9926595 R01 - 2015-2016 RANGER EV Service Manual
© Copyright Polaris Industries Inc.
1.23
WARNING
Wear eye protection.
1. Turn key OFF, and remove seat and storage trays.
2. Push lever tabs in direction shown to unlock cell
covers.
3. Remove cell covers and check each cell. Add
distilled water as required to bring level to 1/4 (6mm)
below bottom of fill well (A) in each cell.
4. Inspect O-rings on cell caps and replace if damaged.
5. Install caps and slide levers to the locked position.
BATTERY TESTING - OVERVIEW
The use of a battery discharger is important to accurately
determine overall battery capacity and to identify weak or
faulty cells or batteries in a battery set. Weak or faulty
batteries can be replaced individually; it is not necessary
to replace all batteries at the same time.
After fully charging the batteries, the discharger unit is
connected and a discharge cycle begun. The discharger
applies a resistive load to the batteries (56.25 amps for a
48 volt battery set) and automatically keeps track of the
time elapsed between start and end of the discharge
cycle. A discharge cycle ends when the batteries reach
42 volts, and the discharger shuts off automatically.
When the discharger shuts off, the elapsed time to
discharge (42 volts) is then noted from the discharge unit
display.
A good battery set will take longer to discharge to the 42
volt level than a battery set with a faulty battery or
batteries. If one battery in a set is weak, the other
batteries must make up for the deficiency, and the
discharge time to 42 volts will be less than that of a good
battery set.
Ambient temperature is a factor in the amount of time it
takes to discharge a set of batteries. Therefore, an
adjustment table is provided in the test procedure to
make it easy to calculate an accurate temperature-
adjusted discharge time. Note that temperatures above
80° F require no adjustment, and actual discharge time is
taken directly from the display of the discharger.
If the adjusted discharge time is 175 minutes or more, no
further testing is required, as all batteries are in good to
excellent condition.
If discharge time took less than 175 minutes, the
discharger is re-started and the voltage of each battery
tested under load and recorded. A weak or faulty battery
or batteries will be identified by a noticeably lower
voltage reading than other “healthy” batteries in the set.
NOTE: When the discharger is re-started for battery
testing, it will load the batteries for a 3-minute period,
allowing ample time to test the voltage of each of the
eight batteries in the set.
Batteries that fall below the service limit under load must
be replaced.
See Battery Testing Procedure to perform the discharge
cycle and test each battery.
Read discharger unit instructions for complete
information on features, operation, and program settings
prior to connecting the unit. Only basic instructions for
technicians familiar with the Lester Discharge Unit are
provided in this manual.
Equipment required:
Battery Discharger - Lester 36/48 is recommended.
(Available through Bosch Automotive Service Solutions
and Commercially Available).
GENERAL / BATTERY
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