Rebuilding a DC forklift motor (mostly about turning a damaged commutator)
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- Опубликовано: 5 дек 2018
- Here’s a video I shot while rebuilding a large DC traction motor from a Daewoo/Doosan forklift. The motor is about 11” in diameter, 14” long and weighs 200lbs (that’s 28cm x 35cm @ 80kg for those in the modern world).
The motor, and the forklift it belongs to, have low hours but the previous owner had overloaded the drive motor often and hard enough to damage the brushes and commutator and even melt some of the brass brush holder.
This video primarily covers my attempt to repair the commutator on the lathe but also shows some steps in reassembly and final test of rebuild motor.
To my profound relief it seems to be virtually good as new 
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Nice work!
good work keep it up buddy
Thank you Sir! this gives me hope!
So glad to hear it. That's why I recorded and uploaded it :-)
You need to clean up also between commutator lamels. It has proberly weared brushes causing that damage, the copper coils looks good and there is no solder trowing out by heat.
Damn you're smart!!!
I dunno about that but I am very happy, and relieved, that the forklift motor worked when I put it all back together.
I have what appears to be the exact same motor but with Caterpillar branding. The label only mentions voltage and OEM part numbers. You don’t happen to know who makes it or what the specs are, do you?
If it's the same as mine it's a Daewoo/Doosan lift. Many were sold with Caterpillar branding in here in Canada and surely in the US as our market isn't worth the hassle. I have a certain amount of information on the Daewoo variant of the machine as I have a service manual for it. I suspect Cat-branded machines are identical. What do you want to know about it?
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What the speed of the motto
Motor
These big dc forklift traction motors tend to spin pretty slowly from what I've heard. Maybe 1500 to 2000 rpm but mostly they're built for torque at low speeds in an application where weight is an asset rather than a problem. The motor mates directly to the différential and only has a couple steps of reduction before getting to the drive wheels (input reduction in diff, diff reduction and final drive planetaries au each wheel). So the short answer is VERY SLOW by dc motor standards.
kW?
I don't know. It's not specified in the service manual I have and it's a48V system so not being pushed very hard. The traction side of the controller looks to be built for about 600A peak so theoretical max 600x50V = 20kW but it probably never gets to full current at full system voltage. My bet is that it rarely goes over 20kW but could be pushed a lot harder with a blower to cool it.
And I guess I should keep in mind that the old brush holder was melted so maybe that's the weak link.