Search found 47 matches

by Ribfeast
Sep 11 2019 12:48am
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

I rearranged the cells in the pack, and moved #16 to #15. All seems to be working well now, so maybe there was a loose connection on the eyelet terminal that was doing the voltage measurements, or the bolt to the cell link was loose. Will keep an eye on it over the next few weeks.
by Ribfeast
Sep 08 2019 11:41pm
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

Cheers, I shot them an e-mail this morning, will see what they say.
Might do a juggle of the pack tonight or over the next few days, I'd say the cells have 20-30 cycles on them.
by Ribfeast
Sep 08 2019 6:57pm
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

So I was driving up a hill with the pack around 70-80% charged over the weekend, and the Zeva BMS started beeping at me and cut the kart off from the pack, complaining about a low cell. Reset the BMS and took the remainder of the hill more slowly to not stress the pack, and checked it all over. Appe...
by Ribfeast
Jun 03 2019 12:38am
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

3 flashes might be the same issue mine had. I'm hoping it was just old age (2600hrs) vs the marginally higher lithium voltage. The details of the conversion are on the previous few pages, but basically: Remove lead acid batteries Remove rust remnants Spray the bay Put in a Formply floor (or whatever...
by Ribfeast
May 15 2019 5:41pm
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

Yeah might give that a try sometime, nothing to lose now.
The controller seems to have recalibrated itself and now drives the same as the old one. Must be some pretty clever electrickery going on inside.
by Ribfeast
May 14 2019 5:31pm
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

Installed the controller in the kart last night finally, great to have it up and running again! Had to adjust the accelerator stop button to eliminate a 2-flashes issue. For some reason this new controller appears to draw a bit more current than the old one, so maybe it has some different motor para...
by Ribfeast
May 09 2019 9:51pm
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

New controller has arrived at work, can't wait to get home and fit it! It's a generic one with the same model number, hopefully there is no Toro-specific programming in the old one.
by Ribfeast
May 02 2019 6:13pm
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

I bridged F1 to A1 one last night and then hooked up F2 and A2 to a bench power supply dialed to 50V 20A, and the motor spun, and upon inspection the brushes look OK, almost new judging by the amount of meat on them. Measuring A1 to A2 is less than an ohm, same for F1 to F2, so everything seems norm...
by Ribfeast
May 01 2019 5:25am
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

Just rechecked, only getting 1 volt between Pin 8 (contactor) on the Controller, and the 12V switched pole. The controller is supposed to drop pin 8 to ground when ready, and it doesn't seem to be doing this, it just floats up to positive voltage. Tried fooling it with a resistor but no luck. Going ...
by Ribfeast
Apr 30 2019 10:12pm
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

It's a Sevcon Millipak 633T46301. Toro's heavily marked up version is 110-2569. I'll check the motor brushes tonight, and double check the resistance of the contactor coil to confirm it is 126 ohms. The contactor does work when energized manually though. I've already removed the controller from the ...
by Ribfeast
Apr 30 2019 5:25pm
Forum: Motor Technology
Topic: Sevcon controller faulty
Replies: 0
Views: 191

Sevcon controller faulty

My girlfriend parked up the Toro Workman MDE 48V kart yesterday and then went to use it later in the afternoon, it makes all the right noises (reverse beep etc) but the main contactor doesn't click on, and getting 4 flashes on the dash. Tried bridging the 2 large terminals on the contactor to allow ...
by Ribfeast
Apr 30 2019 5:20pm
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

My girlfriend parked up the kart yesterday and then went to use it later in the afternoon, it makes all the right noises (reverse beep etc) but the main contactor doesn't click on, and getting 4 flashes on the dash. Tried bridging the 2 large terminals on the contactor to allow current flow but this...
by Ribfeast
Apr 15 2019 12:25am
Forum: Large EV General Discussion
Topic: Suzuki kei truck at 50kph flat ground
Replies: 15
Views: 1618

Re: Suzuki kei truck at 50kph flat ground

My kart is pretty much a golf kart, I think it has a 5kW motor and I've peaked it at around 15kW in spikes. For something with that weight I'd recommend more like 20kW nominal, or more. Unless it is just for use around a private property? Or look into one of these and convert it to lithium? http://p...
by Ribfeast
Apr 15 2019 12:21am
Forum: Large EV General Discussion
Topic: John Deere E-Gator rebuild(Picturestory)
Replies: 36
Views: 4968

Re: John Deere E-Gator rebuild(Picturestory)

That should be a weapon! They have a fast discharge rate compared to the LiFEPO4 cells in mine!
by Ribfeast
Apr 08 2019 7:40pm
Forum: Large EV General Discussion
Topic: John Deere E-Gator rebuild(Picturestory)
Replies: 36
Views: 4968

Re: John Deere E-Gator rebuild(Picturestory)

The shunt tells the BMS how much current you are pulling (or charging), so it can then calculate your state of charge from how much current was removed from the pack. Most BMS including the Zeva use them. My lithium battery peaks in the low 300A range, hence the need for the larger 500A shunt. A shu...
by Ribfeast
Apr 02 2019 10:22pm
Forum: Large EV General Discussion
Topic: John Deere E-Gator rebuild(Picturestory)
Replies: 36
Views: 4968

Re: John Deere E-Gator rebuild(Picturestory)

Looks great! I think my Toro has the same speed limit - 25k forward, 10k reverse. Probably the same Sevcon controller too. Might pay to test your individual cells occasionally in case you get a low one, I had one of mine go low prematurely last week and the BMS alerted me to it before I caused damag...
by Ribfeast
Apr 02 2019 10:19pm
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

Finally mounted up the inverter, here's a quick video of the BMS and inverter doing their thing, with the air compressor running off it. https://imgur.com/a/Kux2ZZB Next step is to install some LED headlights, 6x4 inch. Something like this: https://www.aliexpress.com/item/HJYUENG-led-work-light-4-X-...
by Ribfeast
Apr 01 2019 9:48pm
Forum: Large EV General Discussion
Topic: John Deere E-Gator rebuild(Picturestory)
Replies: 36
Views: 4968

Re: John Deere E-Gator rebuild(Picturestory)

Hi John, this is what I used to protect the batteries in my similar build: http://zeva.com.au/index.php?product=135 Zeva BMS. I also ordered the optional screen which I think should be a must, as you can then configure the high/low voltage cutoffs, see current draw etc. You'll also need 2 contactors...
by Ribfeast
Mar 14 2019 7:43pm
Forum: Large EV General Discussion
Topic: Industrial golf cart turned into solar generator.
Replies: 4
Views: 1745

Re: Industrial golf cart turned into solar generator.

This just came up if you are in Australia, dirt cheap, and would have jumped on it myself when I was building mine had I known... https://www.gumtree.com.au/s-ad/alfredton/miscellaneous-goods/lithium-batteries-and-charger/1212695536?utm_source=com.samsung.android.messaging&utm_medium=social&utm_camp...
by Ribfeast
Mar 14 2019 4:50pm
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

Cheers :) I've picked up a 2000W pure sine 48V inverter (4000W peak), it appears to run my compressor, power tools, heat gun and other items easily, problem is it is so big I can't mount it anywhere on the kart! But it could run the 650W server rack, or a fridge for many hours if there is a power ou...
by Ribfeast
Mar 14 2019 4:47pm
Forum: Large EV General Discussion
Topic: John Deere E-Gator rebuild(Picturestory)
Replies: 36
Views: 4968

Re: John Deere E-Gator rebuild(Picturestory)

Nah you went to a lot more trouble than I did, with respraying, fabrication etc. I'm fortunate mine came with a plastic roof and windscreen, and plastic tray, so I just needed to spray paint where the old batteries were.

You can upload your images to imgur.com which may help them load faster.
by Ribfeast
Mar 13 2019 7:11pm
Forum: Large EV General Discussion
Topic: John Deere E-Gator rebuild(Picturestory)
Replies: 36
Views: 4968

Re: John Deere E-Gator rebuild(Picturestory)

Very similar to my build!

https://endless-sphere.com/forums/viewt ... 4#p1449374

Can't get pictures to work on yours though?
Lithium makes an amazing difference hey!
by Ribfeast
Mar 03 2019 5:35pm
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

Some pictures :) https://imgur.com/a/pH8l9tN Just need to do a few tweaks to the voltage limits for charging etc, currently it is set a bit conservative. I'd also like to upgrade the white battery monitoring wires to thicker ones so that the current shunting works better, I think they are a bit thin...
by Ribfeast
Mar 01 2019 8:35pm
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

Wired it all up yesterday with BMS etc and took it for a spin, runs like an absolute animal now, goes up hills like they aren't there, seems to peak at around 185A draw with just me in it on a moderate 30 degree hill. Drove it to a mate's place and we took it up a 45 degree hill together and hit 300...
by Ribfeast
Feb 27 2019 5:48pm
Forum: Large EV General Discussion
Topic: Toro Workman MDE conversion
Replies: 49
Views: 4840

Re: Toro Workman MDE conversion

Power supply has arrived and I have been performing a balance charge for the last few days. Have the power supply set at 3.45V and it has been hovering at around 8-10A output without dropping (bank is wired as parallel, ie 1600Ah). Pack is sitting around 3.35V. Around 1.7kwh has been sent to the pac...