2015 Polaris Ranger Diesel / Crew Diesel Owners Manual
2015 Polaris Ranger Diesel / Crew Diesel Manual
2015 Polaris Ranger Diesel / Crew Diesel manual content summary:
- 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 1
PMS 419 RANGER® Diesel RANGER CREW® Diesel Owner's Manual for Maintenance and Safety - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - 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. WARNING The engine exhaust from this product - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 3
operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a Factory Certified Master - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 4
omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. The original instructions for this vehicle are in English. Other languages are provided as translations of the original - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 5
TABLE OF CONTENTS Introduction ...4 Safety ...8 Features and Controls ...21 Operation ...35 Winch Guide ...56 Emission Control Systems ...64 Maintenance ...65 Specifications ...100 POLARIS Products...104 Troubleshooting ...105 Warranty ...108 Maintenance Log ...113 Index ...115 3 - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 6
area. The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. DANGER - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 7
hands on the steering wheel (if driving) or on a passenger hand hold. • Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels. • Always use the cab nets (or doors) while riding in this vehicle. Always keep hands, feet and all other body parts - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 8
INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 9
INTRODUCTION European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 10
SAFETY Safe Riding Gear The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance of injury. Long Sleeves Eye Protection Long Pants Gloves Over-the-Ankle Boots Helmet - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 11
clean. Gloves Wear gloves for comfort and for protection from sun, cold weather and other elements. Boots Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle with bare feet or sandals. Clothing Wear long sleeves and long pants to protect arms and legs. Rider - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 12
of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 13
or hand holds and brace yourself. • Do not put any part of your body outside of the vehicle for any reason. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA TRAINING (rohva.org). 7179983 11 - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 14
WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES Read Operation and Maintenance Manual for more detailed loading information. 1000 lbs. 600 lbs. 1000 (795 kg) (612 kg) 7180135 Clutch Cover Warning WARNING Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 15
Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this entire manual and all labels carefully. Follow the operating procedures described. • Never allow anyone under the - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 16
chance of skidding or sliding out of control. • Never operate your vehicle in fast-flowing water or in water deeper than that specified in this manual. See page 48. Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 17
the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer. Allow a greater distance for braking. • Always place the transmission in PARK before getting out - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 18
the vehicle properly in different situations and on different types of terrain. All operators must read and understand the Owner's Manual and all warning and instruction labels before operating the vehicle. All operators should review the safety DVD provided with this vehicle and take a ROHVA - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 19
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. • Do not exceed vehicle weight capacities. The vehicle's maximum weight capacity is listed - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 20
or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels. Unauthorized Use of the Vehicle Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 21
improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner's manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 22
slippery surfaces as described in this owner's manual. See page 46. Operating on Frozen Bodies have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you or other accident, have a qualified service dealer inspect the entire machine for possible - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 23
FEATURES AND CONTROLS Component Locations Your vehicle is equipped with cab nets on both sides of the vehicle. Cab nets (or doors, if equipped) must be used by both operator and passengers at all times. Any illustrations without cab nets are only to allow component identification. Always use the cab - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 24
at idle. Tip: Maintaining shift linkage adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems. Using Low Range Always shift into low gear for any of the following conditions. • Operating in rough terrain or over obstacles • Loading - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 25
(AWD) • Differential Lock (2WD) • Differential Unlock Press the top of the rocker switch to engage All Wheel Drive (AWD). See page 54 for operating instructions. Move the rocker switch to the center position to lock the differential and operate in rear wheel drive. Press the bottom of the switch to - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 26
FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine. Brake Pedal Throttle Pedal Throttle Pedal Push the throttle pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 27
FEATURES AND CONTROLS Seat and Storage Compartments The electrical compartment is located under the center rear-most seat. Never use this area for storage. Storage compartments are located under all other seats. Remove the storage bin under the right rear-most passenger seat to access the battery. - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 28
FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the left side of the vehicle near the driver's seat. Use only the recommended diesel fuel. See page 37. Hood Latches Remove the hood to access the coolant overflow bottle, the radiator cap and the headlight adjustment screws. To - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 29
in any way. No device can assure occupant protection in the event of a rollover. Always follow all safe operating practices outlined in this manual to avoid vehicle rollover. WARNING! Vehicle rollover could cause severe injury or death. Always avoid operating in a manner that could result in vehicle - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 30
FEATURES AND CONTROLS Cab Nets Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Cab nets (or doors) must be used by both operator and passengers at all times. Make sure all latches are - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 31
FEATURES AND CONTROLS Seat Belts This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all seats. Always make sure the seat belts are secured for all riders before operating. The driver's seat belt is equipped with a seat belt interlock. Vehicle speed will be limited to 15 - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 32
of vehicle speed in MPH or km/h. 2. Information Display Area - Odometer / Trip Meter / Tachometer / Engine Temperature / Engine Hours / Service Info - LCD display of the service hour interval, total vehicle miles or km., total engine hours, a trip meter, engine RPM and engine temperature. . 13 - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 33
. 8. Check Engine MIL - Illuminated when the ECM has detected a Diagnostic Trouble Code in the engine management system. 9. Unit Lock - N/A on this user, a flashing wrench symbol alerts the operator that the preset service interval has been reached and maintenance should be performed. The wrench - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 34
area which displays the following information: odometer, trip meter, RPM, battery voltage, engine temperature, air temperature, engine hours, trouble codes, service interval, and clock. Units of Measurement Distance Temperature Time Miles (MPH) Fahrenheit 12-Hour Clock Kilometers (KM/H) Celsius 24 - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 35
FEATURES AND CONTROLS Instrument Cluster Information Display Area Tachometer (RPM) Engine RPM can be displayed digitally. Engine Temperature Engine temperature can be displayed in °F or °C. Refer to "Units of Measurement" to change the format. Clock The clock displays the time in a 12-hour or 24- - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 36
interval hours in 5 hour increments to a maximum of 100 hours. 4. To turn off the service interval function, toggle the MODE button until "OFF" is displayed. Check Engine / Trouble Code Display The diagnostic mode is accessible only when the check engine MIL has been activated. Use the following - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 37
of control, accident or rollover, which may result in serious injury or death. Read and understand all warnings outlined in the safety section of this manual. Break-In Period The break-in period for your new RANGER is the first 50 hours of operation. No single action on your part is - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 38
OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition. Item Brake system/pedal travel Brake fluid Front - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 39
OPERATION Fuel Recommendations NOTICE: For the best engine performance, to prevent engine damage and to comply with EPA/CARB warranty requirements, use ONLY the recommended diesel fuels. Use only CLEAN diesel fuel. POLARIS recommends the following diesel fuels for use in this vehicle: • Ultra Low - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 40
in FAME may result in plugging of fuel filters and increased bacterial growth. 3. High viscosity at low temperatures may result in fuel delivery problems, injection pump seizures and poor injection nozzle spray atomization. 4. FAME may have adverse effects on some elastomers (seal materials) and may - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 41
fuel up to a maximum B20 (20% biodiesel blend) concentration. Operating Conditions with B20 Bio-diesel Fuel Blends Engine Warranty Damages, performance or service concerns determined to be caused by the use of bio-diesel fuel not meeting the specifications outlined above are not considered to be - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 42
OPERATION Fuel Recommendations Refueling The fuel tank filler cap is located on the right side of the vehicle near the passenger seat. Remove the cap and add the recommended fuel to the bottom of the filler neck. Do not overfill. Cold Weather Operation Cold weather operation can result in fuel - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 43
OPERATION Cold Weather Operation Bio-Diesel Blended Fuel NOTICE: Never use bio-diesel blended fuel containing more than 20% bio-diesel in this vehicle. See page 38. Bio-diesel blended fuel has unique qualities that should be considered before using it in this vehicle: • Cold weather conditions can - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 44
OPERATION Operating Conditions NOTICE: Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear. • Avoid operating in the presence of chemical gases or fumes. • Avoid operating in a corrosive atmosphere such as salt water spray. • NEVER - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 45
OPERATION Starting the Engine NOTICE: NEVER use an engine starting aid such as ether. Engine damage will result. Before operating this vehicle in cold weather, review the cold weather operation information beginning on page 40. Always wait for the glow plug indicator light to turn off before - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 46
(or doors) while riding in this vehicle. 5. Place the transmission in PARK. 6. Start the engine and allow it to warm up. 7. Apply the service brakes and shift the transmission into gear. 8. Check your surroundings and determine your path of travel. 9. Keeping both hands on the steering wheel, slowly - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 47
board. Allow more time and distance for braking. 10. Always follow all operating guidelines as outlined on safety labels and in this manual. Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 48
OPERATION Driving on Slippery Surfaces WARNING Skidding or sliding can cause loss of control or rollover (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 - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 49
OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. 2. 3. 4. Always travel straight uphill. Avoid excessively steep hills. Keep both feet on the floor. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 50
normal. Avoid applying brake and throttle at the same time. NOTICE: After running your vehicle in water, it's critical that you perform the services outlined in the Periodic Maintenance Chart beginning on page 65. Give special attention to engine oil, transmission oil, all gearcase fluids, and all - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 51
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. - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 52
OPERATION Parking the Vehicle 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 ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights. 3. - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 53
with extra caution. Always attach the tow load to the hitch point designated for your vehicle. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. USE EXTREME CAUTION when - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 54
OPERATION Towing Loads Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. 2. Always shift to low gear for towing. 3. When towing - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 55
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. Place the transmission in PARK. 3. Ensure that the cargo is positioned evenly or toward the front of the cargo box. 4. Release - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 56
in reverse for at least 10 feet (3 m). 3. Stop completely. 4. Shift into low gear and drive forward. 5. If the front gearcase remains locked after following these instructions, see your dealer for service. 54 - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 57
OPERATION All Wheel Drive (AWD) Locking the Differential NOTICE: Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning. Slow the vehicle to nearly stopped before engaging the differential. Locking the differential - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 58
WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Your - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 59
WINCH GUIDE Winch Safety Precautions 13. Never winch up or down at sharp angles. a vertical load. 21. Never immerse or submerse your winch in water. Take your winch to your dealer for service if this occurs. 22. Always inspect your winch and winch cable before each use. 23. Never winch the hook - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 60
GUIDE result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Each winching situation is unique. • Take your time to . 2. Never operate a winch or a vehicle in need of repair or service. 3. Always apply your vehicle's park brake and/or park mechanism to hold - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 61
WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY. A. - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 62
WINCH GUIDE Winch Operation 8. Read and adhere to the following information for vehicle's centerline. Attach the winch cable hook to the anchor point or the stuck vehicle's frame following instructions in this manual. D. Re-engage the clutch on the winch. E. Slowly winch in the slack in the winch - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 63
WINCH GUIDE Winch Operation 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 64
WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or "shock" loading. Shock loading may tension a winch cable - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 65
WINCH GUIDE Winch Maintenance and Service Safety WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 66
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your POLARIS vehicle - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 67
cause or see your dealer Maintenance Chart Key Ź Perform these operations more often for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) D Have an authorized POLARIS dealer perform - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 68
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval ( (800) Ź Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 69
when parts are replaced Inspect daily; adjust as needed Adjust as needed Ź Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 70
MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 65, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 71
MAINTENANCE Engine Oil Oil Check Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull. CAUTION! Always remove all cargo from the cargo box before lifting the box to access engine components. Access the oil fill cap, - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 72
MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Always change the oil filter whenever changing oil. The crankcase drain plug is located on the bottom of the crankcase. Access the drain - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 73
MAINTENANCE Engine Oil Oil and Filter Change 12. Reinstall the drain plug. Torque the drain plug to 29.5 ft. lbs. (40 Nm). 13. Remove the oil fill cap and add 2.5 quarts (2.4 l) of recommended oil. Reinstall the fill cap. 14. Start the engine and check for leaks. 15. Stop the engine and wait 15 - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 74
MAINTENANCE Gearcases Gearcase Specification Chart RANGER Diesel/RANGER CREW Diesel Gearcase Specifications Gearcase Main Gearcase (Transmission) Front Gearcase Lubricant AGL Gearcase Lubricant & Transmission Fluid Demand Drive Fluid Capacity 40.6 oz. (1200 ml) 6.76-7.6 oz. (200-225 ml) Fill Plug - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 75
Remove the fill plug. Check the oil level. 4. Add the recommended oil as needed. 5. Reinstall the fill plug. Torque to specification. Oil Change 1. Support the vehicle securely with a jackstand. 2. Remove the fill plug. 3. Place a drain pan under the drain plug. 4. Remove the drain plug. Allow the - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 76
MAINTENANCE Cooling System The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 77
MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 1. Position the - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 78
(PVT) System WARNING Failure to comply with the instructions in this warning can result in severe injury or clutch and vent system when replacing the belt. • See your dealer as outlined in the owner's manual. • This PVT system is intended for use on POLARIS products only. Do not install it in - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 79
MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal If a belt fails, always clean any debris from the duct and from the clutch and engine compartments when replacing the belt. WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 80
from the entire clutch air duct passage. 12. Check for signs of damage to seals on the transmission and engine. See your dealer promptly for service if any seals appear to be damaged. Tip: Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 81
There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. Place the transmission the process. 7. Take the vehicle to your dealer for service as soon as possible. 79 - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 82
has no visible water, dry the air box. 4. Thoroughly dry the air pre-cleaner located under the hood. 5. Take the vehicle to your dealer for service as soon as possible, whether you succeed in starting it or not. 6. If water has been ingested into the PVT follow the procedure on page - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 83
Filter Systems Air Filter Always change the air filter at the 5 Latches intervals outlined in the Periodic Maintenance Chart beginning on page 65. Service the air filter more Air frequently if the vehicle is operated Filter in wet or dusty conditions or at high throttle for extended periods - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 84
the spark arrester could result in serious injury or death. • Do not perform service on the spark arrester while the system is hot. Exhaust system temperatures can reach 1000° F. Allow components to cool sufficiently before proceeding. • Remove any combustible - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 85
MAINTENANCE Alternator Belt Belt Adjustment Check the alternator belt at the correct service interval as outlined in the Periodic Maintenance Chart beginning on page 65. Stop the machine on a flat level surface. Put the gear selector in Park, - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 86
separator daily for leaks. Drain water and replace the separator at the intervals outlined in the Periodic Maintenance Chart beginning on page 65. Service the separator more frequently if the vehicle is operated with inferior fuel. CAUTION! Both fuel and water will drain from the separator during - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 87
operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your dealer for service if throttle problems arise. Throttle Freeplay If the throttle pedal has excessive play due to cable stretch or misadjustment, it will cause a delay - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 88
MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 24. 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 - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 89
MAINTENANCE Brakes Brake Inspection 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Check brake discs for signs of cracks, excessive corrosion, warping or other damage. Clean any - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 90
MAINTENANCE Suspension Adjustments The front and rear suspensions can be adjusted to provide a stiffer suspension, if necessary. 1. Remove the top shock mounting bolts from the inside mounting positions. 2. Reposition the shocks to the outside mounting holes. 3. Reinstall the shock mounting bolts. - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 91
death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use POLARIS-approved following items occasionally for tightness, and if they've been loosened for maintenance service. Do not lubricate the stud or the lug nut. Nut Type Lug Nut - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 92
tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer. 3. Attach the wheel nuts and washers and finger tighten. 4. Carefully lower the - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 93
vehicle at night or in low light conditions until the headlight is replaced. 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 - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 94
MAINTENANCE Lights Headlight Beam Adjustment X X 8" (20 cm) 25 ft. (7.6 m) 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight and make a mark - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 95
15A 15A 20A 30A 15A 30A Brake Lights Fuel Pump Drive System Accessories, 12V Power Receptacle Engine Control Module Lights Power Steering (if equipped) Feature Supported Power Steering Fuse (if equipped) 93 - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 96
not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 95 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the fully charged battery in the battery holder - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 97
charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging. For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 98
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose, - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 99
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. • Avoid the use of automotive products, some of which can scratch the finish of your vehicle. • Always use clean - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 100
MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 65. Battery Maintenance See page 94 for storage and charging procedures. Fluid Levels Inspect the fluid - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 101
MAINTENANCE Removal from Storage 1. Charge the battery if necessary. Install it in the vehicle. 2. Fill the fuel tank with fuel. 3. Check all the points listed in the Daily Pre-Ride Inspection section on page 36. Tightness of the bolts, nuts and other fasteners should be checked by an authorized - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 102
SPECIFICATIONS RANGER Diesel Maximum Weight Capacity Dry Weight Test GVW - Rollover Protection System (ROPS) Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Hitch Tongue Capacity Max. Cargo Box Load* Overall Length Overall Width (box) Overall Width (tires) Overall Height Wheelbase - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 103
SPECIFICATIONS RANGER Diesel Driving System Type Shift Type Transmission Gear Ratio - High Transmission Gear Ratio - Low Transmission Gear Ratio - Reverse Front Drive Ratio Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Hood Headlight Taillights - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 104
SPECIFICATIONS RANGER CREW Diesel Maximum Weight Capacity Dry Weight Test GVW - Rollover Protection System (ROPS) Fuel Capacity Engine Oil Capacity Coolant Capacity Towing Capacity Hitch Tongue Capacity Max. Cargo Box Load* Overall Length Overall Width (box) Overall Width (tires) Overall Height - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 105
SPECIFICATIONS RANGER CREW Diesel Driving System Type Shift Type Transmission Gear Ratio - High Transmission Gear Ratio - Low Transmission Gear Ratio - Reverse Front Drive Ratio Tire Size - Front Tire Size - Rear Tire Pressure - Front Tire Pressure - Rear Brakes, Front/Rear Hood Headlight Taillights - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 106
POLARIS PRODUCTS Part Number 2878473 2879832 2878068 2878069 2877922 2877923 2870465 2880514 2880513 2871312 2871322 2871423 2876160 2872276 2871460 2871515 2871551 2871329 2872189 2871956 2859044 15W-40 Diesel Oil (2 qt./1.9 l) 5W-40 Synthetic Diesel Oil (2 qt./1.9 l) Gearcase / Transmission - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 107
TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 108
TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose starter connections Loose electronic control box connections Solution Recharge the battery to - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 109
TROUBLESHOOTING Engine Runs Irregularly, Stalls or Misfires Possible Cause Poor fuel quality or incorrect fuel Low fuel level Clogged fuel filter Clogged air filter Loose ignition - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 110
BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage. Warranty Coverage And Exclusions - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 111
of unsuitable attachments or parts, the use of contaminated fuels, the use of fuels, oils, lubricants or fluids other than those recommended in this manual, unauthorized alterations or modifications, ordinary wear and tear, and rust or corrosion. This warranty does not cover the cost of parts and/or - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 112
must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product. Outside the Country where your product - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 113
for the performance of the required maintenance listed in your owner's manual. Kohler Co. recommends that you retain all receipts covering maintenance on your off-road engine to a Kohler Co. dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 114
WARRANTY COVERAGE Kohler Co. will repair or replace emission control system parts, components and sub-assemblies found to be defective with respect to materials or workmanship at no cost to you including engine exhaust system related diagnosis, labor and parts. The choice and responsibility of the - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 115
MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 113 - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 116
MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 114 - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 117
INDEX A Accessory Outlets ...22 Air Filter ...81 Air Filter Cleaning ...81 All Wheel Drive ...54-55 Disengaging AWD...54 Engaging AWD ...54 Locking the Differential...55 All Wheel Drive Switch ...23 Alternator Belt ...83 Alternator Belt, Adjustment ...83 Arrester, Spark, Warning ...82 Auxiliary - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 118
...104 Polishing the Vehicle...97 Power Steering...24 Power Steering Unit (Cleaning) ...90 Pre-Ride Inspection ...36 Product Part Numbers ...104 Programmable Service Interval ...34 Public Lands ...64 PVT Break-In ...35 PVT Drying ...79 PVT System...76-79 PVT Warning...76 PVT, Cleaning Debris - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 119
...79 Transporting the Vehicle ...99 Tread Depth ...89 Trip Meter ...32 Trouble Code Display...34 S Safety Labels...10-12 Safety Symbols ...4 Safety, Winch Maintenance ...63 Seat Belts ...29 Seat Removal ...25 Service Interval ...34 Severe Use Definition ...65 Shifter ...22 Shifting Gears ...22 - 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 120
- 2015 Polaris Ranger Diesel / Crew Diesel | Owners Manual - Page 121
HELMET AND PROTECTIVE GEAR. ALL RIDERS MUST WEAR SEAT BELTS. NEVER USE ON PUBLIC ROADS. NEVER USE WITH DRUGS OR ALCOHOL. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc. 2100 Hwy
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PMS 419
Owner's Manual
for Maintenance and Safety
RANGER
®
Diesel
RANGER
CREW
®
Diesel