Toro e2065 - Manuals
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Manual Toro e2065
Summary
Workman e2050/e2065 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 an...
Workman e2050/e2065 Page 1 – 1 Safety (Rev. B) Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS 2 . . . . . . . . . . . . . . . . . . . . . . Before Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mai...
Rev. D Workman e2050/e2065 Page 1 -- 2 Safety (Rev. B) 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 t...
Workman e2050/e2065 Page 1 – 3 Safety (Rev. B) 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. 2. Make sure machine is in safe operating condition by keeping all n...
Workman e2050/e2065 Page 1 – 4 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 ...
Workman e2050/e2065 Page 1 – 5 Safety (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 y...
Workman e2050/e2065 Page 2 – 1 Product Records and Maintenance (Rev. B) Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS 2 . . . . . . . . . . . Decimal and Millimeter Equivalents 2 . . . . . ....
0.09375 Workman e2050/e2065 Page 2 – 2 Product Records and Maintenance (Rev. B) Equivalents and Conversions
Workman e2050/e2065 Page 2 – 3 Product 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 clearl...
Workman e2050/e2065 Page 2 – 6 Product Records and Maintenance (Rev. B) Other Torque Specifications SAE Grade 8 Steel Set Screws Thread Size 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 + 1...
Workman e2050/e2065 Page 2 – 7 Product Records and Maintenance (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 regular vehicle maintenance. Product Records ...
Workman e2050/e2065 Page 3 – 1 Electrical System (Rev. B) Chapter 3 Electrical System Table of Contents ELECTRICAL DIAGRAMS 2 . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION 3 . . . . . . . . . . . . . . . . . . . . . Opening Battery Circuit 3 . . . . . . . . . . . . . . . . . . . . . ...
Workman e2050/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 Diagrams.
Workman e2050/e2065 Page 3 – 3 Electrical System (Rev. B) 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. The vehicle controller monitors operator and vehicle in- puts to deter...
Workman e2050/e2065 Page 3 – 4 Electrical System (Rev. B) 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. Eight, 6 volt, deep cycle ba...
Workman e2050/e2065 Page 3 – 5 Electrical System (Rev. B) 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...
Rev. D Workman e2050/e2065 Page 3 -- 7 Electrical System (Rev. B) 36/48 Volt Battery Discharge Unit The 36/48 Volt Battery Discharge Unit (TOR4106) is rec- 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 th...
Workman e2050/e2065 Page 3 – 8 Electrical System (Rev. B) Troubleshooting CAUTION 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 ...
Workman e2050/e2065 Page 3 – 9 Electrical System (Rev. B) 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 ...
Workman e2050/e2065 Page 3 – 10 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). F...
Workman e2050/e2065 Page 3 – 11 Electrical System (Rev. B) 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 ne...
Workman e2050/e2065 Page 3 – 12 Electrical System (Rev. B) 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...
Rev. A Workman e2050/e2065 Page 3 – 13 Electrical System (Rev. B) 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 a...
Workman e2050/e2065 Page 3 – 15 Electrical System (Rev. B) Battery Discharge Indicator and Hour Meter Gauge The combination battery discharge indicator and hour meter gauge is located on the dash panel (Fig. 19). The battery indicator identifies state of charge of the bat- tery pack. The battery ind...
Workman e2050/e2065 Page 3 – 16 Electrical System (Rev. B) 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 directi...
Workman e2050/e2065 Page 3 – 17 Electrical System (Rev. B) 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...
Workman e2050/e2065 Page 3 – 19 Electrical System (Rev. B) 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 an...
Workman e2050/e2065 Page 3 – 20 Electrical System (Rev. B) Main and Accessories Contactors Two contactors (solenoids) are used on the Workman e2050 and e2065 for circuit control. The main contactor provides current to the vehicle con- troller and is energized when the on/off switch is ON. The main c...
Workman e2050/e2065 Page 3 – 22 Electrical System (Rev. B) 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: The upper 10 ampere fuse (F2) supplies power to the on/o...
Workman e2050/e2065 Page 3 – 23 Electrical System (Rev. B) Fusible Links The wiring harness for the Workman includes three (3) fusible links for circuit protection (Fig. 37). Two fusible links attach to the same main contactor post as the main fuse. One of these fusible links (FL2) is used for the s...
Workman e2050/e2065 Page 3 – 24 Electrical System (Rev. B) 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 ...
Workman e2050/e2065 Page 3 – 25 Electrical System (Rev. B) 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-...
Workman e2050/e2065 Page 3 – 26 Electrical System (Rev. B) 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...
Rev. D Workman e2050/e2065 Page 3 -- 28 Electrical System (Rev. B) Service and Repairs Battery Service 1. Battery (8 used) 2. Battery rod (2 used) 3. Negative cable to vehicle 4. Lock washer (2 used per battery) 5. Hex nut (2 used per battery) 6. Cable terminal boot 7. Battery cable (6 used) 8. Posi...
Workman e2050/e2065 Page 3 – 32 Electrical System (Rev. B) Battery Storage If the vehicle will be stored for any period of time, check battery electrolyte level, adjust level if needed and then connect battery charger to vehicle. Allow charger to re- main connected to vehicle during storage to preve...
Workman e2050/e2065 Page 3 – 33 Electrical System (Rev. B) 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. Inspection 1. Make sure that on/off switch is OFF. Raise and ...
Workman e2050/e2065 Page 3 – 34 Electrical System (Rev. B) Traction Motor 1. Socket head screw (6 used) 2. Flat washer (6 used) 3. Flange nut 4. Support bracket 5. Carriage screw 6. Transaxle mount plate 7. Rubber damper 8. Traction motor 9. Fan 10. Roll pin (2 used) 11. Washer 12. Socket head screw...
Workman e2050/e2065 Page 3 – 35 Electrical System (Rev. B) 4. Disconnect wires from traction motor (Fig. 52): A. While retaining lower nut, remove upper nut and wire connector from motor terminals A1, A2, F1 and F2. B. Unplug motor temperature sensor from vehicle wire harness. Note location of cable...
Workman e2050/e2065 Page 3 – 38 Electrical System (Rev. B) Traction Motor Service 1. Frame and field assembly 2. Armature 3. Brush lead (2 used) 4. Cap screw (2 used per brush lead) 5. Cap screw (4 used) 6. Cap screw (8 used) 7. Brush (8 used) 8. High temperature sensor 9. Headband 10. Bolt (4 used)...
Workman e2050/e2065 Page 3 – 42 Electrical System (Rev. B) Battery Charger 1. Upper case 2. Transformer 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 t...
Workman e2050/e2065 Transaxle and Brakes (Rev. B) Page 4 – 1 Chapter 4 Transaxle and Brakes Table of Contents SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 4 . . . . . . . . . . . . . . . . . . . . . . . . . Brakes 4 . . . . . . . . . . . . . . . . . . . . ...
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
Workman e2050/e2065 Transaxle and Brakes (Rev. B) Page 4 – 4 Troubleshooting Brakes ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Problem ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Possible Cause ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁ Á...
Workman e2050/e2065 Transaxle and Brakes (Rev. B) Page 4 – 8 Service and Repairs Rear Wheels and Brakes Figure 3 1. Lug nut (5 used per wheel) 2. Wheel assembly 3. Brake drum 4. Axle shaft 5. Wheel stud (5 used per wheel) 6. Flange head screw (4 used per brake) 7. Brake assembly (RH shown) 8. Nut (4...
Workman e2050/e2065 Transaxle and Brakes (Rev. B) Page 4 – 12 Rear Brake Service (Workman e2065) 1. Brake backing plate 2. Washer head screw 3. Brake shoe 4. Lower spring 5. Wheel cylinder 6. Parking brake lever (LH shown) 7. Belleville washer 8. Adjuster lever 9. Dust cover 10. Flat washer 11. Bolt...
Workman e2050/e2065 Transaxle and Brakes (Rev. B) Page 4 – 15 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. 2. Have a helper pump brak...
Workman e2050/e2065 Transaxle and Brakes (Rev. B) Page 4 – 17 Removal (Fig. 8) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety. 2. Chock whe...
Workman e2050/e2065 Transaxle and Brakes (Rev. B) Page 4 – 19 Brake Master Cylinder Service (Workman e2065) Disassembly (Fig. 11) 1. Remove reservoir and flange seal. Push in on the push rod so the stop pin can be removed. 2. Disconnect lower end of the dust cover from the housing. 3. Push in on the...
Workman e2050/e2065 Transaxle and Brakes (Rev. B) Page 4 – 26 Transaxle Service 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 8. Retaining ring 9. Endcap plug 10. Ball bearing 11. Vent elbow 12. Transaxle housing 13. Bearing 14. Ca...
Workman e2050/e2065 Page 5 – 1 Chassis (Rev. B) Chapter 5 Chassis Table of Contents SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 3 . . . . . . . . . . . . . . . . . . . . . . . . . Suspension and Steering 3 . . . . . . . . . . . . . . . . . . . . SERVICE A...
Workman e2050/e2065 Page 5 – 3 Chassis (Rev. B) Troubleshooting Suspension and Steering ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Problem ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Possible Cause ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁ Á ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ Front end is ...
Workman e2050/e2065 Page 5 – 5 Chassis (Rev. B) 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. The lower the air pressure, the less the compaction and tire ma...
Workman e2050/e2065 Page 5 – 6 Chassis (Rev. B) Upper Steering 1. Nut 2. Lock washer 3. Steering wheel 4. Flange lock nut 5. Steering 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 1...
Workman e2050/e2065 Page 5 – 8 Chassis (Rev. B) Steering Gearbox 1. Gasket 2. Hex washer head screw (4 used) 3. Seal 4. Sector gear 5. Flat washer 6. Ball bearing 7. Output shaft spacer 8. Stepped washer 9. Flange head screw with patch lock 10. Ball bearing 11. Input shaft spacer 12. Flat washer 13....
Workman e2050/e2065 Page 5 – 14 Chassis (Rev. B) Front Wheels and Lower Steering (Workman e2065) 1. Wheel assembly 2. Lug nut (5 used per wheel) 3. Dust cap 4. Cotter pin 5. Nut retainer 6. Jam nut 7. Tab washer 8. Bearing cone 9. Bearing cup 10. Wheel hub 11. Wheel stud (5 used per hub) 12. Bearing...
Workman e2050/e2065 Page 5 – 16 Chassis (Rev. B) A–arm and Frame Pivot Yoke 1. Ride height adjustment bolt 2. Bushing 3. Grease fitting 4. A–arm (LH) 5. Flange nut 6. Lock 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...
Workman e2050/e2065 Page 5 – 20 Chassis (Rev. B) Seat Base 1. Seat 2. Seat bracket 3. Rubber receptacle 4. Rivet 5. Cap screw (4 used per seat) 6. Screw 7. Holding post 8. Seat base 9. Seat base tray 10. Flange head screw (8 used) 11. Flat washer (4 used) 12. Front frame 13. Screw (4 used) 14. Floor...
Workman e2050/e2065 Page 5 – 22 Chassis (Rev. B) Front Hood 1. Hood 2. Flange head screw (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. Head...
Workman e2050/e2065 Page 5 – 24 Chassis (Rev. B) Cargo Bed 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) 1...
Rev. B Workman e2050 Electrical Diagrams Page 6 – 1 Chapter 6 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATIC Electrical Schematic 3 . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL CIRCUIT DRAWINGS On/Off Switch Turned On 4 . . . . . . . . . . . . . . . . . . . . Run Circuit ...
Rev. B Page 6 – 3 Electrical Schematic Workman e2050/e2065 Contactors shown de–energized RUN 15 14 M1 M2 FL3 BU B BK BK BK 4 Y W 16 13 1 2 4 5 F2 F1 FL1 FL2 F1 FRONT HORN SWITCH W HORN SWITCH HOOK UP R (PEDAL NOT PUSHED IN) (+) 4 HR ENABLE 3 SETUP + 2 SENSE A 1 CW 7 FET OUT8 (–) 6 IGN + 5 SENSE B T ...
Rev. B Page 6 – 4 RUN 15 14 M1 M2 FL3 BU B BK BK BK 4 Y W 16 13 1 2 4 5 F2 F1 FL1 FL2 F1 FRONT HORN SWITCH W HORN SWITCH HOOK UP R (PEDAL NOT PUSHED IN) CW T VIO/BK Y PK OR NC NC NC OR R/W OFF 11 PROGRAMMING 9 DIAGNOSTIC LIGHT 8 MAIN CONTACTOR 5 CHARGER 2 FOR/REV F3 10 A SEVCON B+ 10 GA R A1 ARMATUR...
Rev. B Page 6 – 6 RUN 15 14 M1 M2 FL3 BU B BK BK BK 4 Y W 16 13 1 2 4 5 F2 F1 FL1 FL2 F1 FRONT HORN SWITCH W HORN SWITCH HOOK UP R (PEDAL NOT PUSHED IN) CW T VIO/BK Y PK OR NC NC NC OR R/W OFF 11 PROGRAMMING 9 DIAGNOSTIC LIGHT 8 MAIN CONTACTOR 5 CHARGER 2 FOR/REV F3 10 A SEVCON B+ 10 GA R A1 ARMATUR...
Page 6 – 7 Electrical Harness Drawing Workman e2050
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