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59

MAINTENANCE

Gearcases

Gearcase Specification Chart

Main Gearcase (Transaxle)

Always check and change the main
gearcase oil at the intervals outlined
in the Periodic Maintenance Chart
beginning on page 56. Maintain the
oil level even with the bottom thread
of the fill plug hole.

Refer to the Gearcase Specifications
Chart for recommended lubricants,
capacities and torque specifications.
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 oil level.

4. Add the recommended oil

as needed.

5. Reinstall the fill plug.

Torque to specification.

Gearcase

Lubricant

Capacity

Fill Plug

Torque

Drain Plug

Torque

Main Gearcase
(Transaxle)

Premium ATV Angle

Drive Fluid

20.3 oz.

(600 ml)

14 ft. lbs.

(19.4 Nm)

14 ft. lbs.

(19.4 Nm)

Front Gearcase

Demand Drive Plus

Fluid

5.1 oz.

(150 ml)

8-10 ft. lbs.

(11-13.6 Nm

11 ft. lbs.

(15 Nm)

Fill

Plug

Drain

Plug

Fill Plug

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Содержание Ranger EV 2011

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 _____...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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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