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Toro Workman GTX Electric & Lithium Service Manual
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Toro Workman GTX Electric & Lithium Service Manual

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Form No. 16228SL Rev B
Workman
GTX Electric &
®
Lithium
Original Instructions (EN)

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Summary of Contents for Toro Workman GTX Electric & Lithium

  • Page 1 Form No. 16228SL Rev B Workman GTX Electric & ® Lithium Original Instructions (EN)
  • Page 3 THE TORO COMPANY 2020 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be...
  • Page 4 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.com...
  • Page 5 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.
  • Page 6 This page is intentionally blank. Workman GTX Electric...

  • Page 7: Table Of Contents

    Table Of Contents Chapter 1 - - Safety Chapter 4 - - Transaxle Safety Instructions ......1 -- 2 General Information .
  • Page 8 This page is intentionally blank. Workman GTX Electric...
  • Page 9 Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS ..... . Supervisor’s Responsibilities ....Before Operating .

  • Page 10: Safety Instructions

    To reduce the potential for injury or death, com- quickly. Additional copies of the Operator’s Manual are ply with the following safety instructions. available on the internet at www.Toro.com. WARNING The Workman GTX Electric is an off−highway ve- hicle only. It is not designed, equipped or manufactured for use on public streets, roads or highways.

  • Page 11: While Operating

    12.To assure optimum performance and continued 5. As the first step in any electrical system repair, open safety of the machine, use genuine Toro replacement the battery circuit by disconnecting the conductors be- parts and accessories. Replacement parts and acces-...

  • Page 12: Jacking And Other Instructions

    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 •...

  • Page 13: 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 GTX Electric Page 1 − 5 Safety...
  • Page 14 This page is intentionally blank. Safety Page 1 − 6 Workman GTX Electric...

  • Page 15: Product Records

    Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ......EQUIVALENTS AND CONVERSIONS .

  • Page 16: Equivalents And Conversions

    Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 − 2 Workman GTX Electric...

  • Page 17: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.

  • Page 18: Standard Torque For Dry, Zinc Plated And Steel Fasteners (Inch Series)

    Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...

  • Page 19: Standard Torque For Dry, Zinc Plated And

    Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with Thread Size Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in−lb 644 + 68 N−cm...

  • Page 20: Other Torque Specifications

    Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 7/16 − 20 UNF 65 + 10 ft−lb 88 + 14 N−m Grade 5 1/4 −...
  • Page 21 Chapter 3A Electrical System Table of Contents GENERAL INFORMATION ..... SERVICE AND REPAIRS ..... Operator’s Manual .

  • Page 22: General Information

    General Information The Workman GTX Electric uses a 48 VDC electrical After performing any repair on electrical components on system that is an isolated circuit. The vehicle frame is the vehicle, make sure that wiring is routed and secured not used for any ground connections. so as to prevent abrasion or contact with moving vehicle parts.

  • Page 23: Opening Battery Circuit

    Opening Battery Circuit To prevent allowing a current path through tools used 3. Install the negative cable from the vehicle controller, during vehicle electrical circuit repairs, disconnect the the wire harness ground conductor and the negative conductors between the battery pack and vehicle com- conductors (black and white charger wires) from the bat- ponents as the first step in any electrical system repair.

  • Page 24: Vehicle Operation

    Vehicle Operation The Workman GTX Electric electrical system uses a 48 The vehicle controller is a sealed electronic logic device volt battery pack, an electric traction motor, a vehicle that uses inputs from several vehicle components to controller and numerous other electrical components to control motor speed and direction.

  • Page 25: 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.
  • Page 26 The hand pump hose coupler attaches to the fill 30 inch Tube 30 inch Tube port coupler on the Workman vehicle. Toro Part Number: 131- -8522 Coupler Hand Pump Figure 6...
  • Page 27 Workman GTX Electric vehicle. This tool is used to de- termine the capacity of the Workman battery pack and also for finding a faulty battery (or batteries) in the bat- tery pack. Toro Part Number: TOR4106 Figure 9 Workman GTX Electric Page 3A - - 7...

  • Page 28: Troubleshooting

    Troubleshooting For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and com- CAUTION ponents used on this vehicle (see Electrical Schematic and wire harness drawings in Chapter 6 -- Electrical Drawings). Remove all jewelry, especially rings and watches, before doing any electrical trouble- If the vehicle has any switches by--passed, they must be shooting or testing.
  • Page 29 General Run Problems (Continued) Problem Possible Causes Nothing happens when key switch is turned to ON. Battery charge is extremely low (check battery discharge indicator on dash). Battery cables are loose, corroded or damaged. Cable connection(s) at main contactor is/are loose or corroded.

  • Page 30: Battery Charger Operation

    General Run Problems (Continued) Problem Possible Causes Vehicle runs slowly. The supervision speed limit switch is in the slow position. Tire pressure is low (see Check Tire Pressure in the Service and Repairs section of Chapter 5 -- Chassis). The parking brake is improperly adjusted (see Adjust Parking Brake in the Adjustments section of Chapter 5 -- Chassis).

  • Page 31: Battery Charger Problems

    Battery Charger Problems NOTE: Check battery charger diagnostic LED for pos- sible faults whenever diagnosing on--board battery charger problems (see On--board Battery Charger in the Component Testing section of this chapter). Problem Possible Causes Battery charger does not turn on. AC outlet (electrical supply for charger) circuit breaker or fuse is tripped or blown.

  • Page 32: Component Testing

    Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. disconnect the harness wire connectors from the vehicle key switch before doing a continuity check on the key switch). When testing electrical components for continu- ity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.

  • Page 33: Fuses

    Fuses The Workman fuse block is located under the seat as- sembly (Fig. 11). All fuse block fuses are rated at 80 VDC. The fuse location in the fuse block is shown in Figure 12. The fuses protect circuits as follows: The front 10 amp (80 VDC) fuse protects the power supply to the key switch and all switched circuits.

  • Page 34: Battery Discharge Indicator

    Battery Discharge Indicator The battery discharge indicator identifies the battery pack state of charge and is located on the dash panel (Fig. 14). The discharge indicator reads full (10 indicator bars) af- ter the battery pack has been fully charged (approxi- mately 51 volts).

  • Page 35: Light Switch

    Light Switch The light switch allows the headlights to be turned ON and OFF. This rocker switch is located on the dash panel (Fig. 17). NOTE: The Workman GTX Electric headlight circuit is a 12 VDC circuit. Testing 1. Park vehicle on a level surface, turn key switch to OFF, engage the parking brake and remove key from the key switch.

  • Page 36: Direction Selector Switch

    Direction Selector Switch The direction selector switch allows the direction (for- ward/neutral/reverse) of the vehicle to be changed by the operator and is one of several inputs for the vehicle controller. The direction selector switch is located on the dash panel (Fig. 19). NOTE: Direction selector switch terminals 1, 2 and 3 are used on all Workman GTX Electric vehicles to change the direction of the vehicle.

  • Page 37: Status Indicator Light

    Status Indicator Light The status indicator light is located on the control panel next to the parking brake lever (Fig. 21). During normal operation, the status indicator light should be continu- ously illuminated. A vehicle electrical problem will be identified by a flashing status indicator light. The status indicator and LED on the vehicle controller should have the same condition (off, illuminated or flash- ing).

  • Page 38: Supervision Speed Limit Switch

    Supervision Speed Limit Switch The supervision speed limit switch allows the maximum 5. Replace the speed limit switch if testing determines speed of the vehicle to be set to either performance (16 that the switch is faulty. mph/26 kph) or economy (12 mph/19 kph). The speed 6.

  • Page 39: Parking Brake Switch

    Parking Brake Switch The parking brake switch is used as an input for the vehi- 8. If the brake switch tests correctly and a circuit prob- cle controller to identify when the parking brake is ap- lem still exists, check wire harness for problems (see plied.

  • Page 40: Usb Charge Port

    USB Charge Port The USB charge port can be used to charge or power electrical devices that use a USB port. The charge port has a 5 VDC output and is mounted to the dash (Fig. 27). If the vehicle wire harness is to be disconnected from the charge port, note the wire harness connections at the charge port for assembly purposes.

  • Page 41: Main Contactor (48 Vdc)

    Main Contactor (48 VDC) The main contactor provides provides current to the 48 9. Connect the conductors between the battery pack VDC system circuits (e.g. controller, traction motor) and and vehicle components (see Opening Battery Circuit in is energized by the controller when the key switch is ON. the General Information section of this chapter).

  • Page 42: Accelerator Pedal

    Accelerator Pedal The accelerator pedal is attached to the foot board un- der the dash (Fig. 31). This pedal is used as one of the inputs for the vehicle controller to determine vehicle speed. The electronic control incorporated in the accel- erator pedal is a non--contact, rotary hall effect sensor that varies output voltage based on the pedal position.

  • Page 43: Traction Motor

    72 to 88 in- -lb (8 to 9 N- -m) (Fig. 37). Ap- ply Toro battery terminal protector (see Special Tools) to motor connections after tightening nuts. Refer to Traction Motor and Traction Motor Service in...

  • Page 44: On--Board Battery Charger

    On- -board Battery Charger The Workman GTX Electric on--board battery charger is attached to the left side of the vehicle under the operator seat. Power input to the charger is provided at the charging receptacle by an AC power supply cord. A four (4) wire output cable with three (3) connectors is used to connect the charger to the vehicle electrical system.
  • Page 45 LED Pattern Cause Necessary Action Amber LED is flashing Reduced--power mode: Low Make sure that electrical outlet is providing adequate AC voltage or high internal voltage for charger. charger temperature. Remove operator seat assembly to allow additional cooling air to on--board battery charger. Also, make sure that charger cooling fins are clean.

  • Page 46: Controller

    89 to 106 in- -lb (10 to 12 N- -m) (Fig. 37). Apply Toro battery terminal protector (see Special Tools) to controller connections after tightening terminal screws. Refer to Controller in the Service and Repairs section of this chapter for controller removal and installation infor- mation.
  • Page 47 Status indicator light on dash in good condition, controller replacement may be is faulty. needed. The controller has failed. If necessary, contact your Authorized Toro Distributor for assistance. 1 Flash System inoperable. Turn key switch OFF, wait several seconds and turn key switch ON.
  • Page 48 ON position, and check for normal vehicle operation. If this fault continues to occur, contact your Authorized Toro Distributor for assistance. 11 Flashes A motor encoder (speed Turn the key switch to the OFF position, wait several sensor) fault occurred.
  • Page 49 ON position, and check for normal vehicle operation. If this fault continues to occur, contact your Authorized Toro Distributor for assistance. 13 Flashes An internal controller Turn the key switch to the OFF position, wait several...

  • Page 50: Diode Assembly

    Diode Assembly A diode assembly is included in the Workman GTX Elec- tric wire harness. This diode is used for for circuit logic to allow key switch current to the controller. The diode plugs into the wire harness near the controller and main contactor.

  • Page 51: Reverse Audio Alarm (If Equipped)

    Reverse Audio Alarm (If Equipped) The reverse alarm sounds when the direction switch (forward/reverse) is placed in the reverse position. The alarm is located under the seat assembly attached to the rear frame panel near the fuse block (Fig. 39). Testing IMPORTANT: Make sure to observe polarity on the alarm terminals when testing.

  • Page 52: Service And Repairs

    Service and Repairs Battery Service 95 to 105 in- -lb (10.8 to 11.8 N- -m) RIGHT FRONT Figure 41 1. Battery (8 used) 4. Battery cable with boots 7. Battery hold down (2 used) 2. Hex nut (2 used per battery) 5.

  • Page 53: Battery Removal

    Battery Removal (Fig. 41) CAUTION WARNING To prevent battery damage and personal injury, make sure that batteries are well supported as POTENTIAL HAZARD: they are removed from vehicle. Each battery The battery terminals, metal tools and metal ve- weighs approximately 66 pounds (30 kg). hicle parts could short together.

  • Page 54: Battery Inspection And Maintenance

    4. Check the battery case for dirt and oil. Clean the bat- tery with a solution of baking soda and water, then rinse 9. After connections are made, apply Toro battery ter- battery with clean water. minal protector (see Special Tools) to all battery posts and cable connectors to prevent corrosion.

  • Page 55: Battery Testing

    Battery Testing A. Remove battery filler caps. Do not add water prior to testing specific gravity of battery electrolyte. If When testing batteries in the Workman GTX Electric, it electrolyte level is low, add distilled water and charge is important to periodically test all batteries. Proper per- battery before performing specific gravity test.

  • Page 56: Battery Charging

    Battery Charging Battery Storage When the vehicle is not in use, it is recommended to If the vehicle will be stored for any period of time, use the keep the batteries charged by connecting the on--board on--board battery charger to fully charge batteries. After battery charger to an appropriate electrical outlet.
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  • Page 58: Traction Motor

    Traction Motor 90 to 110 in- -lb (10.2 to 12.4 N- -m) Antiseize Lubricant RIGHT FRONT Figure 44 1. Swing arm 6. Cable (motor W to controller M1) 10. Cable bracket 2. Transaxle assembly 7. Cable (motor V to controller M2) 11.
  • Page 59 Removal (Fig. 44) 9. Pull motor away from transaxle until motor shaft is disengaged from transaxle input shaft. Then, carefully 1. Park vehicle on a level surface, turn key switch to lift motor from vehicle taking care to not damage motor OFF, engage the parking brake and remove key from sensors or vehicle components while motor is being re- the key switch.
  • Page 60 Take care to not damage encoder (speed 105 in- -lb (10.8 to 11.8 N- -m). sensor) while installing motor. 9. After all cable connections are made, apply Toro bat- 5. Secure traction motor to transaxle: tery terminal protector (see Special Tools) to all battery posts and traction motor cable connectors to prevent A.
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  • Page 62: Traction Motor Service

    Traction Motor Service 25 to 33 in- -lb 72 to 88 in- -lb (2.8 to 3.8 N- -m) (8 to 10 N- -m) 25 to 33 in- -lb (2.8 to 3.8 N- -m) 71 to 97 in- -lb (8 to 11 N- -m) Figure 47 1.
  • Page 63 6. Remove four (4) socket head screws and lock wash- ers that secure drive and rear end brackets to stator as- sembly. Remove end brackets from stator. NOTE: After the traction motor has been disas- sembled, it is recommended that a new rear end bracket bearing be installed.
  • Page 64 4. Secure drive and rear end brackets to stator assem- Screw bly with four (4) socket head screws and lock washers. Tightening Tighten screws in two (2) stages using the sequence Sequence shown in Figure 51. Final torque on screws should be from 71 to 97 in- -lb (8 to 11 N- -m).
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  • Page 66: Controller

    Controller 90 to 110 in- -lb (10.2 to 12.4 N- -m) RIGHT FRONT Figure 52 1. Controller 4. Isolator retainer 7. Main contactor 2. Washer head screw (4 used) 5. Isolator 8. On- -board battery charger 3. Washer head screw 6.
  • Page 67 95 to 105 in- -lb (10.8 to 11.8 N- -m). 6. After all cable connections are made, apply Toro bat- tery terminal protector (see Special Tools) to all battery posts and controller cable connectors to prevent corro- sion.
  • Page 68 On- -board Battery Charger RIGHT FRONT Figure 55 1. On- -board battery charger 7. LED holder 12. Flange head screw (4 used) 2. Heat shrink tube 8. Charger function decal 13. Flange nut (4 used) 3. Cord set 9. LH seat base side 14.
  • Page 69 E. Carefully slide remote charger LED indicator out of LED holder in charger bracket. 4. After connections are made, apply Toro battery ter- minal protector (see Special Tools) to all battery posts to 6. Separate charger cable from the clips in the rear prevent corrosion.
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  • Page 71 Chapter 3B Electrical System - - Lithium Table of Contents GENERAL INFORMATION ..... SERVICE AND REPAIRS ..... Operator’s Manual .

  • Page 72: General Information

    General Information The Workman GTX Electric Lithium uses a 48 VDC elec- After performing any repair on electrical components on trical system that is an isolated circuit. The vehicle frame the vehicle, make sure that wiring is routed and secured is not used for any ground connections.

  • Page 73: Opening Battery Circuit

    Opening Battery Circuit WARNING Battery terminals, battery cables, or metal tools could short against metal components causing sparks. Sparks can cause the battery damage and high heat, resulting in personal injury. - - When removing or installing the batteries, do not allow the battery terminals or battery cables to touch any metal parts of the machine.
  • Page 74 After working on the vehicle electrical system, attach 5. Lower and secure cargo bed. battery conductors as follows (Fig. 2): 1. Make sure that key is removed from the key switch. 2. If installed, remove the rubber hose on the positive (+) cable.

  • Page 75: Vehicle Operation

    Electrical System Operation Vehicle Operation The Workman GTX Electric electrical system uses a 48 The vehicle controller is a sealed electronic logic device volt battery pack, an electric traction motor, a vehicle that uses inputs from several vehicle components to controller and numerous other electrical components to control motor speed and direction.

  • Page 76: Display

    Controller Area Network (CAN) bus system. Note: If the display is replaced for any reason, the sys- tem software needs to be reloaded (contact an Author- ized Toro Distributor for assistance). Figure 7 1. Run screen 5. Motor run hours 6.
  • Page 77 Figure 9 Figure 11 1. FORWARD position 1. Active fault indicator 2. Fault code When the direction switch is operated, the direction pos- An active fault code appears on the display when there ition appears on the display (Fig. 9). is an issue with the machine (Fig.

  • Page 78: Can Bis Communications

    START position for the components on the network to be support machine fault diagnosis and maintenance ser- activated. vices of the machine electrical control devices. The Toro Two specially designed, twisted wires form the CAN DIAG connector is located inside the dash.

  • Page 79: Sc1: Lithium--Ion Battery Controller

    If the SC1: Lithium--Ion Battery Controller is re- charger. placed for any reason, the machine software must be updated; contact an Authorized Toro Distributor for as- Note: When the key switch is set to the Off position, sistance. the BMS delays disconnecting the batteries from the machine for approximately 3 seconds to allow time for all of the other machine controllers to shut down.

  • Page 80: Sc2: Traction Controller

    (Fig. 14). The controller uses inputs from sev- any reason, the machine software must be updated; eral vehicle components to accurately control vehicle contact an Authorized Toro Distributor for assistance. speed, direction (forward and reverse) and regenerative braking. Controller inputs include key switch, direction...

  • Page 81: 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.
  • Page 82 Note: Outside of the USA, contact the appropriate government agency in your country for detailed regula- tions on shipping the lithium--ion batteries. Toro Part Number: 137- -9650 Figure 18 Electrical System Workman GTX Electric Lithium Page 3B - - 12...

  • Page 83: Troubleshooting

    Note: If “Unknown Cause” appears as an advisory de- If you are unable to clear this type of advisory, contact scription, a controller software issue may exist. an Authorized Toro Distributor. Workman GTX Electric Lithium Page 3B - - 13...

  • Page 84: Machine Faults

    Machine Faults Machine faults are generated by the machine control- Recent faults can be viewed via the display on the dash- lers to identify an electrical system malfunction (fault) board. A code appears after each fault. that occurs during machine operation. The fault IDs con- form to SAE J2012 standards.
  • Page 85 P0A54 Traction The motor was Current draw from 1) Cycle the key switch. Controller -- commanding more motors exceeds 2) Report incident to Toro Over Current current than the hardware and TAC if fault continues. This hardware and software limits.
  • Page 86 Battery contactor is imbalance. Distributor for assistance. opened. P0AFA Battery -- Low A battery voltage Battery contactor is Contact Toro TAC to recover Voltage was measured to be opened and BMS is the battery. lower than the offline. allowed threshold but is still recoverable.
  • Page 87 Failure P156D Traction An unexpected Wrong software If fault continues, contact Controller -- software error has parameter has been Toro TAC and replace the Internal occurred. detected. controller. Software Traction is disabled. Failure P156E Traction Motor The software is not The software will not Replace controller.
  • Page 88 Over Current measured to be harness for damaged wires. greater than the allowed threshold. 3) Contact an Authorized This is likely due to Toro Distributor for an internal assistance. imbalance in one or more of the batteries. P2BE8 Traction Motor...
  • Page 89 U1117 Source Controller received a The machine is Reprogram the machine Address message from disabled. using Toro DIAG. Contention another controller on Fault the CAN bus using the same source address. U1140 Communicatio The BMS never Battery contactor is...

  • Page 90: General Run Problems

    General Run Problems NOTE: Check the display on dash panel for possible faults whenever diagnosing vehicle electrical circuit problems. Problem Possible Causes Main contactor clicks, but vehicle will not operate. Battery charge is low (check battery discharge indicator on dash). Battery cables are loose, corroded or damaged.
  • Page 91 Problem Possible Causes Traction motor stops during operation. Battery charge is extremely low (check display on dash). Wiring to the traction motor components (e.g. main contactor, controller, traction motor) is loose, corroded or damaged (refer to Electrical Schematic in Chapter 6 -- Electrical Diagrams).

  • Page 92: Battery Charger Problems

    Ensure that the battery is in good condition. Code E--0--0--4 Lithium--ion battery controller (BMS) Contact an Authorized Toro or battery fault detected Distributor for assistance. Code E--0--0--7 Battery amp hour limit exceeded Check all battery cable connections for corrosion or damage.

  • Page 93: Battery Charger Fault Codes

    F--0--0--6, or F--0--0--7 minimum of 30 seconds, then reconnect the charger. The battery charger may require replacement (contact an Authorized Toro Distributor for assistance). Workman GTX Electric Lithium Page 3B - - 23 Electrical System...

  • Page 94: Component Testing

    Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. disconnect the harness wire connectors from the vehicle key switch before doing a continuity check on the key switch). Always check the item being When testing electrical components for continu- ity with a multimeter (ohms setting), make sure tested and the harness connector for damage or corro-...
  • Page 95 Fuse Testing CAUTION When testing fuses for continuity with a multime- ter (ohms setting), make sure that fuse is re- moved from circuit. 89 to 106 in- -lb (10 to 12 N- -m) IMPORTANT: Before removing fuse from con- troller (425 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).

  • Page 96: Can Bus

    OFF position and remove the key from the key switch. 2. The Toro DIAG connector is part of the CAN bus and is located inside the dash. Raise the hood and get access to the DIAG connector. Remove the con-...

  • Page 97: T: Display

    Note: If the display is replaced for any reason, system software needs to be reloaded (contact an Authorized Toro Distributor for assistance). Workman GTX Electric Lithium Page 3B - - 27 Electrical System...

  • Page 98: Sc1: Lithium--Ion Battery Controller

    If the SC1: Lithium--Ion Battery Controller is re- Figure 25 placed for any reason, the machine software must be 1. SC1: Lithium- -ion battery updated; contact an Authorized Toro Distributor for as- controller sistance. Testing the SC1: Lithium- -Ion Battery Controller...

  • Page 99: Sc2: Traction Controller

    89 to 106 in- -lb (10 to 12 N- -m) (Fig. 29). Apply Toro battery terminal protector (see Special Tools) to controller connections after tightening terminal screws. Refer to Controller in the Service and Repairs section of this chapter for controller removal and installation infor- mation.
  • Page 100 Status indicator light on dash components are in good condition, controller is faulty. replacement may be needed. The controller has failed. If necessary, contact your Authorized Toro Distributor for assistance. 1 Flash P156C System inoperable. Turn key switch OFF, wait several seconds and turn key switch ON.
  • Page 101 ON position, and check for normal vehicle operation. If this fault continues to occur, contact your Authorized Toro Distributor for assistance. Workman GTX Electric Lithium Page 3B - - 31 Electrical System...
  • Page 102 ON position, and check for normal vehicle operation. If this fault continues to occur, contact your Authorized Toro Distributor for assistance. 13 Flashes P156D An internal controller Turn the key switch to the OFF position, wait...
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  • Page 104: Key Switch

    Key Switch The Workman GTX Electric Lithium key switch has two (3) positions -- OFF, RUN and START. The START posi- tion is not used on this machine. The key switch is lo- cated on the dash. The key switch is used to energize the SC1: Battery Controller, SC2: Traction Controller and T: Display.

  • Page 105: Light Switch

    Light Switch The light switch allows the headlights to be turned ON and OFF. This rocker switch is located on the dash panel (Fig. 31). NOTE: The Workman GTX Electric headlight circuit is a 12 VDC circuit. Testing 1. Park vehicle on a level surface, turn key switch to OFF, engage the parking brake and remove key from the key switch.

  • Page 106: Direction Selector Switch

    Direction Selector Switch The direction selector switch allows the direction (for- ward/neutral/reverse) of the vehicle to be changed by the operator and is one of several inputs for the vehicle controller. The direction selector switch is located on the dash panel (Fig. 33). NOTE: Direction selector switch terminals 1, 2 and 3 are used on all Workman GTX Electric vehicles to change the direction of the vehicle.

  • Page 107: Supervision Speed Limit Switch

    Supervision Speed Limit Switch The supervision speed limit switch allows the maximum 6. If the speed limit switch tests correctly and circuit speed of the vehicle to be set to e ither performance (16 problem still exists, check wire harness for possible mph/26 kph) or economy (12 mph/19 kph).

  • Page 108: Parking Brake Switch

    Parking Brake Switch The parking brake switch is used as an input for the vehi- 8. If the brake switch tests correctly and a circuit prob- cle controller to identify when the parking brake is ap- lem still exists, check wire harness for problems (see plied.

  • Page 109: Usb Charge Port

    USB Charge Port The USB charge port can be used to charge or power electrical devices that use a USB port. The charge port has a 5 VDC output and is mounted to the dash (Fig. 39). If the vehicle wire harness is to be disconnected from the charge port, note the wire harness connections at the charge port for assembly purposes.

  • Page 110: Main Contactor (48 Vdc)

    Main Contactor (48 VDC) The main contactor provides provides current to the 48 9. Connect the conductors between the battery pack VDC system circuits (e.g. controller, traction motor) and and vehicle components (see Opening Battery Circuit in is energized by the controller when the key switch is ON. the General Information section of this chapter).

  • Page 111: Accelerator Pedal

    Accelerator Pedal The accelerator pedal is attached to the foot board un- der the dash (Fig. 43). This pedal is used as one of the inputs for the vehicle controller to determine vehicle speed. The electronic control incorporated in the accel- erator pedal is a non--contact, rotary hall effect sensor that varies output voltage based on the pedal position.

  • Page 112: Traction Motor

    General Information section of this chapter). When installing cables to motor terminals, torque jam nuts at terminals from 72 to 88 in- -lb (8 to 9 N- -m). Apply Toro battery terminal protector (see Special Tools) to motor connections after tightening nuts.

  • Page 113: On--Board Battery Charger

    If the plug does not fit into the wall receptacle, other grounded plug types are available; contact an author- ized Toro distributor. Do not change the charger or the power--supply--cord plug in any way. The battery pack charging operation is fully automated.

  • Page 114: Diode Assembly

    Diode Assembly A diode assembly is included in the Workman GTX Elec- tric wire harness. This diode is used for for circuit logic to allow key switch current to the controller. The diode plugs into the wire harness near the vehicle fuses next to the on--board battery charger.

  • Page 115: Can Bus Terminator Resistor

    CAN--bus; refer to CAN bus testing, wire harness drawings in Chapter 6 -- Electrical Draw- ings for additional information, or contact an Authorized Toro Distributor for assistance. 9. Lower and secure the hood. Workman GTX Electric Lithium...

  • Page 116: Reverse Audio Alarm (If Equipped)

    Reverse Audio Alarm (If Equipped) The reverse alarm sounds when the direction switch (forward/reverse) is placed in the reverse position. The alarm is located under the seat assembly attached to the rear frame panel below the supervision speed limit switch (Fig. 51). Testing IMPORTANT: Make sure to observe polarity on the alarm terminals when testing.
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  • Page 118: Service And Repairs

    Service and Repairs Battery Service 45 to 55 in- -lb (5 to 6.2 N- -m) 90 to 110 in- -lb 27 to 33 ft- -lb (10 to 12.4 N- -m) (36.5 to 44.5 N- -m) 72 to 88 in- -lb (8 to 10 N- -m) 90 to 110 in- -lb (10 to 12.4 N- -m)

  • Page 119: Battery Removal

    Battery Removal (Fig. 53) WARNING Battery terminals, battery cables, or metal tools could short against metal components causing sparks. Sparks can cause the battery damage and high heat, resulting in personal injury. - - When removing or installing the batteries, do not allow the battery terminals or battery cables to touch any metal parts of the machine.

  • Page 120: Caring For The Lithium--Ion Batteries

    (8 to 10 N--m), then apply battery terminal protector 2. If problems with the batteries exist, an advisory or Toro Part No. 107--0392 or a light layer of grease to the fault may be identified on the display; refer to battery terminals and cable connectors to reduce corro- Troubleshooting in this chapter.

  • Page 121: Battery Charging

    Battery Charging After charging, disconnect the charger from batteries to prevent minimal drain on the batteries. If charger is left When the vehicle is not in use, it is recommended to connected to the batteries for an extended period, it will keep the batteries charged by connecting the on--board shut off after the batteries are fully charged and will NOT battery charger to an appropriate electrical outlet.

  • Page 122: Traction Motor

    Traction Motor 90 to 110 in- -lb (10.2 to 12.4 N- -m) Antiseize Lubricant RIGHT FRONT Figure 55 1. Swing arm 6. Cable (motor W to controller M1) 10. Cable bracket 2. Transaxle assembly 7. Cable (motor V to controller M2) 11.
  • Page 123 Removal (Fig. 55) 9. Pull motor away from transaxle until motor shaft is disengaged from transaxle input shaft. Then, carefully 1. Park vehicle on a level surface, turn key switch to lift motor from vehicle taking care to not damage motor OFF, engage the parking brake and remove key from sensors or vehicle components while motor is being re- the key switch.
  • Page 124 Take care to not damage encoder (speed 88 in- -lb (8 to 9 N- -m). sensor) while installing motor. 9. After all cable connections are made, apply Toro bat- 5. Secure traction motor to transaxle: tery terminal protector (see Special Tools) to all battery posts and traction motor cable connectors to prevent A.
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  • Page 126: Traction Motor Service

    Traction Motor Service 25 to 33 in- -lb 72 to 88 in- -lb (2.8 to 3.8 N- -m) (8 to 10 N- -m) 25 to 33 in- -lb (2.8 to 3.8 N- -m) 71 to 97 in- -lb (8 to 11 N- -m) Figure 58 1.
  • Page 127 6. Remove four (4) socket head screws and lock wash- ers that secure drive and rear end brackets to stator as- sembly. Remove end brackets from stator. NOTE: After the traction motor has been disas- sembled, it is recommended that a new rear end bracket bearing be installed.
  • Page 128 4. Secure drive and rear end brackets to stator assem- Screw bly with four (4) socket head screws and lock washers. Tightening Tighten screws in two (2) stages using the sequence Sequence shown in Figure 62. Final torque on screws should be from 71 to 97 in- -lb (8 to 11 N- -m).
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  • Page 130: Sc2: Traction Controller

    SC2: Traction Controller 90 to 110 in- -lb (10 to 12.4 N- -m) 72 to 88 in- -lb (8 to 10 N- -m) 72 to 88 in- -lb (8 to 10 N- -m) 45 to 55 in- -lb (5 to 6.2 N- -m) 45 to 55 in- -lb (5 to 6.2 N- -m) 72 to 88 in- -lb...
  • Page 131 (8 to 10 N- -m) 88 in- -lb (8 to 9 N- -m). 5. After all cable connections are made, apply Toro bat- tery terminal protector (see Special Tools) to all battery posts and controller cable connectors to prevent corro- sion.

  • Page 132: Sc1: Lithium--Ion Battery Controller (Bms)

    SC1: Lithium- -Ion Battery Controller (BMS) 90 to 110 in- -lb (10 to 12.4 N- -m) 72 to 88 in- -lb (8 to 10 N- -m) 72 to 88 in- -lb (8 to 10 N- -m) 45 to 55 in- -lb (5 to 6.2 N- -m) 45 to 55 in- -lb (5 to 6.2 N- -m)
  • Page 133 72 to 88 in- -lb (8 to 9 N- -m). 5. After all cable connections are made, apply Toro bat- tery terminal protector (see Special Tools) to all battery posts and controller cable connectors to prevent corro- sion.
  • Page 134 On- -board Battery Charger 90 to 110 in- -lb (10 to 12.4 N- -m) 18 to 22 in- -lb (2 to 2.5 N- -m) 36 to 44 in- -lb (4 to 5 N- -m) 45 to 55 in- -lb (5 to 6.2 N- -m) Figure 69 1.
  • Page 135 5. Disconnect charger electrical conductors from vehi- B. Connect the charger interface wire harness (item cle connections: 5) to the machine wire harness (item 8). A. Unplug the power supply cord (item 3) from the C. Plug--in the power supply cord (item 3) to the bat- battery charger (item 1).
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  • Page 137 Chapter 4 Transaxle Table of Contents GENERAL INFORMATION ..... Operator’s Manual ......SPECIFICATIONS .

  • Page 138: General Information

    General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman GTX Electric vehicle. Refer to the Operator’s Manual for additional information when servicing the machine. Page 4 - - 2 Workman GTX Electric Transaxle...

  • Page 139: Specifications

    Specifications Item Description Transaxle Transaxle Fluid Capacity 0.7 quarts (0.66 liters) Transaxle Fluid 10W--30 Motor Oil Workman GTX Electric Page 4 - - 3 Transaxle...

  • Page 140: Service And Repairs

    Service and Repairs Transaxle Assembly 90 to 110 in- -lb (10.2 to 12.4 N- -m) 77 to 95 ft- -lb (105 to 128 N- -m) RIGHT FRONT Antiseize Lubricant Figure 1 1. Transaxle assembly 7. Motor thermistor connector 13. Flange head screw (4 used) 2.
  • Page 141 CAUTION CAUTION The drive motor and transaxle may be hot. To To prevent personal injury, make sure that avoid possible burns, allow all drive compo- transaxle is properly supported as it is removed nents to cool before working on the transaxle. from the vehicle.
  • Page 142 5. Apply antiseize lubricant to the splines of the trans- axle and motor shafts. 10.After connections are made, apply Toro battery ter- minal protector (see Special Tools) to all battery posts 6. Install traction motor to transaxle (see Traction Motor...
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  • Page 144: Transaxle Assembly Service

    Transaxle Assembly Service Apply Rapid- -Curing Anaerobic Adhesive Apply Rapid- -Curing Anaerobic Adhesive Apply Silicone Sealant 55 to 63 ft- -lb (75 to 85 N- -m) 15 to 20 ft- -lb (20 to 27 N- -m) 35 to 45 ft- -lb 16 to 24 ft- -lb (47 to 61 N- -m) (22 to 33 N- -m)
  • Page 145 Disassembly (Fig. 3) 4. Remove the intermediate shaft and gear assembly. A. Punch or drill a small hole in the center of each CAUTION end cap plug (item 10). Insert a suitable sheet metal screw into the hole until the the cap plug is driven from the housing bore.
  • Page 146 Assembly (Fig. 3) B. Position final drive gear over differential case and install four (4) flange head bolts and lock nuts (items 1. Assemble and install the input shaft. 17 and 18). Bolts should be installed from the differ- ential flange side Tighten lock nuts from 55 to 63 ft- - A.
  • Page 147 D. Apply light oil or grease to the inner lip of the oil E. Install the outer snap ring. seal and insert the shaft and bearing assembly into F. Repeat procedure for opposite side. the axle housing. Align the axle shaft splines with those in the differential assembly and drive the axle 5.
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  • Page 149 Chapter 5 Chassis Table of Contents GENERAL INFORMATION ..... Front Brake Caliper Service ....Operator’s Manual .

  • Page 150: General Information

    General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman GTX Electric vehicle. Refer to the Operator’s Manual for additional information when servicing the machine. Thread Forming Fasteners Numerous thread forming fasteners are used to secure Workman GTX frame components.

  • Page 151: Specifications

    Specifications Item Description Front and Rear Tires 205/65 -- 10 Pressure Range 24 to 30 PSI (165 to 207 kPa) Wheel Lug Nut Torque (all wheels) 75 to 95 ft--lb (102 to 128 N--m) Front Wheel Toe--In 0 + 0.125 inch (0 + 3 mm) Brake Fluid DOT 3 Standard Front Suspension Strut Pre--load Adjustment Position...

  • Page 152: Special Tools

    Special Tools Order special tools from your Toro Distributor. Spanner Wrench Use spanner wrench to rotate collar on front suspension strut and rear shock absorber. Collar rotation may be necessary to accommodate installed accessories or heavier vehicle loads. Make sure that vehicle is jacked up off the ground to allow spring to be at full extension before using spanner wrench.
  • Page 153 The legs attach to the rear frame with two (2) flange head screws and nuts for each leg (Fig. 5). Toro Part Number: TOR6040 Figure 4 1. Leg (2 used) 3. Flange nut (4 used) 2.

  • Page 154: Troubleshooting

    Troubleshooting Suspension and Steering Problem Possible Cause Front end is noisy. Front wheel lug nuts are loose. Front suspension struts are loose or worn. Front wheel bearings are loose or worn. Front end components (e.g. tie--rod, spindle, A--arm) are loose or worn.

  • Page 155: Brakes

    Suspension and Steering (continued) Problem Possible Cause Front end shimmies. Front wheel lug nuts are loose. Front wheel alignment (toe--in) is incorrect. Front wheel bearings are loose or worn. Tie rod ends are loose or worn. Steering shaft bearings or joints are loose or worn. Bushings in spindle or A--arm are loose or worn.
  • Page 156 Brakes (continued) Problem Possible Cause Brakes pull to either side. Tire pressure is incorrect or uneven between tires. Brake pads are worn or contaminated. Front wheel alignment (toe--in) is incorrect. Brake rotors are bent or damaged. Tires on same axle are unmatched. Brakes squeal.

  • Page 157: Adjustments

    Adjustments Adjust Parking Brake Checking Parking Brake (Fig. 6) 8. Adjust other rear wheel using steps 4 to 7 above. 1. Apply parking brake with brake lever on dash. 9. Check parking brake adjustment as described in Checking Parking Brake on this page. Make additional 2.

  • Page 158: Adjust Front Wheel Toe--In

    Adjust Front Wheel Toe- -in 1. Adjust tire pressures from 24 to 30 PSI (165 to 207 kPa) before checking front wheel toe--in. 2. Either have an operator on the vehicle operator’s seat or add weight to the driver’s seat equal to the aver- age operator who will run the vehicle.

  • Page 159: Service And Repairs

    Service and Repairs Check Tire Pressure The tire pressure range for front and rear tires is 24 to Higher pressures should be used for heavier payloads 30 PSI (165 to 207 kPa). at higher speeds. Do not exceed the maximum tire pres- sure.

  • Page 160: Front Wheels And Hubs

    Front Wheels and Hubs Lifted suspension models See text for tightening procedure 75 to 95 ft − (102 to 128 N − 35 to 40 ft − (48 to 54 N − Medium Strength Thread Locker 9 to 11 ft −...
  • Page 161 5. Remove the dust cap from the wheel hub. 8. While rotating the wheel hub by hand, torque the jam nut from 15 to 20 in-lb (1.7 to 2.3 N- -m). After tightening, 6. Remove the cotter pin, retainer, jam nut and tab make sure that the wheel hub does not have any free washer.

  • Page 162: Rear Wheels And Hubs

    Rear Wheels and Hubs Lifted suspension models 220 to 240 ft − (299 to 325 N − 35 to 40 ft − (48 to 54 N − Medium Strength Thread Locker 75 to 95 ft − (102 to 128 N −...
  • Page 163 Removal (Fig. 12) 4. Install the wheel hub to the transaxle shaft: 1. Park vehicle on a level surface, turn key switch OFF A. Install hardened spacer, wheel hub and then and remove key from the key switch. Do not apply park- thrust washer onto the transaxle shaft.

  • Page 164: Front Brake Calipers

    Front Brake Calipers RIGHT 9 to 11 ft- -lb (13 to 14 N- -m) FRONT 54 to 66 in- -lb (6.1 to 7.4 N- -m) 35 to 40 ft- -lb (48 to 54 N- -m) Medium Strength 108 to 132 in- -lb Threadlocker (12.3 to 14.9 N- -m) Figure 13...
  • Page 165 7. Inspect front brake rotor for wear or damage. Mini- 8. Bleed brakes (see Bleed Brake System in this sec- mum brake rotor thickness is 0.154” (3.9 mm). If brake tion). rotors need to be removed from vehicle, refer to Front Wheels and Hubs in this section.

  • Page 166: Front Brake Caliper Service

    Front Brake Caliper Service White Lithium Grease 27 to 33 ft- -lb (37 to 44 N- -m) BAF- -12 Assembly Lube Figure 15 1. Bolt (2 used) 4. Caliper bracket 7. Piston (2 used) 2. Caliper body 5. Square seal (2 used) 8.
  • Page 167 Disassembly (Fig. 15) Assembly (Fig. 15) 1. Remove two (2) bolts that secure brake caliper body 1. If caliper body was disassembled, install compon- to the caliper anvil. ents in caliper body: 2. Remove caliper anvil and then slide brake pads from A.

  • Page 168: Rear Brake Calipers

    Rear Brake Calipers 108 to 132 in- -lb 35 to 40 ft- -lb (12.3 to 14.9 N- -m) (48 to 54 N- -m) Medium Strength Threadlocker 54 to 66 in- -lb (6.1 to 7.4 N- -m) RIGHT 9 to 11 ft- -lb (13 to 14 N- -m) FRONT 220 to 240 ft- -lb...
  • Page 169 5. Disconnect brake line from rear brake caliper: C. Rotate brake lever on caliper toward front of vehi- cle and hold lever in place. Then, insert cable into A. Clean brake line area of brake caliper to prevent caliper bracket and slowly release brake lever to contamination of brake system.

  • Page 170: Rear Brake Caliper Service

    Rear Brake Caliper Service 30 to 35 ft- -lb (41 to 47 N- -m) 108 to 132 in- -lb (12.3 to 14.9 N- -m) Figure 18 1. Brake caliper assembly (LH shown) 3. Anti- -rattle spring (2 used) 5. Bleed screw 2.
  • Page 171 Disassembly (Fig. 18) 1. Remove two (2) caliper slide pins that secure brake pads to the caliper assembly. 2. Slide brake pads with attached anti--rattle springs from caliper. 3. Remove anti--rattle springs from brake pads. 4. Clean caliper components with brake cleaner. Inspection 1.

  • Page 172: Parking Brake Cables And Lever Assembly

    Parking Brake Cables and Lever Assembly FRONT RIGHT 200 to 230 in- -lb (23 to 25 N- -m) Figure 20 1. Parking brake lever 7. Clevis pin 13. Washer head screw (3 used) 2. Clevis pin 8. Cable equalizer bracket 14.
  • Page 173 Disassembly (Fig. 20) 3. Secure brake cables to parking brake lever assem- bly: 1. Park vehicle on a level surface, turn key switch OFF and remove key from the key switch. Chock wheels to A. Insert both brake cable ends through parking prevent the vehicle from moving.

  • Page 174: Brake Master Cylinder

    Brake Master Cylinder RIGHT FRONT 75 to 85 in- -lb (8.5 to 9.6 N- -m) Figure 22 1. Master cylinder 4. Brake pedal 7. Flange head screw (2 used) 2. Hair pin 5. Pedal mount 8. Front brake line 3. Clevis pin 6.
  • Page 175 Removal (Fig. 22) 1. Park vehicle on a level surface, turn key switch OFF, apply parking brake and remove key from the key switch. 2. Raise front hood to gain access to master cylinder. 3. Remove hair pin from the clevis pin that connects master cylinder to brake pedal.

  • Page 176: Brake Master Cylinder Service

    Brake Master Cylinder Service Disassembly (Fig. 24) 1. Thoroughly clean outside of master cylinder before disassembly. 2. Remove reservoir and flange seal. Push in on the push rod so the stop pin can be removed. 3. Disconnect lower end of the dust cover from the housing.

  • Page 177: Bleed Brake System

    Bleed Brake System IMPORTANT: To prevent contamination of the brake system, make sure to clean components before dis- assembly. 1. Park vehicle on a level surface, turn key switch OFF, apply parking brake and remove key from the key switch. 2.

  • Page 178: Steering Assembly

    Steering Assembly 16 to 20 ft- -lb (21.5 to 27 N- -m) FRONT RIGHT 16 to 20 ft- -lb 45 to 55 ft- -lb (21.5 to 27 N- -m) (61 to 75 N- -m) Figure 27 1. Steering rack assembly 7.
  • Page 179 8. Lift up on steering column assembly, slide lower 5. Secure lower steering shaft joint to the steering rack steering shaft joint from the steering rack assembly in- input shaft with cap screw and lock washer. Torque put shaft and remove steering column from vehicle. screw from 16 to 20 ft- -lb (21.5 to 27 N- -m).

  • Page 180: Steering Rack Assembly Service

    Steering Rack Assembly Service 45 to 50 ft- -lb (61 to 75 N- -m) 34 to 42 ft- -lb Medium Strength (47 to 57 N- -m) Thread Locker Figure 28 1. Tie rod end (2 used) 4. Bellows clamp (2 used) 7.
  • Page 181 Disassembly (Fig. 28) 3. Secure steering rack in a vise with soft jaws. Clamp on the mounting surfaces of the rack to prevent damage 1. For assembly purposes, measure the distance from to internal components. shoulder on the tie rod track to the location of the tie rod end (Fig.

  • Page 182: Front Suspension

    Front Suspension 200 to 230 in- -lb (23 to 25 N- -m) 200 to 230 in- -lb 80 to 90 ft- -lb (23 to 25 N- -m) (109 to 122 N- -m) 45 to 55 ft- -lb (61 to 75 N- -m) 27 to 33 ft- -lb (37 to 44 N- -m) 45 to 55 ft- -lb...
  • Page 183 3. Chock wheels not being removed. Use a jack to raise 2. If suspension strut assembly was removed from ve- front wheel that is to be removed off the ground. Support hicle, position the top of the strut assembly to the front vehicle with appropriate jack stands beneath the frame.

  • Page 184: Rear Suspension

    Rear Suspension Lifted suspension models 27 to 33 ft − (37 to 44 N − 77 to 95 ft − (104 to 128 N- -m) 27 to 33 ft − (37 to 44 N − 77 to 95 ft − (104 to 128 N −...
  • Page 185 3. Chock front wheels. Use a jack to raise rear wheels 2. Install rear shock absorber(s) if it was removed (Fig. off the ground. Support vehicle with appropriate jack 34): stands beneath the rear frame. A. Position shock absorber(s) to rear frame and 4.

  • Page 186: Swing Arm Mount Assembly

    Swing Arm Mount Assembly 140 to 160 ft- -lb (190 to 216 N- -m) RIGHT FRONT 27 to 33 ft- -lb (37 to 44 N- -m) Figure 36 1. Front frame 5. Isolator (upper portion) 8. Rear suspension mount 2. Swing arm 6.
  • Page 187 Removal (Fig. 36) Installation (Fig. 36) 1. Park vehicle on a level surface, turn key switch OFF 1. If rear suspension mount was removed, position and remove key from the key switch. Make sure to apply mount to front frame and secure with two (2) cap screws, parking brake washers and flange nuts.

  • Page 188: Seat Base

    Seat Base 18 to 22 in- -lb 40 to 45 in- -lb (2.1 to 2.4 N- -m) (4.6 to 5.0 N- -m) 90 to 110 in- -lb (10.2 to 12.4 N- -m) 18 to 22 in- -lb (2.1 to 2.4 N- -m) 40 to 45 in- -lb (4.6 to 5.0 N- -m) RIGHT...
  • Page 189 Disassembly (Fig. 37) 18 to 22 in- -lb 1. Park vehicle on a level surface, turn key switch OFF, (2.1 to 2.4 N- -m) apply parking brake and remove key from the key switch. 2. Remove seat base assembly with attached seats from vehicle.

  • Page 190: Dash

    Dash 40 to 45 in- -lb (4.6 to 5.0 N- -m) 90 to 100 in- -lb (10.2 to 11.3 N- -m) 40 to 45 in- -lb (4.6 to 5.0 N- -m) 40 to 45 in- -lb (4.6 to 5.0 N- -m) 18 to 22 in- -lb (2.1 to 2.4 N- -m) FRONT...
  • Page 191 Removal (Fig. 40) Installation (Fig. 40) 1. Park vehicle on a level surface, turn key switch OFF, NOTE: Do not fully tighten fasteners securing dash un- apply parking brake and remove key from the key til all fasteners are in place. switch.

  • Page 192: Front Fenders, Hood And Bumper

    Front Fenders, Hood and Bumper 7 to 13 in- -lb (0.8 to 1.4 N- -m) 18 to 22 in- -lb (2.1 to 2.4 N- -m) 18 to 22 in- -lb (2.1 to 2.4 N- -m) 40 to 45 in- -lb (4.6 to 5.0 N- -m) 200 to 230 in- -lb (23 to 25 N- -m)
  • Page 193 Removal (Fig. 41) Installation (Fig. 41) 1. Park vehicle on a level surface, turn key switch OFF, NOTE: Do not fully tighten fasteners securing body apply parking brake and remove key from the key components until all fasteners are in place. switch.

  • Page 194: Cargo Bed

    Cargo Bed RIGHT FRONT 133 to 147 in- -lb (15 to 16 N- -m) 140 to 170 in- -lb (16 to 19 N- -m) 27 to 33 ft- -lb (37 to 44 N- -m) Figure 42 1. Cap screw (2 used) 5.
  • Page 195 Disassembly 133 to 147 in- -lb 1. Park vehicle on a level surface, turn key switch OFF, (15 to 16 N- -m) 90 to 110 in- -lb apply parking brake and remove key from the key (10.2 to 12.4 N- -m) switch.
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  • Page 197: Electrical Schematic

    Chapter 6 Electrical Drawings Table of Contents ELECTRICAL DRAWING DESIGNATIONS ..ELECTRICAL SCHEMATIC ....Workman GTX Electric (Serial number below 403448000) .
  • Page 198 Electrical Drawing Designations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BLACK BROWN BLUE GREEN GRAY ORANGE PINK R or RD VIOLET W or WH WHITE Y or YE YELLOW Numerous harness wires used on Workman GTX Elec-...
  • Page 199 122--0525 REV. B BED LIFT SWITCH BED LIFT ACTUATOR KEY SWITCH BATTERY DISCHARGE INDICATOR CONTROLLER DIRECTION SELECTOR SWITCH TRACTION MOTOR STATUS INDICATOR LIGHT SUPERVISION SPEED LIMIT SWITCH Workman GTX Electric ACCELERATOR PEDAL Electrical Schematic Contactors shown de- - energized (Serial Numbers Below 403448000) Page 6 - - 3...
  • Page 200 122--1474 Rev. A Workman GTX Electric Electrical Schematic (Serial Numbers Above 403448001) (Contactors shown as de--energized) Page 6 - - 4...
  • Page 201 122--1662 Rev. B Workman GTX -- Lithium Electrical Schematic (Contactors shown as de--energized) Page 6 - - 5...
  • Page 202 122--0525 REV. B BED LIFT SWITCH BED LIFT ACTUATOR KEY SWITCH BATTERY DISCHARGE INDICATOR CONTROLLER DIRECTION SELECTOR SWITCH TRACTION MOTOR STATUS INDICATOR LIGHT SUPERVISION SPEED LIMIT SWITCH Workman GTX Electric (shown) ACCELERATOR ON Circuit PEDAL (NOT APPLIED) (Key Switch in ON Position) Power Current Control Current Indication Current...
  • Page 203 122--0525 REV. B BED LIFT SWITCH BED LIFT ACTUATOR KEY SWITCH BATTERY DISCHARGE INDICATOR CONTROLLER DIRECTION SELECTOR SWITCH TRACTION MOTOR STATUS INDICATOR LIGHT SUPERVISION SPEED LIMIT SWITCH Workman GTX Electric (shown) ACCELERATOR PEDAL Run Circuits (NOT APPLIED) (Forward) Power Current Control Current Indication Current Page 6 - - 7...
  • Page 204 122--0525 REV. B BED LIFT SWITCH BED LIFT ACTUATOR KEY SWITCH BATTERY DISCHARGE INDICATOR CONTROLLER DIRECTION SELECTOR SWITCH TRACTION MOTOR STATUS INDICATOR LIGHT SUPERVISION SPEED LIMIT SWITCH ACCELERATOR PEDAL Workman GTX Electric (shown) Battery Charging Circuit Power Current Control Current Indication Current Page 6 - - 8...
  • Page 205 122--0524 REV. F MAIN CONTACTOR BATTERY BATTERY COIL MAIN DISCHARGE DISCHARGE INDICATOR INDICATOR CONTACTOR 1 (B+) COIL (KEY POWER) MAIN ACCEL CONTACTOR PEDAL B+ TERM BATTERY STATUS DIRECTION DISCHARGE INDICATOR SELECTOR INDICATOR LIGHT 2 (B- -) SWITCH SUPERVISION SPEED LIMIT SWITCH Workman GTX Electric Wire Harness Drawing - - Main...
  • Page 206 122--0524 REV. F MAIN CONTACTOR BATTERY DISCHARGE INDICATOR 1 (B+) 2 (B--) 4 (KEY POWER) COIL B+ TERM SWITCH STATUS INDICATOR LIGHT DIRECTION SELECTOR SWITCH SUPERVISION SPEED LIMIT SWITCH Workman GTX Electric Wire Harness Diagram - - Main (Serial Numbers Below 403448000) Page 6 - - 10...
  • Page 207 122--1475 Rev. B Workman GTX Electric Wire Haness Drawing - - Main (Serial Numbers Above 403448001) Page 6 - - 11...
  • Page 208 122--1475 Rev. B Workman GTX Electric Wire Haness Diagram - - Main (Serial Numbers Above 403448001) Page 6 - - 12...
  • Page 209 122--1663 Rev. C Workman GTX Lithium Wire Haness Drawing - - Main Page 6 - - 13...
  • Page 210 122--1663 Rev. C Workman GTX Lithium Wire Haness Diagram - - Main Page 6 - - 14...
  • Page 211 122--0839 REV. A Workman GTX Electric Wire Harness Drawing and Diagram - - Cab Power Supply Page 6 - - 15...
  • Page 212 122--0730 REV. D Workman GTX Wire Harness Drawing and Diagram - - Cab Model 07142 Page 6 - - 16...
  • Page 213 122--0818 REV. A Workman GTX Wire Harness Drawing and Diagram - - Light Kit (Cab) Page 6 - - 17...
  • Page 214 122--0785 REV. A Workman GTX Wire Harness Drawing and Diagram - - Light Kit (No Cab) Page 6 - - 18...
  • Page 215 122--3995 REV. A Workman GTX Wire Harness Drawing and Diagram - - EU Tail Light Kit Page 6 - - 19...
  • Page 216 122--0894 REV. A Workman GTX Electric Wire Harness Drawing and Diagram - - Power Upgrade Page 6 - - 20...
  • Page 217 122--1027 Rev. A Workman GTX Electric Wireless Hourmeter Wire Haness Diagram Page 6 - - 21...
  • Page 218 122--1918 Rev. B Workman GTX Lithium Charger Interface Wire Haness Diagram Page 6 - - 22...

Table of Contents