Toro e2050, e2065 User Manual
Part No. 04127SL (Rev. D)
Service Manual
Workman
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing
and repair of major systems and components on the
Workman e2050 and e2065.
REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this
book to insert the Operator’s Manuals and Parts Catalogs for your machine. Replacement Operator’s Manuals are available on the Internet at www.toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
R
e2050 & e2065
This safety symbol means DANGER, WARNING
or CAUTION, PERSONAL SAFETY INSTRUCTION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or repair of the machine.
IMPORTANT: The IMPORTANT notice will give im portant instructions which must be followed to prevent damage to systems or components on the
machine.
E The Toro Company -- 2004, 2006, 2007, 2011
This page is intentionally blank.
Workman e2050/e2065
Table Of Contents
Chapter 1 – Safety
Safety Instructions 1 – 2. . . . . . . . . . . . . . . . . . . . . . . . . .
Jacking and Other Instructions 1 – 4. . . . . . . . . . . . . . .
Safety and Instruction 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
SafetyProduct Records
and Maintenance
SystemBrakes
ElectricalChassisElectrical
Transaxle and
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. . . . . . . . . . . . . . . . .
Diagrams
Workman e2050/e2065
This page is intentionally blank.
Workman e2050/e2065
Table of Contents
Chapter 1
Safety
Safety
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)
Safety Instructions
The Workman e2050 and e2065 are designed and
tested to offer safe service when operated and maintained properly. Although hazard control and accident
prevention are partially dependent upon the design and
configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport,
maintenance and storage of the machine. Improper use
or maintenance of the machine can result in injury or
death. To reduce the potential for injury or death, comply
with the following safety instructions.
Before Operating
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
1. Read and understand the contents of the Operator’s
Manual before starting and operating the machine. Become 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.
While Operating
WARNING
The Workman e2050 and e2065 are off--highway
vehicles only. They are not designed, equipped
or manufactured for use on public streets, roads
or highways.
1. Sit on the operator seat when starting and operating
the vehicle.
2. Before starting the vehicle:
A. Make sure that the battery charger is disconnected from the vehicle charger receptacle.
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 machine. Also tighten any loose nuts, bolts or screws to ensure machine is in safe operating condition.
3. Before getting off the operator seat:
A. Stop vehicle, turn on/off switch OFF and remove
key from switch.
B. Set parking brake.
4. If vehicle is parked on incline, chock or block the
wheels after getting off the vehicle.
B. Engage the parking brake.
C. Make sure accelerator pedal is not depressed.
D. Check position of forward/reverse switch and Hi/
Low speed switch.
Rev. D
Workman e2050/e2065Page 1 -- 2Safety (Rev. B)
Maintenance and Service
1. Before servicing or making adjustments to the vehicle, stop vehicle, turn on/off switch to OFF, engage
parking brake and remove key from the on/off switch.
2. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
3. Do not use open pans of flammable cleaning fluids
for cleaning parts.
4. Keep battery area free of excessive grease, grass,
leaves and dirt.
5. Disconnect batteries before servicing the machine.
Carefully remove one of the battery cables from the battery 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 repairs, 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 battery pack as the last step in any repair.
6. When using metal, uninsulated tools around batteries, do not allow tools to contact both positive and negative battery terminals simultaneously.
7. Remove jewelry and watches before servicing electrical 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.
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 receptacle before plugging the charger power cord into an
outlet. After charging the vehicle batteries, unplug the
charger power cord from the outlet before disconnecting
the charger cord from the vehicle charger receptacle.
12.If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.
13.To assure optimum performance and continued
safety of the machine, use genuine Toro replacement
parts and accessories. Replacement parts and accessories made by other manufacturers may result in nonconformance with safety standards and the warranty
may be voided.
14.When raising the machine to change tires or to perform 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, remove 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 properly supported by blocks or jack stands, the machine may
move or fall, which may result in personal injury (see
Jacking Instructions in the Operator’s Manual and in this
Chapter).
Safety
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)
Jacking and Other Instructions
Jacking Vehicle
DANGER
POTENTIAL HAZARD
• A vehicle that is not properly supported
may become unstable.
WHAT CAN HAPPEN
• The vehicle may move or fall. Personal
injury or damage to the machine may result.
HOW TO AVOID THE HAZARD
• Make sure vehicle is parked on a solid level
surface, such as a concrete floor.
• Make sure On/Off switch is OFF and key is
removed from the switch before getting off
the vehicle.
• Before raising the vehicle, remove any
attachments that may interfere with the safe
and proper raising of the vehicle.
• Always chock or block wheels to prevent
the vehicle from rolling.
• Make sure proper hoists, solid wooden
blocks and jack stands are used to raise
and support the vehicle.
Jacking Locations
1. Jack front of the vehicle on the front of the frame behind the towing tongue (Fig. 1).
1
Figure 1
1. Front frame 2. Towing tongue
1
Figure 2
1. Axle tube 2. Transaxle case
2
2
1
2. Jack rear of the vehicle under each rear axle tube. Do
not jack vehicle below the transaxle case (Fig. 2).
Towing Vehicle
IMPORTANT: Frequent or long distance towing of
the Workman e2050/e2065 is not recommended.
In case of emergency, the vehicle can be towed for a
short distance. See Operator’s Manual for towing information.
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 information.
IMPORTANT: If vehicle is towed, make sure that on/
off switch is in the OFF position and key is removed
from switch.
Workman e2050/e2065Page 1 – 4Safety (Rev. B)
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.
Safety
Workman e2050/e2065 Page 1 – 5 Safety (Rev. B)
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Workman e2050/e2065Page 1 – 6Safety (Rev. B)
Product Records and Maintenance
Table of Contents
Chapter 2
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
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 Instructions, Operator’s Manuals and Parts Catalogs for
those options at the end of this chapter.
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric Fasteners) 5. . . . . . . . . .
Other Torque Specifications 6. . . . . . . . . . . . . . . . . .
Conversion Factors 6. . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
and Maintenance
Product Records
Workman e2050/e2065 Page 2 – 1 Product Records and Maintenance (Rev. B)
Equivalents and Conversions
0.09375
Workman e2050/e2065Page 2 – 2Product Records and Maintenance (Rev. B)
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 specified in this Service Manual.
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Service Manual. 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, hardness of the surface underneath the fastener’s head or
similar condition which affects the installation.
Fastener Identification
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 engagement, etc.
The standard method of verifying torque shall be performed 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.
and Maintenance
Product Records
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Figure 1
Class 8.8 Class 10.9
Metric Bolts and Screws
Figure 2
Workman e2050/e2065 Page 2 – 3 Product Records and Maintenance (Rev. B)
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Grade 1, 5, &
Thread Size
# 6 – 32 UNC
# 6 – 40 UNF
# 8 – 32 UNC
# 8 – 36 UNF
# 10 – 24 UNC
# 10 – 32 UNF
1/4 – 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1125 + 100 140 + 15 1580 + 170
1/4 – 28 UNF 53 + 7 65 + 10 734 + 113 115 + 10 1300 + 100 160 + 15 1800 + 170
5/16 – 18 UNC 115 + 15 105 + 17 1186 + 169 200 + 25 2250 + 280 300 + 30 3390 + 340
5/16 – 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2540 + 280 325 + 30 3670 + 340
3/8 – 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 4 58 + 5
8 with Thin
Height Nuts
in–lb in–lb N–cm in–lb N–cm in–lb N–cm
10 + 2 13 + 2 147 + 23
13 + 2 25 + 5 282 + 30
18 + 2 30 + 5 339 + 56
ft–lb ft–lb N–m ft–lb N–m ft–lb N–m
SAE Grade 1 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
15 + 2 170 + 20 23 + 2 260 + 20
17 + 2 190 + 20 25 + 2 280 + 20
29 + 3 330 + 30 41 + 4 460 + 45
31 + 3 350 + 30 43 + 4 485 + 45
42 + 4 475 + 45 60 + 6 675 + 70
48 + 4 540 + 45 68 + 6 765 + 70
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
3/8 – 24 UNF 17 + 2 18 + 2 24 + 3 35 + 3 47 + 4 50 + 4 68 + 5
7/16 – 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9
7/16 – 20 UNF 29 + 3 29 + 3 39 + 4 55 + 5 75 + 7 77 + 7 104 + 9
1/2 – 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 10 142 + 14
1/2 – 20 UNF 32 + 3 53 + 7 72 + 9 85 + 8 115 + 11 120 + 10 163 + 14
5/8 – 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 20 285 + 27
5/8 – 18 UNF 75 + 10 95 + 15 129 + 20 170 + 15 230 + 20 240 + 20 325 + 27
3/4 – 10 UNC 93 + 12 140 + 20 190 + 27 265 + 25 359 + 34 375 + 35 508 + 47
3/4 – 16 UNF 115 + 15 165 + 25 224 + 34 300 + 25 407 + 34 420 + 35 569 + 47
7/8 – 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81
7/8 – 14 UNF 155 + 25 260 + 30 353 + 41 475 + 45 644 + 61 660 + 60 895 + 81
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
are defined as threads coated with a lubricant such as
oil, graphite or thread sealant such as Loctite.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the miniNOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
mum proof load specified in SAE J429. The tolerance is
approximately +
10% of the nominal torque value. Thin
height nuts include jam nuts.
Workman e2050/e2065Page 2 – 4Product Records and Maintenance (Rev. B)
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws and Studs with
Thread Size Regular Height Nuts
(Class 8 or Stronger Nuts)
M5 X 0.8 57 + 5 in–lb 640 + 60 N–cm 78 + 7 in–lb 885 + 80 N–cm
M6 X 1.0 96 + 9 in–lb 1018 + 100 N–cm 133 + 13 in–lb 1500 + 150 N–cm
M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 27 + 2 ft–lb 36 + 3 N–m
M10 X 1.5 38 + 4 ft–lb 52 + 5 N–m 53 + 5 ft–lb 72 + 7 N–m
M12 X 1.75 66 + 7 ft–lb 90 + 10 N–m 92 + 9 ft–lb 125 + 12 N–m
M16 X 2.0 166 + 15 ft–lb 225 + 20 N–m 229 + 22 ft–lb 310 + 30 N–m
M20 X 2.5 325 + 33 ft–lb 440 + 45 N–m 450 + 37 ft–lb 610 + 50 N–m
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
oil, graphite or thread sealant such as Loctite.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
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 +
nominal torque value.
Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
10% of the
and Maintenance
Product Records
Workman e2050/e2065 Page 2 – 5 Product Records and Maintenance (Rev. B)
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Recommended Torque
Thread Size
Square Head Hex Socket
1/4 – 20 UNC 140 + 20 in–lb 73 + 12 in–lb
5/16 – 18 UNC 215 + 35 in–lb 145 + 20 in–lb
3/8 – 16 UNC 35 + 10 ft–lb 18 + 3 ft–lb
1/2 – 13 UNC 75 + 15 ft–lb 50 + 10 ft–lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size Baseline Torque*
No. 6 – 32 UNC 20 + 5 in–lb
Wheel Bolts and Lug Nuts
Thread Size
7/16 – 20 UNF
Grade 5
1/2 – 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non–lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
No. 6 18 20 20 + 5 in–lb
Threads per Inch
Type A Type B
Recommended Torque**
65 + 10 ft–lb 88 + 14 N–m
80 + 10 ft–lb 108 + 14 N–m
80 + 10 ft–lb 108 + 14 N–m
80 + 10 ft–lb 108 + 14 N–m
Baseline Torque*
No. 8 – 32 UNC 30 + 5 in–lb
No. 10 – 24 UNC 38 + 7 in–lb
1/4 – 20 UNC 85 + 15 in–lb
5/16 – 18 UNC 110 + 20 in–lb
3/8 – 16 UNC 200 + 100 in–lb
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
No. 8 15 18 30 + 5 in–lb
No. 10 12 16 38 + 7 in–lb
No. 12 11 14 85 + 15 in–lb
* Hole size, material strength, material thickness & finish
must be considered when determining specific torque
values. All torque values are based on non–lubricated
fasteners.
Workman e2050/e2065Page 2 – 6Product Records and Maintenance (Rev. B)
Maintenance
Maintenance procedures and recommended service intervals for the Workman e2050 and e2065 are covered
in the Operator’s Manual. Refer to that publication when
performing regular vehicle maintenance.
and Maintenance
Product Records
Workman e2050/e2065 Page 2 – 7 Product Records and Maintenance (Rev. B)
This page is intentionally blank.
Workman e2050/e2065Page 2 – 8Product Records and Maintenance (Rev. B)
Table of Contents
Chapter 3
Electrical System
ELECTRICAL DIAGRAMS 2. . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 3. . . . . . . . . . . . . . . . . . . . .
Opening Battery Circuit 3. . . . . . . . . . . . . . . . . . . . . .
VEHICLE OPERATION 4. . . . . . . . . . . . . . . . . . . . . . . .
SPECIAL TOOLS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 8. . . . . . . . . . . . . . . . . . . . . . . . .
General Run Problems 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
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
System
Electrical
Workman e2050/e2065
Page 3 – 1
Electrical System (Rev. B)
Electrical Diagrams
The electrical schematic, circuit drawings and wire harness drawings for the Workman e2050 and e2065 are
located in Chapter 6 – Electrical Diagrams.
Electrical System (Rev. B)
Page 3 – 2
Workman e2050/e2065
General Information
The Workman e2050 and e2065 use a 48 volt DC electrical system that is an isolated circuit. The vehicle frame
is not used for any ground connections.
The vehicle controller monitors operator and vehicle inputs to determine voltage to the traction motor. If a problem exists that will prevent normal vehicle operation, an
LED on the controller and the 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 allow 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 terminal with lock washer and nut. Torque nuts from 115 to
125 in–lb (13 to 14.1 N–m).
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.
System
Electrical
Battery pack cable routing is shown in Figure 2.
Figure 1
1
2
A
4
Figure 2
1. Negative cable to vehicle 2. Positive cable to vehicle
Workman e2050/e2065
Page 3 – 3
Electrical System (Rev. B)
Vehicle Operation
The Workman e2050 and e2065 electrical system use
a 48 volt battery pack, an electric traction motor, a vehicle controller and numerous other electrical components to allow vehicle operation.
Eight, 6 volt, deep cycle batteries that are connected in
series provide current for a 48 volt DC, high torque traction motor, the vehicle controller and vehicle accessories (headlights, horn, various optional accessories).
The batteries are discharged as the vehicle is used so
charging the batteries after using the vehicle is necessary. A battery discharge indicator gauge on the dash
provides the operator with information on battery charge
level. Demands on the vehicle during use (speed, payload, incline use), battery condition (age, charge level),
ambient temperature and vehicle condition will all put
constraints on how long a vehicle can be used before the
batteries are discharged.
An automatic, 115 VAC (230 VAC on international models) battery charger is included with the vehicle. An interlock switch on the vehicle charger receptacle prevents
the vehicle from operating when the charger cord is
plugged into the vehicle.
The electric traction motor directly drives a double reduction 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 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 contactor (solenoid). The controller also provides regenerative
braking to assist in slowing the vehicle. The controller
has fault detection capabilities to help identify system
problems. Battery current is available to the controller
whenever the on/off switch is ON which energizes the
main contactor. A high current fuse protects this high
current circuit.
The Workman controller also provides a roll off warning
in instances when the vehicle begins to move (roll away)
after being stopped. On an incline and with the on/off
switch in the ON position, if the vehicle starts moving,
the alarm will sound warning the operator that the vehicle is moving. When the vehicle goes into this roll–off
mode, regenerative braking will limit vehicle speed.
Vehicle accessories include headlights, horn and optional 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 traction motor is cooled with an external fan. Additionally, 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)
Page 3 – 4
Workman e2050/e2065
Special Tools
Multimeter
The multimeter can test electrical components and circuits 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 meter in the voltage mode will make sure that excess current 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.
Battery Terminal Protector
Figure 3
System
Electrical
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 terminal.
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 component. Connectors should be thoroughly packed with gel
for effective results.
Figure 4
Workman e2050/e2065
Page 3 – 5
Figure 5
Electrical System (Rev. B)
Battery Watering Dispenser
Use the battery watering dispenser when adding distilled water to vehicle batteries. Obtain watering dispenser locally.
Battery Hydrometer
Use the battery hydrometer when measuring specific
gravity of battery electrolyte. Obtain hydrometer locally.
Figure 6
Battery Lift Strap
Use the battery lift strap to remove and install batteries
from the vehicle. Lift strap allows use of case loops on
battery tops as safe battery lifting points. Obtain battery
lift strap locally.
Figure 7
Figure 8
Electrical System (Rev. B)
Page 3 – 6
Workman e2050/e2065
36/48 Volt Battery Discharge Unit
The 36/48 VoltBattery DischargeUnit (TOR4106) is recommended for quick and accurate load testing for the
batteries on the Workman e2050 and e2065. This tool
is used to determine the capacity of the Workman battery pack and also for finding faulty battery or batteries
in the battery pack.
Order the 36/48 Volt Battery Discharge Unit (TOR4106)
from your Toro Distributor.
Figure 9
System
Electrical
Workman e2050/e2065
Page 3 -- 7
Rev. D
Electrical System (Rev. B)
Troubleshooting
CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical troubleshooting or testing. Disconnect a battery cable
from the battery pack to open the battery circuit
unless a test procedure requires battery voltage.
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).
For effective troubleshooting and repairs, there must be
a good understanding of the electrical circuits and components used on this vehicle (see Electrical Schematic
in Chapter 6).
If the vehicle has any switches by–passed, they must be
reconnected for proper vehicle operation, troubleshooting and safety.
Problem
Main contactor clicks, but vehicle will not operate. Battery charge is low.
Nothing happens when on/off switch is turned to ON. Battery charge is extremely low.
Possible Causes
Battery cables are loose, corroded or damaged.
Cable connection(s) at controller is/are loose or
corroded.
Cable connection(s) at traction motor is/are loose or
corroded.
Traction motor is faulty.
Controller is faulty.
Battery 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.
Electrical System (Rev. B)
Main fuse (F1) is loose or blown.
The on/off switch or circuit wiring is faulty.
Controller is faulty.
Page 3 – 8
Workman e2050/e2065
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).
System
Electrical
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).
Green light on battery charger flashing. Slow flash (once per second): Batteries being charged
Batteries is fully charged. Vehicle ready to operate.
(batteries less than 80% charged). Continue charging.
Rapid flash (four times per second): Batteries being
charged (batteries more than 80% charged). Continue
charging.
Red light on battery charger flashing. Rapid flash: Charger timer shutoff has occurred after
20 hours of charging.
Slow flash: No current to charger. Check AC outlet.
Workman e2050/e2065
Page 3 – 9
Electrical System (Rev. B)
Battery Charger Problems
Problem Possible Causes
Battery charger does not turn on. AC outlet fuse/circuit breaker blown.
AC outlet is faulty.
Vehicle wiring is loose or damaged (see electrical
schematic in Chapter 6 – Electrical Diagrams).
Fusible link FL1 is damaged.
Vehicle charger interlock switch or circuit wiring faulty.
Vehicle charger receptacle or circuit wiring damaged.
Battery charger is faulty.
Battery charger does not turn off. Battery charger is faulty.
NOTE: Charging new batteries or charging batteries in
cold temperatures may require extended charge time
to achieve full charge.
Battery charger fuse blows. Vehicle battery polarity is reversed (vehicle battery
cables incorrectly attached).
The AC outlet circuit breaker or fuse blows when using
the battery charger.
Vehicle charger receptacle polarity is reversed.
Battery charger is faulty.
Overloaded AC circuit.
Battery charger is faulty.
Electrical System (Rev. B)
Page 3 – 10
Workman e2050/e2065
Adjustments
Accelerator Switch Adjustment
1. Position vehicle on a level surface, turn On/Off
switch OFF and remove key. Apply parking brake.
2. Make sure that at complete brake pedal travel, the
park detent and pawl are fully engaged. If needed, adjust the accelerator pedal stop cap screw to allow full engagement (Fig. 11).
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).
5. If distance is incorrect, loosen lock nut and adjust accelerator switch stop cap screw position (Fig. 11).
6. After adjustment, make sure that switch plunger is
not bottomed out when accelerator pedal is released.
7. After adjustment to switch stop cap screw, make
sure that the switch does not open when the parking
brake is engaged. Readjust switch stop cap screw if required.
8. Calibrate accelerator system after adjusting accelerator switch (see Accelerator System Calibration in this
section).
2
3
4
1. Accelerator pedal
2. Accelerator switch
3. Plate
2
1
Figure 10
4. Screw (2 used)
5. Switch stop cap screw
6. Lock nut
1
6
5
System
Electrical
3
Workman e2050/e2065
Page 3 – 11
Figure 11
1. Accelerator switch
2. Switch stop cap screw
3. Accelerator stop cap screw
5/8 inch
(1.6 cm)
1
2
Figure 12
1. Switch stop cap screw 2. Accelerator switch
Electrical System (Rev. B)
Accelerator Potentiometer Adjustment
The accelerator potentiometer is used as one of the inputs for the vehicle controller and is attached to the pedal frame under the dash (Fig. 13). A collar with roll pin on
the accelerator pedal shaft positions the accelerator potentiometer lever.
If the accelerator potentiometer is out of adjustment, the
diagnostic light on the dash will flash six (6) times. Additionally, if vehicle movement is erratic and jerky, potentiometer adjustment and calibration of the accelerator
system should be performed.
Adjustment
1. Position vehicle on a level surface, turn On/Off
switch OFF and remove key.
2. Make sure that accelerator potentiometer is securely
attached to the pedal frame of the machine.
3. Check accelerator switch adjustment and adjust if
necessary (see Accelerator Switch Adjustment in this
section).
4. Check movement of the accelerator potentiometer
lever:
A. With the accelerator pedal released, the roll pin
on the throttle position collar should keep the potentiometer lever from 0.050” to 0.100” (1.3 to 2.5 mm)
from the lower stop on the potentiometer body (Figure 14).
B. With the accelerator pedal fully depressed, the input lever of the potentiometer should not contact the
upper stop on the potentiometer body (Figure 15).
5. If potentiometer lever movement is incorrect, adjust
location of collar on accelerator pedal shaft:
1
4
3
Figure 13
1. Potentiometer
2. Accelerator pedal
3. Throttle position collar
4. Roll pin
5. Set screw (2 used)
1
3
2
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
2
A. Loosen two (2) set screws that secure throttle
position collar to throttle pedal shaft and reposition
collar to allow correct potentiometer movement.
Make sure that there is clearance between roll pin
and side of potentiometer lever to prevent binding.
B. Remove set screws one at a time from collar and
apply Loctite #242 (or equivalent) to set screw
threads. Install and tighten set screws to secure collar to accelerator pedal shaft.
C. Recheck potentiometer lever movement.
6. Calibrate accelerator system after any accelerator
potentiometer adjustment (see Accelerator System Calibration in this section).
Electrical System (Rev. B)
Page 3 – 12
1
3
2
Figure 15
1. Potentiometer lever (accelerator pedal fully depressed)
2. Potentiometer upper stop
3. No lever contact with stop
Workman e2050/e2065
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