw (king pin)
4. Spindle (LH)
5. Front wheel assembly
6. Flat washer
7. Large flat washer
8. Cap screw
11. A–arm (LH)
12. A–arm (RH)
13. Thrust washer
14. Bushing
15. Kingpin sleeve
16. Spindle (RH)
NOTE: Both tie rod assemblies consist of two ball joints
(items 19 and 23) with jam nuts, two slotted hex nuts
(item 17), two cotter pins (item 18) and tie rod (item 21).
Chassis (Rev. B)
Page 5 – 12
Workman e2050/e2065
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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
B. Place thrust washer onto the bottom of the king
pin sleeve. Then position spindle over the hub, king
pin sleeve and thrust washer.
Before jacking up the machine, review and follow
Jacking Instructions in Operator’s Manual and
Chapter 1 – Safety.
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. Secure spindle to A–arm hub with cap screw
(king pin) and lock nut. Torque lock nut from 75 to 100
ft–lb (102 to 136 N–m).
3. Remove front wheel assembly as follows:
D. If tie rod was removed from Pitman arm, insert tie
rod ball joint up through Pitman arm and secure with
slotted hex nut.
A. Remove dust cap carefully from the wheel to pre-
vent damage to the cap.
B. Remove cap screw and two (2) washers that se-
cure the wheel assembly to the spindle. Slide wheel
assembly from the spindle shaft.
E. Insert tie rod ball joint down through the spindle.
Secure with slotted hex nut.
F. Torque slotted hex nut(s) from 20 to 25 ft–lb (27 to
34 N–m) to secure ball joint to spindle (and Pitman
arm, if installed). If necessary, tighten nut to allow
cotter pin to be inserted. Install cotter pin to secure
assembly.
4. Remove spindle as follows:
A. Remove cotter pin and slotted hex nut that secure
tie rod ball joint to the spindle. Separate ball joint from
the spindle.
2. Install front wheel assembly:
B. If necessary, remove tie rod from Pitman arm.
A. Place antiseize lubricant on spindle shaft.
C. Remove lock nut and cap screw (king pin) secur-
ing the spindle to the A–arm. Separate spindle from
the A–arm. Locate and retrieve thrust washer (item
13).
B. Slide wheel assembly onto spindle shaft with the
valve stem facing out.
NOTE: Apply Loctite #242 (or equivalent) to the
threads of the cap screw.
C. Place large washer and then small washer onto
the cap screw. Thread cap screw with washers into
the spindle shaft.
D. Torque cap screw from 135 to 165 ft–lb (183 to
224 N–m).
3. Lower machine to ground. Remove chocks from
wheels.
4. Align steering and toe–in (see Operator’s Manual).
5. Lubricate tie rod ball joints and king pin (see Opera-
tor’s Manual).
Workman e2050/e2065
Page 5 – 13
Chassis (Rev. B)
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Front Wheels and Lower Steering (Workman e2065)
Loctite #242
16
14
See text for
tightening
procedure
13
12
20 to 25 ft–lb
(27 to 34 N–m)
RIGHT
10
8
1
24
6
FRONT
3
30
15
25
11
9
45 to 55 ft–lb
(61 to 74 N–m)
31
36
33
29
26
7
5
32
19
20
2
34
35
23
28
45 to 55 ft–lb
18
27
(61 to 74 N–m)
25
45 to 65 ft–lb
(61 to 88 N–m)
24
21
38
20 to 25 ft–lb
(27 to 34 N–m)
39
22
4
17
37
75 to 100 ft–lb
(102 to 136 N–m)
Figure 6
1. Wheel assembly
14. Seal
15. Brake rotor
16. Socket head screw (4 used per rotor)
17. Lock nut
18. LH spindle
19. Cap screw
27. Ball joint (RH thread)
28. Jam nut (RH thread)
29. Tie rod tube
2. Lug nut (5 used per wheel)
3. Dust cap
4. Cotter pin
30. Pitman arm
5. Nut retainer
31. Ball joint (LH thread)
32. Grease fitting
6. Jam nut
7. Tab washer
20. Brake hose bracket
21. Bushing (2 used per A–arm)
22. Thrust washer
23. RH spindle
33. Jam nut (LH thread)
34. A–arm (RH)
8. Bearing cone
9. Bearing cup
35. A–arm (LH)
10. Wheel hub
36. Grease fitting
11. Wheel stud (5 used per hub)
12. Bearing cup
24. Castle nut
37. Brake caliper (LH shown)
25. Cotter pin
38. Lock washer (2 used per caliper)
39. Cap screw (2 used per caliper)
13. Bearing cone
26. Kingpin sleeve
NOTE: Both tie rod assemblies consist of the following
parts: ball joints (27 and 31), jam nuts (28 and 33), tie rod
tube (29) and grease fittings (32 and 36).
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 – Safety.
Removal (Fig. 6)
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition.
2. Chock wheels not being jacked up. Jack front wheel
off the ground and place blocks beneath the frame.
Chassis (Rev. B)
Page 5 – 14
Workman e2050/e2065
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3. Remove lug nuts and pull wheel assembly from ma-
chine.
D. Insert tie rod ball joints down through the spindle
and up through the Pitman arm. Secure with castle
nuts.
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. If necessary to align holes,
castle nut torque may be slightly more than specifi-
cation. Install cotter pin.
5. Carefully pry dust cap from wheel hub.
6. Remove cotter pin and nut retainer from spindle.
2. Assemble wheel hub:
7. Remove jam nut that secures wheel hub to spindle.
Slide wheel hub with bearings and rotor from spindle.
A. If bearing cups were removed from the wheel
hub, press inner and outer cups into the hub until
they seat against the hub shoulder.
8. Disassemble the wheel hub:
B. Pack both bearings with grease. Install inner
bearing into the cup on inboard side of the wheel hub.
A. Pull the seal out of the wheel hub.
B. Remove bearings from both sides of the wheel
hub. Clean bearings in solvent. Make sure bearings
are in good operating condition. Clean the inside of
the wheel hub. Check the bearing cups for wear, pit-
ting or other noticeable damage. Replace worn or
damaged parts.
IMPORTANT: The lip seal must be pressed in so it is
flush with the end of the hub. The lip of the seal must
be toward the bearing.
C. Apply grease to the inside of the new lip seal and
press it into the wheel hub.
C. If necessary, remove four (4) socket head screws
and brake rotor from wheel hub.
D. If brake rotor was removed, apply Loctite #242 (or
equivalent) to socket head screws and install brake
rotor to hub. Make sure that the brake rotor bore
chamfer is assembled toward the wheel hub.
9. Remove spindle:
A. Remove cotter pin and castle nut securing tie rod
ball joint to the spindle. Separate ball joint from the
spindle. Remove tie rod from Pitman arm if neces-
sary.
3. Slide wheel hub assembly onto spindle. Install outer
bearing, tab washer and jam nut onto spindle.
4. While rotating the wheel by hand, tighten the jam nut
from 75 to 100 in-lb (8.5 to 11.3 N–m) to set the bearings.
Then, loosen the nut until the hub has end play.
B. Remove lock nut and cap screw (19) securing the
spindle to the A–arm. Separate spindle from A–arm.
5. While rotating the wheel by hand, re-tighten the jam
nut from 15 to 20 in-lb (1.7 to 2.3 N–m).
C. Locate and remove thrust washer from bottom of
kingpin sleeve in A–arm. Remove kingpin sleeve
from A–arm if necessary.
6. Position nut retainer over jam nut and install cotter
pin through spindle shaft hole. Install dust cap to hub.
Installation (Fig. 6)
7. Install brake caliper to spindle (see Front Brake Cali-
pers in the Service and Repairs section of Chapter 4 –
Transaxle and Brakes).
1. Install spindle as follows:
A. Position king pin sleeve into the pivot hub of the
A–arm. Sleeve must extend through the bottom of
the hub.
8. Install wheel assembly with valve stem facing out.
Torque lug nuts from 45 to 65 ft–lb (61 to 88 N–m).
B. Place thrust washer onto the bottom of the king
pin sleeve. Then position spindle over the hub, king
pin sleeve and thrust washer.
9. Lower machine to ground.
10.Align steering and toe–in (see Operator’s Manual).
11.Lubricate tie rod ball joints and king pin.
NOTE: Make sure cap screw (19) is inserted down
through the spindle and A–arm hub.
C. Install brake hose bracket (20) onto cap screw
(19). Secure spindle to A–arm hub with cap screw
(19) and lock nut. Torque lock nut from 75 to 100 ft–lb
(102 to 136 N–m).
Workman e2050/e2065
Page 5 – 15
Chassis (Rev. B)
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A–arm and Frame Pivot Yoke
RIGHT
14
FRONT
13
12
11
15
16
8
2
17
240 to 290 ft–lb
(325 to 393 N–m)
2
10
2
9
8
7
1
5
6
4
240 to 290 ft–lb
(325 to 393 N–m)
2
3
Figure 7
7. Lock washer
8. Centering bolt (2 used per A–arm)
9. Travel limiting bolt
10. A–arm (RH)
1. Ride height adjustment bolt
2. Bushing
3. Grease fitting
4. A–arm (LH)
5. Flange nut
6. Lock nut
13. Pivot yoke
14. Rear frame
15. Flat washer (4 used)
16. Cap screw (4 used)
17. Hardened washer
11. Flange head screw (4 used)
12. Flange nut (4 used)
Chassis (Rev. B)
Page 5 – 16
Workman e2050/e2065
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A–arm Removal (Fig. 7)
4. Lower machine to ground. Remove chocks from
wheels.
1. Park vehicle on a level surface, turn on/off switch
OFF, set parking brake and remove key from the on/off
switch.
5. Adjust front ride height (see Operator’s Manual).
6. Make sure that travel limiting bolt and lock nut are
installed and tightened. Tighten lock nut only enough to
snug travel limiting bolt. Do not deform frame plate by
overtightening lock nut.
WARNING
7. Make sure that centering bolts are torqued from 240
to 290 ft–lb (325 to 393 N–m).
Before jacking up the machine, review and follow
Jacking Instructions in Operator’s Manual and
Chapter 1 – Safety.
8. Check front wheel toe–in (see Operator’s Manual).
Adjust toe–in if necessary.
2. Chock wheels not being jacked up. Jack front wheel
off the ground and place blocks beneath the frame.
3. Remove front wheel and spindle from A–arm (see
Lower Steering Removal in this section).
1
2
4. Remove lock nut (item 6) and travel limiting bolt (item
9) from the frame.
NOTE: To aid reassembly, note hole location of ride
height adjustment bolt in A–arm (Fig. 9).
5. Remove flange nut (item 5) and ride height adjust-
ment bolt (item 1) from the adjustment pattern of the A–
arm and frame.
4
3
2
240 to 290 ft–lb
6. Remove two centering bolts (item 8) and lock wash-
ers (item 7) securing the A–arm to the the frame. Lower
A–arm from the frame.
(325 to 393 N–m)
Figure 8
1. Travel limiting bolt
2. Centering bolt
3. A–arm (LH shown)
4. Ride height adj. bolt
A–arm Installation (Fig. 7)
1. Position A–arm to the frame. Secure A–arm to the
frame with two (2) centering bolts (item 8) and lock
washers (item 7). Do not tighten bolts.
6
1
2
7
2. Install spindle and front wheel to the A–arm (see
Lower Steering Installation in this section).
8
4
0
3
5
NOTE: If A–arm is being replaced, look for number be-
tween 200 and 400 written next to the serial tag on the
bottom of the replacement A–arm. This number should
be used to identify the location of the ride height adjust-
ment bolt (Fig. 9):
1
Number from 200 to 220 use hole 4.
Number from 225 to 285 use hole 3.
Number from 290 to 400 use hole 2.
3. Install ride height adjustment bolt (item 1) and flange
nut (item 5) into correct hole location.
Figure 9
1. Front A–arm (LH shown)
Workman e2050/e2065
Page 5 – 17
Chassis (Rev. B)
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Pivot Yoke Removal (Fig. 7)
2. Secure pivot yoke to the front frame tab with cap
screw and hardened washer. Torque cap screw from
240 to 290 ft–lb (325 to 393 N–m).
1. Park vehicle on a level surface, turn on/off switch
OFF, set parking brake and remove key from the on/off
switch.
3. Secure pivot yoke to the rear frame with four cap
screws and flat washers.
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).
4. Install seat base to the front frame (see Seat Base
Installation in this section).
5. Install cargo bed to the rear frame (see Cargo Bed
Installation in this section).
3. Remove cargo bed from the rear frame (see Cargo
Bed Removal in this section).
6. Reconnect removed battery cable to battery termi-
nals. Install lock washer and nut on battery terminals.
Torque nuts from 115 to 125 in–lb (13 to 14.1 N–m).
4. Remove seat base from the front frame (see Seat
Base Removal in this section).
3
2
WARNING
Make sure all tires are chocked to prevent the
machine from moving. Before removing the pivot
yoke, make sure front and rear frames are
supported with jack stands. Support both the
front and back of each frame.
2
1
5. Remove four (4) cap screws and flat washers secur-
ing the pivot yoke to the rear frame (Fig. 10).
4
6. Remove cap screw and hardened washer securing
the pivot yoke to the front frame tab.
5
6
Figure 10
1. Pivot yoke
4. Flange lock nut
WARNING
Support pivot yoke while removing it from the
front frame to prevent dropping and causing
serious injury and damage to the machine.
2. Cap screw & flat washer
3. Rear frame
5. Front frame
6. Diamond pattern
7. Remove four flange head screws and flanged lock
nuts securing the pivot yoke to the front frame. Remove
pivot yoke from the machine.
Pivot Yoke Installation (Fig. 7)
WARNING
Support pivot yoke while installing it to the front
frame to prevent dropping and causing serious
injury and damage to the machine.
1. Position pivot yoke to the front frame so the diamond
pattern faces up (Fig. 10). Secure yoke to front frame
with four flange head screws and flanged lock nuts.
Tighten lower two fasteners first, then tighten upper two
fasteners.
Chassis (Rev. B)
Page 5 – 18
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Workman e2050/e2065
Page 5 – 19
Chassis (Rev. B)
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Seat Base
1
2
3
4
18
17
5
6
7
16
15
14
13
8
9
19
20
22
21
12
RIGHT
FRONT
10
11
10
Figure 11
1. Seat
9. Seat base tray
16. Charger receptacle
17. Switch plate
18. Charger interlock switch
19. Pop rivet (2 used)
20. Lock nut (2 used)
21. Charger wire harness
22. Socket head screw (2 used)
2. Seat bracket
3. Rubber receptacle
4. Rivet
10. Flange head screw (8 used)
11. Flat washer (4 used)
12. Front frame
5. Cap screw (4 used per seat)
6. Screw
7. Holding post
8. Seat base
13. Screw (4 used)
14. Floor mat
15. Charger receptacle plate
Chassis (Rev. B)
Page 5 – 20
Workman e2050/e2065
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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
3. Remove seats from seat base.
4. Remove four (4) screws (item 12) that secure recep-
tacle plate to front of seat base. Unplug charger wire har-
ness from vehicle wire harness and remove receptacle
plate assembly from vehicle.
Figure 12
1. Negative cable to vehicle
2. Positive cable to vehicle
5. On Workman e2065, remove parking brake assem-
bly from seat base (Fig. 13) (see Parking Brake (Work-
man e2065) in the Service and Repairs section of
Chapter 4 – Transaxle and Brakes).
1
6. Remove eight (8) flange head screws (item 10) that
secure seat base to vehicle. Locate and retrieve flat
washers (item 11) from screws that secure front of seat
base.
5
4
2
7. Carefully lift seat base from vehicle.
Installation (Fig. 11)
3
1. Position seat base to the vehicle.
NOTE: Do not tighten fasteners securing the seat base
until all fasteners are in place.
2. Install four (4) flange head screws (item 10) through
holes in front frame and into rear seat base threaded in-
serts. Install four (4) flange head screws (item 10) and
flat washers (item 11) through holes in front frame and
into front seat base threaded inserts.
WORKMAN e2065
3. Starting at the middle of the vehicle, tighten flange
head screws to secure seat base to vehicle.
Figure 13
1. Parking brake cover
2. Brake cable (2 used)
3. Seat base
4. Brake equalizer
5. Parking brake lever
4. On Workman e2065, install parking brake assembly
to seat base (see Parking Brake (Workman e2065) in
the Service and Repairs section of Chapter 4 – Trans-
axle and Brakes).
5. Connect charger wire harness to vehicle wire har-
ness. Secure receptacle plate to seat base with four (4)
screws (item 12).
6. Install seats to vehicle.
7. Reconnect removed battery cable to battery termi-
nals. Install lock washer and nut on battery terminals.
Torque nuts from 115 to 125 in–lb (13 to 14.1 N–m).
Workman e2050/e2065
Page 5 – 21
Chassis (Rev. B)
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Front Hood
3
1
2
2
12
4
11
9
4
9
10
13
5
6
RIGHT
FRONT
7
8
Figure 14
1. Hood
2. Flange head screw (6 used)
3. Dash
4. Flange nut (6 used)
5. Fender (LH shown)
6. Bumper
10. Flange head screw (2 used)
11. Flange head screw (2 used)
12. Headlight mount (2 used)
13. Headlight (2 used)
7. Flat washer (2 used)
8. Cap screw (2 used)
9. Flat washer (4 used)
Chassis (Rev. B)
Page 5 – 22
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Removal (Fig. 14)
5. Connect wire harness connectors to headlight termi-
nals with screws.
1. Park vehicle on a level surface, turn on/off switch
OFF, set parking brake and remove key from the on/off
switch.
6. Reconnect removed battery cable to battery termi-
nals. Install lock washer and nut on battery terminals.
Torque nuts from 115 to 125 in–lb (13 to 14.1 N–m).
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).
1
3. Remove screws attaching the wire harness connec-
tors to each headlight.
2
4. Remove two (2) cap screws (item 8) and flat washers
(item 7) that secure bumper to vehicle. Remove bumper.
5. Remove both flange head screws (item 11) securing
the center–lower hood to the front frame support.
6. Remove flange nut (item 4), both flat washers (item
9) and flange head screw (item 10) securing the hood to
each fender front.
Figure 15
1. Negative cable to vehicle
2. Positive cable to vehicle
7. Remove both flange nuts (item 4) and flange head
screws (item 2) securing the hood to the top of each
fender.
8. Remove two (2) flange head screws (item 2) secur-
ing the hood to the dash. Remove hood from the vehicle.
Installation (Fig. 14)
1. Position hood to the vehicle.
NOTE: Do not tighten fasteners securing the hood until
all fasteners are in place.
2. Install fasteners removed during hood removal:
A. Two (2) flange head screws (item 2) that fasten
hood to the dash.
B. Two (2) flange head screws (item 2) and flange
nuts (item 4) that fasten hood to the top of each fend-
er.
C. Flange head screw (item 10), two flat washers
(item 9) and flange nut (item 4) that fasten hood to
each fender front.
D. Two flange head screws (item 11) that fasten cen-
ter–lower hood to the front frame support.
3. Tighten all fasteners securing the hood.
4. Secure bumper to vehicle with two (2) cap screws
(item 8) and flat washers (item 7).
Workman e2050/e2065
Page 5 – 23
Chassis (Rev. B)
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Cargo Bed
5
35 to 55 in–lb
(4 to 6.2 N–m)
6
3
7
8
4
10
11
2
9
1
12
13
35 to 55 in–lb
(4 to 6.2 N–m)
17
14
15
16
15
100 to 200 in–lb
(11.3 to 22.6 N–m)
33
32
31
18
30
19
20
21
22
23
29
RIGHT
FRONT
24
25
26
27
28
Figure 16
1. Cargo bed
2. Striker plate (2 used)
3. Screw (3 per striker plate)
4. Tailgate channel
5. RH latch rod
6. RH latch bracket
7. Grip knob
8. Tailgate
9. LH latch rod
10. Screw (2 per bracket)
11. LH latch bracket
12. Screw (2 per bracket)
13. Spring
23. Prop rod bracket
24. Flat washer
14. Flat washer
25. Push nut
15. Flange head screw (2 per bracket)
16. Pivot bracket (2 used)
17. Flange head screw (6 used)
18. Box brace (3 used)
19. Flange head screw (5 per brace)
20. LH pivot bracket
21. Flange head screw (2 per bracket)
22. Flange head screw (2 used)
26. Latch pin (2 used)
27. Lock nut (2 used)
28. Carriage screw (2 used)
29. Rear frame
30. RH pivot bracket
31. Flange head screw (4 used)
32. Tension spring
33. Latch rod
Removal (Fig. 16)
Installation (Fig. 16)
1. Park vehicle on a level surface, turn on/off switch
OFF, set parking brake and remove key from the on/off
switch.
1. Reassemble cargo bed using Figure 16 as a guide.
2. Position cargo bed to the frame locking the latch rod
(item 33) to the latch pins (item 26).
2. Remove two (2) flange head screws (item 21) that
secure RH and LH pivot brackets (items 30 and 20) to
the rear frame.
3. Secure both pivot brackets (items 30 and 20) to the
rear frame with flange head screws (item 21).
3. Release latch rod (item 33) from the latch pins (item
26). Remove cargo bed from the frame. Disassemble
cargo bed as necessary using Figure 16 as a guide.
Chassis (Rev. B)
Page 5 – 24
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Chapter 6
Electrical Diagrams
Table of Contents
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 . . . 7
Electrical Harness Wiring Diagram: Workman
e2050 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Harness Drawing: Workman e2065 . . . 9
Electrical Harness Wiring Diagram: Workman
e2065 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Workman e2050
Page 6 – 1 Rev. B
Electrical Diagrams
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Page 6 – 2
Workman e2050
Electrical Diagrams
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F3 10 A
BU
PK
FUSE
HOLDERS
IGNITION–SWITCH
OFF RUN
F2 10 A
R
ACCESSORIES
CONTACTOR
(SOLENOID)
HORN
W
BK
OR
HORN SWITCH
BATT. CHG.
HOOK UP
R/W
R
FL1
HEADLIGHTS, 24V
GN
Y
Y
1
3
4
6
INTERLOCK
CHARGER
SWITCH
(CHARGER
PLUGGED IN)
STATE OF CHARGE
FL2
2
5
INDICATOR
OR
GE 4589
GE 4589
LIGHT SWITCH
BU
A
OR
HOUR METER
BK
2
1
3
4
6
F1
355 A
BU/W
5
BK
FL3
B
BU
A
FORWARD/REVERSE
(IN FORWARD)
BK
B
OPTIONS
FRONT
3 (NC)
2 (NO)
1 48 VDC INPUT
2 FOR/REV
4
1
1
2
3
4
5
6
OR
PROGRAMMER
PORT
MAIN
PK
ACCELERATOR PEDAL SWITCH
(PEDAL NOT PUSHED IN)
CONTACTOR
(SOLENOID)
OPTIONS
REAR
3 ACCELERATOR PEDAL
4 HI/LOW
B+
BU
4 GA
HI / LOW SPEED SWITCH
(IN OFF (HI) POSITION)
Y
M2
F1
5 CHARGER
NC
10 GA
VIO/BK
BU/W
48V BATT ARRAY
6V x 8
6 HIGH TEMP/LOW BATTERY
7 BACKUP ALARM
8 MAIN CONTACTOR
9 DIAGNOSTIC LIGHT
10 ACCELERATOR POT
11 PROGRAMMING
12 12 VDC OUTPUT (100 mA)
13
BK
(DEEP CYCLE)
MOTOR TEMP SENSOR
(180 C)
W/BK
FIELD F1
FIELD F2
A1 ARMATURE
DRIVE MOTOR
DIAGNOSTIC LED
GN
T
A2 ARMATURE
STATE OF CHARGE
INDICATOR
BACKUP ALARM
HORN
(–)
CW
NC
10 GA
4 GA
ACCELERATOR POT
+ 12V
W
F2
M1
B–
BK
BN
SENSE A 1
5 SENSE B
6 IGN +
(+)
SETUP +
2
NC
NC
NC
NC
HR ENABLE
3
7 FET OUT
8 (–)
14
MILLIPAK
(+) 4
GY
SEVCON
CONTROLLER
W
15
16
HOUR METER
BK
PROGRAMMING
SPLICE
Workman e2050/e2065
Electrical Schematic
Contactors shown de–energized
Page 6 – 3
Rev. B
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F3 10 A
BU
PK
FUSE
HOLDERS
IGNITION–SWITCH
OFF RUN
F2 10 A
R
ACCESSORIES
CONTACTOR
(SOLENOID)
HORN
(ENERGIZED)
(IN RUN)
R/W
W
BK
OR
HORN SWITCH
BATT. CHG.
HOOK UP
R
FL1
HEADLIGHTS, 24V
GN
Y
Y
1
3
4
6
FL2
INTERLOCK
CHARGER
SWITCH
(CHARGER NOT
PLUGGED IN)
STATE OF CHARGE
2
5
INDICATOR
OR
GE 4589
GE 4589
LIGHT SWITCH
BU
A
OR
HOUR METER
BK
2
1
3
4
6
F1
355 A
BU/W
5
BK
FL3
BU
A
B
FORWARD/REVERSE
(IN FORWARD)
OPTIONS
FRONT
3 (NC)
2 (NO)
1 48 VDC INPUT
2 FOR/REV
4
1
1
2
3
4
5
6
OR
BK
B
PROGRAMMER
PORT
MAIN
PK
ACCELERATOR PEDAL SWITCH
(PEDAL NOT PUSHED IN)
CONTACTOR
(SOLENOID)
(ENERGIZED)
OPTIONS
REAR
3 ACCELERATOR PEDAL
4 HI/LOW
B+
BU
4 GA
HI / LOW SPEED SWITCH
(IN OFF (HI) POSITION)
Y
M2
F1
5 CHARGER
NC
10 GA
VIO/BK
BU/W
48V BATT ARRAY
6V x 8
6 HIGH TEMP/LOW BATTERY
7 BACKUP ALARM
8 MAIN CONTACTOR
9 DIAGNOSTIC LIGHT
10 ACCELERATOR POT
11 PROGRAMMING
12 12 VDC OUTPUT (100 mA)
13
BK
(DEEP CYCLE)
MOTOR TEMP SENSOR
(180 C)
FIELD F1
FIELD F2
A1 ARMATURE
W/BK
DIAGNOSTIC LED
DRIVE MOTOR
A2 ARMATURE
GN
T
BACKUP ALARM
HORN
(–)
CW
NC
10 GA
4 GA
ACCELERATOR POT
+ 12V
W
F2
M1
B–
BK
BN
(+)
NC
NC
NC
NC
14
MILLIPAK
GY
SEVCON
W
15
16
CONTROLLER
BK
PROGRAMMING
SPLICE
Workman e2050/e2065
On/Off Switch Turned On
Power Current
Control Current
Indication Current
Page 6 – 4
Rev. B
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F3 10 A
BU
PK
FUSE
HOLDERS
IGNITION–SWITCH
OFF RUN
F2 10 A
R
ACCESSORIES
CONTACTOR
(SOLENOID)
HORN
(ENERGIZED)
(IN RUN)
R/W
W
BK
OR
HORN SWITCH
BATT. CHG.
HOOK UP
R
FL1
HEADLIGHTS, 24V
GN
Y
Y
1
3
4
6
FL2
INTERLOCK
CHARGER
SWITCH
(CHARGER NOT
PLUGGED IN)
STATE OF CHARGE
2
5
INDICATOR
OR
GE 4589
GE 4589
LIGHT SWITCH
BU
A
OR
HOUR METER
BK
2
1
3
4
6
F1
355 A
BU/W
5
BK
FL3
B
FORWARD/REVERSE
(IN FORWARD)
BU
A
OPTIONS
FRONT
3 (NC)
2 (NO)
1 48 VDC INPUT
2 FOR/REV
4
1
1
2
3
4
5
6
OR
BK
B
PROGRAMMER
PORT
MAIN
PK
ACCELERATOR PEDAL SWITCH
(PEDAL PUSHED IN)
CONTACTOR
(SOLENOID)
(ENERGIZED)
3 ACCELERATOR PEDAL
4 HI/LOW
B+
M2
F1
BU
OPTIONS
REAR
4 GA
HI / LOW SPEED SWITCH
(IN OFF (HI) POSITION)
Y
5 CHARGER
NC
10 GA
VIO/BK
BU/W
48V BATT ARRAY
6V x 8
6 HIGH TEMP/LOW BATTERY
7 BACKUP ALARM
8 MAIN CONTACTOR
9 DIAGNOSTIC LIGHT
10 ACCELERATOR POT
BK
(DEEP CYCLE)
MOTOR TEMP SENSOR
(180 C)
W/BK
A1 ARMATURE
FIELD F1
FIELD F2
DIAGNOSTIC LED
DRIVE MOTOR
A2 ARMATURE
GN
T
BACKUP ALARM
HORN
(–)
11 PROGRAMMING
CW
NC
ACCELERATOR POT
10 GA
4 GA
+ 12V
W
12 12 VDC OUTPUT (100 mA)
13
F2
BK
BN
(+)
NC
NC
NC
NC
M1
B–
14
MILLIPAK
GY
SEVCON
W
15
16
CONTROLLER
BK
PROGRAMMING
SPLICE
Workman e2050/e2065
Run Circuit (Forward)
Power Current
Control Current
Indication Current
Page 6 – 5
Rev. B
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F3 10 A
BU
PK
FUSE
HOLDERS
IGNITION–SWITCH
OFF RUN
F2 10 A
R
ACCESSORIES
CONTACTOR
(SOLENOID)
HORN
(NOT ENERGIZED)
(OFF)
R/W
W
BK
OR
HORN SWITCH
BATT. CHG.
HOOK UP
R
FL1
HEADLIGHTS, 24V
GN
Y
Y
1
3
4
6
INTERLOCK
CHARGER
SWITCH
STATE OF CHARGE
FL2
2
5
INDICATOR
OR
(CHARGER
GE 4589
GE 4589
PLUGGED IN)
LIGHT SWITCH
BU
A
OR
HOUR METER
BK
2
1
3
4
6
F1
355 A
BU/W
5
BK
FL3
B
FORWARD/REVERSE
(IN FORWARD)
BU
A
OPTIONS
FRONT
3 (NC)
2 (NO)
1 48 VDC INPUT
2 FOR/REV
4
1
1
2
3
4
5
6
OR
PROGRAMMER
PORT
BK
B
MAIN
PK
ACCELERATOR PEDAL SWITCH
(PEDAL NOT PUSHED IN)
CONTACTOR
3 ACCELERATOR PEDAL
4 HI/LOW
B+
(SOLENOID)
BU
OPTIONS
REAR
(NOT ENERGIZED)
4 GA
HI / LOW SPEED SWITCH
(IN OFF (HI) POSITION)
Y
M2
F1
5 CHARGER
NC
10 GA
VIO/BK
BU/W
48V BATT ARRAY
6V x 8
(DEEP CYCLE)
(CHARGING)
6 HIGH TEMP/LOW BATTERY
7 BACKUP ALARM
8 MAIN CONTACTOR
9 DIAGNOSTIC LIGHT
10 ACCELERATOR POT
11 PROGRAMMING
BK
MOTOR TEMP SENSOR
(180 C)
W/BK
FIELD F1
FIELD F2
A1 ARMATURE
DRIVE MOTOR
A2 ARMATURE
DIAGNOSTIC LED
GN
T
BACKUP ALARM
HORN
(–)
CW
NC
ACCELERATOR POT
10 GA
4 GA
+ 12V
W
12 12 VDC OUTPUT (100 mA)
13
F2
M1
B–
BK
BN
(+)
NC
NC
NC
NC
14
MILLIPAK
SEVCON
GY
W
15
16
CONTROLLER
BK
PROGRAMMING
SPLICE
Workman e2050/e2065
Battery Charging Circuit
Power Current
Control Current
Indication Current
Page 6 – 6
Rev. B
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Workman e2050
Electrical Harness Drawing
Page 6 – 7
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PINK
RED/WHITE
ORANGE
ORANGE
RED
WHITE
ORANGE
RED/WHITE
BLACK
BLUE/WHITE
BLUE
BLACK
BROWN
WHITE/BLACK
BLUE/WHITE
YELLOW
BLUE
ORANGE
BLACK
BLACK
PINK
YELLOW
VIOLET/BLACK
WHITE
BLUE/WHITE
BROWN
GREEN
BLACK
TAN
TAN
TAN
GRAY
BLACK
BLACK
BLUE
BLUE
BLACK
RED/WHITE
BLUE
BLUE
GREEN
ORANGE
BLUE
ORANGE
Workman e2050
Electrical Harness
Wiring Diagram
Page 6 – 8
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Workman e2065
Electrical Harness Drawing
Page 6 – 9
Rev. B
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PINK
RED/WHITE
ORANGE
ORANGE
RED
WHITE
ORANGE
RED/WHITE
BLACK
BLUE/WHITE
BLUE
BLACK
BROWN
WHITE/BLACK
BLUE/WHITE
YELLOW
BLUE
ORANGE
BLACK
PINK
YELLOW
VIOLET/BLACK
WHITE
BLACK
BLUE/WHITE
BROWN
GREEN
BLACK
TAN
TAN
TAN
GRAY
BLACK
BLACK
BLUE
BLUE
BLACK
RED/WHITE
BLUE
BLUE
ORANGE
BLUE
GREEN
ORANGE
ORANGE
Workman e2065
Electrical Harness
Wiring Diagram
Page 6 – 10
Rev. B
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