So we double checked everything and found no issues. We proceeded to remove the battery, clean everything and check for loose wires. We found a sparking wire on the drive motor.

We cleaned up the end of the wire that has a hook on the end that makes contact on the drive motor near the rear left. My boss proceeded to tighten down the bolt it hooks around and broke the head off the bolt.

Now we need to figure out where to get a new stud. Any ideas?


Thanks

John

i would check what Brewski mentioned but it goes even farther than that. Check the condition of the contactor itself, if it's worn out it can effect the way the tips make and break even with new tips. A worn armature in the contactor can cause it to hang up or bind not allowing the tips to move freely and if this occurs the tips will not contact each other well triggering the code 23 or 24.

Defective 1A, RB, SP or FW contactors can also trigger this code, an open motor circuit between A1 and A2 also can trigger this code. Check for open circuit or loose connection between positive side of RB contactor coil and PB2 on control card. Check the terminal connections at the plug on the control card as well, you can also use some needle nose pliers and put a slight twist on the pins to insure they will make a positive connection with the plug.

The best way to check to see if you are getting connection is to check for volt drop across the contact tips when the are closed. You also need to check the opposite contactor for volt drop on the normally closed tips. If I remember correctly there is a 14 or 16 gauge wire connected to one of the buss bars the sends a signal to the control card so it knows there is a connection being made. The problem could be in the small gauge wire or connector at the card.

So my boss had me replace the copper contacts on the forward/reverse blocks but we are still getting the code 24 and no forward or reverse.

When we energise the system you can see the forward and reverse plungers move forward and make an audible click when the accelerator is depressed but we don't get any wheel movement.

Thanks

John

This would apply if this is a EV100 controller.

Most common cause is that the contacts
on one of the direction contactors or the
RB contactor does not close correctly to
make an electrical connection.