2012-2014 Polaris Ranger EV LSV OEM Service & Repair Manual

GENERAL / BATTERY 1.1 CHAPTER 1 GENERAL / BATTERY 1 © Copyright 2012 Polaris Sales Inc. 9923943 - 2012-2013 POLARIS EV - LSV Service Manual REGARDING THE RANGER EV / POLARIS EV-LSV . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 OPERATING THE RANGER EV / POLARIS EV-LSV . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 WORKING ON THE RANGER EV / POLARIS EV-LSV . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 TOWING THE RANGER EV / POLARIS EV-LSV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4 VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6 GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 2012-2013 RANGER EV / POLARIS EV-LSV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 2012 RANGER EV / POLARIS EV-LSV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 2013 RANGER EV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 FEATURES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 PARKING BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10 DRIVE MODE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 BATTERY DISCHARGE INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11 CHARGE STATUS INDICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 BATTERY CHARGING CORD / BATTERY CHARGER. . . . . . . . . . . . . . . . . . . . . . . . . 1.12 HEADLIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 HOUR METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 12 VOLT AUXILIARY POWER OUTLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12 AUXILIARY 12 VOLT TERMINAL BOARD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 DIRECTION SELECTOR SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 ALL WHEEL DRIVE (AWD) SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13 INDICATOR LIGHT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15 TURN SIGNAL / HAZARD / HORN SWITCH (LSV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 TROUBLESHOOTING - VEHICLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 INDEX TO BATTERY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16 BATTERY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19 BATTERY ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19 MAIN POWER CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.19 BATTERY TERMINAL FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 BATTERY CONTACTOR FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 BATTERY CLEANING (EXTERNAL SURFACES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20 BATTERY TERMINAL CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.21 BATTERY WATER LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23 BATTERY TESTING - OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.23 BATTERY DISCHARGE AND TESTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 1.25 BATTERY SPECIFIC GRAVITY TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 BATTERY REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28 BATTERY TERMINAL ORIENTATION AND CABLE ROUTING . . . . . . . . . . . . . . . . . . 1.30 BATTERY CABLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.31 BATTERY CABLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32 BATTERY STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33 ACCESSORY INSTALLATION PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.33 BATTERY CHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34 REFERENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36

1.2 GENERAL / BATTERY © Copyright 2012 Polaris Sales Inc. 9923943 - 2012-2013 POLARIS EV - LSV Service Manual SPECIAL INFORMATION REGARDING THE RANGER EV / POLARIS EV-LSV Operating The RANGER EV / POLARIS EV- LSV If you are not familiar with the controls, features, or safe operation of RANGER EV / POLARIS EV-LSV vehicles, read the Owner’s Manual thoroughly before you operate the vehicle. If you are an experienced RANGER EV / POLARIS EV- LSV technician and have read and become familiar with safe vehicle operation, a basic description of the switches and controls unique to the RANGER EV / POLARIS EV- LSV is included in this manual (See “FEATURES AND CONTROLS” on page 1.10). Working On The RANGER EV / POLARIS EV- LSV Improper contact between battery terminals can result in electrical shorts. Electrical shorts can result in burns. The RANGER EV / POLARIS EV-LSV is equipped with eight 12-volt lead/acid batteries arranged in two banks of four batteries each. Each bank of batteries delivers 48 volts to a high efficiency AC induction motor via the motor controller unit and a key switch-controlled main contactor. Batteries, controller, and contactor are located under the seat. Here are a few key differences to remember when working on the RANGER EV / POLARIS EV-LSV. 48 VOLT FUSES AND RELAYS Be aware that some of the fuses and relays on the RANGER EV / POLARIS EV-LSV are 48 volt; they may look similar to their 12 volt counterparts, but they are not the same and must not be substituted with other types. The fuse voltage and current rating is clearly marked on the fuse box label. Refer to Chapter 8 of this manual (Electrical) for more information and diagnostics for electrical system components. Battery information is in this chapter (Chapter 1). GENERAL SAFETY REMINDERS Wear the proper protective gear. Shield your eyes when working on the RANGER EV / POLARIS EV-LSV. Working on or around lead-acid batteries can be dangerous if you do not take precautions and follow proper handling, charging, and service procedures while you work. Read the entire BATTERY SAFETY section of this manual. Remove all jewelry or metal objects that could come in contact with battery terminals as you work in or around the battery compartment; including (but not limited to): • Rings, chains, wrist watches, bracelets, etc. If battery access is not required for the task at hand, keep storage trays and the seat in place to reduce the chance of a dropped tool or other conductive object making contact with the battery cables or terminals. THE MAIN POWER CONNECTOR / BATTERY CHARGER Some service procedures require special precautionary steps to reduce the chance of electrical shorts and avoid damage to expensive components. Always read and understand the entire procedure and be sure you have the proper tools and equipment before you begin. DO NOT disconnect or work on any electrical component without first disconnecting the Main Power Connector (page 1.19). DO NOT work on the vehicle with the battery charger connected. RANGER EV / POLARIS EV-LSV “FLOATING” CHASSIS The RANGER EV / POLARIS EV-LSV frame and other chassis components ARE NOT used as a conductor (ground path) for electrical components and therefore not at ground potential. NEVER connect accessories or other wiring to the frame or chassis. See “Accessory Installation Precautions” on page 1.33. NEVER work on the vehicle with the battery charger connected. TIRE PRESSURE Tire pressure for all tires is 20 psi (138 kPa) due to the tire design used on the RANGER EV / POLARIS EV-LSV. WARNING Use insulated tools or insulate any tools used within the battery area to prevent sparks or battery explosion caused by shorting the battery terminals or wiring. Remove the batteries or cover the exposed terminals with an insulating material.

1.3 GENERAL / BATTERY 1 © Copyright 2012 Polaris Sales Inc. 9923943 - 2012-2013 POLARIS EV - LSV Service Manual Towing The RANGER EV / POLARIS EV-LSV 1. Place direction selector in NEUTRAL 2. Turn key switch OFF. NOTICE When towing the vehicle, the key MUST be in the OFF position or severe motor damage will occur.

1.4 GENERAL / BATTERY © Copyright 2012 Polaris Sales Inc. 9923943 - 2012-2013 POLARIS EV - LSV Service Manual VEHICLE IDENTIFICATION Model Number Designation Example: R13RC08GA Vehicle Identification Number (VIN) Designation Example: 52CRC08G0C3000000 GROUP MODEL YEAR CHASSIS DRIVELINE ENGINE CATEGORY OPTION REGION 1st digit 2/3rd digit 4th digit* 5th digit* 6th digit* 7th digit* 8th digit* 9th digit** 10th digit A = ATV R = RANGER 11 12 13 C = Sportsman 6x6 D = Sportsman Tour E = Trail Boss F = Sportsman Youth G = Sport H = RANGER 6x6 J = RZR XP K = Sport Youth M = Sportsman N = Trail Blazer P = Phoenix R = RANGER Midsize S = RZR T = Sportsman X2 U = RANGER Fullsize V = RZR W = Multi-pass RGR X = Multi-pass RZR Z = Sportsman XP A = 2x4 Chain B = 2x4 Shaft C = 4x4 AC Drive E = 4x4 Shaft / IRS G = 4x4 Chain rear / shaft front H = 4x4 Shaft / IRS J = 2x4 Swing arm Manual N = 4x4 Shaft ADC P = 2x4 / IRS Manual R = 6x6 Shaft / IRS T = 4x4 Shaft / Trailing Arm X = 4x4 Shaft EBS Displacement in cc divided by 10 and rounded to two digits (i.e. 50 = 498cc) - - - - - - - - - - - - For electric vehicles 08 = 48 Volt 12 = 72 Volt A = ORV D = Diesel E = EU On-road F = INT’L G = EV L = LSV M = Military S = Scandinavian V = EU On-road C = Calif. - - OR - - 5 = 550 6 = 570 7 = 760 8 = 850 9 = 875 E = EPS D = Diesel F = D + E * = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively ** = 9th digit will be used on color/featured versions of models (not including the base) First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN. World Mfg. ID Vehicle Descriptors Vehicle Identifiers Chassis Driveline Engine Size Engine Modifier Category Check Digit Model Year * Mfg. Location Individual Serial No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 5 2 C R C 0 8 G 0 C 3 0 0 0 0 0 0 * Model Year: A = 2010; B = 2011; C = 2012; D = 2013

1.5 GENERAL / BATTERY 1 © Copyright 2012 Polaris Sales Inc. 9923943 - 2012-2013 POLARIS EV - LSV Service Manual Vehicle and Motor Serial Number Locations Whenever corresponding about a Polaris utility vehicle, be sure to refer to the vehicle identification number (VIN) and the motor model and serial number. The VIN can be found stamped on the lower frame rail on the front LH side of the vehicle and on the dash in front of the steering wheel (see Figure 1-1). The drive motor model and serial number can be found on a label (A) applied to the motor (see Figure 1-2). Figure 1-1 VIN Figure 1-2 A

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2012-2014 Polaris Ranger EV LSV OEM Service & Repair Manual

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