Polaris 2013 Ranger EV Owner'S Manual For Maintenance And Safety Download

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Owner's Manual

for Maintenance and Safety

RANGER

Summary of Contents for 2013 Ranger EV

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

Page 2: ...ARNING 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 death ...

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

Page 4: ... with another vehicle 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 non Polaris approved accessories they may seriously affect stability ALWAYS Wear your seat belt Vehicle rollover could cause severe injury or death Wear a helmet eye protection glove...

Page 5: ...al vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and rec ommendations in this owner s manual Your manual contains instructions for minor mainte nance but information abo...

Page 6: ...lt between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liabil ity can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in...

Page 7: ...3 TABLE OF CONTENTS Introduction 4 Safety 6 Features and Controls 16 Operation 29 Maintenance 40 Specifications 56 POLARIS Products 57 Troubleshooting 58 Warranty 59 Maintenance Log 62 Index 63 ...

Page 8: ...ory Action Sign indicates an action that NEEDS to be taken to avoid a hazard Failure to follow the warnings contained in this manual can result in severe injury or death A POLARIS RANGER is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over ob...

Page 9: ...all any accessory that grounds to the vehicle chassis The chassis is a floating ground to protect against electrical short circuits and hazards We strongly recommend that consumers do not install on a POLARIS RANGER any equip ment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the ...

Page 10: ...rgo box WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce ...

Page 11: ...d For maximum life charge your vehicle at every opportunity Use only the charger supplied with the vehicle Inspect battery connections regularly Failure to properly maintain your batteries will void warranty coverage 7176414 Battery Compartment Warning WARNING SULFURIC ACID in batteries will burn skin eyes and clothing Do not tip batteries Keep vent caps tight and level In event of injury flush wi...

Page 12: ...an result in Severe Injury or Death NEVER Operate At speeds too fast for your skills or the conditions After or while using Alcohol or Drugs On hills steeper than 15 degrees 15 On public roads a collision can occur with a another vehicle With more than one passenger or a passenger under age twelve or who cannot comfortably reach the floor and hand holds On paved surfaces pavement may seriously aff...

Page 13: ... country which has granted approval The approval number and serial number will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 ...

Page 14: ...le is for off road use only Never operate on public roads Always avoid paved surfaces Never consume alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Always travel at a speed proper for the terrain visibility and operating conditions and your experience Never attempt jumps or other stunts Always inspect your vehicle each time you use it to make sure it s in ...

Page 15: ...hen it s safe to proceed 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 labels Never modify this vehicle through improper installation or use of accessories Never exceed the stated load capacity for this vehicle Cargo should be properly distributed and ...

Page 16: ...eases the risk of serious injury in the event of an accident or sudden stop Riders must wear seat belts at all times Always make sure the seat belts are secured for both the operator and passenger before riding Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident Operator and passeng...

Page 17: ...ged Vehicle Operating a damaged vehicle can result in an accident After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes accelerator steering system and electrical system Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator s risk of losing control Always operate at...

Page 18: ...f control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively slippery surfaces Always reduce speed and...

Page 19: ...h local authorities and residents to confirm ice conditions and thickness over your entire route Vehicle operators assume all risk associated with ice conditions on frozen bodies of water Unauthorized Use of the Vehicle Leaving the keys in the vehicle can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the key when the vehicle is not in use Hot D...

Page 20: ...EATURES AND CONTROLS Component Locations ROPS Cab Frame Console Hip Bar Cargo Box Headlights Front Bumper Brush Guard Tailgate Latch Releases Receiver Hitch CV Boot Rear Caliper Tailgate Taillight Reflector ...

Page 21: ...er 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 Switch 12 Indicator Lights 2 10 3 1 4 5 11 9 8 6 7 12 ...

Page 22: ...o left most bars begin to flash battery damage may occur with continued operation Stop the vehicle and recharge the batteries Hour Meter The hour meter records and displays the hours of actual vehicle movement since manufac ture Auxiliary 12 Volt Terminal Board The 12 volt terminal board is located under the hood It contains constant 12 volt switched 12 volt and ground terminals that can be used t...

Page 23: ...d as far as possible Charge Status Indicator When charging the batteries the charge status indicator light flashes and changes color to indicate the status of the charge Refer to the table below Key Switch Move the direction selector switch to neutral then turn the key to the ON position to activate the electrical circuits Tip The accelerator will not start the motor if the direction selector swit...

Page 24: ...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 to the center position to select the maximum range mode Use this mode to operate the vehicle a greater distance or for a longer time period This mode limits both speed and torque to obtain the maximum ...

Page 25: ... Switch The AWD switch has three positions All Wheel Drive AWD Differential Lock Two Wheel Drive 2WD and Off 1WD Turf Mode Press the top of the switch to engage All Wheel Drive AWD See page 39 for operating instructions Move the switch to the center position to lock the differ ential and operate in two wheel drive 2WD Press the bottom of the switch to unlock the differential and allow the rear dri...

Page 26: ...o 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 to elevated temperature Steady Power delivery terminated to protect against overheating If either occurs stop the vehicle and turn the key off Allow the motor and controller to cool adequately before ...

Page 27: ...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 Controller or motor out of temperature range 13 Software fault of Blinks Code Definition Solution 1 Battery high voltage Check battery size and condition reset charger interrupt AC power for 15 seconds 2 Ba...

Page 28: ...to 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 vehicle operation and bat tery charging Recharge batteries fully at the end of each day the vehicle is operated allowing adequate time for the charger to complete its charge cycle The batteries in this vehi...

Page 29: ...arger temperature which allows it to operate more efficiently and shorten charge times See pages 49 50 for charging procedures 1 Always use extension cords with the appropriate ratings for the country in which it is used In North America this is a UL rating The cords must also be rated for the condi tions in which they are used such as being rated for protection from oil in a garage or workshop en...

Page 30: ... the last connection to be made The main power connector is located under the seat on the driver s side of the controller tray adjacent to the main line contactor To disconnect unplug the con nector To disconnect the battery pack from the vehicle completely disconnect the main power connector then remove the B wire from the battery terminal WARNING Insulate any tools used within the battery area t...

Page 31: ...s braking when the pedal is released For additional speed control or to stop the vehi cle apply the service brakes Roll Over Protection System ROPS The Rollover Protective Structure ROPS on this vehicle meets OSHA 1928 53 rollover performance requirements Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way No device can assure occupant prote...

Page 32: ... 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 center Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle 1 Push the latch plate into the buckle until it clicks The latch plate must slide smoothly into the ...

Page 33: ...Inspect lubricate if necessary 41 Rear suspension Inspect lubricate if necessary 41 Steering Ensure free operation 45 Tires Inspect condition and pressure 6 46 Wheels fasteners Inspect ensure fastener tightness 46 Frame nuts bolts fasteners Inspect ensure tightness Accelerator Ensure proper operation 27 Indicator lights switches Ensure operation 22 Headlamp Check operation apply POLARIS dielectric...

Page 34: ...10 Keeping both hands on the steering wheel release the brake pedal and gradually push the accelerator toward the floor to begin driving 11 Drive slowly Practice maneuvering and using the accelerator and brakes on level sur faces 12 Do not carry a passenger until you have at least two hours of driving experience with this vehicle Never carry more than one passenger in this vehicle Never allow a pa...

Page 35: ...g 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 avoiding quick sharp turns which can cause skids 4 Engage all wheel drive before wheels begin to lose traction NOTICE Severe damage to the drive train may occur if the AWD is engaged while the wheels...

Page 36: ...he vehicle to roll straight downhill while applying light brake pressure to control speed Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Exercise extreme caution 3 Avoid cr...

Page 37: ...ly avoiding rocks and obsta cles 4 Avoid operating through deep or fast flowing water 5 After leaving water always dry the brakes by applying light pressure to the pedal repeat edly until braking action is normal Driving Over Obstacles Follow these precautions when operating over obstacles 1 Always check for obstacles before operating in a new area 2 Look ahead and learn to read the ter rain Be co...

Page 38: ...Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at sharp angles 6 Never accelerate suddenly Parking on an Incline Avoid 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 wheels on the downhill side 15 ...

Page 39: ...te with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely aff...

Page 40: ...ther loca tion or you may lose control of the vehicle 5 Never tow a trailer on a grade steeper than 15 Towing the RANGER NOTICE When towing the vehicle the key MUST be in the OFF position or severe motor damage will occur Follow these procedures when towing the vehicle 1 Place the direction selector in neutral 2 Turn the key off 3 Always follow these precautions when towing this vehicle Do not ope...

Page 41: ... 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 box release lever 10 Lift the front of the cargo box to dump the cargo 11 Lower the cargo box and push down securely to latch 12 Close the tailgate and secure both tailgate latches WARNING Operating th...

Page 42: ...ing the RANGER for a long distance or on public streets always use a trailer with an approved load rating greater than the RANGER s curb vehicle weight of 1700 lbs 771 kg plus any installed accessories or 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 latc...

Page 43: ...early stopped before engaging the differential Locking the differential in slippery or low traction conditions helps improve traction Move the rocker switch to the center position 2WD to lock the differential and operate in rear wheel drive Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently This mode of operation is well suited to tur...

Page 44: ...ith safe 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 of approximately 10 MPH 16 km h Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race styl...

Page 45: ...nthly Inspect periodically Battery terminals 25 H Monthly Inspect and clean page 51 Battery fluid levels 25 H Monthly Add as needed page 51 Battery terminals 25 H Monthly Inspect torque to specification Front gearcase oil 25 H 1 M Perform a break in oil level check Main gearcase oil Transaxle 25 H 1 M Perform a break in oil level check General lubrication 50 H 3 M Lubricate all fittings pivots cab...

Page 46: ...ain plug is located on the lower right side of the main gearcase near the fill plug Refer to the Gearcase Specifications Chart for recommended lubricants capacities and torque specifications 1 Remove the fill plug 2 Place a drain pan under the drain plug Remove the drain plug Allow the oil to drain completely 3 Wipe the magnetic end of the drain plug clean to remove accumulated metallic filings 4 ...

Page 47: ...d on the left side of the front gearcase 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed 4 Reinstall the fill plug Torque to specification Oil Change 1 Support the vehicle securely with a jackstand 2 Remove the front tire on the driver s side 3 Remove the fill plug 4 Place a drain pan under the drain plug 5 Remove the drain p...

Page 48: ...res ervoir are unknown See page 41 for fluid recommenda tions 1 Position the vehicle on a level surface 2 View the brake fluid level at the reservoir in the driver s side wheel well The level should be between the upper MAX and lower MIN level lines 3 If the fluid level is lower than the upper level line add brake fluid to the upper MAX line 4 Apply the brake forcefully for a few seconds and check...

Page 49: ...urn 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 or catchy have the steering system inspected by an authorized POLARIS dealer Spring Adjustment Adjust the rear shock absorber springs by rotating the adjustment cams either clockwise or counter clock...

Page 50: ...vehicle by placing a suitable stand under the frame 4 Remove the wheel nuts and washers Remove the wheel Wheel Installation 1 Set the park brake Place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling whi...

Page 51: ...e it 4 Install the new lamp Tip Make sure the tab on the lamp locates properly in the housing 5 Reinstall the harness assembly into the headlight assembly Headlight Beam Adjustment 1 Place the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Appl...

Page 52: ...hind 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 indicator light assembly from the console panel 4 Locate the expired lamp Using a screwdriver rotate the lamp 1 4 turn counter clockwise 5 Grip the lamp with a needle nose pliers and remove it from the assembly 6 Install the new lamp...

Page 53: ...sult 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 Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt m...

Page 54: ...vel 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 Inspect the charging cord and extension cord for cracks loose connections and frayed wiring Replace any damaged components promptly 7 Always connect the vehicle charger to the extension cord first...

Page 55: ... tap water to enter the batteries Battery Replacement With proper care and maintenance as outlined in this owner s manual battery life could be extended up to four years or longer depending on the amount of use When battery replace ment is necessary please see your authorized POLARIS dealer WARNING Handling batteries and electrical components improperly can result in serious injury or death Do not...

Page 56: ...of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Avoid directing water toward electrical components including batteries wiring and switches Washing the V...

Page 57: ... air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent 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 chrom...

Page 58: ...f the vehicle as recommended in the Periodic Main tenance Chart beginning on page 40 Battery Maintenance See pages 49 51 for procedures Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 40 Front and rear gearcase fluid if equipped Main gearcase fluid Brake fluid change every two years and any time the fluid looks dark or c...

Page 59: ...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 coated materials They do not allow enough ventilation to prevent condensa tion and may promote corrosion and oxidation WARNING Do not cover the vehicle while the charger is connected Dangerous levels of ...

Page 60: ...ngle 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 with 8 12 volt US12VXC batteries in series parallel configuration Maximum speed 25 MPH 40 2 km h Range in Max Range mode on flat ground 50 miles 80 5 km may vary with driving conditions Throttle Red...

Page 61: ...le movement Auxiliary power 12 volt accessory outlet Rider restraints Automotive style 3 point seat belts Multi mode switch L M H Low Max Range High Headlights taillights brake lights Dual 50 watt Storage Glove box Part Number Description Gearcase Lubricants 2871653 Premium ATV Angle Drive Fluid 8 oz 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 l 2877922 Demand Drive Plus Fluid qt 95 l...

Page 62: ...night Loose battery connections Check all connections and tighten Loose contactor connections Check all connections and tighten Loose electronic control box connections Inspect clean reinstall connectors Required torque exceeds motor capability In neutral cycle key off and on select low range then select direction ...

Page 63: ...s warranty does not cover accidental damage normal wear and tear abuse or improper handling This war ranty also does not cover any vehicle that has been altered structurally modified neglected improperly main tained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of...

Page 64: ...or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at POLARIS exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUEN TIA...

Page 65: ...uthorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If You Move If you move to another country be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present ...

Page 66: ...62 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 67: ...me 53 D Differential Locking 39 Direction Selector 21 Discharge Indicator 18 Disengaging AWD 39 Drive Mode Switch 20 D Driving Downhill 32 Driving in Reverse 34 Driving on a Sidehill 32 Driving on Slippery Surfaces 31 Driving Over Obstacles 33 Driving Procedure 30 Driving Through Water 33 Driving Uphill 32 Dumping the Cargo Box 37 E Equipment Modifications 5 Eye Protection 9 F Fluid Change Front G...

Page 68: ... Reverse Operaton 34 Riding Gear 9 Roll Over Protection System 27 ROPS Cab Frame 27 S Safety Labels 6 8 Safety Symbols 4 Seat Belt Inspection 28 Seat Belts 28 Seat Removal 27 Severe Use Definition 40 Shock Spring Adjustment 45 Signal Words 4 Specifications Gearcase 42 Speed Towing 36 Steering Wheel Inspection 45 Storage 52 54 Storage Tips 54 Storage Removal 55 Storing the Vehicle 55 Switches AWD S...

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Polaris 2013 Ranger EV, Owner'S Manual For Maintenance And Safety

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