FG00061
PARTS-SERVICE
September 20, 1996
E30-50FR
GRAM
Subject: Encoder Pulleys
Plugging on one or both sides during straight travel can cause motors and/or amplifiers to overheat. Fault
codes 55L/R, 64L/R, and 66L/R may indicate loose encoder pulleys, or drive shaft insert pulleys.
If this is suspected, then perform the following procedure on both encoders on the 36-Volt E30-50FR
trucks.
1. Tilt the mast fully forward, then disconnect the battery and discharge the capacitor bank.
Note: Discharge the capacitor bank by turning the key on after disconnecting the battery. The display will
come on and then go out, indicating the capacitor bank is discharged.
2. Remove the front cover.
3. Remove the encoder belt cover, loosen the hex standoffs, and remove the encoder belt.
4. Disconnect the encoder harness from the encoder and remove the hex standoffs to remove the encoder
mount plate.
5. Remove the pulley from the encoder and reinstall as follows:
a. Apply LocTite®680 to the encoder shaft. Do not allow LocTite® to get into the bearing on the
encoder.
b. Install one set screw, align it with the flat on the encoder shaft, and slide the pulley down as far as
the set screw will allow - leaving a small even gap between the pulley and the encoder.
Loctite®680 Loctite®680
Figure 1
c. Apply LocTite®680 to both set screws and tighten. ...continued
We reserve the right to make changes in design or add improvements without incur-
ring the obligation to make such changes in equipment previously manufactured.
FG00061
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d. Set the assembly upside down and allow to dry for at least 15 minutes.
e. If possible, do not install the encoder on the truck for another 12 hours to allow full cure of the
LocTite®.
6. It is not necessary to remove the drive shaft insert from the motor when performing this step, however, if
the insert is loose, remove it, clean the threads, apply LocTite® 242, reinstall it, and torque to 5 ft-lb.
Remove the pulley from the drive shaft insert and reinstall as follows:
a. Apply LocTite®680 to the drive shaft insert.
b. Slide the pulley onto the shaft with a twisting motion to spread the LocTite®.
c. Apply LocTite®680 to both set screws and tighten.
7. Install the encoder mount plate, connect the encoder harness, install and adjust the encoder belt, and
install the encoder belt cover.
8. Install the front cover, connect the battery, and test the truck for proper operation.