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POLARIS OFF-ROAD VEHICLES

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RANGER EV Battery Maintenance

Ranger E V

Instead of using gasoline, the Polaris RANGER EV is powered by eight 12-volt batteries. The batteries are located under the seat.
Your RANGER EV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.
When performing maintenance on your RANGER EV, always observe all battery safety warnings and safe-handling procedures as outlined on the vehicle’s safety labels and in your Owner’s Manual.

Battery Handling Precautions

  • Always make sure that all electrical accessories are grounded directly to the negative post on the terminal board. Never use the chassis or body as a ground connection.
  • Keep the battery terminals and connections clean and free of corrosion at all times. If cleaning is necessary, remove the 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 the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional battery.
  • Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.
  • Always maintain a full charge on the batteries. For best battery life, avoid discharging the batteries more than 80 percent.
  • Make sure new batteries are fully charged before using.
  • New deep cycle batteries need 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 battery charging.
  • Recharge batteries fully at the end of each day the vehicle is operated. Allow adequate time for the charger to complete its charge cycle. The batteries in your RANGER EV do not have a memory effect. Frequent charging will extend their life.
  • Avoid charging your RANGER EV at ambient air temperatures above 120 degrees Fahrenheit (49 C). Closed, unvented storage buildings often exceed this temperature when exposed to direct sunlight.
  • 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. The Polaris Auxiliary Battery Kit is part number 2880555.
  • Never connect a 12-volt accessory directly to the batteries. Always connect any powered accessory to a 12-volt auxiliary outlet or terminal board.
  • Never connect jumper cables to any of the batteries of this vehicle.
  • Use only insulated tools when working in the battery compartment.

Ambient Temperature Implications on Batteries

  • Battery range decreases as ambient temperature decreases. This can affect the battery range by up to 30 percent.
  • Batteries discharge when left uncharged. They can discharge up to 13 percent per month (with higher rates in warmer climates) with the key off and much faster if the key is left on.
  • Batteries can freeze if left uncharged or at low ambient temperatures.

Battery temp

Battery Charging
When your RANGER EV is not in use, park the vehicle and connect the battery charger. The charging cord is located inside the right front bumper.

Note that 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. Always ensure a minimum of five air changes per hour in the charging area. Never charge the batteries in an area subject to a flame or spark, including areas containing gas or propane water heaters and furnaces. Do not smoke in the charging area.

Always follow these precautions when charging the batteries:

  • Position the vehicle on a level surface.
  • Make sure the charging area is well-ventilated.
  • Make sure the key is off.
  • Open the hood and any door enclosures or zippers. This will decrease charger temperature, which allows it to operate more efficiently. It also will shorten charge times.
  • Always use an extension cord with a minimum rating of 20 amps. Make sure the extension cord has the appropriate rating for the country in which it is used. In North America, this is a UL rating. The cords also must be rated for the conditions in which they are used, such as be rated for protection from oil in a garage or workshop environment.
  • Use the proper cord wire gauges for the cord length used. If the cord has 14 gauge wires, use a cord no longer than 25 feet. If the cord has 12 gauge wires, use a cord no longer than 50 feet. If the cord has 10 gauge wires, use a cord no longer than 100 feet.

    Cord length
     
  • Inspect the charging cord and extension cord for cracks, loose connections and frayed wiring. Replace any damaged components promptly.
  • Always connect the vehicle charger to the extension cord first and then plug the cord into a wall receptacle.
  • Make sure the charger uses a dedicated circuit to prevent overloading. If charging multiple vehicles, each vehicle should use a dedicated circuit. The vehicle should be plugged into a dedicated 120 volt AC outlet with a minimum of a 15-amp circuit breaker. If using a power cord that has a Ground Fault Interrupter (GFI) on it, do not plug it into a GFI wall socket. If using a GFI wall socket, use a cord without GFI. Only one GFI is recommended.
  • When disconnecting the charger, always disconnect the extension cord from the wall receptacle first and then disconnect the cord from the vehicle’s charging cord.
  • A normal charge cycle can vary between 8 and 12 hours, depending on battery configuration and the state of charge. Before unplugging the vehicle, locate the charger box and verify that there is a solid green light and solid yellow light on the side panel. This indicates the charger has completed a full charge.

    Charging icons
     
  • The battery life indicator will not read accurate unless a full charge is reached. A solid green light is required for the battery indicator to reset itself. If the charger box shows a flashing red light, a fault has occurred. Your Polaris Dealer can assist.

Battery charging tip

Battery Operation Range
Range is significantly affected by tire pressure, alignment, terrain and driving style. Always maintain proper tire pressure as specified on your vehicle’s safety labels. Maximum driving range also is affected by ambient temperature, the number of times the batteries have been fully cycled and the drive mode used.

Battery Operating Temperature
Your RANGER EV will not operate if one or more of the batteries has an internal temperature below 14 F (-10 C).

When not in use, park the vehicle and connect the battery charger. When the vehicle is connected to the charger, batteries are maintained at full performance operating temperature in addition to receiving a full charge.

If the vehicle is not connected to the charger while parked in cold weather, battery temperatures may drop below 14 F (-10 C). If this occurs, connect the vehicle to the charger to increase battery temperature before operating. When batteries are extremely cold, battery temperature will increase by approximately 17-27 F (10-15 C) per hour while charging.

Turning the key on also will active the battery heaters, but battery power will be used quickly. This method is not recommended if the state of charge (SOC) is low.
Note that the vehicle may require up to 45 minutes of charging for the batteries to reach operating temperature, depending on their current internal temperature. It may take additional time for the batteries to reach a 100 percent SOC.

Operating temperature

Operating temperature

Battery Conditioning
New batteries initially cannot hold all of their capacity. The approximate capacity of the battery pack increases as the number of charge cycles increases.

Battery conditioning

Auxiliary Batteries
Vehicles with EPS/Lithium-Ion batteries are equipped with an auxiliary battery. During storage, this battery must be trickle charged. If the vehicle does not operate when removed from storage, be sure to check the auxiliary battery voltage first.

The Auxiliary Battery Kit (part number 2880555) also may be purchased separately for models not equipped with it. For more information, view the installation instructions.

In order to avoid overcharging, the auxiliary battery charging system only functions when the key is in the ON position. The auxiliary battery recharges from the drive system batteries while you are driving your RANGER EV. To prevent possible accidents and injuries, Polaris strongly recommends against leaving the key in the ON position while recharging the drive system batteries.

Battery Access
To access the batteries, remove the seat and then remove the storage tray, if equipped. Before removing the seat to access the batteries, make sure any wire or metal items (including seat belt latches) remain clear of the battery compartment to avoid causing a short circuit to the electrical system.

Battery Inspections
Inspect battery terminal connections monthly. Clean batteries as recommended. Using an insulated wrench, torque bolts to 8 ft lbs (11 Nm).

Battery Replacement
With proper care and maintenance, as outlined in your Owner’s Manual, battery life could be extended up to four years or longer, depending on the amount of use. When battery replacement is necessary, please see your Polaris Dealer.

Handling batteries and electrical components improperly can result in serious injury or death. Do not attempt to remove batteries or battery cables. Always see your Polaris Dealer for battery-related service.

Battery warning

Fluid Levels and Battery Maintenance for Conventional Batteries
A poorly maintained battery will deteriorate rapidly. For vehicles with flooded batteries, maintenance should be performed on a monthly basis. Vehicles used daily or in hotter climates require more frequent battery maintenance.

Clean the tops of the batteries, cables and terminals with a plastic brush, using a mixture of one tablespoon baking soda and one cup water. Rinse thoroughly. Never use a high-pressure washer or compressed air for cleaning. This possibly could force contaminants into the cells.

Check the battery fluid level often. Add only distilled water. Tap water contains minerals that are harmful to a battery. Unless the plates are exposed before charging, distilled water should be added to a battery after charging. If the plates (3) are exposed, add water to about 1/8 inch (3 mm) above the plates and then charge. Check the fluid level again after charging. Maintain the fluid level 1/4 inch (6 mm) below (1) the bottom of the fill well (2) in the cell cover. Do not overfill.

Battery fluid

Disconnect the battery power before checking the fluid level.

Main Power Connector
When disconnected, the main power connector disconnects the battery pack from all electrical components with the exception of the contactor. Before servicing your RANGER EV, unplug the main power fuse. This fuse is located inside the right front wheel well.
The main power connector is located under the cargo box, behind the seats. To disconnect, unplug the connector. After servicing the vehicle, the main power connector should be the last connection to be made.
Damage to electrical connections and components will occur if they are unplugged before the main power connector is disconnected. Always disconnect both the main power fuse and the main power connector before servicing or unplugging any electrical components.

Main power connector

Battery Care During Storage
Before putting your RANGER EV into storage, clean the batteries. Remove corrosion with a plastic 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 the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional battery.

Fully charge the batteries for storage. Leave the charger connected to maintain a full charge during the storage period, or check 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.

Do not cover the vehicle while the charger is connected. Dangerous levels of hydrogen gas could accumulate.

For more tips, read Storing Your RANGER.

Note that all battery and electrical service must be performed only by an authorized service facility. Your Polaris Dealer can assist. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.