Polaris 2013 Ranger EV Owner's Manual For Maintenance And Safety
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Polaris 2013 Ranger EV Owner's Manual For Maintenance And Safety

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RANGER EV
Owner's Manual
for Maintenance and Safety

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  • Page 1 RANGER EV Owner's Manual for Maintenance and Safety...
  • Page 2 WARNING 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 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.
  • Page 5 Factory Certified Master Service Dealer® (MSD) Technician. Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty...
  • Page 6 POLARIS and RANGER are registered trademarks of POLARIS Industries Inc. Copyright 2012 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of produc- tion components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 7: Table Of Contents

    Specifications ........56 POLARIS Products........57 Troubleshooting .

  • Page 8: Introduction

    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 obstacles, if you fail to take proper precautions.

  • Page 9: Vehicle Identification Numbers

    The warranty on your POLARIS RANGER is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increase its speed or power.

  • Page 10: Safety

    If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.
  • Page 11 • Do not charge with storage 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 BATTERY LIFE •...
  • Page 12 • 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.
  • Page 13 0006.31 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, Z87.1, or CE.
  • Page 14 • Always follow proper procedures for turning. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. • Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident.
  • Page 15 SAFETY Operator Safety • Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills. Check the terrain carefully before descending a hill. Never travel downhill at high speed. Avoid going downhill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill where possible.

  • Page 16: Seat Belts

    SAFETY Operator Safety WARNING Failure to operate the RANGER properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures. Age Restrictions This vehicle is an ADULT VEHICLE ONLY.
  • Page 17 SAFETY Operator Safety Operating With a Load on the Vehicle The weight of both cargo and passengers impacts vehicle operation. For your safety and the safety of others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the instructions in this manual for loading, tire pressure, gear selection and speed.
  • Page 18 SAFETY Operator Safety Operating on Public Roads Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads. In some areas it's unlawful to operate this vehicle on public streets, roads and highways.
  • Page 19 • Insulate any tools used within the battery area to prevent sparks or battery explosion caused by short- ing the battery terminals or wiring. Remove the batteries, or cover the exposed terminals with an insu- lating material. FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1-800-342-3764.

  • Page 20: Features And Controls

    FEATURES AND CONTROLS Component Locations ROPS Frame Headlights Cargo Console Front Bumper/Brush Guard Tailgate Latch Releases Tailgate Taillight Reflector Receiver Hitch CV Boot/Rear Caliper...
  • Page 21 FEATURES AND CONTROLS Console 1. Park Brake Lever 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.

  • Page 22: Hour Meter

    FEATURES AND CONTROLS Console Battery Discharge Indicator The battery discharge indicator displays the amount of charge removed (used) from fully charged batter- 100% Remains (Full Charge) ies. When the batteries are fully charged, the right- most bar illuminates, indicating 0% has been used. 50% Remains 50% Discharged The charge status indicator will be solid green (see...

  • Page 23: Key Switch

    FEATURES AND CONTROLS Console Park Brake Lever To help prevent the vehicle from rolling, set the park brake when parking the vehicle. When the park brake is set and the park brake indicator is illuminated, motor speed is limited. If the accelerator is applied, this limiting feature prevents operation, which protects the park brake pads from excessive wear.

  • Page 24: Drive Mode Switch

    FEATURES AND CONTROLS Console Drive Mode Switch CAUTION! Changing the drive mode switch position while driving High could result in an automatic increase or decrease in speed without a change to accelerator pedal pressure. Maximum Press the top of the switch to select high mode. Use high Range mode for most trail-riding conditions.

  • Page 25: Headlight Switch

    FEATURES AND CONTROLS Console Direction Selector Switch When the direction selector is in the center position, the vehicle is in neutral. The vehicle will not move if the accel- Forward erator is depressed. Place the switch in neutral before turn- ing the key on.
  • Page 26 FEATURES AND CONTROLS Console Indicator Panel Lights Indicator Panel The indicator lights activate when the key is in the ON position. Indicator Status Indicates Malfunction Electrical malfunction (flash sequence on controller indicates type; see troubleshooting guide on page 23) Steady Key was turned on in forward or reverse (switch to neutral, then to forward or reverse) Park Brake...
  • Page 27 (reversing direction without releasing the accelerator, turning the key on while in forward or reverse), select neutral and turn the key off and on to clear the error. If the error does not clear, please see your POLARIS dealer for diagnosis and repair. # of Blinks...
  • Page 28 • Never connect an auxiliary battery to the factory-installed DC-to-DC converter. If more than 10 amps are needed for accessories, always install the POLARIS-approved auxiliary accessory battery kit.
  • Page 29 FEATURES AND CONTROLS Batteries Battery Conditioning New batteries cannot initially hold all of their capacity. The approximate capacity of the bat- tery pack increases as the number of charge cycles increases. # of Charge Cycles: Percent of Full Capacity: 100% Ambient Temperature Implications on Batteries 1.
  • Page 30 FEATURES AND CONTROLS Main Power Connector NOTICE: Damage to electrical connections and components will occur if they are unplugged before the main power connector is disconnected. Always disconnect the main power connector before servicing or unplugging any electrical components. When disconnected, the main power con- Main Power Connector nector disconnects the battery pack from all electrical components, with the excep-...

  • Page 31: Trailer Hitch Bracket

    OSHA 1928.53 rollover Frame 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 protection in the event of a rollover. Always follow all safe operat- ing practices outlined in this manual to avoid vehi- cle rollover.

  • Page 32: Seat Belt Inspection

    FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts for the operator and passenger. Always make sure the seat belts are secured for all riders before oper- Latch Plate ating. The center of the seat is NOT equipped with a seat belt. Never allow a passenger to ride between the operator and passenger seats.

  • Page 33: Operation

    Inspect, ensure tightness Accelerator Ensure proper operation Indicator lights/switches Ensure operation Headlamp Check operation, apply POLARIS dielectric grease when lamp is replaced Brake light/tail lamp Check operation, apply POLARIS dielectric grease when lamp is replaced Seat belts Check length of belt for damage, check latches for proper...
  • Page 34 OPERATION Driving Procedure 1. Disconnect the charging cable (if connected). 2. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. 3. Sit in the driver's seat and fasten the seat belt. 4. Apply the brakes. Place the direction selector in neutral (N).

  • Page 35: Driving On Slippery Surfaces

    OPERATION Driving On Slippery Surfaces WARNING Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces. Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1.

  • Page 36: Driving Uphill

    OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid steep hills (15° maximum). 3. Keep both feet on the floor. 4. Always check the terrain carefully before ascending any hill. 5. Never climb hills with excessively slip- pery or loose surfaces.

  • Page 37: Driving Through Water

    OPERATION Driving Through Water Your POLARIS vehicle can operate through water up to a maximum recommended depth equal to the floorboards. NOTICE: Serious damage can occur to the electrical system and batteries if the vehicle is operated in water deeper than the floorboards.

  • Page 38: Driving In Reverse

    OPERATION Driving in Reverse Follow these precautions when operating in 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 lightly for stopping. 5.

  • Page 39: Hauling Cargo

    OPERATION Hauling Cargo WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: Never exceed the maximum weight capacity of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the trailer tongue.

  • Page 40: Towing Loads

    OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake insta- bility. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. 2.

  • Page 41: Dumping The Cargo Box

    OPERATION Dumping the Cargo Box 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. 3. Set the park brake. 4. Place the direction selector in neutral. 5.

  • Page 42: Transporting The Ranger

    OPERATION Parking the RANGER 1. Apply the brakes. Stop the vehicle on a level surface. 2. When parking inside a garage or other structure, be sure that the structure is well venti- lated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.

  • Page 43: Locking The Differential

    OPERATION All Wheel Drive (AWD) Press the top of the rocker switch to engage All Wheel Drive (AWD). Once enabled, the AWD remains enabled until the switch is turned off. The AWD switch may be turned on or off while the vehi- cle is moving.

  • Page 44: Maintenance

    Perform these operations more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer perform these services. WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.

  • Page 45: Lubrication Recommendations

    D Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer perform these services. Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 40, or more often under severe use, such as wet or dusty conditions.

  • Page 46: Gearcase Specification Chart

    40. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart for recom- mended lubricants, capacities and torque specifica- tions. See page 57 for the part numbers of POLARIS products. Fill Plug Drain Plug...

  • Page 47: Front Gearcase

    Refer to the Gearcase Specifications Chart on page 42 for recommended lubricants, capaci- ties and torque specifications. See page 57 for the part numbers of POLARIS products. Oil Check The front gearcase fill plug is located on the left side of the front gearcase.

  • Page 48: Brake Fluid

    MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 27. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING! After opening a bottle of brake fluid, always discard any unused portion.

  • Page 49: Steering Wheel Inspection

    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-clockwise to increase or decrease spring tension.

  • Page 50: Wheel Removal

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer. 2. Attach the wheel nuts and washers and finger tighten.

  • Page 51: Headlight Beam Adjustment

    MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.

  • Page 52: Brake Lights

    MAINTENANCE Lights Brake Lights When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. 1. Turn the key to the ON position. 2. Depress the brake pedal. The brake light should come on after about 10mm (0.4 in.) of pedal travel.
  • Page 53 MAINTENANCE Batteries WARNING Battery posts, terminals and related components contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Always wash your hands after touching or handling the batteries. WARNING Charging a damaged battery can result in serious injury. Never attempt to charge a frozen or bulging battery.

  • Page 54: Battery Charging

    MAINTENANCE Batteries Battery Charging When not in use, park the vehicle and connect the battery charger. The vehicle’s charging cord is located inside the charge plug holder on the console. WARNING! Failure to provide adequate ventilation while charging batteries can result in an explosion. Hydrogen gas is emitted during charging and will rise and accumulate at the ceiling.

  • Page 55: Battery Cleaning

    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.

  • Page 56: Cleaning And Storage

    NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.

  • Page 57: Polishing The Vehicle

    MAINTENANCE Cleaning and Storage Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehi- cle.
  • Page 58 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 52. Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main- tenance Chart beginning on page 40.

  • Page 59: Removal From Storage

    MAINTENANCE Storing the Vehicle Any time the vehicle will be parked for more than a few hours, follow the recommended storage procedures: 1. Make any necessary repairs and clean the vehicle. See page 52. 2. Clean the batteries. See page 51. 3.

  • Page 60: Specifications

    SPECIFICATIONS RANGER EV Dimensions Dry Weight 1750 lbs. (793.8 kg) Ground Clearance 10 in. (25.4 cm) Length 108 in. (274.3 cm) Width 56.5 in. (143.5 cm) Height 73 in. (185.4 cm) Wheelbase 72 in. (183 cm) Turning Radius 150 in. (381 cm) Load Capacity Box Dimensions (Inside) 32 x 42 x 11.5 in.

  • Page 61: Polaris Products

    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 POLARIS PRODUCTS 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: Troubleshooting

    TROUBLESHOOTING Vehicle Will Not Operate Possible Cause Solution Low battery voltage Recharge the battery overnight 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: Warranty

    LIMITATIONS OF WARRANTIES AND REMEDIES The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This war-...
  • Page 64 The POLARIS limited warranty excludes any battery failures that are not caused by a defect in material or work- manship. Warranty claims for battery replacements require specific testing as outlined by the POLARIS Warranty Department and the battery manufacturer, U.S.
  • Page 65 If Purchased From A Private Party: If you purchase a POLARIS product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. You must nonetheless warranty regis- ter your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle.

  • Page 66: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 67: Index

    INDEX Accelerator Pedal ......27 Driving Downhill ......32 All Wheel Drive .
  • Page 68 Charge Status Indicator... . 23 Polaris Products ......57 Malfunction Indicator .

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