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Workman e2050/e2065

Transaxle and Brakes (Rev. B)

Page 4 – 4

Troubleshooting

Brakes

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Problem

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Possible Cause

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Á ÁÁÁÁÁÁÁÁÁÁÁÁ

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Brake pedal goes to the floor.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

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).

ÁÁÁÁÁÁÁÁÁÁÁÁÁ

Á ÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁ

Brake pedal is spongy.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Rear brake drums are excessively worn or cracked.

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).

ÁÁÁÁÁÁÁÁÁÁÁÁÁ

Á ÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁ

Brakes pull to either side.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

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.

ÁÁÁÁÁÁÁÁÁÁÁÁÁ

Á ÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁ

Brakes squeal.

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Á ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

Brake lining is glazed or saturated.

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.

Содержание WorkmanR e2050

Страница 1: ...anu als are available on the Internet at www toro com The Toro Company reserves the right to change product specifications or this publication without notice This safety symbol means DANGER WARNING or...

Страница 2: ...Workman e2050 e2065 This page is intentionally blank...

Страница 3: ...leshooting 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 Adjustm...

Страница 4: ...Workman e2050 e2065 This page is intentionally blank...

Страница 5: ...ter 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 Veh...

Страница 6: ...now 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 deca...

Страница 7: ...an explode Keep cigarettes sparks and flames away from the batteries Always service store and charge the vehicle batteries in a well ventilated area 10 Never use an open flame to check level or leakag...

Страница 8: ...en 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 be hind the towing tongue Fig 1 2 Jack rear of the vehicle u...

Страница 9: ...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...

Страница 10: ...Workman e2050 e2065 Page 1 6 Safety Rev B This page is intentionally blank...

Страница 11: ...nd Steel Fasteners Inch Series 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Conversion Factors 6 MAINTENANCE 7 Product Records Insert Oper...

Страница 12: ...0 09375 Workman e2050 e2065 Page 2 2 Product Records and Maintenance Rev B Equivalents and Conversions...

Страница 13: ...orque feature hard ness of the surface underneath the fastener s head or similar condition which affects the installation As noted in the following tables torque values should be reduced by 25 for lub...

Страница 14: ...16 2 22 3 30 3 41 4 43 4 58 5 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...

Страница 15: ...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 ab...

Страница 16: ...00 in lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF Grade 5 65 10 ft lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1...

Страница 17: ...enance Rev B Maintenance Maintenance procedures and recommended service in tervals for the Workman e2050 and e2065 are covered in the Operator s Manual Refer to that publication when performing regula...

Страница 18: ...Workman e2050 e2065 Page 2 8 Product Records and Maintenance Rev B This page is intentionally blank...

Страница 19: ...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 A...

Страница 20: ...2050 e2065 Page 3 2 Electrical System Rev B Electrical Diagrams The electrical schematic circuit drawings and wire har ness drawings for the Workman e2050 and e2065 are located in Chapter 6 Electrical...

Страница 21: ...s to prevent abrasion or contact with moving parts Opening Battery Circuit To prevent allowing a current path through tools used during vehicle electrical circuit repairs remove one of the battery cab...

Страница 22: ...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 b...

Страница 23: ...to 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 tha...

Страница 24: ...s 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 lif...

Страница 25: ...mmended 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 batter...

Страница 26: ...cle 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...

Страница 27: ...r 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 potentiomete...

Страница 28: ...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 te...

Страница 29: ...ance 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...

Страница 30: ...o 2 5 mm from the lower stop on the potentiometer body Fig ure 14 B With the accelerator pedal fully depressed the in put lever of the potentiometer should not contact the upper stop on the potentiome...

Страница 31: ...uld 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...

Страница 32: ...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...

Страница 33: ...aches 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...

Страница 34: ...TE 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 Testing The switch te...

Страница 35: ...s illuminated and the vehicle status light is not illuminated check the vehicle status light and cir cuit wiring See Controller in this section and your Operator s Manual for information on a flashing...

Страница 36: ...g 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...

Страница 37: ...seat base 3 Locate charger interlock switch on rear of receptacle plate Disconnect harness connector from the switch 4 Check the continuity of the switch by connecting a multimeter ohms setting acros...

Страница 38: ...f the battery cables see Opening Battery Circuit in the General Information sec tion of this chapter and Fig 32 2 Locate contactor that is to be tested Disconnect all vehicle harness electrical connec...

Страница 39: ...or connections were removed use Figure 34 as a guide for reattaching cable and wire harness connections 8 Reconnect battery cable that was removed from bat tery pack 1 Main contactor 2 Cable to contro...

Страница 40: ...ted 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 Testing CAUTION When testing fuses for continuity...

Страница 41: ...t 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 If...

Страница 42: ...to determine whether continuity exists between the switch terminals for both switch positions Verify continuity between switch termi nals using the following table PLUNGER POSITION CONTINUITY NO CONT...

Страница 43: ...ermine current flow to the traction motor 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...

Страница 44: ...ontroller 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 plu...

Страница 45: ...ck main contactor wire and cable connections If problem continues contactor replacement may be necessary 5 Flashes The charger cord is plugged into the vehicle charger receptacle Turn on off switch OF...

Страница 46: ...T 13 to 14 1 N m 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...

Страница 47: ...hicle 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 wit...

Страница 48: ...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 Follow all instructions and comply with all saf...

Страница 49: ...e 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...

Страница 50: ...ehicle 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...

Страница 51: ...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 mat...

Страница 52: ...4 15 115 to 125 in lb 13 to 14 1 N m 19 Removal Fig 51 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from switch 2 Remove cargo bed from vehicle see Cargo B...

Страница 53: ...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 r...

Страница 54: ...wires to traction motor Fig 52 A Make sure that fasteners and cable connectors are properly positioned on motor terminals Fig 56 B Install correct cable connector and nut to motor terminals A1 and A2...

Страница 55: ...Workman e2050 e2065 Page 3 37 Electrical System Rev B This page is intentionally blank Electrical System...

Страница 56: ...and latch them in the open position on the spring holders Slide brushes from the brush holders 3 Use an arbor press or a bearing puller to remove the armature from the commutator end head and frame an...

Страница 57: ...using the following procedure Fig 59 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...

Страница 58: ...ty instructions including wearing eye and respiratory protec tion 5 After undercutting use No 00 sandpaper to lightly remove any burrs left from the undercutting operation Clean commutator with dry oi...

Страница 59: ...d field assembly and secure with four 4 bolts Torque bolts from 120 to 140 in lb 13 6 to 15 8 N m 4 Ensure the brushes are pushed out of the way 5 While supporting the inner race of the bearing in com...

Страница 60: ...former 3 Lower case 4 SCR assembly 5 Control board 6 Relay 7 Circuit breaker 8 AC cordset 9 DC cordset 10 Ammeter 11 Fuse 12 Diode assembly Figure 65 3 4 5 8 6 7 9 1 2 10 11 12 For service of the batt...

Страница 61: ...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 Mas...

Страница 62: ...Workman e2050 e2065 Transaxle and Brakes Rev B Page 4 2 This page is intentionally blank...

Страница 63: ...Workman e2050 e2065 Transaxle and Brakes Rev B Page 4 3 Specifications Item Description Transaxle Transaxle Fluid Capacity 2 quarts 1 9 liters Transaxle Fluid 10W 30 Motor Oil Transaxle and Brakes...

Страница 64: ...ms are excessively worn or cracked 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...

Страница 65: ...Incorrect brake lining material Brake pedal linkage is binding Brake cable is binding Workman e2050 Wheels lock up when braking Brake linings are contaminated Brake linings are loose or damaged Wheel...

Страница 66: ...fully to raise the brake lever away from the brake rod clevis 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...

Страница 67: ...Workman e2050 e2065 Transaxle and Brakes Rev B Page 4 7 This page is intentionally blank Transaxle and Brakes...

Страница 68: ...wheel off the ground using a jack and place jack stand or blocks beneath the rear frame to support vehicle NOTE To remove brake drum it may be necessary to loosen brake cable adjustment or remove bra...

Страница 69: ...at hole in drum aligns with hole in wheel hub on axle 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...

Страница 70: ...e spring 5 Auto adjust spring 6 Shoe cup spring loaded 7 Brake shoe 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 1...

Страница 71: ...pect brake shoe webbing for deformation Replace parts as necessary C Inspect hold down pins and shoe cups for bends rust and corrosion Replace as necessary 3 Inspect backing plate surfaces which conta...

Страница 72: ...6 CAUTION Be careful when removing springs from brake shoes The springs are under heavy load and may cause personal injury 1 Remove upper and lower springs from brake shoes 2 Remove shoe hold down cup...

Страница 73: ...an not be re moved by light sanding with emery cloth or other suit able abrasive Replace plate if cracked warped or excessively rusted 4 Inspect adjuster levers for deformation Replace lev ers if defo...

Страница 74: ...nion fitting 23 Rear brake tube 24 Rear brake hose 25 Hose bracket 2 used 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 r...

Страница 75: ...til pedal fades to floor Close bleeder valve before re leasing pedal 4 Repeat procedure until a continuous flow of brake fluid with no air bubbles is released from bleeder valve Make sure fluid level...

Страница 76: ...er 2 per caliper used 4 Cap screw 2 per caliper used 5 Wheel hub assembly 6 Brake rotor 7 Socket head screw 4 per rotor used 8 Spindle LH shown 9 A arm LH shown 10 Brake master cylinder 11 Wheel assem...

Страница 77: ...e orientation of inner and outer pads as the pads are not the same 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 fr...

Страница 78: ...to prevent contamination Remove both brake lines from master cylinder Cap ends of brake lines and position them away from master cylinder 4 Remove flange head nuts from cap screws that se cure master...

Страница 79: ...are thoroughly clean 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...

Страница 80: ...le equalizer bracket 5 Parking brake lever 6 Curved washer 7 Lock nut 8 Flat washer 9 Flange head screw 4 used 10 Flat washer 2 used 11 Screw 2 used 12 Cap screw 13 Cotter pin 14 Clevis pin 15 Parking...

Страница 81: ...om machine Take care to not damage brake cables while removing them from seat base opening 7 Remove brake cables from parking brake support and cable equalizer bracket using Figure 12 as a guide Assem...

Страница 82: ...pin 2 used 10 Washer 11 Socket head screw 12 Lug nut 5 used per wheel 13 Wheel assembly 14 Brake drum 15 Transaxle 16 Flange head screw 4 used 17 Cotter pin 18 Clevis pin 19 Brake cable 20 Transaxle v...

Страница 83: ...hapter 1 Safety 5 Jack up rear of vehicle enough to remove rear wheels A Chock the front and rear of both front tires to pre vent the vehicle from moving B Support both sides of the rear frame with ja...

Страница 84: ...ing 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...

Страница 85: ...Workman e2050 e2065 Transaxle and Brakes Rev B Page 4 25 This page is intentionally blank Transaxle and Brakes...

Страница 86: ...used 21 Final drive gear 22 Differential assembly 23 O ring 24 Intermediate shaft gear 25 Flange head screw 4 per brake 26 LH brake assembly 27 Oil seal 28 Retaining ring 29 Bearing retaining ring 30...

Страница 87: ...ension 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 Whe...

Страница 88: ...n Front tire 22 x 9 5 10 4 ply pressure 8 to 22 PSI 0 55 to 1 52 bar Rear tire 22 x 9 5 10 4 ply pressure 8 to 22 PSI 0 55 to 1 52 bar Front wheel cap screw torque Workman e2050 135 to 165 ft lb 183 t...

Страница 89: ...are loose or worn Steering linkage is loose or worn Tie rod ends are loose or worn Steering gear is incorrectly adjusted Front end shimmies Front wheel lug nuts are loose Front wheel bearings are loo...

Страница 90: ...ssure 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 p...

Страница 91: ...imum tire pres sure 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 align...

Страница 92: ...gearbox 6 Cap screw 7 Lock washer 8 Steering shaft 9 Cap screw 3 used 10 Upper steering bushing 11 Carriage bolt 4 used 12 Steering column 13 Dust cover 14 Collar 15 Pitman arm 16 Steering wheel cove...

Страница 93: ...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 loc...

Страница 94: ...r 9 Flange head screw with patch lock 10 Ball bearing 11 Input shaft spacer 12 Flat washer 13 Cap screw 14 Grease fitting 15 Steering housing cover 16 Steering housing 17 Pinion gear 18 Oil seal 19 Pi...

Страница 95: ...set 1 If ball bearings were removed A Press new bearing into housing from the inside first B Turn housing over Insert spacer and press new bearing into housing 2 If seals items 3 and 18 were removed p...

Страница 96: ...retaining ring 3 Wheel stud 5 per wheel 4 Wheel hub 5 Spacer 6 Tire wheel assembly 7 Lug nut 5 per wheel 8 Flat washer 9 Large flat washer 10 Cap screw 11 Dust cap Figure 3 7 4 3 2 2 1 6 5 8 9 10 11...

Страница 97: ...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 space...

Страница 98: ...8 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 Figure 5 FRONT RIGHT 1 6 5 4 3 2 8 7 9 14 13 12 1...

Страница 99: ...the hub B Place thrust washer onto the bottom of the king pin sleeve Then position spindle over the hub king pin sleeve and thrust washer NOTE Make sure cap screw king pin is inserted down through the...

Страница 100: ...g 37 Brake caliper LH shown 38 Lock washer 2 used per caliper 39 Cap screw 2 used per caliper Figure 6 20 to 25 ft lb 27 to 34 N m 75 to 100 ft lb 102 to 136 N m 20 to 25 ft lb 27 to 34 N m 45 to 65 f...

Страница 101: ...b with cap screw 19 and lock nut Torque lock nut from 75 to 100 ft lb 102 to 136 N m D Insert tie rod ball joints down through the spindle and up through the Pitman arm Secure with castle nuts E Torqu...

Страница 102: ...nut 7 Lock washer 8 Centering bolt 2 used per A arm 9 Travel limiting bolt 10 A arm RH 11 Flange head screw 4 used 12 Flange nut 4 used 13 Pivot yoke 14 Rear frame 15 Flat washer 4 used 16 Cap screw 4...

Страница 103: ...lock washers item 7 Do not tighten bolts 2 Install spindle and front wheel to the A arm see Lower Steering Installation in this section NOTE If A arm is being replaced look for number be tween 200 an...

Страница 104: ...njury and damage to the machine 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 WARNI...

Страница 105: ...Workman e2050 e2065 Page 5 19 Chassis Rev B This page is intentionally blank Chassis...

Страница 106: ...t base tray 10 Flange head screw 8 used 11 Flat washer 4 used 12 Front frame 13 Screw 4 used 14 Floor mat 15 Charger receptacle plate 16 Charger receptacle 17 Switch plate 18 Charger interlock switch...

Страница 107: ...1 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...

Страница 108: ...6 used 3 Dash 4 Flange nut 6 used 5 Fender LH shown 6 Bumper 7 Flat washer 2 used 8 Cap screw 2 used 9 Flat washer 4 used 10 Flange head screw 2 used 11 Flange head screw 2 used 12 Headlight mount 2 u...

Страница 109: ...ange 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 fastene...

Страница 110: ...4 used 32 Tension spring 33 Latch rod Figure 16 FRONT RIGHT 25 23 27 28 24 26 22 21 29 6 3 8 13 4 7 2 1 14 5 9 10 11 12 17 15 16 15 19 20 18 31 32 30 33 100 to 200 in lb 11 3 to 22 6 N m 35 to 55 in l...

Страница 111: ...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 Wirin...

Страница 112: ...Workman e2050 Electrical Diagrams Page 6 2 This page is intentionally blank...

Страница 113: ...ERSE 12V ACCELERATOR PEDAL SWITCH 1 BN ACCELERATOR POT BU W GY BU W BU NC NC NC IGNITION SWITCH 7 BACKUP ALARM 4 HI LOW 1 48 VDC INPUT F2 10 A CONTROLLER MILLIPAK 3 B 6 OR 4 GA 10 GA 4 GA W 355 A 5 2...

Страница 114: ...M 4 HI LOW 1 48 VDC INPUT F2 10 A CONTROLLER MILLIPAK 3 B 6 OR 4 GA 10 GA 4 GA W 355 A 5 2 3 6 4 1 BK BACKUP ALARM MOTOR TEMP SENSOR ACCESSORIES W BK HOUR METER INDICATOR FUSE FIELD F1 A2 ARMATURE Y G...

Страница 115: ...M 4 HI LOW 1 48 VDC INPUT F2 10 A CONTROLLER MILLIPAK 3 B 6 OR 4 GA 10 GA 4 GA W 355 A 5 2 3 6 4 1 BK BACKUP ALARM MOTOR TEMP SENSOR ACCESSORIES W BK HOUR METER INDICATOR FUSE FIELD F1 A2 ARMATURE Y G...

Страница 116: ...I LOW 1 48 VDC INPUT F2 10 A CONTROLLER MILLIPAK 3 B 6 OR 4 GA 10 GA 4 GA W 355 A 5 2 3 6 4 1 BK BACKUP ALARM MOTOR TEMP SENSOR ACCESSORIES W BK HOUR METER INDICATOR FUSE FIELD F1 A2 ARMATURE Y GE 458...

Страница 117: ...Page 6 7 Electrical Harness Drawing Workman e2050...

Страница 118: ...K BLACK GREEN BLACK TAN TAN BLACK BLUE BLUE BLUE ORANGE BLUE ORANGE BLACK ORANGE GREEN FUSIBLE LINK BLACK BLACK YELLOW BLUE BLACK BLACK YELLOW BLACK BLACK BLACK RED BLACK TAN RED WHITE GRAY BROWN VIOL...

Страница 119: ...Rev B Page 6 9 Electrical Harness Drawing Workman e2065...

Страница 120: ...NK BLUE WHITE YELLOW BLUE YELLOW RED RED RED VIOLET BLACK BLUE WHITE ORANGE WHITE BLACK BLUE WHITE WHITE FUSIBLE LINK FUSIBLE LINK WHITE RED YELLOW BLACK BLACK BLACK RED BLACK TAN RED WHITE GRAY BROWN...

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