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Hi all - I recently bought a used Ranger EV Li-ion that would not charge (way below book value) - I thought I had diagnosed it down to the 12V battery, but could still not get the on-board delta-Q to charge the main (Brammo batteries). The symptom is a sequence of flashing LEDs on the charger and charger relay clicks - from what I can tell the BMC is cycling the charger through the installed programs in an infinite loop. I was able to trickle charge the main pack and the Ranger drives fine. Delta-q was helpful - I verified the charger is working as expected. Polaris was not helpful at all - support site will not provide any help to diagnose - (they will not provide documentation or the digital wrench tools to diagnose). The local dealer admits they don't usually work on EV's and expect to replace the batteries at >$10k - I have read several posts about dealers replacing everything and still not fixing the root cause. I could not find any documentation on the Brammo batteries (they seem fine, but are blinking a code with green LEDs when the ignition is on). If anyone has documentation on the battery system (or how the Brammo-based system normally charges), I would greatly appreciate it. I could replace the battery system, but it would be a shame if it's not necessary...
 

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This is going to be a challenge. Brammo was purchased by Polaris. Polaris used their technology in the Victory Empulse and the Ranger EV LI. The Ranger implementation was a problem from the start and the motorcycle was discontinued in 2017. This is an extreme long shot: try contacting Craig Bramscher he might point you to someone that is willing to assist.
Brammo, Inc.
Brammo Bullhead Logo.png
IndustryVehicle Manufacturing
FoundedAshland, Oregon (2002)
FounderCraig Bramscher
HeadquartersTalent, Oregon
,
United States
Area servedNorth America
Key peopleCraig Bramscher (Founder)
ProductsElectric vehicle drivetrains
OwnerCummins Inc.
 

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Discussion Starter #4
What year is it?

Get a service manual for it so you can decode the flashes and troubleshoot the problem.
thanks - sorry, it's a 2016 and it looks brand new. I did buy the service manual, but it only shows you the charger LED and Diagnostic trouble codes (SPN/FMI). There are no faults shown in the charger or the instrument panel. I also bought a diagnostic cable for the charger that allowed me to download charge logs and change the algorithms - but the charger seems healthy. The LED's on the batteries themselves are behind a glass window (had to remove the side fenders on the Ranger) and they are flashing some repeating patterns - these are the codes I would like to understand. The battery LEDs are flashing green, so they may not have a fault either. The guy I bought it from inherited it from his uncle who passed away - it looks like they had let the aux battery discharge to 6V and the main pack to 39V (which is still a relatively safe 3.25V per cell). It seems like a battery controller issue (maybe code/configs got corrupted when the aux battery died?), but I'm afraid the dealer will not know how to fix it without replacing everything. I bought an adapter from the digital wrench socket to an OBD2 , but haven't found software that can correctly talk to the VCM. The Polaris "Digital Wrench" is only sold to dealers. It's been interesting, but frustrating.
 

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Discussion Starter #5
This is going to be a challenge. Brammo was purchased by Polaris. Polaris used their technology in the Victory Empulse and the Ranger EV LI. The Ranger implementation was a problem from the start and the motorcycle was discontinued in 2017. This is an extreme long shot: try contacting Craig Bramscher he might point you to someone that is willing to assist.
Brammo, Inc.
Brammo Bullhead Logo.png
IndustryVehicle Manufacturing
FoundedAshland, Oregon (2002)
FounderCraig Bramscher
HeadquartersTalent, Oregon
,
United States
Area servedNorth America
Key peopleCraig Bramscher (Founder)
ProductsElectric vehicle drivetrains
OwnerCummins Inc.
thanks! worth a try...

After a lot of digging, it seems like Polaris tried to use a lead-acid charger to charge lithium ion batteries. The Battery controller looks like it uses the "tap method" to change the delta-Q charging algorithms on-the-fly. If the charger gets stuck on an algorithm (maybe due to an error in the BMC), it overcharges the Li-ion pack - I have seen a few posts on this forum and others that sound like that failure mode. I asked Polaris if there was a Service Bulletin and they said no. I have had other Polaris equipment that works great, but I probably bought a headache here...
thanks again
 
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