Nearly FinishedElectrical ComponentsAdapter PlateBolting Motor to TransmissionReady for the Battery BoxBattery BoxTransmission CouplerAlternator MountMotor Mount
OwnerGeorge Fox University
LocationNewberg, Oregon United States map
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Vehicle1992 Ford Ranger
Low speed grounds and maintenance vehicle
converted and used by George Fox
University Plant Services for mowing lawns
and other short grounds and maintenance
related errands.
MotorAdvanced DC L91-4003 Series Wound DC
6.7" Dia.
72-120 volt
130 amps continuous
150 amps for one hour
500 amps peak
13 HP continuous
15 HP for one hour
43 HP peak
DrivetrainAdvanced DC L91-4003 motor directly
coupled to stock 5 speed (clutch-less one
speed use).
ControllerAlltrax AXE 7245
24 to 72 Volt Input
Current Limit: 450 amps
30 second rating: 450 amps
2 minute rating: 450 amps
5 minute rating: 350 amps
1 hour rating: 200 amps
Batteries6 Trojan T-1275, 12.00 Volt, Lead-Acid, Flooded
12V, 120 AH @ 5 Hr Rate
Dimensions (L,W,H): 12-7/8", 7-1/8",
10-7/8"
Weight 82 lbs.
System Voltage72 Volts
ChargerQuick Charge SCO7210
Quick Charge Select-A-Charge On Board
72 Volt 10 Amp Charger
Dimensions (L,W,H): 9", 6-1/2", 6"
Weight: 26 lbs.
HeaterNone
InstrumentationStock instruments plus battery pack
voltage meter.
Top Speed40 MPH (64 KPH)
Being a low speed maintenance vehicle
the clutch was eliminated during the
conversion with the intention of only
using 1st gear. The truck tops out at
around 25mph in 1st gear and 40 mph in
3rd. Upshifting is not too difficult,
but downshifting is nearly impossible
without coming to a complete stop.
AccelerationAcceleration is good from 0-25mph. From
there on acceleration is very slow and
impractical.
Range9 Miles (14 Kilometers)
Cruising at 25mph will yield an
estimated 9 mile range at 75% depth of
discharge. The longest trip so far was
7 miles, after which the battery had
plenty of capacity to spare. Round trip
from physical pant to main campus is
1.65 miles so running 5 loads of grass
clippings and lawn mowers is possible.
Watt Hours/Mile450 Wh/Mile
At 25 mph the batteries are supplying
165.7 Amps at 67.9 Volts (11,250 Watts).
EV Miles
Start:121,896 Miles (196,130 Kilometers)
Current:121,945 Miles (196,209 Kilometers)
Total:49 Miles (78 Kilometers)
Seating Capacity2 adults
Conversion Time200 Hrs. (approximate) over the course of
2 months.
Conversion Cost$3,738 for parts and materials. This
excludes metal scraps used for making the
battery box, motor mounts, alternator
bracket etc.
Additional FeaturesAn alternator is mounted to the motors auxiliary shaft to
help charge the 12V battery. The alternators field is
only energized when the brakes are applied via the brake
switch and and a relay. A 1 amp trickle charger is
connected to the 12V system whenever the vehicle is
plugged in. No DC/DC converter is used.

3/4" thick Owens Corning Foamular rigid foam insulation
surrounds the batteries. The waste energy from
charging/discharging keeps them warm during occasionally
freezing winter weather.

Since the 1992 Ranger did not come with manual brakes,
the master cylinder, brake pedal, and firewall plate off
an older Ranger were adapted. This eliminated the need
for a vacuum pump to supply the brake booster.

code by jerry