2019 Gem EL XD Brainstorm

I have probably 5 meters in my house/garage somewhere. However, the second my wife or kids move a tool… its gone forever. :weary_face:

@JarJarJava @AssyRequired

I went digging a little deeper today. I found another lose orange connection into that main 48v traction contactor/ selonoid. So, I will replace that selonoid with another OEM one, and replace that wire.

(Yes, I disconnected the negative to both the 12v and 48v system :high_voltage::battery:)

But I found a spot against the wall that I believe that wire harness should be tied into. It has a spot open next to another harness that is hooked in. What are your thoughts? @AssyRequired I am sorry for anything I may have said earlier that was out of line. Please forgive my caveman behavior :face_with_peeking_eye:. If you still want to help, I will do everything step by step without doubting the master. :100:

I’m not sure I understand what you are trying to describe here.

I have no frame of reference here. Is this a bundle of wires / part of the harness where the connector corroded away? Or is this a battery ground?

What does this connector represent or what is wrong with it? Again, no frame of reference.

This appears to be a power cable, 4/0 possibly connected to a buss. What does this represent or what is the issue here besides it looks like some azzhat parked this GEM at the bottom of Puget Sound for about a year.

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Typing on the phone on this forum causes challenges. Sorry it’s coming off confusing. I’ll try again in separate messages.

This wire bundle is the one that leads to a broken off/missing circle connector. (That I believe should be attached to the grounding plate- or whatever that plate is) in the next message I’ll send).

This is where I think that broken wire bundle should be attached to. (There is a wire that looks a lot like it, and an open slot where it looks like something was attached at some point).

Are you sure that’s a ground?

The other lug / the cable that is still attached is tagged BMC V+. The plastic shell just above the connection is marked V+. BMC is the battery moinitor & control, that’s a dedicated hot lead.

I do not 100% recognize what that device is that the buss bar is part of. I do not recognize it at this extreme close up, Nor can I tell if what I circled in yellow is a dielectric spacer and you are looking at two buss bars with V+ on the left and V- on the right or is it just a hold down bracket and the hole you pointing to is on the + buss.

And the cable that had the lug corrode away, all I can tell you for the information presented is “Yes,it’s a cable. You are correct, the end appears to be missing. Pass the beer nuts.”

It’s not identified, it’s not traced back the other end, which may or may not be the source. The tag on there that I can see looks like it may just be the part number and revision for that section. I can’t make out the entire number, but if you run a search on that part number, you may land on a 3rd party vendor site that has exploded parts diagrams and descriptions that may help solve the mystery.

From where I’m sitting, you basically took a closeup picture of a pimple, and asked “Who’s ass is this on?” Honestly, I have no idea, times a few million since you can’t even tell me the results of the taste test.

I’ll check my E2 later, but I’m pretty sure that wire bundle is just a bunch of wires looped back to the connector and the other end doesn’t connect to anything. That’s how the disconnect works- by disconnecting the plug, the 12v and 48v lines can’t make a complete circuit to turn on the Gem Car. The fact that it turns on at all means that harness is working as expected.

I have learned that the 48v relays are prone to burning out, especially the one for the charger. There are two identical relays for the 48v section- one for the charger and one for a subsystem. Try swapping them and seeing if you can get the charger working. Pretty sure that white relay in your picture is one of them.

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I appreciate you looking into it for me! Would be great to know if it’s actually hooked up to something or not. I plan to go through all the relays here shortly. :100::smiling_face_with_sunglasses:

No idea if it’s a ground. :man_shrugging:t2:.

I can supply other photos later when I get back home. It’s hard to know what’s common knowledge and what needs to be broken down further. Thank you for working through this with me.

I tried to do less zoom this time. Photos are the harness location. And where I suspect that wire was connected to (unless it was not supposed to be connected to anything, but I’m still on standby until I hear back from @Tsumi).

Did some digging on the part number to that harness and nothing came up. Probably in some service manual lock down…

I’m about to get the numbers to all the fuses and other quick replaceable items and get them shipped out in the meantime. Still waiting on the new selonoid (old one is rusty and the two little wires connected on the top were super crusty inside

).

@JarJarJava so that wall plate appears to be the main grounding plate. It has four holes that two currently have ground wires running to/from it. See photo. The missing hole as pictured before is at the bottom.

@Tsumi @JarJarJava

Tsumi if you can confirm if that bundle goes to the solenoid I would be super appreciative. Should be right in the front. I found a broken circle connecter connected to the right facing pole of the solenoid. (The second one is to the orange wire that recently broke off). I don’t want to hit anything against that hot unless I’m sure that’s where it went. But now the clues are pointing that way.

Oh, it’s just the SERVICE DISCONNECT LINE…. Yes, needs to be connected to the hot on the selonoid… :man_facepalming:t2: Now I just need to wait for the new selonoid…

Yes, I just checked and mine was connected to the 48v solenoid. There’s some 12v lines looped within that harness as well.

Thank you for verifying! Tsumi- The man the myth the legend. :high_voltage::battery::100:

Your stack of 8x10 glossy photos with circles and arrows and a paragraph on the back has to be one of the funniest responses I have ever read.. Well played sir, well plaid…

After looking at them, I’m not sure WTF is going on with the wiring, it’s not adding up.

From one angle, that buss bar does look like it may be attached to the A-pillar on the frame. But… V+ is hot, it’s not normally used as ground (V-). Maybe it’s just the angle, but positive grounds are not very common,

What is more concerning to me is that it looks like someone may have actually taken this vehicle out for a long drive on a short pier. It really does like this vehicle was partially submerged in salt or brackish water. Everything located low in this vehicle, pretty much without exceptions, looks to be corroded. Everything I’m seeing is rusted, corroded, too much oxidation, there is even an iron oxide stain on a non-ferrous metal part (around the orange wire attached by ring terminal), that is classic electrolysis transfer for a deposit to settle there in a circular radius like that around a source of voltage. In the photo below I’m seeing what appears to be a waterline - where the white crap that covers everything stops above a certain point and it’s nearly completely non-existent above that. I had to zig-zag the line a bit because of the angle of the photo, and maybe some of this, like the erosion of the welds, may have occurred at different times in the past which may explain why the weld erosion appears to have been painted over, but other items have not gotten the rattle can repair.

If this vehicle did in fact spend time as an artificial reef, you’re in for a metric shitton of work and expense. Every electrical connection will have to pulled apart and cleaned, most components are going to need to be replaced, and at the end of it all, it may run again but you’ll be chasing gremlins out of it for as long as you own it.

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This is the main safety disconnect for all systems.


Disconnecting it kills all power except main B+ to main contactor, hot side.

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This is bmc. B- goes through it. The copper bar is a shunt to monitor all current through low side. The other side iirc is 12v system connection.
Sorry if not helpful. I am not following this thread closely.


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Yea I’m okay if it went swimming… As long as I can get it to work. Time will tell if that main disconnect getting reconnected will do the trick. Fingers crossed!