Polaris Ranger EV 2011 Page 61 Owner'S Manual Download

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MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Perform these procedures more often for vehicles subjected to severe use.

Have an authorized POLARIS dealer perform these services.

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours

Calendar

Miles

(Km)

Steering

Pre-Ride

Inspect and make

adjustments as needed.

See Pre-Ride Checklist on

page 38.

Front suspension

Pre-Ride

Rear suspension

Pre-Ride

Tires

Pre-Ride

Brake fluid level

Pre-Ride

Brake pedal travel

Brake system

Pre-Ride

Wheels/fasteners

Pre-Ride

Frame fasteners

Pre-Ride

Batteries

Pre-Ride

Headlamp/tail
lamp

Daily

Check operation; apply
dielectric grease if replacing

Brake pad wear

10 H

Monthly

Inspect periodically

Battery terminals

25 H

Monthly

Inspect and clean (page 73)

Battery fluid levels

25 H

Monthly

Add as needed (page 74)

Battery terminals

25 H

Monthly

Inspect; torque to
specification

Front gearcase oil
(if equipped)

25 H

Monthly

Inspect level; change yearly

Rear gearcase oil
(if equipped)

25 H

Monthly

Inspect level; change yearly

General
lubrication

50 H

3 M

Lubricate all fittings, pivots,
cables, etc.

Steering

50H

6 M

Lubricate

Front Suspension

50 H

6 M

Lubricate

Rear Suspension

50 H

6 M

Lubricate

Wiring

100 H

12 M

Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.

Front wheel
bearings

100 H

12 M

Inspect; replace as needed

Brake fluid

200 H

24 M

Change every two years

Toe adjustment

Inspect periodically; adjust
when parts are replaced

Headlight aim

Adjust as needed

Summary of Contents for Ranger EV 2011

Page 1: ...PMS 419 Owner s Manual for Maintenance and Safety RANGER EV...

Page 2: ...RNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or deat...

Page 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW...

Page 4: ...e With more than ONE passenger or with passengers under age twelve or who cannot comfortably reach the floor and hand holds On paved surfaces pavement may seriously affect handling and control With no...

Page 5: ...pro duced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but in...

Page 6: ...and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication...

Page 7: ...3 TABLE OF CONTENTS Introduction 4 Safety 7 Features and Controls 22 Operation 38 Maintenance 56 Specifications 80 POLARIS Products 82 Troubleshooting 83 Warranty 84 Maintenance Log 90 Index 92...

Page 8: ...ading the manual The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTI...

Page 9: ...per precautions Read this owner s manual Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle This vehicle is an ADULT VEH...

Page 10: ...ur key number and mating it with one of your existing keys The key switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame VIN _____...

Page 11: ...cause serious injury or death Never carry passengers in cargo box Maximum Box Load 500 lbs 227 kg IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TI...

Page 12: ...rtment Improper con tact between battery terminals can result in electrical shorts ELECTRICAL SHORTS can result in burns Do not use high pressure water to wash the battery compart ment Damage to the v...

Page 13: ...orage or weather cover on vehicle or with the cab enclosure doors closed as fire and explosion are possible Refer to Owner s Manual or contact your local POLARIS dealer with any questions TO MAXIMIZE...

Page 14: ...g speed 10 MPH 16 km h drivetrain damage will occur if towed faster than 10 MPH 16 km h Set parking brake before leaving vehicle Turn Power On key to Off posi tion and remove when not in use When towi...

Page 15: ...s pavement may seriously affect handling and control With non POLARIS approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover could cause severe injury or...

Page 16: ...ver and any passenger must wear helmet eye protection and seat belt at all times Always keep arms and legs inside the cab frame while the vehicle is in motion Always keep both hands on the steering wh...

Page 17: ...ls Always follow proper procedures for climbing hills as described in this manual Check the terrain carefully before attempting to climb a hill Never climb hills with excessively slippery or loose sur...

Page 18: ...d in reverse move slowly Avoid turning at sharp angles in reverse Always use the proper size and type of tires specified in this manual Always maintain proper tire pressure as specified on safety labe...

Page 19: ...r poses Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your POLARIS RANGER is terminated if any eq...

Page 20: ...out proper instruction increases the risk of an accident The operator must understand how to operate the vehicle properly in different situations and on different types of terrain All operators must r...

Page 21: ...e charging Failure to Inspect Before Operating Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident Always inspect your RANG...

Page 22: ...assenger s skills Operating on Pavement This vehicle s tires are designed for off road use only not for use on pavement Operating this vehicle on paved surfaces including sidewalks paths parking lots...

Page 23: ...ving Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or hole...

Page 24: ...ssure to control speed Improper Hill Climbing Climbing hills improperly can cause loss of control or vehicle overturn Always follow proper procedures for climbing hills as described in the owner s man...

Page 25: ...the vehicle which could result in an accident or overturn Always remove the key when the vehicle is not in use Hot Drive Systems The motor and controller are very hot during and after use of the vehi...

Page 26: ...22 FEATURES AND CONTROLS Component Locations ROPS Cab Frame Console Hip Bar Cargo Box Headlights Front Bumper Brush Guard...

Page 27: ...ped with a receiver hitch bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage always heed the warnings and towing capacities outl...

Page 28: ...r 2 Headlight Switch 3 Charge Status Indicator 4 AWD Switch 5 Battery Discharge Indicator 6 Hour Meter 7 Charge Plug Holder 8 12V Auxiliary Outlet 9 Drive Mode Switch 10 Direction Selector 11 Key Swit...

Page 29: ...ossible Avoid discharging the batteries more than 80 NOTICE If the two left most bars begin to flash battery damage may occur with continued operation Stop the vehicle and recharge the batteries Hour...

Page 30: ...ke connector or switch under the hood malfunctions or becomes disconnected or if the switch has moved Check for disconnection then see your dealer promptly if this feature fails to operate properly Al...

Page 31: ...when the key is turned on Switch to neutral then choose forward or reverse Turn the key to the OFF position to disable all electrical circuits The key can be removed from the switch when it is in the...

Page 32: ...ed will be limited to a maximum of 10 MPH 16 km h and regenerative braking increases to improve control in aggressive terrain Return the mode switch to high mode for normal operation Move the switch t...

Page 33: ...itch The AWD switch has three posi tions All Wheel Drive AWD Dif ferential Lock Two Wheel Drive 2WD and Off 1WD Turf Mode Press the top of the switch to engage All Wheel Drive AWD See page 54 for oper...

Page 34: ...neutral then to forward or reverse Park Brake Steady Engaged park brake Gear Position Steady Selected gear forward neutral reverse Motor Controller High Temperature Flashing Reduced performance due t...

Page 35: ...n in forward or reverse switch to neutral then to forward or reverse 1 Data or configuration error 2 Sequence fault 3 Power fault 4 Contactor issue 6 Throttle input error 7 Voltage protection 8 Contro...

Page 36: ...o be cycled several times before reaching full capacity 50 125 cycles depending on type Capacity will be limited during this time Make sure vent caps are installed properly and securely during vehi cl...

Page 37: ...arger temperature which allows it to operate more efficiently and shorten charge times See pages 71 72 for charging procedures 1 Always use extension cords with the appropriate ratings for the country...

Page 38: ...he last connection to be made The main power connector is located under the seat on the driver s side of the con troller tray adjacent to the main line contactor To dis connect unplug the connec tor T...

Page 39: ...is set to either forward or reverse To begin moving or to increase vehicle speed gradually push the accelerator pedal toward the floor Holding the accel erator pedal down continuously will accelerate...

Page 40: ...l safe operating practices out lined in this manual to avoid vehicle rollover WARNING Vehicle rollover could cause severe injury or death Always avoid operating in a manner that could result in vehicl...

Page 41: ...sure the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten 4 To release the seat belt press the square red button in the buckle s cen...

Page 42: ...Inspect lubricate if necessary 58 Rear suspension Inspect lubricate if necessary 58 Steering Ensure free operation 65 Tires Inspect condition and pressure 7 66 Wheels fasteners Inspect ensure fastener...

Page 43: ...4 Apply the brakes Place the direction selector in neutral N 5 Turn the key to the ON position Wait about a second for the contac tor to close before continuing 6 Move the direction selector to forwa...

Page 44: ...ast two hours of driving experience with this vehicle Never carry more than one passenger in this vehicle Never allow a passenger to ride in the cargo box 13 To stop the vehicle release the accelerato...

Page 45: ...weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down before entering slippery areas 3 Maintain a high level of alertness reading the trail and...

Page 46: ...es 6 Proceed at a steady rate of speed 7 Never go over the crest of a hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 8 If the vehicle s...

Page 47: ...caution 3 Avoid crossing the side of a steep hill 15 maximum Driving Downhill When driving downhill follow these precautions 1 Avoid steep hills 15 maximum 2 Always descend a hill with the direction...

Page 48: ...water deeper than the floorboards Follow these procedures when operating through water 1 Determine water depths and current before entering water 2 Choose a crossing where both banks have gradual inc...

Page 49: ...e operating in a new area 2 Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating o...

Page 50: ...reverse 1 Always check for obstacles or people behind the vehicle Always inspect left and right fields of vision before backing 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightl...

Page 51: ...id parking on an incline if possible If it s unavoidable follow these precautions 1 Apply the brakes 2 Set the park brake 3 Place the direction selector in neutral 4 Turn the key off 5 Block the rear...

Page 52: ...ads Slow down and drive in the lowest gear available SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPE...

Page 53: ...d operator passenger accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle Never exceed the following capacities WARNING Driving with passengers in the cargo...

Page 54: ...cause serious injury to the operator or bystanders Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box 9 Stand clear and pull up on the cargo bo...

Page 55: ...braking distance 3 Do not tow more than the recommended weight for the vehicle See the towing capacity chart below and the specifications charts begin ning on page 80 4 Attach a trailer to the traile...

Page 56: ...n the key off Remove the key to prevent unauthorized use Towing the Vehicle NOTICE When towing the vehicle the key MUST be in the OFF position or severe motor damage will occur Follow these procedures...

Page 57: ...cargo Follow these guidelines when transporting the RANGER 1 Place the direction selector in neutral 2 Set the park brake 3 Remove the key to prevent loss 4 Secure the seat hood and tailgate latches...

Page 58: ...witching to AWD NOTICE Switching to AWD while the rear wheels are spinning may cause severe drive train damage Always switch to AWD while the rear wheels have traction or are at rest Locking the Diffe...

Page 59: ...cked after turning the AWD switch off If this occurs you may notice increased steering effort and some vehicle speed restriction Perform the following proce dure to unlock the front gearcase 1 Stop th...

Page 60: ...fe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed...

Page 61: ...se if replacing X n Brake pad wear 10 H Monthly Inspect periodically Battery terminals 25 H Monthly Inspect and clean page 73 Battery fluid levels 25 H Monthly Add as needed page 74 Battery terminals...

Page 62: ...ginning on page 56 or more often under severe use such as wet or dusty conditions Items not listed in the chart should be lubricated at the general lubrication interval Item Lube Method Brake Fluid DO...

Page 63: ...See page 82 for the part numbers of POLARIS products Oil Check The fill plug is located at the right rear of the vehicle 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Check the oi...

Page 64: ...torque specifications 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the oil to drain completely 4 Wipe the magnetic end of the drain plug clean to remo...

Page 65: ...Refer to the Gearcase Specifications Chart on page 59 for recommended lubricants capacities and torque specifications See page 82 for the part numbers of POLARIS products Oil Check The front gearcase...

Page 66: ...de 3 Remove the fill plug 4 Place a drain pan under the drain plug 5 Remove the drain plug Allow the oil to drain completely 6 Clean the drain plug Reinstall the drain plug Torque to specification 7 A...

Page 67: ...drop which can lead to early brake fade and the possibility of accident or severe injury Change the brake fluid every two years and any time the fluid becomes contaminated the fluid level is below the...

Page 68: ...ystem for fluid leaks 2 Check the brake pedal for excessive travel or a spongy feel 3 Check the friction pads for wear damage and looseness 4 Inspect the brake disc spline and pad wear surface for exc...

Page 69: ...n the steering wheel left and right There should be 0 8 1 0 20 25 mm of freeplay at the outer rim of the steering wheel 3 If there is excessive freeplay or strange noises or the steering feels rough o...

Page 70: ...iginal equipment size and type when replacing tires Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Axle and Wheel Nut Torque Specifications Inspect the following it...

Page 71: ...he wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rota tion WARNING Improperly installed wheels can adversely affect tire wear and vehicle...

Page 72: ...fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp Headlight Lamp Replacement 1 Open the hood CAUTION Hot components can cause burns to skin Allow l...

Page 73: ...urn the key on Turn the headlights on 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 cm below the mark placed on the wall Include the weight of a rider on...

Page 74: ...behind the console panel and lift the release to unplug the light from the harness 3 Using a flathead screwdriver press on the tab on the top of the light to remove the indi cator light assembly from...

Page 75: ...ult in an explosion and cause serious injury or death Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flus...

Page 76: ...surface 2 Make sure the charging area is well ventilated 3 Make sure the key is off 4 Open the hood and any door enclosures or zippers 5 Always use a extension cord with a minimum rating of 20 amps 6...

Page 77: ...o clean remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat battery terminal...

Page 78: ...l to a battery Unless the plates are exposed before charging distilled water should be added to a battery after charging If the plates are exposed add water to about 1 8 inch 3 mm above the plates the...

Page 79: ...way to clean your POLARIS vehicle is with a gar den hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with...

Page 80: ...abel becomes illegible or comes off con tact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Grease all zerk fittings immediately after was...

Page 81: ...Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodical...

Page 82: ...f the vehicle as recommended in the Periodic Maintenance Chart beginning on page 56 Battery Maintenance See pages 71 74 for procedures Fluid Levels Inspect the fluid levels Add or change fluids as rec...

Page 83: ...ck battery voltage each month during storage and recharge as needed to maintain a full charge If the charger remains connected check it monthly to verify proper operation Tip Do not use plastic or coa...

Page 84: ...le 48 volt high efficiency AC induction motor Motor peak 30 HP Controller 650 Amp Sevcon Gen IV controller with multi mode driving and regenerative braking Battery pack 11 7 kw battery pack at 48V DC...

Page 85: ...lisle All Trail II Tire pressure 20 psi 137 9 kPa Features Cup holders Dual cup holders Indicator panel Indicates directional selection park brake and motor or controller malfunction Charge indicator...

Page 86: ...23 Demand Drive Plus Fluid 2 5 gal 9 5 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 oz 89 ml cartridge 2871423 Premium All Season Greas...

Page 87: ...ight Loose battery connections Check all connections and tighten Loose contactor connections Check all connections and tighten Loose electronic control box connections Inspect clean reinstall connecto...

Page 88: ...ty period through a POLARIS dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days Upon receipt of this regist...

Page 89: ...rized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the vehic...

Page 90: ...ined by the POLARIS Warranty Department and the battery man ufacturer U S Battery prior to replacement If the POLARIS Warranty Department in conjunction with U S Battery determines that the failure of...

Page 91: ...E REMEDY FAILED OF ITS ESSENTIAL PUR POSE Some states do not permit the exclusion or limitation of incidental or consequen tial damages or implied warranties so the above limitations or exclusions may...

Page 92: ...r warranty terms will remain in effect Lubricants Mixing lubricant brands or using non recommended lubricants may cause component damage We recommend the use of POLARIS lubricants for this vehicle Dam...

Page 93: ...nty coverage You may also be required to obtain documentation from POLARIS Industries in order to register your vehicle in your new country You should warranty register your vehicle at a local POLARIS...

Page 94: ...90 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 95: ...91 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 96: ...7 31 Charging Batteries 72 Charging Cord 26 72 Chrome Wheel Care 77 Cleaning and Storage 75 78 Component Locations 22 23 Console 24 30 Corrosion Removal Chrome 77 D Differential Locking 54 Direction S...

Page 97: ...34 Maintenance Precautions 21 Maintenance Periodic 56 57 Malfunction Indicator 31 Modifications 15 O Obstacles 45 Oil Change Front Gearcase 62 Main Gearcase 60 Transaxle 60 Oil Level Front Gearcase 61...

Page 98: ...res Nut Torque 66 Tread Depth 66 Wheel Installation 67 Wheel Removal 67 Towing Loads 51 Towing Speed 51 Towing the Vehicle 52 Trailer Hitch Bracket 23 Transaxle 59 60 Transporting the RANGER 53 Troubl...

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