2001-2004 GEM Owners Manual
Contents
1. OWNER S MANUAL TABLE OF CONTENTS SECTION PAGE 1 INTRODUCTION cnica ne 4 2 VEHICLE IDENTIFICATION AND 5 6 3 THINGS TO KNOW 10 4 UNDERSTANDING THE FEATURES OF YOUR VEHICLE cece eee 12 5 OPERATION AND MAINTENANCE 55sec eee eee ee eee yh y yh y nenn nn anna yn 26 6 WARRANTIES AND CUSTOMER SERVICE 2 0 0 6 cee eee hh hn 40 7 WORDINDEX 1 io sd eda e hog EAS ui waq aqa Waq aa waqaq 45 INTRODUCTION CONTENTS Bl About This 4 M Cautions Warnings and Notes 4 4 INTRODUCTION Wr C ABOUT THIS MANUAL Thank you for purchasing your Global Electric Motor cars GEM Neighborhood Electric Vehicle Your ve hicle is designed to operate exclusively on battery power It is an emission free vehicle The ideal applica tion for a battery powered vehicle is when the daily driving pattern is predictable and the distance is short Customer safety and satisfaction is of genuine con cern to 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 before operating your vehicle It2. Parking Brake 0005 Figure 5 Parking Brake 1 Charging Receptacle 2 Parking Brake two passenger model shown The Parking Brake see figure 5 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 to OFF and have not applied the Parking Brake The warning is disabled in turf posi tion UNDERSTANDING THE FEATURES OF YOUR VEHICLE 17 Parking Brake Control Logic The GEM control logic will not allow vehicle motion without the Parking Brake being fully released With the Key Switch in the ON position and the Parking Brake set the BDI will display 04 for an error code as a reminder to release the Parking Brake When the Key Switch is turned to OFF a warning beep road position only will sound to remind you to set the Parking Brake NOTE The Parking Brake is adjustable and should be checked periodically by a trained service technician Check the Maintenance Schedule WARNING When stopped on a hill use the Parking Brake to hold your position CAUTION Always engage the Parking Brake when you leave the vehicle 18 UNDERSTANDING THE FEATURES OF YOUR VEHICLE Master Disconnect Switch 0006 Figure 6 Master Disconnect Switch The Master Disconnect Switch see figure 6 is located under the bench seat on the passenger side rear seat
3. GEM strongly recommends that you use tires equivalent to the originals in quality and performance when replace ment is needed Failure to use equivalent replacement tires may adversely affect the safety handling and ride of your vehicle We recommend that you contact your original equipment dealer on any questions you may have on tire specifications or capability OPERATION AND MAINTENANCE 35 WARNING Tire Changing and Jacking Points Do not use a tire size other than that specified on your vehicles tire label Improper size tires can cause vehicle compo nents to wear out prematurely and may change your vehicles ride handling and steering behav ior In addition it may affect the accuracy of your speedometer odometer Using tire sizes other than specified on your vehicles tire label could cause you to lose control and have an accident resulting in serious injury or death Never use a tire smaller than the minimum tire size listed on your vehicle s tire label Using a smaller tire could result in tire overload and Figure 16 Jacking Points 0066 In the event of a flat tire GEM recommends using the failure 1 GEM dealer network to change it since they have Failure to equip your vehicle with tires having proper equipment Should you choose to change the adequate speed capability can result in sudden tire yourself you need to observe the following tire failure and loss of vehicle control precautions
4. Overloading your tires is dangerous Like under inflation overloading can cause tire failure Use e Park the vehicle on a firm level surface avoid ice or tires of the recommended load capacity for your slippery areas vehicle never overload them e Set the parking brake and block both the front and rear of the tire diagonally opposite the jacking posi NOTE The vehicle s tire information can be found on tion For example if the right front tire is being the VIN Certification label see Figure 1 changed block the left rear wheel 36 OPERATION AND MAINTENANCE Use a small floor style jack or low profile scissors jack only Jack vehicle only from side of vehicle ON THE MAIN FRAME RAIL at point where the tub support and the main frame rail are welded see fig 16 Alter native locations would include the rear frame rail and the center of the front cross member Lug Nut Torque Specification 50 ft Ibs or 41 N m WARNING Getting under a jacked up vehicle is dangerous The vehicle could slip off the jack and fall on you Never get any part of your body under a vehicle that is on a jack Never start or run the motor when the vehicle is on a jack If you need to get under the vehicle make sure the vehicle is first located on a flat solid surface and is supported securely by automotive jack stands or take the vehicle to a service center where a technician can put it on a hoist CAUTION Jacking any other location t
5. 43 Customer Service Department 4 Discharge Indicator 12 EMERGENCIES 26 Error Code 12 17 26 Extended Warranty 42 Foot Brake Pedal 16 Fuses 36 43 GEM 4 7 8 10 14 16 17 18 20 22 23 26 27 30 32 34 45 47 38 40 41 42 43 Global Electric Motorcars 4 Horn Button 12 15 INDICATORS 12 INSTRUMENT POD 12 13 14 15 Jacking 35 36 Key 6 7 13 14 17 26 29 32 37 Lap Belt 18 19 Left Turn Signal Indicator 13 Light Switch 12 15 Maintenance 4 17 27 30 33 38 41 42 Master Disconnect Switch 18 32 Motor 4 7 8 14 15 16 36 37 40 41 42 43 New Owner Registration 43 Paks 22 Parking Brake 12 17 26 30 35 38 Power Saver Features 13 Protection 7 8 19 20 27 38 40 Right Turn Signal Indicator 13 Road Turf Switch 12 14 SAFETY 4 10 23 26 27 33 34 41 Seat Adjustment 21 Seat Belt Warning Light 13 15 SEAT BELTS 18 19 38 Shoulder Belt 18 Specifications 4 6 7 8 34 41 43 Tire or Tires 7 8 33 34 35 38 40 42 Transmission 7 8 Transporting 23 26 Turn Signal Lever 12 15 Upper Dash 21 Vehicle Direction Switch 12 14 Vehicle Identification Number or VIN 4 6 33 35 37 43 WARNING 4 10 12 13 14 15 17 19 20 21 22 23 27 28 34 35 36 Warranty or Warranties 22 27 32 40 41 42 43 Window Wiper Switch 15 Zero Speed Detect 7 8 14 NOTES NOT
6. amounts of prevents operation of the vehicle and the BDI is water disabled The indicator light will inform you of the Battery gas is flammable and explosive Keep battery charge status flame or sparks away from the battery or any other booster source with an output greater than 12 volts Don t allow cable clamps to touch each other Zivan Charger Battery posts terminals and related accessories contain lead and lead compounds Wash your RED LED shows that the battery is in the initial hands after handling charge phase BLINKING RED LED shows that the battery charger CAUTION has reached 80 of charge It is essential when replacing the cables on the battery that the positive cable is attached to YELLOW LED shows that the battery charger has the positive post and the negative cable is reached 90 of charge attached to the negative post Battery posts are identified on the battery case as positive GREEN LED shows that the battery has reached and negative Cable clamps should be tight on the terminal posts and free of corrosion 100 of charge mms OPERATION AND MAINTENANCE 29 CAUTION Charge batteries fully before extended periods of use If the BDI reads between 25 and 90 the battery pack should be recharged If the BDI reads below 25 the battery pack should be put on charge as soon as possible A full recharge cycle BDI indicating near 0 can take up to 10 hours Most recharge cyc
7. has been de signed for your enjoyment and safety Maintenance schedules and general care instructions are also in cluded This manual is applicable to all four of the GEM mod els E825 Two Passenger E825 4 Four Passenger E825 Small Utility and E825 Large Utility If questions arise after reading the manual contact GEM Customer Service at 1 866 764 0616 Please have your VIN and date of purchase information available when you contact our Customer Service Department NOTE All information and specifications in this Owner s Manual are current at the time of printing However due to GEM s policy of continuous product development we reserve the right to make changes at any time without written notice or obligation CAUTIONS WARNINGS AND NOTES Throughout this book you will find the words WARN ING and CAUTION These serve as reminders to be especially careful WARNING indicates an im mediate hazard which could result in an accident or bodily injury CAUTION identifies something that could result in damage to your vehicle You will also find information preceded by the word NOTE Notes are for your information and to make procedures more easily understood VEHICLE INFORMATION VEHICLE IDENTIFICATION AND SPECIFICATIONS CONTENTS Bl Vehicle Information 6 6 VEHICLE IDENTIFICATION AND SPECIFICATIONS INN 0001 Figure 1 VIN Certification Labe
8. or the specific work you want done If you ve had an accident or work done that is not on your maintenance log let the service advisor know Tt VARRANTIES AND CUSTOMER SERVICE 43 CHANGE OF ADDRESS OR NEW OWNER Change Of Address Please copy the form at the right and mail to GEM at LE d EIL Egg EIL Egg ggg the address below so our warranty records can be kept Vehicle Identification Number current See Vehicle Identification and Specifications section New Owner Registration Resale Please copy the form at the right and mail to GEM at Last Name the address below Our Warranty Department can assist you in maintaining your new vehicle First Name Global Electric Motorcars LLC Warranty Department 3601 7 th Avenue NW Fargo North Dakota 58102 Street Address City State Zip Code Phone WORD INDEX CONTENTS Word Index ee 45 INDEX 45 Accelerator Pedal 14 16 26 Accessory Plug 36 ALCOHOL 10 21 BASIC OPERATION 26 Battery 2 7 8 10 12 13 26 27 28 29 30 31 32 28 40 41 42 BDI 12 13 17 27 28 29 Brake Fluid 13 33 38 41 Brake Warning Light 12 13 CAUTION 4 13 14 15 16 17 19 20 21 22 27 28 29 31 32 33 36 37 Certification Label 6 33 35 Change Of Address 43 Charge Receptacle 29 30 Charge Status Light 12 13 Charger 7 8 13 28 29 30 37 Cleaning 16 31 37 Customer Assistance 42 Customer Service 4 40 41 42
9. the seat belt warning light This switch is labeled ON to operate and OFF to stop NOTE The wiper has a current limiting feature which interrupts operation if the current draw from the wiper motor gets too high This typically occurs when the wiper is dragging on a dry window The interruption will usually only last a few seconds 0003 Figure 3 Windshield Wiper 1 Wiper Blade and Arm CAUTION A damaged or worn wiper blade may reduce vision and prevent you from seeing well enough to drive safely A worn blade could damage windshield glass If your blade becomes damaged or worn replace it Foot Brake Pedal 0004 Figure 4 Foot Controls 1 Foot Brake Pedal 2 Accelerator Pedal 16 UNDERSTANDING THE FEATURES OF YOUR VEHICLE The Foot Brake Pedal see figure 4 is located on the floor to the left of the accelerator pedal To slow or stop the vehicle firmly press the foot brake pedal CAUTION Always accelerate slowly to prevent possible injury to yourself or others CAUTION When cleaning the GEM do not spray water directly on or in the accelerator pedal Accelerator Pedal The Accelerator Pedal see figure 4 is located on the floor close to the center of the vehicle and is used to control your speed Pressing down on the pedal will increase speed Letting up on the pedal will reduce power to the electric motor and vehicle speed will slowly decrease
10. to maximize the battery pack life while recharging the pack in the shortest time with available household current 110 volt 15 amp A C outlet The following guidelines will insure that you get the maximum battery life and performance out of your GEM electric vehicle New batteries will not deliver their full capabilities until they have been discharged and recharged 10 to 20 times Batteries should be fully charged before first use of new vehicle When recharging it is preferable to have the bat tery pack at close to room temperature Do not have in direct sunlight on hot pavement or in excess heat of 110f or higher Batteries should be charged after each period of use Lead Acid batteries do not develop a memory and need not fully discharge before recharging WARNING Always wear safety glasses or approved eye protection when servicing the vehicle Wear a full face shield when working with batteries around batteries or electrical connectors Always use insulated tools when working 28 OPERATION AND MAINTENANCE WARNING Battery Charger Battery fluid is a corrosive acid solution and can The battery charger is located under the dashboard burn or even blind you and is an integral part of the vehicle Do not allow battery fluid to contact eyes skin or clothing If acid splashes in eyes or on the skin When the battery charger is active the control circuit flush the area immediately with large
11. Cleaning the Interior Use mild liquid detergent and warm water to clean the interior Rinse with a cloth dampened with warm or cool water CAUTION Do not rinse the interior of your vehicle Direct water on the Charger Plug Windshield Dash Panel or instrument Panel could damage the electrical system Cleaning the Exterior The best way to preserve your vehicles finish is to wash the vehicle regularly Use mild liquid detergents only no strong soaps or chemical detergents and rinse promptly Dry the finish with a soft clean chamois or towel to avoid surface scratches and water spotting NOTE It is not recommended washing in direct sun light 38 OPERATION AND MAINTENANCE INN Protection From the Elements Covering your vehicle is optional However prolonged exposure to UV light may deteriorate the exterior and interior finish Protecting the vehicle with a GEM custom vehicle cover or equivalent is recommended VEHICLE MAINTENANCE SCHEDULE TASK MONTHLY 1 Check all six batteries for proper water level x 2 Check battery terminals for tight connections x 3 Check battery terminals for tight connections x 4 Check tires for correct PSI and wear x 5 Check for proper operation of parking brake x E X X X 6 Check brake fluid reservoir for proper brake fluid level 8 Check seat belts for proper operation 9 Check headlights horn turn signal windshield X wiper and brake lights for proper opera
12. ES U fs Global Electric Motorcars LLC GEM A DaimlerChrysler Company 3601 7th Avenue NW Fargo ND 58102 Phone 866 764 0616 Fax 701 232 9528 Website WWW gemcar com Part 1010 00020 030702
13. RES OF YOUR VEHICLE ww 6 To release the belt push the red button on the buckle The belt will automatically retract to its stowed posi tion If necessary slide the latch plate down the web A frayed or torn belt could rip apart in a collision bing to allow it to retract fully and leave you with no protection Inspect the belt system periodically checking for cuts frays or WARNING loose parts Damaged parts must be replaced 7 immediately Do not disassemble or modify the Abelt that is buckled into the wrong buckle will not system Seat belt assemblies must be replaced protect you properly The lap portion could ride too after an accident if they have been damaged high on your body possibly causing internal inju bent retractors torn webbing etc ries Always buckle your belt into the buckle nearest ou belt that is too loose will not protect you as well In a sudden stop you could move to far forward in 7 creasing the possibility of injury Wear your seat Maximum occupancy is limited to four people for belt snugly the GEM four passenger vehicle and two people A belt that is worn under your arm is very danger for the GEM two passenger vehicle ous Your body could strike the inside surfaces of the vehicle in a collision increasing head and neck injury A belt worn under the arm can cause internal injuries Ribs aren t as strong as shoulder bones Wear the belt over your shoulder so that your str
14. URES OF YOUR VEHICLE Accessory Plug Optional 0007 Figure 10 Accessory Plug 1 Accessory Plug Cover The optional accessory plug see figure 10 is located on the lower dash above the passenger foot well This plug will accept a standard automotive 12 volt acces sory jack and is intended for moderate power accesso ries such as a cellular phone They will not operate large current items such as cigarette lighters WARNING Damage to electrical components and circuit board may occur from improper use Figure 11 Swivelpak and Linkspak 1 Release Handle 2 Pak Cover 3 Pak Cover Lock Paks are available from your dealer and they are interchangeable CAUTION Use only GEM approved Paks Other Paks may cause damage to the Pak system or vehicle and will void warranty a UNDERSTANDING FEATURES OF YOUR VEHICLE 23 At the rear of the vehicle located between the taillights is a release handle To remove an installed Pak or install a different one 1 Empty Pak completely 2 Steady the Pak to prevent it from falling 3 Rotate the release handle clockwise to release the Pak 4 Remove the Velcro safety strap Lift the empty Pak off the GEM 6 Position the new Pak onto the brackets on the power portion of the back and reapply the Velcro safety strap 7 Push forward to engage lock Test to make sure Pak is secure This is a two stage locking system If not secure repeat proce
15. dure 8 It is advised to keep the Pak latch in a locked posi tion when operating or transporting the vehicle WARNING The capacity of the Pak is not intended for any type of passenger use Doing so could result in personal injury OPERATION AND MAINTENANCE CONTENTS Bl Basic 26 What Do In Emergencies 26 Bl Basic Maintenance 27 Bl Care and 37 M Vehicle Maintenance Schedule 26 OPERATION AND MAINTENANCE BASIC OPERATION The control and safety features of the GEM vehicle can seem confusing at first so here is a simplified list of how to start the vehicle and drive it away 1 Make sure the disconnect switch is in the on posi tion Turn key switch on Fully release the parking brake Move direction switch to desired position Press accelerator pedal and go gt WN WHAT TO DO INEMERGENCIES Error Code Summary and Explanation Error codes are used by the control system to indicate conditions that prevent the vehicle from operating All error codes are preceded by a minus sign The following chart summarizes the most frequent error codes and their remedies 04 Parking Brake engaged Full release parking at key on brake Pedal depressed while Release pedal and direction switch is in neutral select desired direction Pedal depressed a
16. ed they should be replaced or cleaned as necessary Failure to do so may cause them to overheat during operation 4 The hold down straps should be snug to keep batter ies from moving while vehicle is in motion but not so tight as to crack or buckle the battery case 5 Any worn insulation or frayed wires should be re placed immediately NOTE After each use the batteries should be placed on charge The batteries should never be left discharged any longer then absolutely necessary Battery Disposal Lead acid batteries are completely recyclable Return whole scrap batteries to 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 environ mental officials regarding disposal information 32 OPERATION AND MAINTENANCE Battery Care During Storage To allow for extended storage time the GEM vehicles have several features to enhance battery life The control system has been designed to minimize current drain during storage A fully charged vehicle can be safely left with the power key switch off for up to two weeks without any significant loss of charge a Figure 14 Master Disconnect Switch To eliminate battery charge loss due to control system current drain the Maste
17. ehicle to a complete stop before changing the position of the VDS switch Road Turf Switch The Road Turf Switch See figure 2 is located on the top inside right of the Instrument Pod The switch is labeled TURF and ROAD TURF When the switch is in this position the accelera tion and speed of the GEM is limited to prevent dam age to soft surfaces ROAD This mode refers to APPROVED TRAFFIC routes based on Low Speed Vehicle LSV regulations for your area In the road position higher speed and acceleration to the GEM is allowed a UNDERSTANDING FEATURES OF YOUR VEHICLE 15 Turn Signal Lever The Turn Signal Lever see figure 2 is located on the lower left side of the Instrument Pod For a left turn move the lever down until it clicks For a right turn move the lever up until it clicks CAUTION The turn signal lever is not a self canceling turn signal unit After completing the turn return the lever to the center position Horn Button The Horn Button see figure 2 is located on the top left side of the Instrument Pod You can sound the horn by pressing it Light Switch The Light Switch see figure 2 is located on the left side of the Instrument Pod The Switch is labeled ON to turn the front headlamps and the rear tail lamps on OFF to turn the lamps off Window Wiper Switch The Window Wiper Switch see figure 2 is located on the Instrument Pod directly under
18. eight empty 72 volt shunt GE motor Front wheel drive direct couple Dana Spicer differential GE solid state controller with Key Switch Input High pedal disable Under voltage detector Thermal sensor protection Zero speed detect Anti Runaway 12 Two ply street rated tires Six 12 volt deep cycle batteries Proprietary 72 volt DC charger with charge status LED using 110 volt AC house current 55 inches Length 126 5 inches 69 75 inches Turning Radius 17 6 101 inches 1280 Ib GVW 2100 Ib loaded 8 VEHICLE IDENTIFICATION AND SPECIFICATIONS GEM E825 Utility Vehicle Short Box Specifications Motor 72 volt shunt GE motor Transmission Front wheel drive direct couple Dana Spicer differential Speed Control GE solid state controller with Key Switch Input High pedal disable Under voltage detector Thermal sensor protection Zero speed detect Anti Runaway Aluminum Bed 34 inches X 48 inches Tire 12 Two ply street rated tires Battery Pack Six 12 volt deep cycle batteries On Board Charger Proprietary 72 volt DC charger with charge status LED using 110 volt AC house current Width 55 inches Length 109 inches Height 69 75 inches Turning Radius 19 7 Wheelbase 71 1 inches Curb Weight 1160 Ib GVW 18950 Ib empty loaded GEM E825 Utility Vehicle Long Box Specifications Motor 72 volt shunt GE motor Transmission Front wheel drive direct c
19. hase If this is not on file we will not honor your warranty claim To obtain warranty service you must contact the nearest GEM retailer and make your vehicle available for inspection and repair during the warranty period Your GEM dealer should be able to provide service during normal busines hours and within a reasonable time depending upon workload and availability of necessary parts Further information warranty service may be obtained from regarding Global Electric Motorcars LLC 3601 7th Avenue NW Fargo North Dakota 58102 Normal Service hours 7am 7pm M F CST 1 866 764 0616 Changes by GEM in design or equipment made during the course of ownership shall not apply to any GEM vehicle previously manufactured or purchased mms AND CUSTOMER SERVICE 41 This Warranty shall not apply to damage or repair costs caused by a Failures to operate maintain and service as specified in the application GEM Owner s Manual b Abuse misuse neglect accident collision or operation of other than the specified design use and speed c Alteration or repair outside of factory specifications d Use of components including batteries not speci fied in the applicable owner s manual or any damage avoidable with the proper use of specified GEM components e Fading deterioration or weathering of seats floor mats composite parts or paint caused by ordinary wear and tear of exposure This warrant
20. hen the proper jacking points may cause major vehicle body damage Fuses The Fuse box is located under the hood on the passenger side attached to the frame You must remove the plastic fastener and lift the protective rubber cover to gain access NS A 209 um A UA ly 7 u P Ahr J Figure 17 Fuse Box 4 Brake 5A ATC 5 Accessory plug 3A ATC 6 Window Wiper 7 5A ATC 1 Turn signal 3A ATC 2 Headlights 10A ATC 3 Horn 3A ATC mms OPERATION AND MAINTENANCE 37 Key Replacement As a security precaution local key duplicators do not have the blanks or the codes to make you keys To obtain an extra or replacement key for your vehicle please call Global Electric Motorcars LLC at 1 866 764 0616 You will need your key code and VIN number CARE AND CLEANING Cleaning the Seats To clean the seats of your GEM vehicle use warm water and rub with a clean damp cloth to remove dirt Substances such as tar asphalt and other soils will stain if not removed quickly Use a clean cloth and solvent type vinyl cleaner and then wash the area thoroughly with a damp cloth and mild liquid detergent Finish by rinsing with cool water Custom ordered fabrics might require different cleaning procedures Contact your dealer Cleaning the Windshield or Sun Roof Normal dust and dirt can be removed using a liquid household glass cleaner Do not use abrasive cleaners on the windshield as they will cause scratches
21. icle is equipped with six 12 volt batteries Two are located under the front hood and four are located under the bench seat To keep batteries in good working condition follow the maintenance sched ule to the above right Monthly 1 Check water level 2 Wash tops and terminals of batteries 4 Check hold down strap tension 5 Check for worn insulation or frayed wires i 0022 Figure 13 Battery Water Level 1 Fill cap 2 Battery plates 3 Water level mms OPERATION AND MAINTENANCE 31 CAUTION If battery wire terminals are damaged or 1 The water level in the batteries should be checked monthly The level should be at least a 1 2 inch above the plates and to within 1 8 inch from the bottom of the vent well Add water only after charging unless the water level is below the top of the plates In this case add just enough water to cover the plates charge then check recheck the level NOTE For best battery life add only distilled water CAUTION Never charge batteries if plates are exposed above water level 2 Batteries should be kept clean and free of corro sion Wash tops and terminals of batteries with a solution of baking soda and water 1 cup baking soda per gallon of water once per week NOTE Do not allow the cleaning solution to enter the battery 3 Be sure battery terminals are tight If just cleaned let terminals dry and then spray them with battery anti corrosion spray corrod
22. l 1 VIN Location two passenger model shown For both the two and four passenger model vehicles the vehicle identification number VIN can be found on the VIN Certification Label located on the 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 Identification Number in the space provided to the right Vehicle Identification Number VIN Key Dash Key Pack Latch Date purchased a VEHICLE IDENTIFICATION AND SPECIFICATIONS GENERAL SPECIFICATIONS GEM E825 Specifications Motor Transmission Speed Control Tire Battery Pack On Board Charger Width Height Wheelbase Curb Weight empty 72 volt shunt GE motor Front wheel drive direct couple Dana Spicer differential GE solid state controller with Key Switch Input High pedal disable Under voltage detector Thermal sensor protection Zero speed detect Anti Runaway 10 Two ply street and turf rated tires Six 12 volt deep cycle batteries Proprietary 72 volt DC charger with charge status LED using 110 volt AC house current 55 inches Length 98 5 inches 68 inches Turning Radius 13 5 71 1 inches 1100 Ib GVW 1600 Ib loaded GEM E825 4 Four Passenger Specifications Motor Transmission Speed Control Tire Battery Pack On Board Charger Width Height Wheelbase Curb W
23. les will be much shorter NOTE Recharge cycles are encouraged anytime the BDI reads below 90 CAUTION On vehicles equipped with a Zivan charger an intermittent audible alarm and flashing Charge Status Indicator means that an alarm situation has occurred and there is a problem with the charger When there is an alarm the battery charger stops supplying current Have the vehicle checked by a trained service technician NOTE After charging the BDI will read slightly high until the batteries have time to settle which can be approximately an hour Driving the vehicle for over a minute will obtain a more accurate reading In hot climates battery self discharge will increase In cold climates batteries will freeze if not properly charged Battery Charge Receptacle 0005 Figure 12 Charge Receptacle 1 Charging Receptacle 2 Parking Brake 30 OPERATION AND MAINTENANCE The Battery Charge Receptacle see figure 12 is lo cated on the front tub below the passenger seat on the two passenger model and on the rear tub of the four passenger model It accepts a standard 3 wire grounded extension cord and should not exceed the following 12 gauge wire 50 feet in length e 14 gauge wire 25 feet in length Insert the proper extension cord into the battery charger receptacle see figure 12 and then plug into a 110 volt A C 15amp breaker outlet GFI is recom mended Battery Care The Gem veh
24. ning export GEM service please contact Global Electric Motorcars LLC Normal Service Hours 3601 7 th Avenue NW 7am 7pm M F CST Fargo North Dakota 58102 1 866 764 0616 42 WARRANTIES AND CUSTOMER SERVICE Normal Business Hours Web Site 8am 5pm M F CST WWW gemcar com 1 888 871 4367 Some states do not allow the exclusion or limitation of incidental consequential or other damages or limitation on the length of an implied warranty so the above limitations and exclusions may not apply to you This warranty gives you specific legal rights you may also have other rights which vary from state to state NOTE See your dealer to obtain a copy of a detailed warranty description Battery and Tires Warranty The Batteries and Tires are warranted through their respective manufactures The warranty information is located in your Owner s Manual packet Extended Warranty For information regarding purchase of an extended warranty call or write to Global Electric Motorcars IF YOU NEED CUSTOMER ASSISTANCE Prepare For Appointment If you re having warranty work done be sure to have the right papers with you Take your warranty folder All work to be performed may not be covered by the warranty discuss additional charges with the service manager Keep a maintenance log of your vehicle s service history This can often provide a clue to the current problem Prepare A List Make a written list of your vehicle s problems
25. nt Pod 12 Bl Indicators 12 Controls io Sr 13 Bl Seat Belts 18 MB Convenience Items 21 12 UNDERSTANDING THE FEATURES OF YOUR VEHICLE INSTRUMENT POD INDICATORS Battery Discharge indicator BDI The Battery Discharge Indicator see figure 2 is located in the center of the Instrument Pod and performs the following functions Battery Discharge Indicator BDI MPH Speed Indicator Accumulated Miles Error Code Display PWN At key on with the parking brake released the BDI will display the battery percent of charge The indicator will then alternate between MPH and battery status The battery status is displayed in 3 digits and the battery icon will light For example 100 equals 100 charge Figure 2 Instrument Pod 1 Signal L 7 R T Signal Seat Belt i ER i id pn nb When the key is turned off the LED display will show n Light Switch 8 Windshield Wiper Switch the odometer reading and the hourglass icon will light 4 L Turn Signal Brake Warning Light 9 Road Turf Switch 5 Battery Discharge Indicator BDI 10 Vehicle Direction Switch NOTE If an error code is displayed it 18 preceded by amp Charge Status Light Ti Key Switch a minus sign and the tool icon will light For a description and explanation of common error codes see the Erro
26. of your vehicle Tire inflation pressures are provided on your vehicle s VIN Certification Label see figure 1 Three primary areas are affected by improper tire pressure 1 Safety Under inflation increases tire flexing and can result in tire failure Over inflation results in a tire losing its ability to cushion shock Objects on the road and chuckholes could cause tire damage that may result in tire failure Unequal tire pressure can cause steering problems You could lose control of your vehicle 34 OPERATION AND MAINTENANCE mmm 2 Economy Improper inflation pressures can cause uneven wear patterns to develop across the tire tread These abnor mal wear patterns will reduce tread life resulting in a need for earlier replacement Under inflation also in creases tire rolling resistance and results in lower range 3 Ride Comfort and Vehicle Stability Proper tire inflation contributes to a comfortable ride Over inflation produces a jarring and uncomfortable ride Both under inflation and over inflation affect the stability of the vehicle and can produce a feeling of sluggish response or over responsiveness WARNING Improperly inflated tires are dangerous and can cause accidents Always drive with each tire inflated to the recommended pressure Replacement Tires The tires on your new vehicle provide a balance of many Characteristics They should be inspected regu larly for wear and correct inflation pressure
27. on gest bones will take the force in a collision A shoulder belt placed behind you will not protect you from injury during a collision You are more likely to hit your head in a collision if you do not wear your shoulder belt The lap and shoulder belt are to be used together a UNDERSTANDING FEATURES OF YOUR VEHICLE 21 CONVENIENCE ITEMS Seat Adjustment 4 passenger only The front seats on the 4 passenger 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 body pressure move forward and rearward on the seat to assure the seat adjusters have latched Upper Dash 0009 Figure 9 Upper Dash 1 Cup Holder 2 Glove Box Door 3 Package Tray The Glove box see figure 9 is located on the top center of the upper dash and is equipped with a lock to protect your items There is a package tray and four cup holder locations see figure 9 on the upper dash One package tray with two cup holders on the driver side and one package tray with two cup holders on the passenger side CAUTION Liquids can damage electrical components and the circuit board Handle liquids with care Do not spray water directly into the upper or lower dash WARNING Drinking alcohol can seriously impair your ability to operate this vehicle 22 UNDERSTANDING THE FEAT
28. on four passenger models You must first lift the seat cushion to observe the switch It is clearly labeled ON and OFF The switch is intended to provide an easy way to disconnect all power on the vehicle during long term storage After disconnect is turned off some power may still be in the system until all capacitors have drained NOTE The Master Disconnect Switch must be on for operation and charging Seat Belts 0008 Figure 7 Seat Belts 1 Belt 2 Latch 3 Buckle The GEM is equipped with seat belts for both the driver and passengers On the 2 passenger model and the rear seats on the 4 passenger model are equipped with Lap Shoulder Belts The front seats on the 4 passenger model are Lap Belts only a UNDERSTANDING THE FEATURES OF YOUR VEHICLE 19 Research has shown that seat belts save lives And they can reduce the seriousness of injuries in a collision Some of the worst injuries happen when people are thrown from the vehicle Seat belts provide protection from that and they reduce the risk of injury by striking the inside of the vehicle Everyone needs to buckle up all the time Even on short trips WARNING e Wearing 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 the best Wearing your belt in the wrong place could make your injuries in a collision much worse Yo
29. ouple Dana Spicer differential Speed Control GE solid state controller with Key Switch Input High pedal disable Under voltage detector Thermal sensor protection Zero speed detect Anti Runaway Aluminum Bed 73 inches X 48 inches Tire 12 Two ply street rated tires Battery Pack Six 12 volt deep cycle batteries On Board Charger Proprietary 72 volt DC charger with charge status LED using 110 volt AC house current Width 55 inches Length 147 inches Height 69 75 inches Turning Radius 16 1 Wheelbase 101 inches Curb Weight 1240 Ib GVW 2300 Ib empty loaded THINGS TO KNOW BEFORE YOU OPERATE YOUR VEHICLE CONTENTS Bl Driving and 10 II Safety Information 10 THINGS TO KNOW BEFORE YOU OPERATE YOUR VEHICLE DRIVING AND ALCOHOL Drunk driving is one of the most frequent causes of accidents Your driving ability can be seriously im paired with blood alcohol levels far below the legal minimum If you are drinking don t drive Ride with a designated non drinking driver call a cab or use pub lic transportation WARNING Driving after drinking alcohol can lead to an accident Your perceptions are less sharp your reflexes are slower and your judgment is impaired when you have been drinking Never drink and then drive SAFETY INFORMATION Your vehicle is battery powered Handled improperly batteries can be dangerous Follow these precautions du
30. r Code Summary on page 26 mms UNDERSTANDING FEATURES OF YOUR VEHICLE 13 Charge Status Light The Charge Status Light see figure 2 is located on the Instrument Pod directly above the BDI This light will illuminate during charging For additional information about the Charge Status Light and how it works see the subject Battery Charger later in this manual Left Turn Signal Indicator and Brake Warning Light The Brake Warning Light see figure 2 is a dual function indicator It serves as a left turn signal indicator and as a brake warning light If the brake warning light is on there may be a problem with your braking system It could be an indication of e Low brake fluid Air in the brake system An out of adjustment switch CAUTION Have your brakes checked immediately by a trained service person if your brake warning light comes on when braking Right Turn Signal Indicator and Seat Belt Warning Light The Seat Belt Warning Light see figure 2 is a dual function indicator It serves as a right turn signal indicator and as a seat belt warning light This light will be displayed for 5 seconds after Key On as a reminder to fasten your seat belt CONTROLS Power Key Switch The Power Key Switch see figure 2 is located on the right side of the Instrument Pod With the key in the switch you have 2 positions Turn the key switch for ward for the on power position Turning the key swi
31. r Disconnect Switch must be turned off if the vehicle will be left for more than 2 weeks NOTE Batteries should be fully charged before storing longer then 48 hours For storing your vehicle for extended periods of time 60 days or more it is recommended that you make arrangements to have the vehicle recharged every 60 days while in storage CAUTION Batteries can be permanently damaged and the warranty voided if they are allowed to sit for an extended period of time at very low charge Brake Fluid Level Figure 15 Brake Fluid Reservoir 3 Maximum Level 4 Minimum Level 1 Reservoir 2 Cap The Brake Fluid Reservoir is located under the hood on the bulkhead to the rear of the left front tire The fluid level of your brake system is a very important safety component You should check it according to the Vehicle Maintenance Schedule by observing the side of the reservoir and noting its level The fluid level should be at the full mark If it approaches the minimum level fill with DOTS brake fluid and see your dealer for service immediately OPERATIONAND MAINTENANCE 33 NOTE The vehicle is equipped with a four wheel hydraulic braking system only use standard DOT3 brake fluid from an unopened container CAUTION Brake fluid will remove paint Immediately clean up any fluid that gets on a painted surface Tires Proper tire inflation pressure is essential to the safe and satisfactory operation
32. ring charging and recharging operations to avoid personal injury or damage to electrical components in the vehicle Read the Owner s Manual before operating this ve hicle Do not smoke Batteries can emit explosive hydro gen gases when charging Keep sparks and flames away from the battery area of the vehicle Tools wires and metal objects can cause sparks when shorted across a battery Follow all instructions carefully when dealing with batteries The batteries in the GEM vehicle are 12 volt deep cycle batteries specially built for electric vehicle application Automotive batteries should never be used Charge batteries in a well ventilated area only Batteries contain acid which causes severe burns Some electrolyte can leak from damaged or defective batteries Avoid contact with skin eyes or clothing In case of external contact flush with cold water for 15 minutes and call a physician immediately Internal contact Drink large quantities of milk or water followed with milk of magnesia or vegetable oil Call a physician immediately Contact with eyes Flush with water for 15 minutes Call a physician immediately WARNING The battery packs contain high voltage which could cause serious or fatal injury if not handled properly Only qualified technicians should handle or service this vehicle and only after consulting the service manual UNDERSTANDING THE FEATURES OF YOUR VEHICLE CONTENTS Bl Instrume
33. t key on Release Pedal 11 15 Low voltage on battery Need to charge bat pack teries before operating High voltage on battery Turn lights on for pack several seconds then cycle key switch NOTE If any other codes are present contact your GEM dealer for assistance Transporting Your Vehicle The best way to transport your vehicle is in an enclosed trailer If it is necessary to haul your vehicle on an open trailer follow these guidelines 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 OPERATION AND MAINTENANCE 27 Secure any items that could be affected by the wind 4 Do not secure across tub of the vehicle There are steel handles located on the front and at the rear of the vehicle Use these with tie downs into each corner of the trailer CAUTION TOWING THE VEHICLE IS NOT RECOMMENDED This vehicle is not designed for dolly towing Any vehicle failures resulting from dolly towing may not be covered by warranty BASIC MAINTENANCE Battery Charging NOTE Recharge cycles are encouraged anytime the BDI reads below 90 The GEM vehicle has a battery control and recharge system especially designed for electric vehicle usage Two of the 6 12 volt lead acid deep cycle batteries are located under the hood and four are located under the bench seat cushion The charging system is designed
34. tch back to the straight up position will turn your vehicle off Power Saver Features When the key switch is turned off power to lights radio and all 12 volt accessories will turn off after about 20 seconds 14 UNDERSTANDING THE FEATURES OF YOUR VEHICLE e With key on and no activity for about 30 seconds the control system enters the standby mode In this mode the main power relay turns off This is noticeable by an audible click When you resume motion the relay closes with another click Zero Speed Detect With the key on accelerator pedal up and speed less than 1 MPH the electric motor armature will resist motion e Warning beeper pulses intermittently with vehicle motion This pulse is intended to indicate that an unattended vehicle may be moving Vehicle Direction Switch VDS The VDS see figure 2 is located on the right side of the Instrument Pod next to the Road Turf Switch This switch is labeled FWD and REV FWD With the Power Key switch turned on and the VDS in the FWD position pushing down on the accel erator pedal will move the vehicle in a forward direc tion REV With the Power Key switch on and the VDS in the REV position Pushing down on the accelerator pedal will move the vehicle in reverse NOTE Your GEM is equipped with a reverse warning device that sounds when the Power Key switch is on and the VDS switch is in the REV position CAUTION Always bring the v
35. tion 7 Check brake lines for leaks WARRANTIES AND CUSTOMER SERVICE CONTENTS Warranties iiis etr ana 40 If You Need Customer Assistance 42 Bl Change Of Address New Owner 43 40 WARRANTIES AND CUSTOMER SERVICE WARRANTIES 12 Month Factory Materials and Workmanship We warrant to the original consumer purchaser or lessee that the GEM will be free from defects in factory materials and workmanship under normal use and service for a period of twelve months from date of sale subject to the terms and provisions contained herein The non transferable warranty for parts and labor shall include the GEM in its entirety Battery and tires are excluded from warranty as they are warranted by their respective manufactures See individual warranty terms and conditions in your owner s packet Additional Conditions Gem will warrant all parts provided under this warranty All GEM parts replaced under warranty become the property of GEM and must be returned to the factory for inspection on request Your authorized GEM dealer will provide parts return service Any other expenses incurred in obtaining warranty repairs including transportation are the responsibility of the purchaser unless otherwise stated in this warranty NOTE To qualify for warranty protection the selling dealer must file the warranty registration form on the Internet site GEM connect within ten days after purc
36. u might suffer internal injuries or you could even slide out of part of the belt Follow these instructions to wear your seat belt safely and to keep your passengers safe too Two people should never be belted into a single seat belt People belted together can crash into one an other in an accident hurting one another badly Never use a lap shoulder belt or lap belt for more than one person no matter what their size Proper Wear Of Your Seat Lap and Shoulder Belt 1 Enter the vehicle and sit back 2 The seat belt latch plate is above the back of your seat Grasp the latch plate and pull out the belt Slide the latch plate up the webbing as far as necessary to make the belt go around your lap 3 When the belt is long enough to fit insert the latch plate into the buckle until you hear a click CAUTION Make sure the button on the buckle faces upward or outward so that you are able to unbuckle your seat belt quickly 4 Position the lap belt hold the latch 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 and pull on the lap belt A snug belt reduces the risk of sliding under the belt in a collision 5 Position the shoulder belt on your chest so that it is comfortable and not resting on your neck The retractor will withdraw any slack in the belt 20 UNDERSTANDING THE FEATU
37. y shall not apply to normal maintenance This maintenance includes but is not limited to battery fluid replenishment brake adjustment brake fluid re plenishment and brake shoes Consumables such as light bulbs fuses etc are not covered Our retailers are independently owned and operated and may sell products other than GEM Therefore you should understand that we are not and cannot be re sponsible for the quality suitability or safety of any non genuine GEM parts accessories or design modifications including labor which may be sold and or installed by our retailers or any damage caused thereby There are no other expressed warranties on your GEM beyond those set forth herein and no implied warranties of merchantability or fitness to the full extent allowed by law GEM and its retailers shall not be liable for loss of use inconvenience lost time commercial loss or any incidental consequential or other damages Export GEM only In the case of GEM NEV S sold outside of the USA defective parts must be returned to the selling retailer and transportation charges prepared by the purchaser Your retailer or GEM will then replace all parts which inspection shall show to be defective under the warranty GEM will cover the shipping charges of warranty parts to the 50 United States but it is the purchaser s responsibility to cover the rest of the shipping charges outside the 50 United States For further information concer
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