GEM eM 1400 Owner'S Manual Download Page 2

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WARNING

Read, understand, and follow all of the instructions and safety precautions in
this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

Summary of Contents for eM 1400

Page 1: ...2015 Owner s Manual for Maintenance and Safety GEM eM 1400 ...

Page 2: ...ARNING Read understand and follow all of the instructions and safety precautions in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death ...

Page 3: ...oyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the GEM Service Manual and should be performed only by an authorized GEM dealer technician If questions arise after reading the manual please contact GEM customer service Be prepared...

Page 4: ...discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions fo...

Page 5: ...3 TABLE OF CONTENTS Introduction 4 Safety 7 Features and Controls 16 Operation 26 Winch Guide 35 Maintenance 44 Specifications 60 Troubleshooting 61 Warranty 62 Maintenance Log 66 Index 68 ...

Page 6: ...iar with their meanings before reading the manual The safety alert symbol indicates a potential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not av...

Page 7: ...er s manual Understand all safety warnings precautions and operating procedures before operating the vehicle Keep this manual with the vehicle at all times This vehicle is an ADULT VEHICLE ONLY You MUST be at least age 16 and have a valid driver s license to operate this vehicle No person under the age of 12 may ride as a passenger in this vehicle Never permit a guest to operate this vehicle unles...

Page 8: ...t key for your vehicle please contact GEM customer service See page 1 Be prepared to provide your key number and VIN Remove the spare key and store it in a safe place A key can be duplicated only by ordering a key blank using your key number and mating it with one of your existing keys The key switch must be replaced if all keys are lost Vehicle Model Number _______________________________________...

Page 9: ...NTROL RESULTING IN SERIOUS INJURY OR DEATH Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo Be careful if load extends over the side of the box 718034...

Page 10: ...ore than one passenger or a passenger under age twelve or who cannot comfortably reach the floor and hand holds With non GEM approved accessories they may seriously affect stability ALWAYS Wear your seat belt if equipped Vehicle rollover could cause severe injury or death Wear a helmet and eye protection and keep hands and feet in vehicle at all times Reduce speed and use extra caution when carryi...

Page 11: ...ontact your local dealer with any questions TO MAXIMIZE BATTERY LIFE Always check and maintain water level monthly Use only distilled water Water level should be kept 1 4 6 mm below fill well Do not overfill the battery Always keep batteries fully charged For maximum life charge your vehicle at every opportunity Use only the charger supplied with the vehicle Inspect battery connections regularly F...

Page 12: ... anyone under the age of 16 to operate this vehicle and never allow anyone without a valid driver s license to operate this vehicle Always make sure the seat belts if equipped are secured for operator and passenger before operating Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels Do not carry a passenger until you have at least two hours of ...

Page 13: ...e to make sure it s in safe operating condition Always follow the inspection procedures described in this manual Always travel slowly and use extra caution when operating on unfamiliar terrain Be alert to changing terrain Always follow proper procedures for turning Make turns slowly especially when the ground is wet greasy bumpy or sloping Never turn the steering wheel abruptly when driving at hig...

Page 14: ...nd items in or on apparel weight of any options or accessories and their contents weight of any additional cargo on the vehicle Equipment Modifications Never install any accessory that grounds to the vehicle chassis The chassis is a floating ground to protect against electrical short circuits and hazards Do not install any non GEM approved accessory or modify the vehicle for the purpose of increas...

Page 15: ...rd hat or helmet and approved eye protection are recommended when appropriate for working or riding conditions GEM recommends wearing approved eye protection bearing markings such as VESC 8 V 8 Z87 1 or CE Never operate or ride in this vehicle while barefoot or while wearing sandals or tennis shoes Operating Without Instruction Operating this vehicle without proper instruction increases the risk o...

Page 16: ...e gear selection and speed Do not exceed vehicle weight capacities The vehicle s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle When more passenger weight is added cargo weight may need to be reduced accordingly The recommended tire pressures are listed in the specifications section of this manual and on a label on the vehicle Always fo...

Page 17: ...oller are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot drive system components Always keep combustible materials away from the drive system Use caution when traveling through tall grass especially dry grass Always inspect areas near the drive system after driving through tall grass weeds brush and other tall ground cover Promptly remove any ...

Page 18: ...16 FEATURES AND CONTROLS Component Locations Console Hip Bar Cargo Box Headlights Front Bumper Brush Guard Tailgate Latch Releases Receiver Hitch Tailgate Taillight Reflector Charge Receptacle ...

Page 19: ...Switch 4 Direction Selector 5 Headlight Switch 6 Charge Status Indicator 7 Battery Discharge Indicator 8 Hour Meter 9 Glove Box Storage Compartment 10 Beverage Holder 11 12V Auxiliary Outlet 12 Park Brake Lever 13 Throttle Pedal 14 Brake Pedal 5 4 6 12 7 3 11 8 2 13 14 10 1 9 ...

Page 20: ...ries The terminals are limited to 10 amps Auxiliary Outlets The 12 volt receptacle can be used to power accessories but is limited to 10 amps the terminal board and 12 volt outlet are fused together at 10 amps Direction Selector Switch When the direction selector is in the center position the vehicle is in neutral The vehicle will not move if the accelerator is depressed Push the top of the switch...

Page 21: ...lever downward as far as possible Charge Status Indicator When charging the batteries the charge status indicator light flashes and changes color to indicate the status of the charge Refer to the table below Key Switch Turn the key to the ON position to activate the electrical circuits Turn the key to the OFF position to disable all electrical circuits The key can be removed from the switch when i...

Page 22: ...cle will not operate when charging unplug charger wait for charge indicator to turn off before operating Park Brake Steady Engaged park brake Gear Position Steady Selected gear forward neutral reverse Motor Controller High Temperature Flashing Reduced performance due to elevated temperature Steady Power delivery terminated to protect against overheating If either occurs stop the vehicle and turn t...

Page 23: ...s Code Definition 1 Data or configuration error 2 Sequence fault 3 Power fault 4 Contactor issue 6 Throttle input error 7 Voltage protection 8 Controller or motor out of temperature range 13 Software fault of Blinks Code Definition Solution 1 Battery high voltage Check battery size and condition reset charger interrupt AC power for 15 seconds 2 Battery low voltage 3 Charge time out battery pack no...

Page 24: ... to be cycled several times before reaching full capacity 50 125 cycles depending on type Capacity will be limited during this time Make sure vent caps are installed properly and securely during vehicle operation and battery charging Recharge batteries fully at the end of each day the vehicle is operated allowing adequate time for the charger to complete its charge cycle The batteries in this vehi...

Page 25: ...iciently and shorten charge times See pages 54 55 for charging procedures The battery charge receptacle is located on the left side panel below the driver s seat 1 Always use extension cords with the appropriate ratings for the country in which it is used In North America this is a UL rating The cords must also be rated for the conditions in which they are used such as being rated for protection f...

Page 26: ... After servicing the vehicle the main power connector should be the last connection to be made The main power connector is located under the seat on the passenger side of the vehicle adjacent to the main line contactor To disconnect unplug the connector WARNING Insulate any tools used within the battery area to prevent sparks or battery explosion caused by shorting the battery terminals or wiring ...

Page 27: ...r braking provides braking when the pedal is released For additional speed control or to stop the vehicle apply the service brakes Seat Removal Pull upward on the rear of the seat to disengage the latches Slide the seat rearward and lift it away from the seat base To reinstall the seat align the front seat tabs with the slots on the front of the seat base Slide the seat fully forward then push dow...

Page 28: ...Brake fluid Ensure proper level 47 Front suspension Inspect lubricate if necessary Rear suspension Inspect lubricate if necessary Steering Ensure free operation 48 Tires Inspect condition and pressure 7 49 Wheels fasteners Inspect ensure fastener tightness 49 Frame nuts bolts fasteners Inspect ensure tightness Accelerator Ensure proper operation 25 Indicator lights switches Ensure operation 20 Hea...

Page 29: ...travel 9 Keeping both hands on the steering wheel release the brake pedal and gradually push the accelerator toward the floor to begin driving 10 Drive slowly Practice maneuvering and using the accelerator and brakes on level surfaces 11 Do not carry a passenger until you have at least two hours of driving experience with this vehicle Never carry more than one passenger in this vehicle Never allow...

Page 30: ... riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down before entering slippery areas 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Engage all wheel drive before wheels begin to lose traction 5 Corre...

Page 31: ...downhill while applying light brake pressure to control speed Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or rollover Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Exercise extreme caution 3 Avoid crossing the side of a steep h...

Page 32: ...possible If it s unavoidable follow these precautions 1 Apply the brakes 2 Set the park brake 3 Place the direction selector in neutral 4 Turn the key off 5 Block the rear wheels on the downhill side Parking the Vehicle 1 Apply the brakes Stop the vehicle on a level surface 2 When parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not c...

Page 33: ...AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME...

Page 34: ...er location or you may lose control of the vehicle 5 Never tow a trailer on a grade steeper than 15 Towing the Vehicle NOTICE When towing the vehicle the key MUST be in the OFF position or severe motor damage will occur Follow these procedures when towing the vehicle 1 Place the direction selector in neutral 2 Turn the key off 3 Always follow these precautions when towing this vehicle Do not opera...

Page 35: ...ox switch to dump the cargo Release the switch after the cargo has dumped or when the box reaches the fully elevated position indicated by a ratcheting sound Press and hold the bottom of the dump box switch to lower the cargo box Release the switch when the box is fully seated on the frame indicated by a ratcheting sound Using Release Lever Stand clear of the cargo box and pull the release lever L...

Page 36: ... park brake 2 Remove the key to prevent loss 3 Secure the seat hood and tailgate latches Ensure that the seats are attached correctly and are not loose WARNING Cargo and other loose vehicle parts may fly off while transporting this vehicle Secure or remove all cargo and inspect the unit for loose parts prior to transport 4 Always tie the frame of the GEM eM 1400 to the transporting unit securely w...

Page 37: ...le winch winch cable and load clear of people especially children and distractions while operating the winch 8 Always turn the vehicle ignition power OFF when it and the winch are not being used 9 Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and mov...

Page 38: ...run through your hands even if wearing heavy gloves 18 Never release the clutch on the winch when the winch cable is under load 19 Never use the winch for lifting or transporting people 20 Never use the winch to hoist or suspend a vertical load 21 Never immerse or submerse your winch in water Take your winch to your dealer for service if this occurs 22 Always inspect your winch and winch cable bef...

Page 39: ...g strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to...

Page 40: ...arts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This will help the spooling of the winch cable and reduce the load on the fairlead D If freeing a stuck vehicle by attaching to a tree use an item such as a tow strap to avoid damaging the tree during winch operation Sharp cables and chains can damage and even kil...

Page 41: ...e moving when using the winch is when that vehicle itself is stuck The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See the Shock Loading section on page 42 For your safety always follow these guidelines when winching a vehicle free A Release the winch clutch and spool out the necessary length of winch cable B Align the...

Page 42: ... is complete especially if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task A Release the clutch on the winch B Feed out the winch cable that is unevenly bunched up in one area C Re engage the winch clutch D Have an assistant pull the winch cable tightly with about 100 lbs 45 kg of tension using the hook...

Page 43: ... cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B A kinked winch cable made of wire rope that has been straightened out is shown at right Even though it may look usable the cable has been permanently and severely damaged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in...

Page 44: ...ing This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading 3 Never tow a vehicle or other object with your winch Towing an object with a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and poss...

Page 45: ...ctivation of the winch 4 For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer 5 Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable 6 Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be ...

Page 46: ...important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Maintenanc...

Page 47: ... system Wheels fasteners Frame fasteners Batteries Headlamp tail lamp Daily Check operation apply dielectric grease if replacing Battery terminals 25 H Monthly Inspect and clean page 56 Battery fluid levels 25 H Monthly Add as needed page 56 Battery terminals 25 H Monthly Inspect torque to specification Transaxle shaft nuts 25 H Monthly Torque bolts to specification see service manual Ź D Brake pa...

Page 48: ...Do not check the fluid level after draining and filling 1 Remove the fill plug 2 Place a drain pan under the drain plug 3 Remove the drain plug Allow the oil to drain completely 4 Clean the drain plug thoroughly with a dry shop towel 5 Reinstall the drain plug Torque to specification 6 Add only the recommended fluid capacity as stated in the specifications chart above 7 Reinstall the fill plug Tor...

Page 49: ...luid 1 Position the vehicle on a level surface 2 View the brake fluid level at the reservoir in the driver s side wheel well The level should be between the upper MAX and lower MIN level lines 3 If the fluid level is lower than the upper level line add brake fluid to the upper MAX line 4 Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings Brake Inspection 1...

Page 50: ...turn the steering wheel left and right There should be 0 8 1 0 20 25 mm of freeplay at the outer rim of the steering wheel 3 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an authorized GEM dealer Spring Adjustment Adjust the rear shock absorber springs by rotating the adjustment cams either clockwise or counter clockwis...

Page 51: ...ehicle Always use GEM approved size and type of tires for this vehicle when replacing tires Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness and if they ve been loosened for maintenance service Do not lubricate the stud or the lug nut Nut Type Location Nut Torque Wheel ...

Page 52: ...on on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your GEM dealer 2 Atta...

Page 53: ...l on the connector not on the wiring 3 Turn the lamp counter clockwise to remove it 4 Install the new lamp Tip Make sure the tab on the lamp locates properly in the housing 5 Reinstall the harness assembly into the headlight assembly Headlight Beam Adjustment 1 Place the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall 2 Measure the distance from the floor to the...

Page 54: ...ole panel and lift the release to unplug the light from the harness 3 Using a flathead screwdriver press on the tab on the top of the light to remove the indicator light assembly from the console panel 4 Locate the expired lamp Using a screwdriver rotate the lamp 1 4 turn counter clockwise 5 Grip the lamp with a needle nose pliers and remove it from the assembly 6 Install the new lamp Using a scre...

Page 55: ... your GEM dealer NOTICE Always install fuses with the recommended amperage to avoid damage to the electrical system Tip See the label attached to the inside of the fuse access panel for the function and amp rating of each fuse Fuse Feature Supported 2A LSV Indicator Lamps 10A Lights Accessories 12V Power Receptacle 20A 48V Charger Chassis 25A 14V Charger 30A 48V Fuse Center under passenger seat CH...

Page 56: ...sult in an explosion and cause serious injury or death Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt m...

Page 57: ...Inspect the charging cord and extension cord for cracks loose connections and frayed wiring Replace any damaged components promptly 7 Always connect the extension cord to the charge receptacle on the vehicle first then plug the cord into a wall receptacle 8 Make sure the charger uses a dedicated circuit to prevent overloading If charging multiple vehicles each vehicle should use a dedicated circui...

Page 58: ...le scrap batteries to a distributor manufacturer or lead smelter for recycling For neutralized spills place residue in acid resistant containers with absorbent material sand or earth and dispose of in accordance with local state and federal regulations for acid and lead compounds Contact local and or state environmental officials regarding disposal information You can also contact GEM Customer Ser...

Page 59: ...use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish Avoid directing water toward electrical components including batteries wiring and switches Washing t...

Page 60: ...polishing the finish on your GEM vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehicle Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish ...

Page 61: ...ation and may promote corrosion and oxidation 7 Turn the key off 8 Do not set the park brake 9 Verify that tire pressure is at specification 10 Block the wheels to prevent rolling 11 Fully charge the batteries Leave the charger connected to maintain a full charge during the storage period or check battery voltage each month during storage and recharge as needed to maintain a full charge If the cha...

Page 62: ... Ride Seating 2 Performance Motor configuration Single 48 volt high efficiency AC induction motor Motor rating HP 7 5 HP continuous Controller 450 Amp Sevcon Gen IV controller with regenerative braking Battery pack 10 4 kw battery pack at 48V DC with 8 6 volt US12VXC batteries in series parallel configuration 6 volt AGM optional Maximum speed 19 MPH 30 5 km h Range on flat ground 45 miles 72 km ma...

Page 63: ...r malfunction Charge indicator Digital indicates battery discharge Hour meter Digital indicates cumulative hours of use Auxiliary power 12 volt accessory outlet Rider restraints None Headlights taillights Dual 55 watt Brake lights LED 1 8 watts at 12 volts Storage Glove box Possible Cause Solution Low battery voltage Recharge the battery overnight Loose battery connections Check all connections an...

Page 64: ...ime period POLARIS warrants your vehicle s batteries against defects in materials or workmanship After the first six months in service a defective battery will be replaced on a manufacturer customer shared basis provided that the warranty limit of 8 000 miles 12 900 km or 750 hours has not yet occurred Review the following table for guidelines BATTERY COVERAGE REGISTRATION At the time of sale the ...

Page 65: ...losion or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components general wear items or any parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items The battery coverage included in this warranty provides no co...

Page 66: ...use any GEM Servicing Dealer to perform warranty service In the country where your product was purchased Warranty or Service Bulletin repairs must be done by an authorized GEM dealer If you move or are traveling within the country where your product was purchased Warranty and Service Bulletin repairs may be requested from any authorized GEM dealer that sells the same line as your product Outside t...

Page 67: ... product is registered outside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to Government officials or military personnel on assignment outside of the country where the product was purchased will continue to be cove...

Page 68: ...66 MAINTENANCE LOG Use the following chart to record periodic maintenance DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 69: ...67 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 70: ...or 18 Driving Downhill 29 Driving in Reverse 30 Driving on a Sidehill 29 Driving on Slippery Surfaces 28 Driving Procedure 27 Driving Uphill 29 Dumping the Cargo Box 33 E Equipment Modifications 12 Eye Protection 10 F Fluid Battery 56 Fluid Brake 47 Fuse Replacement 53 G Gross Vehicle Weight Rating 12 GVWR 12 H Hard Hat Helmet 10 Hauling Cargo 31 Headlight Beam Adjustment 51 Headlight Lamp Replace...

Page 71: ...torage Removal 59 Storing the Vehicle 59 Switches Direction Selector 18 Headlight Switch 18 Key Switch 19 T Tire Pressure 7 Tires 49 50 Nut Torque 49 Tread Depth 49 Wheel Installation 50 Wheel Removal 50 Towing Loads 32 Towing Speed 32 Towing the Vehicle 32 Trailer Hitch Bracket 25 Transaxle Oil 46 Transporting the Vehicle 34 Troubleshooting Charge Status Indicator 21 Malfunction Indicator 21 Vehi...

Page 72: ...blic roads a collision can occur with another vehicle With more than one passenger or a passenger under age 12 or who cannot comfortably reach the floor and hand holds With non GEM approved accessories they may seriously affect stability ALWAYS Wear your seat belt if equipped Vehicle rollover can cause severe injury or death Wear a helmet and eye protection and keep hands and feet inside vehicle a...

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