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Taylor-Dunn G0-010-00 User Manual

Taylor-Dunn G0-010-00
362 pages
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The Best Way
To Go
About Your
Business
TAYLOR-DUNN
®
Originally Published [10/23/2018]
Revision [ ], contents subject to change
without notice Taylor-Dunn
®
Mfg.
2114 W. Ball Rd.
Anaheim, CA 92804
(800)-688-8680
(714) 956-4040
(FAX) (714) 956-0504
Visit our Web site: www.taylor-dunn.com
READ THE OPERATOR’S MANUAL BEFORE OPERATING
THIS VEHICLE.
The operator’s manual contains important information
regarding the safe operation of this vehicle.
WARNING
Service Manual
MANUAL #:
2019 G-100
Model Numbers:
G0-010-00
9929758
10/23/2018

Table of Contents

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Taylor-Dunn G0-010-00 Specifications

General IconGeneral
BrandTaylor-Dunn
ModelG0-010-00
CategoryUtility Vehicle
LanguageEnglish

Summary

Service Manual

Introduction

Manual's purpose, scope, and recommendations for users.

Safety Warnings

Explains signal words and symbols used for safety throughout the manual.

Chapter 1: General Information

Vehicle Information

Details vehicle identification, model number, and VIN designations.

Reference Information

Provides information on replacement keys and special tools.

General Specifications

Lists key dimensions, capacities, and weight specifications for the vehicle.

Chapter 2: Maintenance

Periodic Maintenance Chart

Outlines scheduled maintenance intervals and tasks for the vehicle.

Engine Maintenance

Covers engine-related maintenance procedures like oil changes and compression tests.

Cooling System Maintenance

Details coolant level checks, radiator service, and thermostat replacement.

Fuel System and Air Intake Maintenance

Covers maintenance of fuel lines, pump, filter, and air filter service.

Final Drive, Wheel, and Tire Maintenance

Outlines maintenance for wheels, tires, and final drive components.

Steering Maintenance

Covers steering inspection, tie rod end checks, and toe alignment.

Brake System Maintenance

Details brake fluid inspection, pad and disc inspection, and caliper service.

Electrical and Ignition System Maintenance

Covers battery maintenance, charging, and spark plug service.

Chapter 3: Engine / Cooling System

Special Tools for Engine and Cooling System

Lists special tools required for engine and cooling system service.

Engine Lubrication Specifications

Lists oil capacity, type, and minimum pressure specifications for the engine.

Engine Removal

Provides instructions and precautions for removing the engine from the vehicle.

Cooling System Specifications

Lists specifications for coolant temperature and system capacity.

Coolant Drain / Radiator Removal

Provides step-by-step instructions for draining coolant and removing the radiator.

Thermostat Replacement

Details the procedure for replacing the engine thermostat.

Cooling System Bleeding Procedure

Explains how to bleed air from the cooling system after service.

Engine Specifications

Provides detailed specifications for camshaft, cylinder head, cylinder, and valve components.

Engine Disassembly / Inspection - Top End

Covers procedures for disassembling and inspecting the top end of the engine.

Valve Clearance Check / Adjustment

Explains how to check and adjust valve clearance on a cold engine.

Chapter 4: Fuel System

Special Tools for Fuel System

Lists special tools required for fuel system diagnostics and service.

EFI Component Locations

Identifies the locations of major EFI system components on the vehicle.

Air Box / Intake System Service

Details the air box assembly and procedures for its removal and installation.

Electronic Control Unit (ECU) Service

Provides an overview of the ECU's function and basic service information.

ECU Reprogramming (Reflash)

Explains how to reprogram (reflash) the ECU using Digital Wrench software.

Pedal Position Sensor (PPS) Service

Covers the operation, testing, and replacement of the accelerator pedal position sensor.

Fuel Tank / Pump / Sender Service

Details the removal, installation, and testing of the fuel tank, pump, and sender assembly.

Fuel Pump Replacement

Provides instructions for safely replacing the fuel pump assembly.

T-MAP Sensor Replacement

Provides instructions for replacing the Manifold Absolute Pressure sensor.

Crankshaft Position Sensor (CPS) Service

Details the function, testing, and replacement of the crankshaft position sensor.

Ignition Coil Tests

Explains how to test the ignition coil's primary and secondary resistance.

Fuel Injector Replacement

Provides instructions for replacing the fuel injector.

Engine Coolant Temperature Sensor (ECT) Testing

Details testing procedures for the engine coolant temperature sensor.

Trouble Code Display (ETC)

Explains how to access and interpret diagnostic trouble codes from the instrument cluster.

Chapter 5: CVT System

CVT System Overview

Provides an overview of the CVT system, including its components and operation.

CVT Break-in (Drive Belt / Clutches)

Outlines the proper break-in procedure for CVT clutches and drive belt.

Maintenance and Inspection

Lists items to be inspected and maintained for optimal CVT performance.

Overheating / Diagnosis

Provides troubleshooting steps for CVT overheating and related issues.

CVT Disassembly

Provides step-by-step instructions for disassembling the CVT system.

Drive Belt Service

Covers drive belt removal, inspection, and installation procedures.

Clutch Alignment / Offset / Center Distance

Outlines procedures for inspecting and adjusting clutch alignment.

Drive Clutch Service

Covers the assembly view and disassembly of the drive clutch.

Bushing Service

Covers the process of replacing bushings in the clutch components.

Clutch Assembly (Drive)

Provides instructions for assembling the drive clutch.

Driven Clutch Service

Covers the assembly view and disassembly/inspection of the driven clutch.

Clutch Assembly (Driven)

Provides instructions for assembling the driven clutch.

CVT System Troubleshooting

Offers solutions for common CVT system issues like erratic RPM and belt slippage.

Chapter 6: Transmission

General Information and Torque Specifications

Provides general info, torque specs, and special tools for the transmission.

Transmission Assembly View

Shows an exploded view of the transmission components.

Transmission Mounting and Torque Values

Details torque specifications for mounting the transmission.

Shift Lever Service

Covers removal and installation procedures for the shift lever assembly.

Shift Cable Inspection and Adjustment

Details inspection and adjustment procedures for the shift cable.

Transmission Removal

Outlines the procedure for removing the transmission from the vehicle.

Transmission Installation

Provides instructions for installing the transmission into the vehicle frame.

Differential Operation

Explains the operation of the differential lock and unlock modes.

Transmission Disassembly

Provides step-by-step instructions for disassembling the transmission.

Planetary Differential Bushing Replacement

Guides the replacement of bushings in the planetary differential components.

Gear / Shaft / Bearing Inspection

Covers inspection of transmission gears, shafts, and bearings.

Snorkel Gear Backlash Procedure

Explains how to adjust snorkel gear backlash.

Transmission Troubleshooting Checklist

Lists common transmission issues and their potential causes and remedies.

Chapter 7: Final Drive

Special Tools and Torque Specifications

Lists special tools and torque specs for final drive service.

Front Hub / Bearing Service

Covers hub removal, inspection, and bearing replacement procedures.

Hub Installation

Provides instructions for installing the front wheel hub assembly.

Rear Bearing Carrier Service

Details inspection, removal, disassembly, assembly, and installation of the rear bearing carrier.

Rear Drive Shaft Service

Covers the removal and installation procedures for the rear drive shaft.

CV Joint and Boot Replacement

Details the procedure for replacing CV joints and boots.

Chapter 8: Steering / Suspension

General Information and Torque Specifications

Provides general info, torque specs, and special tools for steering and suspension.

Steering Assembly Service

Covers the steering assembly view and component removal/installation.

Steering Wheel Removal

Provides instructions for removing the steering wheel.

Steering Shaft Bearing Replacement

Guides the replacement of steering shaft bearings.

Steering Shaft / Steering Rack Removal

Details the procedure for removing the steering shaft and rack.

Front Strut Service

Covers the assembly view and replacement of the front strut cartridge.

Ball Joint Replacement

Provides instructions for replacing ball joints in the front suspension.

Rear A-Arms Service

Details the removal, replacement, and installation of rear A-arms.

Rear Stabilizer Bar / Linkage Service

Provides instructions for removing and installing the rear stabilizer bar and linkage.

Shocks / Springs Service

Covers the assembly view and replacement of the vehicle's shock absorbers.

Chapter 9: Brake System

General Information and Torque Specifications

Provides general info, brake service specs, torque specs, and special tools.

Brake System Service Notes

Offers general tips for maintaining proper brake system function and pad life.

Brake Noise Troubleshooting

Discusses common causes of brake noise and their remedies.

Hydraulic Brake System Operation

Explains the fundamental operation of the hydraulic brake system.

Master Cylinder Service

Details the removal, installation, and brake pressure switch.

Brake Pedal Service

Covers the removal and installation of the brake pedal assembly.

Brake Bleeding / Fluid Change

Outlines the procedure for bleeding the brake system and changing the fluid.

Front Brake Pads Service

Details the removal, inspection, assembly, installation, and adjustment of front brake pads.

Front Caliper Service

Covers the assembly view, removal, disassembly, inspection, assembly, and installation of the front caliper.

Front Brake Disc Service

Explains how to inspect, remove, and replace the front brake disc.

Rear Brake Pads Service

Details the removal, inspection, and installation of rear brake pads.

Rear Caliper Service

Covers the assembly view, removal, disassembly, inspection, assembly, and installation of the rear caliper.

Rear Brake Disc Service

Explains how to inspect, remove, and replace the rear brake disc.

Brake System Troubleshooting

Lists common brake system issues and their potential causes and remedies.

Chapter 10: Body / Frame

General Information for Body and Frame

Provides general info, torque specs, and special tools for body and frame.

Cab Frame Assembly View

Shows an exploded view of the cab frame components.

Dash Instruments and Controls

Identifies the components of the dash and instrument panel.

Hood, Dash, and Front Fascia

Shows an exploded view of the hood, dash, and front fascia components.

Rear Cargo Box Service

Shows an exploded view of the rear cargo box, tailgate, and support components.

Box Removal and Installation

Provides instructions for removing and installing the rear cargo box.

Body Component Removal

Covers removal of various body components like seat base, bumper, and fender.

Windshield Service

Covers windshield removal and installation procedures.

Roof Service

Details the procedure for removing and installing the vehicle roof.

Floors Removal

Details the procedure for removing the vehicle floor panels.

Decal Replacement

Explains the procedure for replacing decals, including flame treatment.

Chapter 11: Electrical

Special Tools for Electrical System

Lists special tools required for electrical system diagnosis and service.

Battery Conductance Analyzer

Explains the use of a conductance analyzer for battery testing.

Switches and Controls

Covers brake pressure switch, turf switch, and differential solenoid.

Instrument Cluster Overview

Provides an overview and details of the instrument cluster displays.

Headlights Service

Covers headlight adjustment and bulb replacement.

Tail Light / Brake Light Replacement

Details the procedure for replacing LED tail and brake lights.

Charging System Tests

Covers current draw tests, break-even tests, and alternator tests.

Battery Service Procedures

Details battery terminal service, inspection, activation, and removal/installation.

Conventional Battery Testing

Details OCV, Voltage Drop, and Specific Gravity tests for battery condition.

Load Test

Explains how to perform a load test to check battery capacity under load.

Charging Procedure

Provides instructions for charging the vehicle battery.

Starter System Troubleshooting

Covers troubleshooting for starter motor issues and starter drive replacement.

Starting System Testing Flow Chart

A flowchart to diagnose starting system problems.

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