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Taylor-Dunn Break-In and Inspection

This article explains how to properly break in your Taylor-Dunn commercial vehicle.  

Vehicle Inspection  
Before performing the break-in procedures, inspect the vehicle immediately after delivery. Use the following guidelines to help identify any obvious problems:  

  • Examine the contents of all packages and accessories that may have come in separate packages along with the vehicle.  
  • Make sure everything listed on the packing slip is there.  
  • Check that all wire connections, battery cables and other electrical connections are secure.  
  • Check battery cells to be sure they are filled.  
  • Check the tire pressure and tightness of the lug nuts.  
  • Check for any signs of damage. 

Note: New front wheel bearing adjustment must be inspected after the first 20 hours of operation. This includes new vehicle installations. Failure to inspect the bearings after the break-in period may result in premature failure of the bearings. 

Check the operation of each of the following components:  

  • Accelerator pedal  
  • Brake pedal  
  • Parking brake  
  • Key switch  
  • Direction Control Switch  
  • Reverse Warning Alarm (if equipped)  
  • All lights  
  • Steering wheel  
  • Horn 
  • Operator Presence Switch (if equipped) 
  • Shift lever  

What to Do If a Problem Is Found 
If there is a problem or damage as a result of shipping, note the damage or problem on the bill of lading and file a claim with the freight carrier. The claim must be filed within 48 hours of receiving the vehicle and its accessories. Also, notify your Taylor-Dunn Dealer of the claim.  

If there is any problem with the operation of the vehicle, DO NOT OPERATE THE VEHICLE. Immediately contact your Taylor-Dunn Dealer and report the problem. The report must be made within 24 hours of receiving the vehicle and its accessories. The only personnel authorized to repair, modify or adjust any part of this or any Taylor-Dunn vehicle is a factory-authorized service technician. To find a dealer near you, use the Dealer Locator

This section applies to all Taylor-Dunn models except the G-100. 

After the first 10 to 25 hours of operation, perform the following on your vehicle. Check your Operator Manual to determine the exact hour to perform break-in maintenance.  

  • Re-torque wheel nuts.  
  • Inspect all hardware for tightness. 
  • Adjust front wheel bearings.  
  • Check water level of batteries.  

New Battery Break-In     
New batteries require a break-in period of up to 40 cycles. The batteries will not have their full capacity during this break-in period and may result in longer charging times. During this period, it is best not to opportunity charge the vehicle. Make sure the vehicle is discharged down between 20 to 50 percent capacity and allowed to fully charge, completing the full charge cycle.   

The break-in period for your new G-100 vehicle is the first 20 hours of operation or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully.  

Note: Excessive heat buildup during the first 3 hours of operation will damage close fitted engine parts and drive components. Do not operate at full throttle or high speeds during the first 3 hours of use. 

To break in the engine and drivetrain, follow these steps:  

1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline.  

2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the safe operating range.  

3. Complete the New Operator Driving Procedures. See your Operator and Service Manual for more information. 

4. Avoid aggressive use of the brakes.  

5. Vary throttle positions. Do not operate at sustained idle.  

6. Pull only light loads.  

7. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist.  

8. During the break-in period, change both the oil and the filter at 25 hours or one month.  

9. Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter. 

Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors.  

A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high-speed operation during the break-in period. If a belt fails, always clean any debris from the CVT intake and outlet duct and from the clutch and engine compartments when replacing the belt. 

For more information, refer to your Operator and Service Manual.  
For assistance, see your authorized Polaris Commercial dealer. To find a dealer near you, use the Dealer Locator.

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