Taylor-Dunn G0-010-00 Manuals

Taylor-Dunn G0-010-00 Manuals

Manuals and User Guides for Taylor-Dunn G0-010-00. We have 1 Taylor-Dunn G0-010-00 manual available for free PDF download: Service And Replacement Parts Manual

Taylor-Dunn G0-010-00 Service And Replacement Parts Manual

Taylor-Dunn G0-010-00 Service And Replacement Parts Manual (362 pages)

Brand: Taylor-Dunn | Category: Utility Vehicle | Size: 21.04 MB

Table of Contents

General Information 1 Chapter 1 General Information

7
- Table of Contents
  7
- Chapter 1
  8
- Model Number Designation
  8
- Vehicle Identification Number (Vin) Designation
  8
- Vehicle Information
  8
- Vin / Engine Number Location
  8
- Reference Information
  9
  - Replacement Keys
    9
  - Special Tools
    10
  - Master Special Tools Table
    11
- General Specifications
  18
  - Taylor-Dunn
    18
  - Clutching Chart
    19
- Misc. Specifications and Charts
  20
  - Conversion Table
    20
  - Sae Tap / Drill Sizes
    21
  - Metric Tap / Drill Sizes
    22
  - Decimal Equivalents
    23
Maintenance Chapter 2 Maintenance 2

25
- Chapter 2
  27
- Engine and Drivetrain Break-In
  27
- Maintenance
  27
- Periodic Maintenance Chart
  27
  - Pre-Ride / Daily Inspection
    27
  - Cold Weather Operation
    27
  - Break-In Period
    27
- Vehicle Break-In Period
  27
- Brake System Break-In
  28
- Cvt Break-In (Clutches / Belt)
  28
- Periodic Maintenance Chart Key
  28
- Periodic Maintenance Chart
  29
- Grease Lubrication Points
  31
- Component Quick Reference
  32
- Storage Tips
  33
- Lubricants / Service Products
  34
  - Lubricants, Maintenance and Service Products
    34
- Engine
  35
  - Compression and Leakdown Test
    35
  - Engine Oil Level
    35
  - Oil and Filter Change
    35
  - Breather Hose
    36
  - Breather Valve Inspection
    37
  - Valve Clearance
    37
- Cooling System
  38
- Fuel System and Air Intake
  44
  - Fuel System
    44
  - Fuel Lines
    44
  - Fuel Pump / Filter
    44
  - Vent Lines
    44
  - Throttle Pedal Inspection
    44
  - Air Filter Service
    44
  - Engine Air Intake Inspection
    45
  - Cvt Air Intake Inspection
    45
- Transmission and Gearcase
  46
  - Shift Cable Inspection
    46
  - Shift Cable Adjustment
    46
  - Transmission Lubrication
    46
- Final Drive / Wheel / Tire
  48
  - Wheel and Hub Torque Table
    48
  - CV Shaft Boot Inspection
    48
  - Wheel Removal
    48
  - Wheel Installation
    48
  - Tire Inspection
    48
  - Tire Pressure
    49
- Steering
  50
  - Steering Inspection Note
    50
  - Tie Rod End / Steering Inspection
    50
  - Wheel Toe Alignment Inspection
    51
  - Toe Adjustment
    51
  - Camber and Caster
    52
- Suspension
  53
- Brake System
  55
  - Brake Fluid Inspection
    55
  - Brake Hose and Fitting Inspection
    55
  - Brake Pad Inspection
    55
  - Brake Disc Inspection
    55
- Electrical and Ignition System
  57
  - Battery Maintenance
    57
  - Battery Fluid Level (Conventional Battery)
    57
  - Battery Removal
    57
  - Battery Installation
    58
  - Battery Storage
    58
  - Battery Charging
    58
  - Spark Plug Service
    58
  - Main Frame/Engine Ground
    59
Engine / Cooling System Chapter 3 Engine / Cooling System

61
- Chapter 3
  64
- Engine Lubrication Specifications
  64
- General Information
  64
- Oil Pressure Test
  64
- Special Tools
  64
- Engine Oil Flow Chart
  65
- Engine Specifications
  66
- Engine Service
  68
  - Accessible Engine Components
    68
  - Top-End Service (Engine in Chassis)
    68
  - Engine Removal
    68
  - Engine Installation
    71
  - Engine Break-In Period
    73
  - Engine Mounting and Torque Values
    74
  - Setting Tdc (Top-Dead-Center)
    75
- Cooling System
  76
- Troubleshooting
  88
  - Engine Cooling System
    88
- Engine
  90
- Engine Disassembly / Inspection - Top End
  105
  - Valve Cover Removal
    105
  - Camshaft / Carrier Removal
    105
  - Camshaft Sprocket Inspection
    106
- Engine / Cooling System
  107
  - Camshaft / Camshaft Bore Inspection
    107
  - Exhaust Camshaft Decompression Mechanism
    107
  - Cam Chain and Guide Service
    108
  - Cylinder Head Removal
    108
  - Cylinder Head Disassembly
    109
  - Cylinder Head Inspection
    110
  - Cylinder Head Warp Inspection
    110
  - Valve Inspection
    110
  - Combustion Chamber Cleaning
    111
  - Valve Seat Reconditioning
    112
  - Cylinder Removal
    114
  - Cylinder Inspection
    114
  - Piston Removal
    115
  - Piston-To-Cylinder Clearance
    116
  - Piston / Rod Inspection
    116
  - Piston Ring Installed Gap
    117
  - Honing to Oversize
    118
  - Cylinder Hone Selection / Honing Procedure
    118
  - Cleaning the Cylinder after Honing
    118
- Engine Assembly - Top End
  119
  - Piston Ring Installation
    119
  - Piston / Connecting Rod Assembly
    120
  - Cylinder Installation
    121
  - Cylinder Head Installation
    122
  - Valve Sealing Test
    123
  - Valve Clearance Check / Adjustment
    123
  - Valve Lash - Tappet Selection Matrix
    125
  - Exhaust Valve Lash - Tappet Selection Matrix
    125
  - Camshaft Installation / Timing
    126
  - Camshaft Timing - Quick Reference
    129
  - Valve Cover Installation
    130
- Engine Disassembly / Inspection - Lower End
  131
  - Crankcase Disassembly
    131
  - Flywheel / Stator Housing Removal
    131
  - Starter One-Way Clutch Inspection
    132
  - Starter One-Way Clutch Installation
    133
  - Flywheel Installation
    133
  - Stator Removal
    135
  - Stator / Stator Cover Installation
    135
  - Oil Pump Removal
    136
  - Oil Pump Assembly
    138
  - Crankcase Breather Valve / Hose
    140
  - Crankcase Separation
    140
  - Balance Shaft Removal / Inspection
    141
  - Crankshaft Removal
    142
  - Crankshaft Inspection
    143
- Engine Assembly - Lower End
  144
Fuel System Chapter 4 Fuel System

149
- Chapter 4
  151
- Efi Operation Overview
  151
- General Information
  151
- Initial Priming / Starting Procedure
  151
- Principal Components
  151
- Special Tools
  152
- Digital Wrench® - Diagnostic Connector
  153
- Fuel Pressure Gauge Adapter - Pa-48838
  153
- Fuel Pressure Gauge Kit - Pu-43506-A
  153
- Digital Wrench® - Download Website
  154
- Digital Wrench® Diagnostic Softwarepu-47063-B
  154
- Digital Wrench® Smartlink Module Kitpu-47471
  154
- Efi Component Locations
  155
  - Efi Component Locations - Left View
    155
  - Efi Component Locations - Right View
    156
- Line / Hose Routing
  157
  - Fuel Line Routing
    157
  - Vent Line Termination Fitting
    157
- Air Box / Intake System
  158
  - Air Box / Air Filter Assembly View
    158
  - Air Box Removal / Installation
    160
- Electronic Control Unit (Ecu)
  161
  - Ecu Overview
    161
  - Rpm Limit
    161
  - Ecu Service
    161
  - Ecu Replacement
    162
- Electronic Throttle Control
  163
  - Etc Overview
    163
  - Etc Test
    163
  - Etc Replacement
    163
  - Etc Learn Procedure
    163
- Pedal Position Sensor (Pps)
  164
  - Operation Overview
    164
  - Pps Test
    164
  - Pps Replacement
    164
- Fuel Tank / Pump / Sender
  165
  - Fuel Tank Assembly View
    165
  - Fuel Tank Removal
    165
  - Fuel Tank Installation
    166
  - Fuel Sender Test
    166
  - Fuel Pump Test
    167
  - Fuel Pump Replacement
    169
- Temperature / Manifold Absolute Pressure Sensor
  172
  - T-Map Overview
    172
  - T-Map Sensor Test
    172
  - T-Map Sensor Replacement
    172
- Crankshaft Position Sensor
  173
  - Cps Overview
    173
  - Cps Test
    173
    
    Resistance Test
    173
    
    Air Gap Test
    174
    
    Encoder Flywheel / Keyway Inspection
    174
  - Cps Replacement
    175
- Ignition Coil Overview
  176
  - Ignition Coil / Wire Overview
    176
  - Ignition Coil / Wire Test
    176
    
    Coil Pack Connections
    176
    
    Spark Plug Wire Connections
    176
- Fuel Injector
  177
  - Fuel Injector Overview
    177
  - Fuel Injector Test
    177
  - Fuel Injector Replacement
    178
  - Fuel Injector Troubleshooting
    179
- Engine Coolant Temperature Sensor
  180
  - Ect Overview
    180
  - Ect Sensor Test
    180
    
    System Operation Test
    180
    
    Resistance Vs. Temperature Test
    180
- Efi Diagnostics
  181
  - Service Notes - Fuel System
    181
  - Trouble Code Display (Etc)
    181
- Digital Wrench® Operation
  188
  - Digital Wrench® - Diagnostic Connector
    188
  - Digital Wrench® Diagnostic Software Overview
    188
  - Digital Wrench® Version and Update
    188
  - Digital Wrench® Updates
    189
  - Digital Wrench® Communication Errors
    190
  - Guided Diagnostics
    190
  - Digital Wrench® Serial Number Location
    190
  - Digital Wrench® Feature Map
    191
  - Ecu Replacement
    192
  - Ecu Reprogramming (Reflash)
    192
  - Etc Learn Procedure
    194
- Fuel System Troubleshooting
  195
  - Fuel Starvation / Lean Mixture
    195
  - Rich Mixture
    195
  - Poor Idle
    195
Cvt System Chapter 5 Cvt System

197
- Chapter 5
  198
- Cvt System Fastener Torques
  198
- General Information
  198
- Special Tools
  198
- Cvt System Overview
  199
  - Clutching Chart
    199
  - General Operation
    199
  - Drive Clutch Operation
    199
  - Driven Clutch Operation
    199
  - Cvt Break-In (Drive Belt / Clutches)
    200
  - Maintenance / Inspection
    200
  - Overheating / Diagnosis
    201
  - Operating in Low Gear
    201
- Cvt System Service
  202
  - Cvt Sealing, Guard, and Duct Components
    202
  - Cvt Disassembly
    203
  - Cvt Assembly
    204
- Drive Belt
  205
  - Belt Removal
    205
  - Belt Inspection
    205
  - Belt Installation
    206
  - Cvt Break-In (Drive Belt / Clutches)
    206
- Clutch Alignment / Offset / Center Distance
  207
  - Inspection
    207
  - Adjustment
    207
- Drive Clutch Service
  209
  - Drive Clutch Assembly View
    209
  - Clutch Disassembly
    210
  - Shift Weight Inspection
    211
  - Spider Removal
    212
  - Roller, Pin, and Thrust Washer Inspection
    213
  - Button to Tower Clearance Inspection
    213
  - Bearing Inspection
    214
  - Clutch Inspection
    214
  - Bushing Service
    215
  - Clutch Assembly
    218
- Driven Clutch Service
  219
  - Assembly View
    219
  - Clutch Disassembly / Inspection
    220
  - Clutch Assembly
    221
- Cvt System Troubleshooting
  222
  - Troubleshooting
    222
Transmission Chapter 6 Transmission

225
- Chapter 6
  226
- General Information
  226
- Special Tools, Transmission
  226
- Torque Specifications
  226
- Special Tools
  227
- Transmission Assembly View
  228
- Lubrication
  230
- Transmission Gears
  230
- Transmission Mounting and Torque Values
  230
- Shift Lever
  231
  - Removal
    231
  - Installation
    231
- Shift Cable
  232
  - Inspection
    232
  - Adjustment
    232
- Transmission Service
  233
  - Transmission Removal
    233
  - Transmission Installation
    234
- Transmission Internals Service
  237
  - Differential Operation
    237
  - Transmission Disassembly
    238
  - Planetary Differential Disassembly
    243
  - Planetary Differential Bushing Replacement
    244
  - Planetary Differential Assembly
    246
  - Gear / Shaft / Bearing Inspection
    247
  - Snorkel Gear Backlash Procedure
    248
- Troubleshooting
  255
  - Troubleshooting Checklist
    255
Final Drive Chapter 7 Final Drive

257
- Chapter 7
  258
- Final Drive Torque Table
  258
- General Information
  258
- Special Tools
  258
- Front Hub / Bearing
  259
  - Hub Removal / Inspection
    259
  - Hubstrut Bearing Replacement
    260
  - Hub Installation
    261
  - Front Hub/Wheel Exploded View
    262
- Rear Bearing Carrier
  263
  - Inspection
    263
  - Removal
    263
  - Disassembly
    264
  - Assembly
    264
  - Installation
    265
- Rear Drive Shaft
  266
  - Rear Drive Shaft Removal
    266
  - Rear Drive Shaft Installation
    266
- Drive Shaft Service
  267
Steering / Suspension Chapter 8 Steering / Suspension

273
- Chapter 8
  274
- General Information
  274
- Special Tools
  274
- Torque Specifications
  274
- Steering Assembly
  275
  - Steering Assembly View
    275
  - Steering Wheel Removal
    277
  - Steering Shaft Bearing Replacement
    277
  - Steering Shaft / Steering Rack Removal
    278
- Front Strut
  280
  - Assembly View
    280
  - Front Strut Cartridge Replacement
    281
  - Ball Joint Replacement
    281
- Rear A-Arms
  283
  - Removal / Replacement
    283
  - Installation
    284
  - Assembly View
    286
- Rear Stabalizer Bar / Linkage
  286
  - Removal / Installation
    286
  - Assembly View
    287
- Shocks / Springs
  287
  - Shock Removal / Installation
    287
  - Shock Replacement
    287
Brake System Chapter 9 Brake System

289
- Brake Service Specifications
  291
- Chapter 9
  291
- General Information
  291
- Special Tools
  291
- Torque Specifications
  291
- Brake System Notes
  292
  - Brake System Service Notes
    292
  - Brake Noise Troubleshooting
    292
  - Hydraulic Brake System Operation
    293
- Brake System Assembly View
  294
  - Assembly View
    294
- Master Cylinder
  295
  - Removal
    295
  - Installation
    295
  - Brake Pressure Switch
    295
- Brake Pedal
  296
  - Pedal Removal
    296
  - Pedal Installation
    296
- Brake Service Procedures
  297
  - Brake Bleeding / Fluid Change
    297
  - Brake Burnishing Procedure
    298
- Front Brake Pads
  299
  - Pad Removal / Disassembly
    299
  - Brake Pad Inspection
    299
  - Pad Assembly / Installation
    300
  - Pad Adjustment
    300
- Front Caliper
  301
  - Front Caliper Assembly View
    301
  - Front Caliper Removal
    302
  - Front Caliper Disassembly
    302
  - Front Caliper Inspection
    302
  - Front Caliper Assembly
    303
  - Front Caliper Installation
    303
- Front Brake Disc
  305
  - Disc Inspection
    305
  - Disc Removal / Replacement
    305
- Rear Brake Pads
  306
  - Pad Removal
    306
  - Brake Pad Inspection
    306
  - Rear Pad Installation
    307
- Rear Calipers
  308
  - Caliper Assembly View
    308
  - Caliper Removal
    309
  - Rear Caliper Disassembly
    309
  - Rear Caliper Inspection
    310
  - Rear Caliper Assembly
    310
  - Rear Caliper Installation
    310
- Rear Brake Disc
  312
  - Disc Runout
    312
  - Brake Disc Inspection
    312
  - Disc Removal / Replacement
    312
- Troubleshooting
  314
  - Pedal Vibration
    314
  - Caliper Overheats (Brakes Drag)
    314
  - Brakes Lock
    314
Body / Frame Chapter 10 Body / Frame

315
- Chapter 10
  316
- General Information
  316
- Special Tools
  316
- Torque Specifications
  316
- Chassis / Body Assembly Views
  317
  - Cab Frame Assembly View
    317
  - Dash Instruments / Controls
    318
  - Hood / Dash / Front Fascia
    319
  - Floor / Rear Fenders
    320
  - Seat Mounting / Seat Belts
    321
- Rear Cargo Box
  322
  - Cargo Box - Tailgate / Box Support
    322
  - Box Removal
    324
  - Box Installation
    324
- Body Component Removal
  325
  - Lower Seat Base
    325
  - Front Bumper
    325
  - Front Fender
    325
  - Rear Fender
    326
  - Hood / Dash
    326
  - Windshield
    326
  - Roof
    327
  - Floors
    331
- Decals
  332
  - Decal Replacement
    332
Electrical Chapter 11 Electrical

333
- Battery Conductance Analyzer
  335
- Chapter 11
  335
- Components under Hood
  335
- Electrical Service Notes
  335
- General Information
  335
- Special Tools
  335
- Switches / Controls
  336
  - Brake Pressure Switch
    336
  - Turf Switch
    336
  - Differential Solenoid
    336
    
    Rear Differential Solenoid Operation
    336
  - Ignition / Headlight Switch
    337
- Instrument Cluster
  338
  - Overview
    338
  - Rider Information Display
    339
  - Information Display Area
    340
  - Diagnostic Mode
    342
  - Instrument Cluster Pinouts
    343
  - Instrument Cluster Removal
    343
  - Instrument Cluster Installation
    343
- Vehicle Speed Sensor
  344
  - Speed Sensor Location
    344
  - Speed Sensor Testing
    344
- Headlights
  345
  - Headlight Adjustment
    345
  - Headlight Bulb Replacement
    345
  - Headlight Housing Removal
    346
  - Headlight Housing Installation
    346
- Tail Light / Brake Light
  347
  - Led Lamp Replacement
    347
- Cooling System
  348
  - Fan Control Circuit Operation
    348
  - Fan Control Circuit Bypass Test
    348
- Ignition Coil
  349
  - Operation Overview
    349
  - Ignition Coil Tests
    349
    
    Primary Test
    349
    
    Secondary Tests
    349
  - Ignition Coil and Ht Lead Replacement
    350
- Relays
  351
  - Operation
    351
- Fuses / Circuit Breaker
  352
  - Operation
    352
- Charging System
  353
  - Current Draw - Key off
    353
    
    Charging System "Break Even" Test
    353
  - Charging System Alternator Tests
    353
  - Charging System Testing Flow Chart
    355
- Battery Service
  356
  - Battery Terminals / Bolts
    356
  - Battery Terminal Block
    356
  - Battery Activation
    356
  - Battery Inspection
    357
  - Battery Removal / Installation
    357
  - Conventional Battery Testing
    358
  - Ocv - Open Circuit Voltage Test
    358
  - Voltage Drop Test
    358
  - Specific Gravity Test
    358
  - Load Test
    359
  - Charging Procedure
    359
  - Off Season Storage
    359
- Starter System
  360
  - Troubleshooting
    360
    
    Starter Motor Does Not Run
    360
    
    Starter Motor Turns over Slowly
    360
    
    Starter Motor Turns - Engine Does Not Rotate
    360
  - Starter Drive
    360
  - Starter Solenoid Bench Test
    361
  - Starter Solenoid Operation
    361
  - Starting System Testing Flow Chart
    362

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