Shimano EP8 stops working while riding - no fault in log?

[Ted3]

Mine look like carbon not metal. But if bike shuts off 5 times, cleaning with rubbing alcohol will reduce it to 2 times

I have 2 or 4 round pins.

No motor and new battery and new Rosenberger cable, still shuts off

The 2 bigger pins of EP801 are silver-colored when new/free of oxidation.

I noticed that contact cleaner doesn't really help (at least alone), but 5-10 mins of electric toothbrushing and the pin looks like a new again.

For some reason only the right upper pin turns to gold (=gets oxidized).

Your climate is much hotter than mine (I don't usually do long rides when it's over 25C/77F), but in your case the thermal shut down perhaps happens even if the pin isn't visibly oxidized ?

But the first thing I would do is make sure the two pins are clean (silver-colored), and maybe try applying an anti-oxidation paste on them.

 

[Winford]

The 2 bigger pins of EP801 are silver-colored when new/free of oxidation.

On the motor they look carbon, the Rosenberger yes are silver

 

[Ted3]

On the motor they look carbon, the Rosenberger yes are silver

That's weird, could you upload a photo ?
Should look like this:

 

[aFox]

Thanks for this additional information - however, as written before, please create and post the requested service report!
If you are not willing to do so, (at least) I will not be willing to assist further in this issue. You also can connect the (new, "defective") DU-EP800 drive unit solely (without any other components) to your SM-PCE02 interface and create this requested service report - in this case, the drive unit will be solely powered from your computer via the interface.

There it is now. That error code came when testing without speed sensor.

 

[Winford]

Should look like this:

Nope mine are black and look like they are carbon.

 

[Backflip]

There it is now. That error code came when testing without speed sensor.

Sorry for the delayed answer - unfortunately I did not get any notification of your post and just saw your reply today.
So this DU-EP800 drive unit with production number 7HCUIG668DF is from March 2009 and only has a mileage of 592km.
Sure, the W10100 warning wíll be triggered when there is no signal from the speed sensor detected from the drive unit (DU-EP800). In this case there will be no or only little motor support given (see also here):

Maybe also the previous owner has deleted all relevant errors which is easily possible with the cable-bound PCE - interface and the Windows based E-Tube-Project-Professional software.
What exactly has the previous owner of this "defective" DU-EP800 drive unit told you about the "defect"?
As written before already, I am very sure that this issue has nothing to do with the motor firmware. However, if you want to downgrade to a previous motor firmware version urgently you can use an Android smartphone and use this document. If you want to process the downgrade via the PCE - interface, then just send an email to the guys from eMax-Tuning and they will help you.

 

[Ted3]

Nope mine are black and look like they are carbon.

This means there are different revisions of EP801 where the pin coating differs ?

 

[aFox]

Sorry for the delayed answer - unfortunately I did not get any notification of your post and just saw your reply today.
So this DU-EP800 drive unit with production number 7HCUIG668DF is from March 2009 and only has a mileage of 592km.
Sure, the W10100 warning wíll be triggered when there is no signal from the speed sensor detected from the drive unit (DU-EP800). In this case there will be no or only little motor support given (see also here):
View attachment 185857
Maybe also the previous owner has deleted all relevant errors which is easily possible with the cable-bound PCE - interface and the Windows based E-Tube-Project-Professional software.
What exactly has the previous owner of this "defective" DU-EP800 drive unit told you about the "defect"?
As written before already, I am very sure that this issue has nothing to do with the motor firmware. However, if you want to downgrade to a previous motor firmware version urgently you can use an Android smartphone and use this document. If you want to process the downgrade via the PCE - interface, then just send an email to the guys from eMax-Tuning and they will help you.

Nothing to hurry. This is much older then what I think. Yes I think too that someone is cleared log already. Seller was bought lot of motors from bike shop and doesn't know what is problem so all info is what I am inspected. Only thing what I invented is to try reflash firmware because all hardware seems to be working. Must read that android way next.

 

[Winford]

EP801 where the pin coating differs ?

No idea, I thought they were all black, im on third motor in two years, and the first two were dark gray/black pins.Have no looked at this new motor yet

 

[Backflip]

No idea, I thought they were all black, im on third motor in two years, and the first two were dark gray/black pins.Have no looked at this new motor yet

On the motor they look carbon, the Rosenberger yes are silver

The 2 bigger pins of EP801 are silver-colored when new/free of oxidation.

I have seen dozens of DU-EP600 and DU-EP801 drive units and I completely agree to @Ted3 =>
The 2 bigger pins of the motor connector which are carrying the "heavy motor current" are silver-colored when new and free of oxidation, exactly like shown from @Ted3:

These 2 pins turn to a kind of golden color if they get (too) hot and/or oxidyzed:

Very often the Rosenberger plug gets partly molten when the contact restistance will be to high (due to corrosion, vibration or humidity) and the contact then get too hot due to high currents:

Check also this German forum post with a link to a YouTube video from Propain covering this issue and giving some solutions.

 

[Winford]

The 2 bigger pins of the motor connector which are carrying the "heavy motor current" are silver-colored

I swear mine were not silver, and looked like carbon rods. Will take pictures if i ever get in there again. I have not seen this 3rd motor however, nor did I pay a lot attention to the first, they replaced that one at 1800 miles. I was all over the second motor like a dirty shirt. I cleaned that connection many times with rubbing alcohol, which helped. Instead of shutting off 5 + times on a ride, it would cut it back to the normal 2 times. On third motor now, last ride it shut off 5 times, has not been washed in 6 months, so no water near it this year, and I crossed no creeks. What is funny is me and my buddy with identical bike both went 2-3 months with no shut offs, then mine stared on last ride again. Never had a melting socket problem like that either


Meanwhile my Amflow has 1900 trouble free miles and much is a race pace. Only negative is if you ride it hard, they go through the T type cassettes ad chains like crazy. Trying to pay more attention to chain waxing [dipping after cleaning well, after 30 miles instead of 50]

 

[Backflip]

Never had a melting socket problem like that either

Sure, the Amflow definitely is a great bike and the only eBike in town with "melting problems" is a DU-EP801 (and sometimes also DU-EP600) based bike because the main connector of these "generation 2" drive units is an absolutely design - and choice desaster from Shimano.

BTW.: There is a quite cheap offer of a this bike shop for 5,99€ for a complete adapter cabling harness set which also includes the main plug. This cabling harness is intended solely for SIMPLO / Trend Power batteries, however, for this price you can separate the main plug and easily can replace it with a "molten one" if you have some electric skills and tools.