Electric Polaris Ranger

[JRobyn]

Should stir up your electrolyte good!

 

[Xfaxman]

This is the largest load of brush so far! :thumbsup:

 

[NS Gearhead]

View attachment 470464

LOL!!! I love it! Glad to see you're getting some use out of it and having fun at the same time. What's the story? General clean up?

 

[Xfaxman]

LOL!!! I love it! Glad to see you're getting some use out of it and having fun at the same time. What's the story? General clean up?

Yep, had some high wind gusts with thunder storms lately. Lots of dead branches broke off of the oak trees in the woods close to the house.

 

[Xfaxman]

After 4 years of almost daily use, the deep cycle lead acid batteries were getting weak.

After some research I ordered the 8 kWh Lithium Ion conversion kit from: Voltronix

Here are the original batteries, under the seat:

Left side.

Right side.

Removed the side panel.

Removed the batteries.

Removed the battery trays and washed it out.

 

[PRCWI]

I was considering this before we bought our Gravely Atlas. I looked at an EV Ranger but we wanted the bigger bed size and carrying capacity. Can't wait to hear your experience with the conversion.

 

[PRCWI]

Just out of curiosity do you know what the specs are on the electric motor for your EV? I gave my land pride treker I had to my dad and it's having motor issues. Wondering how hard it would be to just convert it from Gas to Electric if we have to replace the motor? That would work way better for what they use it for anyway.

It uses a CVT Clutch drive system and the current motor puts out 1250-1350 rpm at idle and 3800-4000rpm max. So I am thinking if I could find an electric motor that we could put in the same spot as the gas motor that has similar RPM capabilities we could make it work with the existing drive system. It's got plenty of space for batteries under the seat similar to the EV Ranger so I think I could put the batteries in.

I am sure someone has done similar conversions but I am not real familiar with electric motors or the type we would need for this type of conversion.

 

[Xfaxman]

Yep, the specs are 30 horsepower, 3 phase AC, powered from a 48 volt DC Sevcon 650 amp motor controller.

There is a used motor and differential on eBay now:

This is the motor in the EV, under the dump bed:

I have no idea what the motor controller and a 48V battery charger would cost, but I know that I would not try the conversion with Ranger EV parts. :thumbdown:

 

[Xfaxman]

Re: Electric Polaris Ranger, Ordered The Voltronix USA 160Ah Lithium Ion Kit

Beaver Freight delivered the conversion kit today.

Used the V417 to unload it.

They added 1/4" plywood to the skid to make a sturdy shipping crate.

The battery rack modules are bolted to the skid and everything else is bubble wrapped and in custom cut cardboard boxes.

This is the battery charger.

 

[vvanders]

Very cool, should see a significant weight drop from the deep cycle(assuming same capacity).

Not sure what the charger setup is on those but generally it's a good idea to keep them at about 90% charge or less if you're not going to be driving it immediately. LiIon doesn't like 100% charge or < 10% charge for more than a short period of time.

Do keep us updated, looking forward to seeing how it turns out.

 

[Xfaxman]

Do keep us updated, looking forward to seeing how it turns out.

This is the left side battery rack module, still in the crate:

This morning I got the motor controller put back in:

And the right side battery rack module mounting holes drilled and bolted in:

Got the motor cables connected and the left side battery tray bolted in:

 

[rd_macgregor]

How does the volume and weight of the new battery set compare to the old/original?

 

[Xfaxman]

How does the volume and weight of the new battery set compare to the old/original?

Volume under the seat on the driver's side, before:

4 155ah deep cycle lead acid batteries.

After, 1 Lithium-ion battery pack.

Battery weight before, 8 at 90 pounds each = 720 pounds.

Battery weight after, 2 packs at 110 pounds each = 220 pounds.

 

[Xfaxman]

Used the shop crane to put it in on the battery tray, on a 2x4, so I could get the chains off:

Drilled the mounting holes and bolted it down:

 

[JRobyn]

I am wondering if fastening down the battery packs as far outboard as possible might provide the optimum cooling for the Sevcon controller?

 

[Xfaxman]

I have never had any overheating problems, so didn't think about that.

 

[Ford850]

Holy smokes! 500 lbs lighter is a huge difference. I wonder if you'll notice any loss of traction, but gaining 500 lbs of payload capacity is great.

 

[Xfaxman]

I wonder if you'll notice any loss of traction,

I don't think that I have to worry, with the narrow Interco Interforce 27-7.5-14, 6 ply, R1 tread tires:

 

[Xfaxman]

Re: Electric Polaris Ranger Conversion To Lithium-Ion Batteries

Some more progress pictures.


Removed the 2 inch diameter state of charge meter:

Filed a notch on the left side of the hole to clear the plug for the signal cable:

Don't like the way the new one is to be mounted to the supplied block plate. It would not be removable if you believe their claims about the VHB mounting tape. So I made my own mounting system.


Found an old pill bottle. Put the cap on the back of the new meter with VHB tape:

Had a small plastic Black Pepper jar and used an 1-1/4 hole saw on it:

Used the old trick to mark a straight line around a cylindrical object, used a pencil against the left side of the hose clamp:

Cut the bottom off at the required height:

Drilled the pill bottle for a short 6-32 all thread, held in place by double nuts:

Drilled a hole in the side of the retaining device for the signal cable:

Assembled to a piece of cardboard to simulate the dashboard and show how it works, Rear view:

Side view:

Front view:

 

[rd_macgregor]

Wow, I was surprised at how big the difference was between the new and old batteries. If cost was no object, you could double (it doesn't look like triple would fit) the capacity of the new set and still have a lighter load of batteries with considerably increased operating range.