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Old 06-14-2017, 04:10 PM
RndmGuy06 RndmGuy06 is offline
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Default Donor Raymond Forklift - EV Project Kick-off

Mission Statement.
I am looking to pull useful components out of a Raymond Forklift for an Electric Vehicle Conversion.

Back Story about forklift.
Was told it lost a control board and was pushed aside. Assuming all useful components are functional.

Intermediate Goal
Build Proof of Concept EV to gain practice and commute to work (2 miles each way.)
Min Range 25 miles
Min Speed 50 mph
Voltage 48 - 84 DC
Amp Unknown (400+ ?)
Donor Vehicle Varied based on ability of Forklift equipment

End Goal (Completely new project)
Use the skills from this project to build a true EV. 85 mph sustained (Utah Freeway Speeds). 100 mile range. Donor Vehicle Mazda RX8. Quicker than stock. Probably AC & Lipo.

---

Donor Forklift specs I can find...
Model 537-CRS30T
Capacity 3000 lbs
Battery Volts 48 volt
No: 24-125-13-493AHL-B
Amp Hr. Capacity: 750 AH
Truck Weight without Battery 10,225 lbs
Truck weight with Battery 13,625 lbs

Motors (Raymond Specific)
579-273 Motor, DC Aux RayBuilt
579-274 Motor, DC Lift RayBuilt
579-275 Motor, DC Drive RayBuilt

---

Can you help me?
What components should I take from this forklift? I cannot find the motor specs anywhere. I have pictures & can get dimensions.

What I am planning to take...
Drive Motor
Lift Motor
Controller
Throttle
Batteries

Thank you for reading to this point! I would love any comments you may have

Last edited by RndmGuy06; 06-14-2017 at 04:15 PM. Reason: Added Formatting
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  #2  
Old 06-14-2017, 04:12 PM
RndmGuy06 RndmGuy06 is offline
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Default Re: Donor Raymond Forklift - EV Project Kick-off

1 - Forklift
2 - Motor Bay
3 - Drive Motor
4 - Hydro Lift Motor
5 - Junction Box
Attached Images
File Type: jpg IMG_5460.JPG (2.10 MB, 10 views)
File Type: jpg IMG_5444.JPG (2.33 MB, 16 views)
File Type: jpg IMG_5445.JPG (1.89 MB, 14 views)
File Type: jpg IMG_5442.JPG (1.77 MB, 12 views)
File Type: jpg IMG_5446.jpg (1.21 MB, 4 views)

Last edited by RndmGuy06; 06-14-2017 at 04:14 PM. Reason: Added More Photos
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  #3  
Old 06-14-2017, 05:54 PM
Duncan Duncan is offline
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Default Re: Donor Raymond Forklift - EV Project Kick-off

Hi
Those look amazingly clean and new bits!

If you have the complete machine you can sell
The batteries - no use whatsoever in an EV - but worth money
The mast and forks - farmers here put them on the back of tractors
The Body - it will be heavy and worth a bit as scrap

Motors - the drive motor is most useful
Measure it - 9 inches diameter or 11 inches is good - read the thread about re-using a forklift motor

You will want all of the contactors heavy wire and connectors - you will be able to use most of them

Also keep the throttle and anything else that looks useful

Voltage 84v will probably NOT give you 50 mph - think in terms of 144v minimum
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Old 06-15-2017, 03:05 AM
boekel boekel is offline
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Default Re: Donor Raymond Forklift - EV Project Kick-off

Nice one, I have picked parts of a similar truck.

see post 2233 and further:
http://www.diyelectriccar.com/forums...-7598p224.html

nice sepex motor (9inch , 13 inch long) tapered axle on drive end, I use the flat axle on the other end (where the brake is on) in a boat.







the pump motor is nice and big too, with a continuous duty, driven by a Curtis 1204-503 48V/100A controller in 'my' truck.
I can't find pictures of it atm.

Battery 750Ah? 48V nice for a boat or off grid energy storage.
These trucks are scrapped also because the control levers (joystick) aren't produced anymore.

lot's of good cables also. truck itself is very heavy.

Oh and motor comes off easy just remove the small bolts on the flange and lift with another forklift, it's stuck on the drive unit by the sealer compound in between, you can see the blue stuff on this photo:



I also took the dc motor used for steering the truck, it has a nice gearbox on it and I was able to sell it for 250 euro's!
[edit] i don't see the steering motor, this one might bee hydraulic?

Last edited by boekel; 06-15-2017 at 03:09 AM.
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Old 06-15-2017, 08:51 AM
RndmGuy06 RndmGuy06 is offline
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Default Re: Donor Raymond Forklift - EV Project Kick-off

Quote:
Originally Posted by boekel View Post
Nice one, I have picked parts of a similar truck.
...
nice sepex motor (9inch , 13 inch long) tapered axle on drive end, I use the flat axle on the other end (where the brake is on) in a boat.
...
the pump motor is nice and big too, with a continuous duty, driven by a Curtis 1204-503 48V/100A controller in 'my' truck.
I can't find pictures of it atm.

Battery 750Ah? 48V nice for a boat or off grid energy storage.
These trucks are scrapped also because the control levers (joystick) aren't produced anymore.

lot's of good cables also. truck itself is very heavy.

Oh and motor comes off easy just remove the small bolts on the flange and lift with another forklift, it's stuck on the drive unit by the sealer compound in between, you can see the blue stuff on this photo:
Boekel. Thank you for your reply. Just checked the forklift plate. "6 HR 930 Amp." Not sure that that means. I hadn't thought of off grid storage yet. Been contemplating solar at our home.

Drive Motor. How fast can I spin this thing? Up to 5000 rpm? Do you know what an estimated max power would be? Thank you for the link and photos. Glad I am not the only one on a budget trying to take components from a forklift!

[Moderators. Any Idea where my response to Duncan went? I responded last night. Had hyperlinks and everything.]

Last edited by RndmGuy06; 06-15-2017 at 08:53 AM. Reason: Added Forum Question.
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  #6  
Old 06-15-2017, 09:28 AM
RndmGuy06 RndmGuy06 is offline
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Default Re: Donor Raymond Forklift - EV Project Kick-off

Quote:
Originally Posted by Duncan View Post
Hi
Those look amazingly clean and new bits!
...
Voltage 84v will probably NOT give you 50 mph - think in terms of 144v minimum
Duncan. Thank you for your quick reply last night! I replied last night and said a Moderator needs to approve it. Don't know where it went. I'll see what I can remember.

Not 50 mph? Sad. My road only 40. Is that achievable? Do you know if a 48 volt can take 144? I've heard double the rated voltage is usually okay. Triple sounds extreme to me. Seems I will need to build/buy a specific battery system for this.

There is a component list from ForkenSwift. This is what I am hoping to take from this donor.
Drive Motor
Contactors & Heavy Cables
Throttle or Potentiometer
Emergency Kill Switch
Battery Connector
Controller
Maybe a Shunt
Maybe a couple battery cells for bench purposes

Is this list realistic? Any ideas on how to find specs on this motor?
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  #7  
Old 06-15-2017, 03:45 PM
RndmGuy06 RndmGuy06 is offline
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Default Re: Donor Raymond Forklift - EV Project Kick-off

Boekel. You were right. 9.25 inch diameter and 13 inches long. Can I estimate using the size difference to say a Warp9?
Warp9 (20" long) and Forklift (13" long) = 65%

In other words. Can ASSUME 50% of the performance of a Warp9?

NetGain Overview Specs

Or am I crazy?
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  #8  
Old 06-15-2017, 03:56 PM
boekel boekel is offline
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Default Re: Donor Raymond Forklift - EV Project Kick-off

I don't know, keep in mind it is a Sepex motor, so you need a Sepex controller.
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  #9  
Old 06-15-2017, 04:38 PM
RndmGuy06 RndmGuy06 is offline
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Default Re: Donor Raymond Forklift - EV Project Kick-off

Quote:
Originally Posted by boekel View Post
I don't know, keep in mind it is a Sepex motor, so you need a Sepex controller.
Which I am struggling to find @ 72 volt. (50mph @ 48v = 180 amps vs @ 72v = 118 amps)

This guy used dual contollers.
The PWM Field Controller Is Installed

8 months later...bought a series motor.
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