GEM E825 long back - intermittent running.AND charging fault

GEM Forum
1

I have a 2001 e825 long bed utility that has decided to quit with a big event coming up on Thursday. After replacing two faulty batteries yesterday, it ran lurchingly, smoothed out to making regular running sounds, and then lost power and refused to go in reverse. Towed easily on a strap with ignition off, however, as soon as key switch was turned on, it did is jerky pull thing, even with Fwd-Rev switch in the neutral position.

I suspect there is an issue with the forward/reverse relay or some other short in the wiring. I could really use a good circuit diagram to test it with. I have emailed Rodney to request the PDF.

Oh, and the charge light is blinking green, no sound of the cooling fan apparent. Flashes green for a while, and then goes to the Euro siren fault sound.

I confess I should have gotten it out of winter mothballs earlier, but we have had a long, cold, wet spring here in Vermont.
This truck has had the DC/DC converter recall/upgrade, however reverse beeper has never worked.

Any help or suggestions would be greatly appreciated,

Bobat2
(Bob Atchinson, Plainfield, VT)

2

My guess is brushes.
Rodney will know more.

3

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| | Inwo
May 8 |

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| My guess is brushes.
Rodney will know more. |

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Thanks; I will remove the motor band, and scope it out.
Bob

4

Typical performance with unit that has been stored. Stuck brushes and commutator fouled. Remove brushes and sand 4 sides. Brushes nwwd to be sloppy in holders. Black motors built by AMD are more prone to this as they are built with closer clearances. Commutator needs to be cleaned up with 280 or 320. 90% of the motors I service are for this reason.

Rodney

1 Like
5

Do I need to drop the motor to clean the brushes? I have a blue 8HP Ride4Fun motor with stainless steel ventilated band.

Thanks,
Bob

6

I do
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In a message dated 5/9/2017 1:12:31 AM US Eastern Standard Time, electricforum@discoursemail.com writes:
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I do
bobat2
May 9Do I need to drop the motor to clean the brushes? I have a blue 8HP Ride4Fun motor with stainless steel ventilated band.
Thanks,
Bob
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In Reply ToOld_HouseboaterModerator
May 8Typical performance with unit that has been stored. Stuck brushes and commutator fouled. Remove brushes and sand 4 sides. Brushes nwwd to be sloppy in holders. Black motors built by AMD are more prone to this as they are built with closer clearances. Commutator needs to be cleaned up with 280 or 32…Visit Topic or reply to this email to respond.
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7

Thanks! I am down to crunch time now, as our running race event is coming up on Thursday. I am taking a mental health day off from work tomorrow to get the rig going. Charger is still an issue. I plugged it in last night, and didn’t want to do anything but error code beep. However, batteries were down to 11.6x, so now are being charged individually. The little rheostat that adjusts for different styles of batteries had slipped off its 8 pins, and was rattling around in the case. There are no remaining markings, however, to align with the notch in the dial. Does anyone know the settings by angle? I have Trojan xhs 30 batteries. I tried the spare charger out of an extra GEM, and although it looked good, it didn’t make a sound, nor show any voltage increase at B+<>B-.
Thanks for the help. I am keeping my fingers crossed.
Bob