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9926595 R01 - 2015-2016

RANGER

EV Service Manual

8.3

GENERAL INFORMATION

SPECIAL TOOLS

PART

NUMBER

TOOL DESCRIPTION

PV-43568

Fluke 77 Digital Multimeter

Commercial-

ly Available

Battery Hydrometer (Temperature
compensated with numerically
graduated scale) (Not floating ball type)

PU-47063

Digital Wrench® Diagnostic Software

PU-47471

Digital Wrench SmartLink Module Kit

Dealers may order special tools through Polaris’ official
tool supplier, Bosch Automotive Service Solutions, by
phone at 1-800-345-2233 or on-line at

http://polaris.

service-solutions.com/

BATTERY MAINTENANCE / TESTING

See Chapter 1 “General / Battery” for battery service
procedures, maintenance, and connections.

ELECTRICAL SERVICE NOTES

Note the following when diagnosing an electrical
problem:

• BATTERY INFORMATION - All battery information

including Safety, Maintenance, Service, and Testing is
in Chapter 1

General Information and Battery

• FLOATING CHASSIS - Unless the battery charger is

connected to a wall outlet, the chassis on the

RANGER

EV is not used as a conductor and is not at

ground potential. The ground wire in the wire harness
must be used as a ground reference for your meter or
when instructed to connect a wire on the vehicle to
“ground”.

• Do not service the electrical system when charging the

batteries. The chassis is at ground potential when the
charger of the vehicle is connected to a wall outlet,
which increases the chance of an electrical short.

• 48 VOLT FUSES AND RELAYS - Some fuses and

relays are 48 Volt and must not be substituted with
similar looking 12 volt parts.

• Disconnect the Main Power Connector (See Chapter

1) before disconnecting any electrical component. The
Main Power Connector should be the last connection
made after servicing the vehicle.

• Refer to wiring diagram or the system break-out

diagram for electrical component resistance
specifications and location on the vehicle.

• When measuring resistance of a component that has a

resistance value under 10 Ohms, remember to
subtract meter lead resistance from the reading.
Connect the leads together and record the resistance.
The true resistance is equal to tested value minus lead
resistance.

• Be sure your meter leads are in the proper jack for the

test being performed (i.e. 10A jack for current
readings). Refer to the Owner’s Manual included with
your meter for more information.

• Voltage, amperage, and resistance values included in

this manual are obtained with a Fluke 77 Digital
Multimeter (PV-43568) or an equivalent Fluke meter.
Readings obtained with other meters may differ.

• Pay attention to the prefix on the multimeter reading

(K, M, etc.) and the position of the decimal point.

• For resistance readings, isolate the component being

tested by disconnecting it from the wiring harness or
power supply.

• Verify battery voltage and general battery condition.
• Inspect battery and contactor terminal cleanliness,

condition, and fastener torque.

• Inspect all connections at the controller
• Connectors in a circuit - Separate the connector and

closely inspect terminal pins or sockets for corrosion.
Verify all pins are aligned in mating connectors. Check
wires closely to be sure pins and sockets are secure
(locked in) the connector housing.

• Secure all wiring to prevent contact with sharp edges

or moving parts after service.

OVERHEAT CONTROL CIRCUIT
OPERATION

Overheating of the controller or drive motor will illuminate
the TEMP light on the indicator light panel. When the
TEMP lamp is on, the controller will reduce performance
or terminate power delivery (if severe overheating exists)
until the overheat condition has passed. Operation will
return to normal when the controller and /or motor has
cooled.

GENERAL WIRE COLOR FUNCTION

Following is a description of wire color function for the
main circuits on the

RANGER

EV. Some exceptions may

occur. Always refer to the system wiring schematics or to
the main chassis and sub-harness schematics for
reference.

WIRE COLOR

PRIMARY CIRCUIT FUNCTION

RD/WH

48 Volt Switched Power

RD/BK

14.0 Volt Switched Power

Ground