GEM 2005 Owner's Manual
2005 Owner’s Manual
Introduction
CONTENTS
About this Manual ........................................................................2
Cautions, Warnings and Notes ....................................................3
GEM Owner’s Manual - Page 1
Introduction
ABOUT THIS MANUAL
Thank you for purchasing your GEM. Your vehicle is designed to
operate exclusively on battery power. It is an emission free vehicle.
The ideal application for a battery-powered vehicle occurs when the
daily driving pattern is predictable and the distance is short.
Customer safety and satisfaction is of genuine concern 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. The Owner’s Manual has been
designed for your enjoyment and safety. Maintenance schedules and
general care instructions are included.
This manual is applicable to all four of the GEM models: The GEM
e2 (Two Passenger NEV), GEM e4 (Four Passenger NEV), GEM
eS (Two Passenger Short-back NEV), and the GEM eL (Two
Passenger Long-back NEV).
GEM Owner’s Manual - Page 2
Introduction
If questions arise after reading the manual, contact GEM Customer
Service at 1-866-764-0616. Please have your Vehicle Identification
Number (VIN) and date of purchase information available.
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 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 find the words “WARNING!” and
“CAUTION!” These serve as reminders to be especially careful.
“WARNING!” indicates an immediate hazard, which could result in an
accident causing 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
make procedures more easily understood.
GEM Owner’s Manual - Page 3
Vehicle Identification and Specifications
CONTENTS
Vehicle Information ......................................................................5
General Specifications .................................................................6
GEM Owner’s Manual - Page 4
0001
1
Vehicle Identification and Specifications
VEHICLE INFORMATION
Figure 1 - VIN/Certification Label Location
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.
Vehicle Identification Number (VIN):
__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|
Key # ___________
Optional Pak # _______________
Date purchased: _____ /_____ /_____
GEM Owner’s Manual - Page 5
Vehicle Identification and Specifications
GENERAL SPECIFICATIONS
GEM e2 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: 10” Two-ply street and turf 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: 99 inches
Height: 68 inches
Turning Radius: 12’ 3”
Wheelbase: 72 inches
Curb Weight: 1078 lb.(EMPTY)
GVW: 1600 lb.(LOADED)
GEM Owner’s Manual - Page 6
Vehicle Identification and Specifications
GENERAL SPECIFICATIONS
GEM e4 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: 128 inches
Height: 70 inches
Turning Radius: 16’ 6”
Wheelbase: 102 inches
Curb Weight: 1271 lb.(EMPTY)
GVW: 2100 lb.(LOADED)
GEM Owner’s Manual - Page 7
Vehicle Identification and Specifications
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)
GEM Owner’s Manual - Page 8
Vehicle Identification and Specifications
GENERAL SPECIFICATIONS
GEM eL 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: 144 inches
Height: 70 inches
Turning Radius: 16’ 6”
Wheelbase: 102 inches
Curb Weight: 1192 lb.(EMPTY)
GVW: 2300 lb.(LOADED)
GEM Owner’s Manual - Page 9
Things to Know Before You Operate Your Vehicle
CONTENTS
Driving and Alcohol .................................................................... 11
Safety Information ......................................................................12
GEM Owner’s Manual - Page 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 impaired 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 public
transportation.
WARNING!
Driving after drinking alcohol can lead to an accident. Your
perceptions are less sharp, your reflexes are slower, and your
judgement is impaired when you have been drinking. Never
drink and then drive.
GEM Owner’s Manual - Page 11
Things to Know Before You Operate Your Vehicle
SAFETY INFORMATION
WARNING!
Your vehicle is battery powered. Handled improperly, batteries
can be dangerous. Follow the precautions provided on pages
12-13 during charging operations to avoid personal injury or
damage to electrical components in the vehicle.
• Read the Owner’s Manual before operating this vehicle.
• Charge batteries in a well-ventilated area only.
• Keep children away from the batteries during charging.
• Batteries can emit explosive hydrogen 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 either 12-volt flooded or gel
batteries, specially built for electric vehicle application. Automotive
batteries should neverbe used.
• Some electrolyte can leak from damaged or defective flooded
batteries. Avoid contact with skin, eyes, or clothing.
GEM Owner’s Manual - Page 12
Things to Know Before You Operate Your Vehicle
• Batteries contain acid, which causes severe burns. If battery fluid
is on your skin, flush the affected areas with water for at least 15
minutes and then seek medical assistance.
• Internal contact: Get medical assistance as soon as possible.
• Contact with eyes: Flush with water and get medical assistance
as soon as possible. While you are being driven to get medical
assistance, continue to rinse your eyes by using a sponge or soft
cloth saturated with water.
WARNING!
The battery packs contain high voltage that could cause serious
or fatal injury if not handled properly. Only qualified technicians should handle or service this vehicle, after consulting the
service manual.
GEM Owner’s Manual - Page 13
Understanding the Features of Your Vehicle
CONTENTS
Instrument Pod ...........................................................................15
Windshield Wiper .......................................................................27
Foot Controls .............................................................................28
Parking Brake ............................................................................29
Main Disconnect Switch .............................................................31
Seat Belts ...................................................................................32
GEM Owner’s Manual - Page 14
Understanding the Features of Your Vehicle
INSTRUMENT POD
1
3
6
4
5
2
Figure 2 - Instrument 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
NOTE: Further explanation of these vehicle features are found on the next
few pages.
GEM Owner’s Manual - Page 15
Understanding the Features of Your Vehicle
Turn Signal/Windshield Wiper/Horn Lever
Figure 3 - Turn Signal Lever
The turn signal lever is multi-functional, controlling the turn signals, horn and
wiper. Figure 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.
CAUTION!
The turn signal lever is not self-canceling. After
completing the turn, return the lever to the center
GEM Owner’s Manual - Page 16
Understanding the Features of Your Vehicle
Horn
Press the turn signal lever inward, toward the instrument pod to activate the
horn.
Windshield Wiper
Press the turn signal lever towards the steering wheel to turn on the
windshield wiper. Pull the turn signal lever away from the steering whell to
turn off.
Trip/Odometer Switch
The momentary trip switch has three functions: toggle between the
odometer and the 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 Switch
1. Pressing the trip switch for less than 2 seconds will toggle between the
odometer and tripmeter modes on the display.
2. Pressing the trip switch for 3-9 seconds, while the display is in the trip
mode, will reset the tripmeter to zero. (TRIP must be lit on the display
- page 20).
3. Pressing the trip switch for 10-12 seconds, while the display is in the
odometer mode will change the display functions from MPH to km/h and
miles to km.
GEM Owner’s Manual - Page 17
Understanding the Features of Your Vehicle
Headlight Switch
This switch turns the headlights and rear running lights on and off.
Vehicle Direction Switch
Drive High
With the key turned on and “High” selected, pushing down on the accelerator
pedal will move the vehicle in a forward direction with the speed range of 0-25
mph. This mode refers to “APPROVED TRAFFIC” routes based on Low Speed
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 015 mph. When “Low” is selected, the acceleration and speed of the GEM is
limited.
Reverse
With the key switch on and “Reverse” selected, pushing down on the accelerator
pedal will move the vehicle in reverse. The top speed in the reverse direction
is limited for safety.
NOTE: Your GEM is equipped with a reverse warning device that sounds when
the key is on and the vehicle direction switch is in the reverse position.
GEM Owner’s Manual - Page 18
Understanding the Features of Your Vehicle
CAUTION!
Always bring the vehicle to a complete stop before changing the position of the vehicle direction switch.
Key Switch
When the key is in the “ON” position (turned clockwise), the display
will light up and all accessories may be turned on. When the key is in
the “OFF” position, the car will not drive but accessories and lights will
remain on for approximately 20 seconds.
CAUTION!
Do not leave the key in the “ON” position when not in
use. Doing so discharge the batteries.
Zero Speed Detect
If the vehicle is moving when the key switch is on and accelerator
pedal up, the electric motor will resist vehicle motion.
GEM Owner’s Manual - Page 19
Understanding the Features of Your Vehicle
LCD Display
A
B
C
D
E
F
G
H
Figure 4 - LCD Display
GEM Owner’s Manual - Page 20
P
O
N
M
L
JI
K
Understanding the Features of Your Vehicle
LCD Display Indicators
A LEFT TURN
B BRAKE FAILURE 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 HEADLIGHTS
N SERVICE
O RIGHT TURN
P SPEEDOMETER / ERROR CODE
NOTE: These indicators are defnined on the next several pages.
GEM Owner’s Manual - Page 21
Understanding the Features of Your Vehicle
Turn Signals
The blinking turn signal arrows correspond to the direction of the turn
signal lever.
Brake Failure Warning
If the brake warning icon is lit, there may be a problem with your
braking system. It could be an indication of the following.
• Low brake fluid
• Air in the brake system
WARNING!
Have your brakes checked immediately by a trained service person if the brake failure warning indicator is lit.
High Motor Temperature
If the high motor temperature icon is lit, your motor may be
overheating. This is usually a symptom of overworking the motor.
Steep grades and heavy loads will quickly heat the motor and
shorten motor life.
GEM Owner’s Manual - Page 22
Understanding the Features of Your Vehicle
CAUTION!
If the high motor temperature warning indicator is lit,
pull over and park the vehicle in a cool location as soon
as possible. Wait until motor temperature is reduced and
the high motor temperature icon turns off to drive. If this
condition persists, contact your service provider.
Odometer/Tripmeter
The odometer indicates the total distance the vehicle has been
driven. This is useful in keeping a record for maintenance. The
odometer can be displayed in kilometers or miles. To change from
miles to kilometers or to change from odometer to tripmeter, see the
Trip/Odometer Switch section on page 17. The tripmeter is useful
for keeping tack of specific distances traveled.
Speedometer/Error Code
The speedometer indicates driving speed in either miles-perhour (MPH) or kilometers-per hour (km/h). To switch between
MPH and km/h, see the Trip/Odometer Switch section on page
17. If the Service icon is lit, an error code will be displayed at the
speedometer location. See page 44 for information regarding error
codes.
GEM Owner’s Manual - Page 23
Understanding the Features of Your Vehicle
Charger Connected
The charger connected icon and state of charge gauge turns on approximately 8-10 seconds after the extension cord is plugged in. After charging
is done, both indicators remain lit. To know if the charge is complete, all ten
bars on the state of charge should be lit. If both the charger connected and
state of charge are not lit, the charger may not be charging. If this occurs,
make sure the 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 remains in the battery pack. There are 10 bars: 1 red, 1 yellow, and 8 green. After a full charge
all the bars should be lit. The far right green bar will be the first to turn off
once the battery pack voltage begins to drop. The percent full charge corresponding to each bar is shown below.
Bar Color % Full Charge
1 Red (Far Left) Less Than 10
2 Yellow 10-20
3 Green 20-30
4 Green 30-40
5 Green 40-50
6 Green 50-60
7 Green 60-70
8 Green 70-80
9 Green 80-90
10 Green (Far Right) 90-100
GEM Owner’s Manual - Page 24
Understanding the Features of Your Vehicle
Current Limiting Mode
The current limiting mode is designed to protect the batteries and motor. If
the current limiting mode icon is lit, it is an indication of one of the following
issues.
Battery Pack Over-Voltage
Battery over-voltage typically occurs when the vehicle is descending down
hills after being fully charged. 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-Voltage
Battery under-voltage would coincide with a low charge reading on the state
of charge gauge. If you continue to drive, the acceleration and power will
begin to decrease. The controller will eventually shut the vehicle down before
allowing battery damage to occur. If the charge is low and the current limiting
icon is lit, pull the vehicle over to a safe location and charge the vehicle.
GEM Owner’s Manual - Page 25
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