Polaris MS4000 User manual

ASAP Service and Maintenance Manual
ASAP Installed Systems
Maintenance: 3-47
Charging Air Force: 3-6
Charging System with Battery Brain and No Generator:7-10
Charging System with Battery Brain and Generator without Push Button: 11-15
Charging System with Battery Brain and Generator: 16-20
Charging System without Load Manager: 21-24
Dropping the Generator: 25-26
Getting to the Drive Belt: 27-28
Getting to the Drive Belt New Style: 29-31
Removing Blue Power Steering Wire: 32-33
Removing Load Manager (Wiring Schematic): 34
Rewinding the Roll-Up Door: 35-36
Wiring Diagrams: 37-47
Component Manuals: 48
Battery Brain: 48-55
Blizzard Wizard: 56-59
Curtis Cab: 60-69
Darley Davey Pump: 70-89
Dual Pro Charger: 90-96
Dometic Climate Control: 97-105
Federal Signal: 106-128
Electra Steer: 129-140
Hannay Hose Reel: 141-147
Honda Pump Engine: 148-167
Pro Tournament Battery Charger: 168-176
1

Warn Winch: 177-208
Whelen Lightbar: 209-211
Polaris
Chassis: 174-672
Polaris Owner’s Manual: 212-348
Polaris Service Manual: 349-708
2

Charging Air Force
Introduction
The ASAP has two batteries, one battery is located under the hood. This battery is for the Polaris
Ranger functions. This battery starts the engine, runs the ignition system, headlights, turn signals,
power steering system and Aux. cooling fan. This battery is for all Polaris chassis related items.
The other battery is located under the driver’s seat (this can be accessed by pulling up on the front
edge of the seat, lifting in the areas of between the driver’s legs and the passenger legs).
This battery is the deep cycle battery; it runs all emergency lighting, dome lights, windshield
wipers, generator starter, A\C control panel, 12 volt outlet in rear patent compartment.
Polaris Battery:
The Polaris battery is charged two ways:
1. Polaris engine
2. Onboard battery charger
If the Polaris engine is running the engine charges the battery.
If the shoreline is plugged in, the onboard battery charger charges the battery.
If the generator is running the onboard battery charger charges the battery.
Any time the generator is running, the onboard battery charger is on and charging batteries
The only time the onboard charger is not charging the Polaris battery is if the ignition key is in
the “on” position or the Polaris engine is running. This is to prevent double charging.
Note: There is a solenoid that only allows one device to charge the Polaris battery at one
time. By turning the ignition key to the “on” position, the solenoid breaks the connection from
the onboard battery charger to the Polaris battery.
(This creates a red blinking light on the onboard battery charger).
As a safety measure, this solenoid does not allow current from the battery charger to enter the
system when the Polaris engine is running. The engine stator is charging the battery when the
engine is running.
Q. When would you find yourself on this type of situation?
A. If you were driving the ASAP and running the generator.
Q. Is it okay to drive the ASAP with the generator running?
A. Yes
Q. Is it okay to have the shoreline plugged in all the time?
A. Yes, anytime the ASAP is stationary and you have access to 110 volt outlet, it should be
plugged in. The battery charger will automatically shut off when your batteries are full.
3

The Polaris battery is located under the hood and the steel solenoid is located near this battery.
This battery size is considered a CB30L-B. Always replace it with one that is equivalent.
Deep Cycle Battery:
The deep cycle battery is charged only one way:
1. Onboard battery charger
If the shoreline is plugged in, the onboard battery charger charges the battery.
If the generator is running the onboard battery charger charges the battery.
Any time the generator is running the onboard battery charger is on and charging the deep
cycle battery.
Q. Is it okay to drive the ASAP with the generator running?
A. Yes
Q. Is it okay to have the shoreline plugged in all the time?
A. Yes, anytime the ASAP is stationary and you have access to a 110 volt outlet, it should
be plugged in. The battery charger will automatically shut off when your batteries are full.
4

The deep cycle battery is located under the driver. Its size is considered a group 27. When
replacing this battery always replace it with a Group 27 Deep Cycle battery.
This battery needs to be charged daily to prevent discharge.
If the deep cycle battery gets discharged completely (less than 2 volts), the onboard battery
charger will not start charging the battery.
You will need to hook up an external battery charger like one you would put on your car or attach
a pair of jumper cables from another vehicle for a couple of minutes.
If using an external charger it will need to be used for approximately one half hour. This will put
enough charge into the battery to allow the onboard charger to start charging the battery.
Note: The onboard battery charger will not start charging a battery that is completely
dead. The charger thinks that that battery may have a shorted cell in it and prevents the
charging process from starting for safety reasons.
Start Charging the Batteries
To start charging the batteries you can do it one of two ways. You can simply plug in an
extension cord into the shoreline receptacle located near the driver’s door. Or you can start the
generator. After you do one or the other, locate the onboard battery charger. It will be located
under the dash on earlier models and under the hood on newer models.
Observe the red L.E.D bar graph. The more red lights you have the more the battery is
discharged. As the battery charges up the lights will one by one go out resulting in just one red
light. It then will turn green, indicating the battery is fully charged. The charger has two indivual
battery chargers within the one case, so they are completely separate from each other. So you may
have one green light on one battery and red lights showing on the other battery.
5

The following picture shows the charging status.
Notice that even with three red lights on, the battery has 14.0 volts in it. That’s still a pretty good
battery.
If the battery was completely dead, it will take at least 8 hours to recharge the deep cycle
battery up to a full charge status.
Shoreline Location:
The shoreline is located near the driver’s door.
6

Charging System with Battery Brain and No
Generator
Introduction
The ASAP has two batteries, one battery is located under the hood. This battery is for the Polaris
Ranger functions. This battery starts the engine, run’s the ignition system, headlights, turn
signals, power steering system and (optional) aux. cooling fan. This battery is for all Polaris
chassis related items.
The other battery is located under the driver’s seat (this can be accessed by pulling up on the
front edge of the seat, lifting in the areas of between the driver’s legs and the passenger legs).
This battery is the deep cycle battery; it runs all emergency lighting, dome lights, windshield
wipers, A\C control panel, and 12 volt outlet in patent compartment.
Polaris Battery:
The Polaris battery is charged two ways:
1. Polaris engine
2. Onboard battery charger
If the Polaris engine is running the engine charges the battery.
If the shoreline is plugged in, the onboard battery charger charges the battery.
Q. Is it okay to have the shoreline plugged in all the time?
A. Yes, anytime the ASAP is stationary and you have access to 110 volt outlet, it should be
plugged in. The battery charger will automatically shut off when your batteries are full.
The Polaris battery is located under the hood.
This battery size is considered a CB30L-B. Always replace it with one that is equivalent.
7

Deep Cycle Battery:
The deep cycle battery is charged only one way:
1. Onboard battery charger
If the shoreline is plugged in, the onboard battery charger charges the battery.
The deep cycle battery is located under the driver. Its size is considered a group 27.
When replacing this battery always replace it with a Group 27 Deep Cycle battery.
This battery needs to be charged daily to prevent discharge.
The deep cycle battery has a load manager device that monitors the battery voltage at all times.
As long as the battery voltage is above 10.5 volts the green light is illuminated on the dash
indicating the battery is in an okay status.
If the voltage drops below 10.5 volts the green light will go out, indicating the battery needs
charging. (The green light will only work if the ignition key is in the on position)
Green indicating light
8

If you find yourself in an emergency situation and your deep cycle battery drops below the 10.5
volts which will cut or turn off all auxiliary power you can push the push button on the dash near
the windshield to regain 12 volt battery power.
At that point you are running on only the remaining battery voltage and you will run
the battery dead. This is to be done only if absolutely necessary.
Start Charging the Batteries
To start charging the batteries you simply plug an extension cord into the shoreline receptacle
located near the driver’s door.
Observe the red L.E.D light on the battery charger located under the hood. It will turn green,
indicating the batteries are fully charged. The charger has two indivual battery chargers within the
one case, so they are completely separate from each other and the battery charger is completely
waterproof. (Refer to the battery charger manual for further information).
It will take at least 8 hours to recharge the deep cycle battery up to a full charge status if it
was completely down
Shoreline Location:
The shoreline is located near the driver’s door.
Over ride button for
the battery brain
9

10

Charging System with Battery Brain and
Generator without Push Button
Introduction
The ASAP has two batteries, one battery is located under the hood. This battery is for the Polaris
Ranger functions. This battery starts the engine, runs the ignition system, headlights, turn signals,
power steering system and the optional auxiliary cooling fan.
This battery is for all Polaris chassis related items.
The other battery is located under the driver’s seat (this can be accessed by pulling up on the
front edge of the seat, lifting in the areas between the driver’s legs and the passenger legs).
This battery is the deep cycle battery; it runs all emergency lighting, dome lights, windshield
wipers, generator starter, A\C control panel, 12 volt outlet in the patent compartment. And any
other optional equipment that may be on the unit
The ignition switch and master switch do not have to be “ON” in order to charge batteries
Polaris Battery:
The Polaris battery is charged two ways:
1. By the Polaris engine
2. By the onboard battery charger
If the Polaris engine is running the engine charges this battery.
If the shoreline is plugged in, the onboard battery charger charges the battery.
If the generator is running the onboard battery charger charges the battery.
Any time the generator is running the onboard battery charger is on and charging batteries
The only time the onboard charger is not charging the Polaris battery is if the ignition key is in
the “ON”position or the Polaris engine is running. This is to prevent double charging.
Note: There is a solenoid that only allows one device to charge the Polaris battery at one
time. By turning the ignition key to the “on” position, a solenoid breaks the connection from the
onboard battery charger to the Polaris battery.
As a safety measure this solenoid does not allow current from the battery charger to enter the
system when the Polaris engine is running. The engine stator charges the battery when the engine
is running.
Q. When would you find yourself in this type of situation?
A. If you were driving the ASAP and running the generator.
Q. Is it okay to drive the ASAP with the generator running?
A. Yes
Q. Is it okay to have the shoreline plugged in all the time?
A. Yes, anytime the ASAP is stationary and you have access to 110 volt outlet, it should be
plugged in. The battery charger will automatically shut off when your batteries are full.
11

The Polaris battery is located under the hood and the steel solenoid is located near this battery.
This battery size is considered a CB30L-B. Always replace it with one that is equivalent.
Deep Cycle Battery:
The deep cycle battery is charged only one way:
1. By the onboard battery charger
If the shoreline is plugged in, the onboard battery charger charges the battery.
If the generator is running the onboard battery charger charges the battery.
Any time the generator is running the onboard battery charger is on and charging the deep
cycle battery.
Since the deep cycle battery can only be charged via the onboard battery charger it is good
practice to keep the shoreline plugged in often or run the generator.
This is only needed of course if you have been running any of the accessories that are
connected to the deep cycle battery.
12

A quick way to determine what is connected to the deep cycle battery is to turn off the
master switch that is located between the driver’s legs. This switch runs everything that is
connected to the deep cycle battery. So if you’re not sure, turn that item in question “on”
and then turn the master switch off. If the item in question turns off then is run off the deep
cycle battery.
If it stays on then it is run off the Polaris battery and the factory electrical system.
The deep cycle battery is located under the driver. Its size is considered a group 27. When
replacing this battery always replace it with a Group 27 Deep Cycle battery.
This battery needs to be charged daily to prevent discharge.
13

The deep cycle battery has a load manager device that monitors the battery voltage at all times.
As long as the battery voltage is above 10.5 volts the green light is illuminated on the dash
indicating the battery voltage is in an okay status.
If the voltage drops below 10.5 volts the green light will go out indicating the battery needs
charging. When the green light goes out the battery voltage is below 10.5 volts. This condition
will make the load manager device shut down all deep cycle battery functions.
The green light only works if the ignition key is in the “ON” position
Start Charging the Batteries
To start charging the batteries you can do it one of two ways.
1. You can simply plug an extension cord into the shoreline receptacle located near the driver’s
door.
Or
2. You can start the generator.
After you do one or the other, locate the onboard battery charger. It is located under
the hood.
Observe the red L.E.D light. It will turn green, indicating the batteries are fully charged. The
charger has two separate battery chargers within the one case, so they are completely separate
from each other. Refer to the battery charger manual for further information.
It will take at least 8 hours to recharge the deep cycle battery up to a full charge status if it
was completely down to 10.5 volts
Shoreline Location:
The shoreline is located near the driver’s door.
14

15

Charging System with Battery Brain and
Generator
Introduction
The ASAP has two batteries, one battery is located under the hood. This battery is for the Polaris
Ranger functions. This battery starts the engine, runs the ignition system, headlights, turn signals,
power steering system and (optional) aux. cooling fan.
This battery is for all Polaris chassis related items.
The other battery is located under the driver’s seat (this can be accessed by pulling up on the
front edge of the seat, lifting in the areas of between the driver’s legs and the passenger legs).
This battery is the deep cycle battery; it runs all emergency lighting, dome lights, windshield
wipers, generator starter, A\C control panel, 12 volt outlet in patent compartment.
(The ignition switch and master switch do not have to be “ON” in order to charge batteries)
Polaris Battery:
The Polaris battery is charged two ways:
1. Polaris engine
2. Onboard battery charger
If the Polaris engine is running the engine charges the battery.
If the shoreline is plugged in, the onboard battery charger charges the battery.
If the generator is running the onboard battery charger charges the battery.
Any time the generator is running the onboard battery charger is on and charging batteries
The only time the onboard charger is not charging the Polaris battery is if the ignition key is in
the “on” position or the Polaris engine is running. This is to prevent double charging.
Note: There is a solenoid that only allows one device to charge the Polaris battery at one
time. By turning the ignition key to the “on” position, the solenoid breaks the connection from
the onboard battery charger to the Polaris battery.
As a safety measure this solenoid does not allow current from the battery charger to enter the
system when the Polaris engine is running, as the engine stator is charging the battery when the
engine is running.
Q. When would you find yourself on this type of situation?
A. If you were driving the ASAP and running the generator.
Q. Is it okay to drive the ASAP with the generator running?
A. Yes
Q. Is it okay to have the shoreline plugged in all the time?
A. Yes, anytime the ASAP is stationary and you have access to 110 volt outlet, it should be
plugged in. The battery charger will automatically shut off when your batteries are full.
16

The Polaris battery is located under the hood and the steel solenoid is located near this battery.
This battery size is considered a CB30L-B. Always replace it with one that is equivalent.
Deep Cycle Battery:
The deep cycle battery is charged only one way:
1. Onboard battery charger
If the shoreline is plugged in, the onboard battery charger charges the battery.
If the generator is running the onboard battery charger charges the battery.
Any time the generator is running the onboard battery charger is on and charging the deep
cycle battery.
17

The deep cycle battery is located under the driver. Its size is considered a group 27. When
replacing this battery always replace it with a Group 27 Deep Cycle battery.
This battery needs to be charged daily to prevent discharge.
The deep cycle battery has a load manager device that monitors the battery voltage at all times.
As long as the battery voltage is above 10.5 volts the green light is illuminated on the dash
indicating the battery voltage is in an okay status.
If the voltage drops below 10.5 volts the green light will go out indicating the battery needs
charging. When the green light goes out the battery voltage is below 10.5 volts. This condition
will make the load manager device shut down all deep cycle battery functions.
(The green light will only work if the ignition key is in the on position)
If you find yourself in an emergency situation and your deep cycle battery drops below the 10.5
volts which will cut or turn off all auxiliary power, you can push the push button on the dash near
the windshield to regain 12 volt battery power. At that point you are running on only the
remaining battery voltage and you will run the battery dead. This is to be done only if absolutely
18

necessary. It would be better to start the generator which would turn on the on board battery
charger.
NOTE:
You might find yourself in a situation where you have the master switch in the on position, the
ignition key in the on position and the green light is not on but you know that the deep cycle
battery is up in charge.
Hold the Over ride button for two seconds until you here the load manager “click”.
Sometimes the load manger may see a condition where it kicks itself off or someone may
accidently push the over ride button by mistake. Either of these conditions will result in having no
deep cycle battery functions even though the battery is up.
So just remember if you happen to have lost auxiliary power for no apparent reason. You first
need to hold the over ride button in for a couple of seconds to reset the load manager.
You will either get power back or the load manger will kick back out. If it kicks out your battery
is low.
Start Charging the Batteries
To start charging the batteries you can do it one of two ways. You can simply plug in an
extension cord into the shoreline receptacle located near the driver’s door. Or you can start the
generator. After you do one or the other, locate the onboard battery charger. It is located under
the hood.
Observe the red L.E.D light. It will turn green, indicating the batteries are fully charged. The
charger has two separate battery chargers within the one case, so they are completely separate
from each other. Refer to the battery charger manual for further information.
It will take at least 8 hours to recharge the deep cycle battery up to a full charge status if it
was completely down
Over ride button
for the battery
19

Shoreline Location:
The shoreline is located near the driver’s door.
20