BT -E8010 POWER CONNECTOR CRACK.

C

Cyclopath1000

Active member
Joined
Apr 26, 2019
Messages
325
Reaction score
130
Location
Davis Ca
I have 2 batts. Haven't used the original in months. Took it out on a moderately gnarly Sedona trail and kept flickering off and also the dreaded W013. examined it to find the negative terminal cracked and one half the copper is gone.
I'm wondering if the ball of aluminum foil is my only option. I'm under the impression that Shimano doesn't really fix things or sell parts to do so. Am I wrong.
16378940464992637166574805743030.jpg
16378941170598370748488783201640.jpg
1637894159268787124134918463414.jpg


One picture ( last I hope ) is what the unbroken battery looks like.
 
⚡ EMTB Pro Go Pro — Living Intelligence Reports, exclusive discounts & ad-free Up to 25% off Peaty's, PEMBREE, Magicshine & more · Ad-free browsing · Pro badge See the deals →
Cyclopath1000 said:
I have 2 batts. Haven't used the original in months. Took it out on a moderately gnarly Sedona trail and kept flickering off and also the dreaded W013. examined it to find the negative terminal cracked and one half the copper is gone.
I'm wondering if the ball of aluminum foil is my only option. I'm under the impression that Shimano doesn't really fix things or sell parts to do so. Am I wrong. View attachment 76760View attachment 76761View attachment 76762

One picture ( last I hope ) is what the unbroken battery looks like.
Click to expand...
es.aliexpress.com

0.59￡ 15% de DESCUENTO|Conector de alta corriente chapado en oro, adaptador de D SUB de 5 + 2 clavijas, Pin mecanizado, cable de Flash dorado completo, 7W2 30A, 1 ud.|Conectores| - AliExpress

¡Compra fácil, vive mejor! Aliexpress.com
es.aliexpress.com es.aliexpress.com

p2.jpg


p1.jpg
 
Wow !! But then it's dedicated to that one batt. I have 2 batts, one without damage one with. But I do see the logic if it is reliable. What exactly is the broken input that I posted. Is it a negative. I tried a multimeter but couldn't get a DC reading. What are the two little center leads vs the two larger leads. Can you explain what each of the four does. The one batt rebuilder in socal says they don't have access to any Shimano parts.
 
I had many problems with this connector error e010.

In aliexpress buy this connector 0.59￡ 15% de DESCUENTO|Conector de alta corriente chapado en oro, adaptador de D SUB de 5 + 2 clavijas, Pin mecanizado, cable de Flash dorado completo, 7W2 30A, 1 ud.|Conectores| - AliExpress

They are really two AW14 large section wires and two thin wires (communication wires).

The plastic battery box and the battery-motor cable must be removed. And then match the 4 wires.

It requires additional work on the docking tray box so that the new connectors can be moved, but after doing this, the dreaded e010 error no longer appeared. It would be necessary to protect the connection in some way so that moisture does not enter the new connection, this can be achieved with a couple of turns of very fine plastic
 
Seeing you have been in there, and that only the large negative port is cracked and missing the copper pickups, would you think it's safe to shove a wad of aluminum foil blindly into only that one pickup to try and obtain connectivity or is there stuff behind that plug that warms one not to create a short circuit in there ?
 
Placing aluminum foil in these types of connections is useless at all. Aluminum is so soft that it does not hold strongly. The shimano electrical connections have caused me so many problems, as well as the adjustment of the battery, that I finally opted to change the connections of my two batteries. Since then not a single problem. The battery now does not need to be fine tuned.
My solution seems very radical, but it is being effective.
I am lucky to have completely disassembled my bt8010 battery

p3.jpg
 
Now I'm starting to understand your motivations. It's obvious to me that this connector is going to fail. I just ordered a third battery ( $616 yikes) and if I keep this bike , which I love , and which I have yet to see anything significantly superior, I can see evolving into your fix. I would even contemplate doing your solution to all three batteries. Are you done kind of electronics wizard or can any lugnut figure this out ?
 
Cyclopath1000 said:
Now I'm starting to understand your motivations. It's obvious to me that this connector is going to fail. I just ordered a third battery ( $616 yikes) and if I keep this bike , which I love , and which I have yet to see anything significantly superior, I can see evolving into your fix. I would even contemplate doing your solution to all three batteries. Are you done kind of electronics wizard or can any lugnut figure this out ?
Click to expand...
If you have knowledge of soldering with tin you can do it yourself, if you do not have it, it is better to have someone help you than if you know this topic. The connector can be bought in AliExpress for a super cheap price, nothing to do with the replacement that Shimano sells you, as long as it is the connection tray, there is no replacement for the battery connector
 
16383150684558073932273115042732.jpg


So this rediculous squared. This plug could be changed correctly at any iPhone fixit shop or even by me if and only if Shimano bothered to support their stuff. This is a $10 part.
 
Indeed it is ridiculous, but shimano does not offer you any spare parts. I had it very clear, and more now that I have found this AS150U connector that is better protected from moisture. You can be sure that this new connector will not break again, it is much more robust, and you do not have to adjust the battery precisely.
 
Your solution is radical but reasonable. I sent a repair request to Shimano warrenty and expect it to be turned down.

I'm curious if other brands such as Bosch have these kinds of issues. I was going to stick with shamomif I ever bought a.sexond ebike but now I'm wondering if that's a wise choice.

The third battery is getting prepared for shipping. If I can get another 2-3 years out of my current bike without another expensive purchase I might be able to justify 300/year for battery replacement. I also expect this connector issue to become a.real.shimano headache as in all these batteries fail at the connector so they might have to offer a solution.
 
fyi: as expected shimano blew me off. not willing, caring to, etc,etc to help me out. all i wanted was to purchase the part. why should they give a hoot.
 
Cyclopath1000 said:
I have 2 batts. Haven't used the original in months. Took it out on a moderately gnarly Sedona trail and kept flickering off and also the dreaded W013. examined it to find the negative terminal cracked and one half the copper is gone.
I'm wondering if the ball of aluminum foil is my only option. I'm under the impression that Shimano doesn't really fix things or sell parts to do so. Am I wrong. View attachment 76760View attachment 76761View attachment 76762

One picture ( last I hope ) is what the unbroken battery looks like.
Click to expand...
I had the same issue.

My solution was to repair the connector.

I milled a hole through the connector with a dremel and inserted a thin brass plate (self made connector plate) and soldered a bridge over to the negative cable connector - then I used some silicone filler to make it somewhat water proof.

Be really careful around the cable connectors, they're really brittle and can snap off really easy.

I don't have any pictures and I really don't want to tear the battery apart again :)

Shimano connector.png
 
  • Like
Reactions: bAV
Can you snap a picture of the outside of the connector after your fabrication? What you did is exactly what I was contemplating to do.
 
Yes a picture of the battery connector from outside that shows where you did the milling would help.
 
Cyclopath1000 said:
Can you snap a picture of the outside of the connector after your fabrication? What you did is exactly what I was contemplating to do.
Click to expand...

I did the milling from inside out, there's a thin layer of resin on top of the connectorplate which is pretty easy to get through with a dremel and a milling bit. The brass plate is bent double to make a snug fit for the connector.

Connector.png
 
Does the plate behind also carry a negative charge or is it isolated from the brass?
 
I'm following this - copycat style


The "glue" is softer than the plastic.. Just be super careful not to grind away the copper

I was able to bend the original connector back into shape - not sure if heating it helped.
The challenge now is to stop it from happening again. My idea is to glue a thin sheet of carbon to the surface to reinstate the slot (so it's not gouged) - if this works. photo to come..
Failing that, it's going to be a leave on bike and charge on bike situation.


IMHO - This is 100% a design flaw - I installed a brand new battery (carefully) and on the first install, I can see the mark on the plastic.. It's almost as if the pins on the bike are bent - but that connector is brand new, and I have two bikes and they both measure the same spacing,

What's clear - the ground pin is longer.. IMHO - given this is my second battery that has failed ( gone 100% dead) it's as if the ground loses connection (that's why the pin is longer), the battery shits the bed - at over 600 USD - and instant warrantb denial - shimano has some explaining to do

Charge on the Bike from now I guess -

IMG_8682.JPG IMG_8681.JPG
 
  • Like
Reactions: bAV
Anyhoo.. i used a donor battery for the connections - if anyone wants a perfectly good set of cells _ (BMS is fried) LMK
 
You must log in or register to reply here.
Keep reading
    Browse all

    Community Stats

    Since 2018
    674K
    Messages
    41,811
    Members
    Join 30,000+ Riders, it's free!
    Back
    Top