GEM e2 2005 Owner'S Manual Download Page 9

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GEM Owner’s Manual - Page 8

GENERAL SPECIFICATIONS

GEM eS Speciﬁcations

Motor:

72-volt shunt GE motor

Transmission:

Front wheel drive direct -

couple Dana Spicer differential

Speed Control:

GE solid state controller with:

* Motor thermal protection

* Battery under-voltage protection

* Regenerative brakes

* Top speed regulation

Tire:

12” Two-ply street rated tires

Battery Pack:

Six 12-volt ﬂooded or gel batteries

Secondary Power Supply:

Dual output 30A DC/DC converter

On Board

Charger:

Proprietary 72-volt DC charger

110-volt AC house current

Width:

55 inches

Length:

108 inches

Height:

70 inches

Turning Radius:

12’ 3”

Wheelbase:

72 inches

Curb Weight:

1140 lb.(EMPTY)

GVW:

1850 lb.(LOADED)

Vehicle Identification and Specifications

Summary of Contents for e2 2005

Page 1: ...2005 Owner s Manual...

Page 2: ...GEM Owner s Manual Page 1 Introduction CONTENTS About this Manual 2 Cautions Warnings and Notes 3...

Page 3: ...o GEM For this reason we have supplied you with this Owner s Manual designed to acquaint you with the proper and safe use of your GEM vehicle Please take the time to read and understand the manual bef...

Page 4: ...duct developm2ent we reserve the right to make changes at any time without written notice or obligation CAUTIONS WARNINGS AND NOTES Throughout this book you will nd the words WARNING and CAUTION These...

Page 5: ...GEM Owner s Manual Page 4 Vehicle Identification and Specifications CONTENTS Vehicle Information 5 General Speci cations 6...

Page 6: ...e left rear inside portion of the vehicle roof panel The VIN indicates the model year the model type and the serial number of the vehicle NOTE Be sure to record the Vehicle Identi cation Number in the...

Page 7: ...ltage protection Regenerative brakes Top speed regulation Tire 10 Two ply street and turf rated tires Battery Pack Six 12 volt ooded or gel batteries Secondary Power Supply Dual output 30A DC DC conve...

Page 8: ...voltage protection Regenerative brakes Top speed regulation Tire 12 Two ply street rated tires Battery Pack Six 12 volt ooded or gel batteries Secondary Power Supply Dual output 30A DC DC converter O...

Page 9: ...r voltage protection Regenerative brakes Top speed regulation Tire 12 Two ply street rated tires Battery Pack Six 12 volt ooded or gel batteries Secondary Power Supply Dual output 30A DC DC converter...

Page 10: ...voltage protection Regenerative brakes Top speed regulation Tire 12 Two ply street rated tires Battery Pack Six 12 volt ooded or gel batteries Secondary Power Supply Dual output 30A DC DC converter O...

Page 11: ...GEM Owner s Manual Page 10 Things to Know Before You Operate Your Vehicle CONTENTS Driving and Alcohol 11 Safety Information 12...

Page 12: ...low the legal minimum If you are drinking don t drive Ride with a designated non drinking driver call a cab or use public transportation Things to Know Before You Operate Your Vehicle Driving after dr...

Page 13: ...ventilated area only Keep children away from the batteries during charging Batteries can emit explosive hydrogen gases when charging Keep sparks and ames away from the battery area of the vehicle Tool...

Page 14: ...h causes severe burns If battery uid is on your skin ush the affected areas with water for at least 15 minutes and then seek medical assistance Internal contact Get medical assistance as soon as possi...

Page 15: ...GEM Owner s Manual Page 14 CONTENTS Instrument Pod 15 Windshield Wiper 27 Foot Controls 28 Parking Brake 29 Main Disconnect Switch 31 Seat Belts 32 Understanding the Features of Your Vehicle...

Page 16: ...NSTRUMENT POD 1 Turn Signal Windshield Wiper Horn Lever 2 Trip Odometer Switch 3 Headlight Switch 4 Vehicle Direction Switch 5 Key Switch 6 LCD Display Figure 2 Instrument Pod NOTE Further explanation...

Page 17: ...igure 3 illustrates how to activate the different functions Turn Signal For a left turn move the lever down until it clicks For a right turn move the lever up until it clicks Understanding the Feature...

Page 18: ...he tripmeter to reset the tripmeter and to change the function of the speedometer and odometer from miles per hour MPH to kilometers per hour km h and miles to kilometers Using the Trip Odometer Switc...

Page 19: ...ed Vehicle LSV regulations for your area Drive Low With the key turned on and Low selected pushing down on the accelerator pedal will move the vehicle in a forward direction with the speed range of 0...

Page 20: ...r will not drive but accessories and lights will remain on for approximately 20 seconds Do not leave the key in the ON position when not in use Doing so discharge the batteries CAUTION Always bring th...

Page 21: ...GEM Owner s Manual Page 20 LCD Display Understanding the Features of Your Vehicle Figure 4 LCD Display A B C D E F G H P O N M K J I L...

Page 22: ...LURE WARNING C HIGH MOTOR TEMPERATURE WARNING D ODOMETER TRIPMETER E CHARGER CONNECTED F STATE OF CHARGE G CURRENT LIMITING MODE H SEAT BELT WARNING I REVERSE J DRIVE LOW K DRIVE HIGH L NOT USED M HEA...

Page 23: ...h your braking system It could be an indication of the following Low brake uid Air in the brake system Have your brakes checked immediately by a trained ser vice person if the brake failure warning in...

Page 24: ...istances traveled Speedometer Error Code The speedometer indicates driving speed in either miles per hour MPH or kilometers per hour km h To switch between MPH and km h see the Trip Odometer Switch se...

Page 25: ...disconnect switch is in the ON position More information on the charger and charging of the batteries is discussed on pages 46 50 State of Charge The state of charge gauge indicates how much capacity...

Page 26: ...ed During descent the regen mode is activated which returns current to the battery by using the motor as a generator In some extreme cases the battery pack might get overcharged Battery Pack Under Vol...

Page 27: ...drive High Low Reverse corresponds to the position of the vehicle direction switch More information regarding this switch can be found on pages 18 Service If the Service icon is lit an error code wil...

Page 28: ...becomes damaged or worn replace it CAUTION WINDSHIELD WIPER NOTE Operation of the windshield wiper is interrupted should the current draw from the wiper motor become too high This typically occurs wh...

Page 29: ...le rmly press the foot brake pedal Accelerator Pedal The accelerator pedal Figure 6 is located on the oor close to the center of the vehicle and is used to control your speed Pressing down on the peda...

Page 30: ...GEM Owner s Manual Page 29 Understanding the Features of Your Vehicle PARKING BRAKE Figure 7 Parking Brake Two Passenger Figure 8 Parking Brake Four Passenger 1 2...

Page 31: ...is located to the right of the driver To apply the parking brake lift the handle To release press the button on the end of the handle and lower it A warning will sound whenever you turn the key switch...

Page 32: ...OFF The switch is intended to provide an easy way to disconnect all power to the vehicle during long term storage After disconnect is turned off some power may still be in the system until all capacit...

Page 33: ...32 SEAT BELTS 1 Belt 2 Latch 3 Buckle GEM is equipped with seat belts for both driver and passengers Understanding the Features of Your Vehicle Figure 10 Seat Belts Bench Seat Figure 11 Seat Belts Bu...

Page 34: ...g a seat belt incorrectly is dangerous Seat belts are designed to go around the large bones of your body These are the strongest parts of your body and can take the forces of a collision best Wearing...

Page 35: ...ion the lap belt plate across your thighs below your abdomen To remove slack in the lap belt portion pull up a bit on the shoulder belt To loosen the lap belt if it s too tight tilt the latch plate an...

Page 36: ...op you could jerk too far forward increasing the possibility of injury Wear your seat belt snugly A belt that is worn under your arm is very dangerous Your body could strike the inside surfaces of the...

Page 37: ...anding the Features of Your Vehicle A frayed or torn belt could rip apart in a collision and leave you with no protection Inspect the belt system periodically checking for cuts frays or loose parts Da...

Page 38: ...nger models are equipped with manual seat adjustments The seat adjustment handle is directly under the front of the seat Move the handle to the side and move the seat to the desired position Using bod...

Page 39: ...3 Package Tray 4 Glove Box Key The glove box Figure 13 is located on the top center of the upper dash and is equipped with a lock to protect against theft or damage The upper dash also contains a pack...

Page 40: ...nking alcohol can seriously impair your ability to operate this vehicle WARNING Basketpak Standard Figure 14 Basketpak Liquids can damage electrical components and the circuit board Handle liquids wit...

Page 41: ...ver 3 Pak Cover Lock Paks are available from your dealer and they are interchangeable Use only GEM approved Paks Other Paks may cause damage to the Pak system or vehicle and will void war ranty CAUTIO...

Page 42: ...kwise to release the Pak 4 Remove the Velcro safety strap 5 Lift the empty Pak off the GEM 6 Position the new Pak onto the brackets and apply the Velcro safety strap 7 Push forward to engage lock Test...

Page 43: ...right of the fuse access panel This plug will accept a standard automotive 12 volt accessory jack and is intended for moderately powered accessories such as a cellular phone It or accessory plugs will...

Page 44: ...GEM Owner s Manual Page 43 Operation and Maintenance CONTENTS Basic Operation 44 What To Do In Emergencies 44 Basic Maintenance 46 Care and Cleaning 66 Vehicle Maintenance Schedule 68...

Page 45: ...in the control system to indicate conditions that prevent the vehicle from operating All error codes are accompanied by the service icon The chart shown below summarizes the most frequent error codes...

Page 46: ...1 Never haul your vehicle while the vehicle is facing rearward on the trailer 2 With the vehicle facing forward pull the trailer at speeds of 55 MPH or less 3 Secure any items that could be affected b...

Page 47: ...ge Two of the six 12 volt ooded or gel batteries are located inside the short and long back bed page 53 or the spat page 54 and four are located under the bench seat cushion The charging system is des...

Page 48: ...sunlight on hot pavement or at temperatures of 110 F or higher Batteries should be charged after each use In the rst few years of life your batteries should provide a range of 25 miles at 72 F At 32 F...

Page 49: ...nal posts and free of corrosion CAUTION WARNING Battery uid is a corrosive acid solution and can burn or even blind you Do not allow battery uid to contact eyes skin or cloth ing If acid splashes in e...

Page 50: ...ar can take 8 hours or more Most recharge cycles will be shorter NOTE Recharge cycles are always encouraged However to condition a new set of batteries it is recommended that you discharge the vehicle...

Page 51: ...3 wire grounded extension cord and should not exceed the following 12 gauge wire 50 feet in length 14 gauge wire 25 feet in length Insert the proper extension cord into the battery charger receptacle...

Page 52: ...y Battery Care Your GEM vehicle is equipped with six 12 volt ooded or gel batteries Both types are shown in Figure 19 Operation and Maintenance 1 2 Each vehicle is programmed at the factory for a part...

Page 53: ...t Cap The detailed view in Figure 20 shows the internal features of a ll well Each battery contains two vent caps and six ll wells In Figure 20 only one vent cap was removed to expose the ll wells See...

Page 54: ...g back bed or the spat Four are located under the bench seat The bed and spat battery access covers are shown in Figures 21 and 22 Both covers can be removed by unscrewing four fasteners Operation and...

Page 55: ...e schedule listed below and discussed on pages 55 56 Monthly Tasks 1 Check water level ooded only 2 Wash tops and terminals of batteries 3 Check terminal connection 4 Check battery hold down bar to in...

Page 56: ...arge then recheck the level NOTE For best battery life add only distilled water 2 Batteries should be kept clean and free of corrosion Wash the tops and terminals of batteries with a solution of bakin...

Page 57: ...harged Battery Disposal Lead acid batteries are recyclable Return whole scrap batteries to distributor manufacturer or lead smelter for recycling For neutralized spills place residue in acid resistant...

Page 58: ...r key switch in the OFF position for up to 10 days It will lose some of its charge during this period NOTE To eliminate battery charge loss due to component current drain the main disconnect switch mu...

Page 59: ...ve and to the rear of the left front tire The uid level of your brake system is a very important safety component You should check it according to the Vehicle Maintenance Schedule by observing the sid...

Page 60: ...n your vehicle s VIN Certi cation Label Figure 1 and are also shown on the side of each tire Three primary areas are affected by improper tire pressure 1 Safety Under in ation increases tire exing and...

Page 61: ...ce a feeling of sluggish response or over responsiveness Improperly in ated tires are dangerous and can cause accidents Always drive with each tire in ated to the recommended pressure located on the t...

Page 62: ...odometer Using tires sized other than speci ed on your vehicle s tire label could cause you to lose control resulting in serious injury or death Never use a tire smaller than the minimum tire size li...

Page 63: ...Points In the event of a at tire GEM recommends using the GEM dealer network or GEM Customer Service to change it because they have the proper equipment Should you choose to change the tire yourself...

Page 64: ...ations include the rear frame rail and the center of the front cross member Lug Nut Torque Speci cation 50 ft lbs or 41 N m Getting under a jacked up vehicle is dangerous The vehicle could slip off th...

Page 65: ...se Access Panel Fuse Access Panel Fuse Block The fuse block Figure 25 is located inside the fuse access panel Figure 26 which is on the lower dash The ignition key opens the fuse access panel To open...

Page 66: ...ation and Maintenance A sticker is attached to the inside of the fuse access panel showing the function and amp rating of each fuse as shown in Figure 27 The Spare and Heater Coil fuses are used for a...

Page 67: ...eld and sun roof as they will cause scratches Operation and Maintenance Be very careful when cleaning the acrylic windows as they can be scratched or damaged Do not use a cleaner with an abrasive a co...

Page 68: ...yl cleaner and then wash the area thoroughly with a damp cloth and mild liquid detergent Finish by rinsing with cool water Cleaning the Interior Use mild liquid detergent and warm water to clean the i...

Page 69: ...ection From the Elements Covering your vehicle is optional however prolonged exposure to UV light may deteriorate the exterior and interior nish Protecting the vehicle with a GEM custom vehicle cover...

Page 70: ...GEM Owner s Manual Page 69 Warranties and Customer Service CONTENTS Warranties 70 Customer Assistance 75 Change of Address Transfer of Warranty 76...

Page 71: ...clude your GEM in its entirety Battery and tires are excluded from warranty as they are warranted by their respective manufacturers See individual warranty terms and conditions in your owner s packet...

Page 72: ...spection and repair during the warranty period Your GEM dealer should be able to provide service during normal business hours and within a reasonable time depending upon workload and availability of n...

Page 73: ...proved battery manufacturer and model information 6 Fading deterioration or weathering of seats oor mats composite parts or paint caused by ordinary wear and tear of exposure This warranty shall not a...

Page 74: ...efective parts must be returned to the selling dealer and transportation charges prepared by the purchaser Your dealer or GEM will then replace all parts which inspection shall show to be defective un...

Page 75: ...r rights which vary from state to state NOTE See your dealer to obtain a copy of a detailed warranty description Battery and Tire Warranty The batteries and tires are warrantied through their respecti...

Page 76: ...to be performed may not be covered by the warranty discuss additional charges with the service provider Keep a maintenance log of your vehicle s service history This can often provide a clue to the c...

Page 77: ...ss below so our warranty records can be kept current Transfer of Factory Warranty Onsite Please copy the form on page 78 and mail to GEM at the address below Warranty will transfer upon completion of...

Page 78: ...__________________________________ Last Name _________________________________________________ First Name _________________________________________________ Street Address _____________________________...

Page 79: ...______ First Name _________________________________________________ Street Address _________________________________________________ City State Zip Code _______________________________________________...

Page 80: ...GEM Owner s Manual Page 79 CONTENTS Word Index 80 Word Index...

Page 81: ...1 55 57 59 63 66 67 Cautions Warnings and Notes 3 Certi cation Label 5 Change of Address or New Owner Forms 76 78 Charge Receptacle 50 Charger Connected Indicator 20 21 24 Charging 46 50 Cleaning 66 6...

Page 82: ...Seat Belts 20 21 26 32 36 Service Indicator 20 21 26 Shoulder Lap Belt 32 36 Speedometer 20 21 23 Speci cations 6 9 State of Charge 20 21 24 Tire or Tires 6 9 59 61 Transmission 6 9 Transporting 45 62...

Page 83: ...GEM Owner s Manual Page 82 Notes...

Page 84: ...GEM Owner s Manual Page 83 Notes...

Page 85: ...1301 39th Street NW Suite 2 Fargo ND 58102 Customer Service 866 764 0616 www gemcar com...

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