Discussion:
TCM FCB25 with intermittant code 24

I'm working on a TCM FCB25 with a EV100 control that has an intermittant code 24. I worked on this truck 3 months ago spending about 12 hours on it and could not get the problem to occur or find anything wrong except the accell pot was out of adjustment. The problem went away and has now (3 months later) returned. But I again can not get the truck to fault or find anything wrong. The customer states that it only happens when the truck is put in foward. The contactors all work properly (no sticking or binding),the coils all read around 13 ohms, all wires and cables are tight and ohm test good, all fuses are good, motor brushes and springs are good, the shift lever tests good, and the pot is ok this time. Not sure where to go from here. I don't want to put a card in it when I can't even verify the fault. Any help would be greatly appricated. Thanks
  • Posted 1 Dec 2010 11:08
  • By certifiedtech
  • joined 5 Aug'10 - 39 messages
  • Ohio, United States
Showing items 1 - 5 of 5 results.
Ahhh the ole code 24

"-24" means there is an open circuit in the main drive circuit when it should be closed (voltage at T2 is less than 88% or something like that).

So basically the question you ask is "is this happening in both directions?"
no one direction only- most likely the F&R contacts have an issue (burnt, welded), less likely but I have run into it: the card has a bad track for a direction (when the contactor won't operate). To determine which is the case an easy test is to swap wires 27 & 23 at PB4 & PB5. This will cause the truck to operate in the opposite direction selected so lift up your drive wheels. If the problem stays in the same wheel direction, the issue is the contactors or the associated wiring. If the problem changes wheel direction, the card is bad. To get the EV100 pin release tool order an A B Y or Z plug kit, they all come with the tool.

Yes the problem is in both directions - Check for an open motor circuit. Check your brushes, connections at the motor, the heavy connections on the control panel (contactors), also a culprit often overlooked is the RB contactor (regen). It must be closed while in normal driving operation. Check it for proper operation and that the tips aren't badly burnt as they do get a walloping.

Those TCMs, aren't they fitted with EVT100 panels (transistorized version of the EV100)? Not that it matters for this code but for others it certainly would.
  • Posted 7 Dec 2010 13:28
  • Modified 7 Dec 2010 13:33 by poster
  • By justinm
  • joined 13 Apr'06 - 604 messages
  • New York, United States
New York, New York its a heluva town..you know that The Bronx is up..and I'm Brooklyn down
the pot most likely didn't have anything to do with it, and it is actually my W.A.G. that your problem is related to the guide pin in the bottom of the armature of the forward contactor, and it causes an intermittent bad connection in the "at rest" position of the forward contactor when you try and drive in rev, the fact that the connection takes longer to "make" than it should is where the code 24 is caused. it could be in a bunch of places in that circuit, that is just a w.a.g. with some experience behind the guess
  • Posted 6 Dec 2010 01:33
  • By edward_t
  • joined 5 Mar'08 - 2,334 messages
  • South Carolina, United States
"it's not rocket surgery"
Hi,
Thanks for the input I replaced the contactor and will just wait and see if that fixes it. What I can't understand though is how adjusting the accell pot made it go away last time since the pot should have nothing to do with the T2 voltage.
  • Posted 5 Dec 2010 10:23
  • By certifiedtech
  • joined 5 Aug'10 - 39 messages
  • Ohio, United States
Being intermittent does make it sound like the contactors.

Also, bad drive motor brushes can give you this code but usually the problem keeps getting worse until it's happening almost all the time.
  • Posted 3 Dec 2010 16:17
  • By lumberjack
  • joined 27 Jul'07 - 181 messages
  • Maryland, United States
replace the directional contactors, and check all power cables for acid damage, replace any cables that the insulation is not perfect.
  • Posted 1 Dec 2010 21:35
  • By edward_t
  • joined 5 Mar'08 - 2,334 messages
  • South Carolina, United States
"it's not rocket surgery"

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