off road kart build

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mikkelibob

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project - manco scorpion electric kart.
stuff: me0909, alltrax AXE 4834, 36v (old 12v 18ah mower batteries for now).

I have a few questions:

battery placement - off road go karts, like mine, often have the little shelf thing that's part of the main frame, that floats above the rear swing arm. It seems like the perfect place for the controller and contactor, but is it too high for the batteries? I don't want to have a potential projectile behind my cranium, but even if I have space next to the motor on the rear swingarm, it seems like I should isolate the batteries from the vibration (to the extent the suspension smooths out the ride of the kart at all). As a fall back I could put batteries next to the drive, but I'd like to save room for a passenger.

wiring question - I've got an alltrax controller and a me0909. I've got precharge resistor, contactor, and diode on the way. But I would really like to see a picture of things wired up on an actual system. For instance, I'm not totally sure how the contactor looks all wired up. A step by step look would be great. There's probably something already like out there, doesn't anybody know where? Also not sure if I need a big kill switch button, and if so, where it goes in the wiring diagram.

great ratio question - I think the me0909 does about 3000rpm at 36v maxed. Kart has 11T sprocket (smallest I can find on a 7/8 shaft), 60T drive sprocket on live axle, and 18 inch rear tires. That's a 5.45:1 ratio. I'm less concerned about high speed (12-15mph would be fun) as more concerned about plowing through high grass on ill maintained ranch roads. Should I try to add an intermediate jackshaft, or just trust in the almighty torque of electric?
 

HelloYOU

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project - manco scorpion electric kart.
stuff: me0909, alltrax AXE 4834, 36v (old 12v 18ah mower batteries for now).

I have a few questions:

battery placement - off road go karts, like mine, often have the little shelf thing that's part of the main frame, that floats above the rear swing arm. It seems like the perfect place for the controller and contactor, but is it too high for the batteries? I don't want to have a potential projectile behind my cranium, but even if I have space next to the motor on the rear swingarm, it seems like I should isolate the batteries from the vibration (to the extent the suspension smooths out the ride of the kart at all). As a fall back I could put batteries next to the drive, but I'd like to save room for a passenger.

wiring question - I've got an alltrax controller and a me0909. I've got precharge resistor, contactor, and diode on the way. But I would really like to see a picture of things wired up on an actual system. For instance, I'm not totally sure how the contactor looks all wired up. A step by step look would be great. There's probably something already like out there, doesn't anybody know where? Also not sure if I need a big kill switch button, and if so, where it goes in the wiring diagram.

great ratio question - I think the me0909 does about 3000rpm at 36v maxed. Kart has 11T sprocket (smallest I can find on a 7/8 shaft), 60T drive sprocket on live axle, and 18 inch rear tires. That's a 5.45:1 ratio. I'm less concerned about high speed (12-15mph would be fun) as more concerned about plowing through high grass on ill maintained ranch roads. Should I try to add an intermediate jackshaft, or just trust in the almighty torque of electric?



Here is the wiring diagram:

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I got rid of my me0909 a long time ago due to defect in manufacturing and I went series-wound DC instead. So I can't help you with that motor. The gearing you have should be low enough for it I would think.
 

mikkelibob

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Do you need the key switch and emergency stop? The kits usually just have the contactor, diode, and fuse.
 

OzFab

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I must have missed this the first time around...

battery placement

Can you provide pics of the kart? Concentrate on the area whaer the swingarm meets the main frame...

great ratio question - I think the me0909 does about 3000rpm at 36v maxed. Kart has 11T sprocket (smallest I can find on a 7/8 shaft), 60T drive sprocket on live axle, and 18 inch rear tires. That's a 5.45:1 ratio. I'm less concerned about high speed (12-15mph would be fun) as more concerned about plowing through high grass on ill maintained ranch roads. Should I try to add an intermediate jackshaft, or just trust in the almighty torque of electric?

Well, that ratio will give you a high top speed; according to our speed calculator & the numbers you provided, you will end up with a top speed around 30mph...

The thing that concerns me is the motor, 4hp is not a lot for a kart of that size; yes, you'll have buckets of torque but, that's pointless if you can't deliver it efficiently...

With those two points in mind, you may want to reconsider the gearing; for example, if you use an 80tooth axle sprocket instead of a 60t, you end up with a 7.2:1 ratio & a top speed of around 22mph, which would be much more tolerable for the motor...

Alternatively, you could spend the extra $65 & buy the stronger me0708 motor... unless you already have the me0909...
 

mikkelibob

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quick wiring question:

In general the alltrax wiring diagram seems pretty simple. I really wish I could find some real world photos of the same diagram made real, but I think I can muddle through.

I've got a Alltrax AXE 4834 and a Curtis Style PB-6 0-5K Ohm Throttle. The throttle has just 2 wires. I'm not understanding how I'm supposed to wire it up. The diagram shows the red wire split, so that one goes into the contactor? Going from the throttle (through a key switch) and into the fuse before the positive battery terminal seems doable, if I can figure out where that wire connects to the throttle.

I think this photo helps some:
http://www.evdrives.com/product_p/thr-pb6.htm

So does the two long wires that come out of the throttle go on pin tab 2 & 3; the "key on" on the pb6 diagram go to tab 1?
 

HelloYOU

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The speed pot is bidirectional. It does not matter how you wire it up. You don't have to use the switch on throttle. Just follow the diagram I gave you and you will be set. If you want no key switch or E-stop then you can omit those. That's just how I wire mine up.
 

mikkelibob

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oy vey, a little embarassing I asked basically the same question back in Jan.

Okay, another question. Does it matter which way the contactor is wired? I.e. is there an in and an out side?
 

mikkelibob

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Need a little trouble shooting. I was able to program the controller with external power, but I don't think I'm getting it power properly from the batteries.

I'm pretty sure I've properly put a wire from B- to the diode, and from the diode to the 1st controller input. Is that the way to do without a key switch? I'm not getting the green on light from the controller. Is that the way it should be set up? I don't think my voltmeter is reading a current coming out of the diode.
 
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