.Vehicle Identication and Specications ......................................8
.Things to Know Before You Operate Your Vehicle ..................... 16
.Understanding the Standard Features of Your Vehicle ..............21
.Understanding the Optional Features of Your Vehicle ...............56
.Operation and Maintenance .......................................................73
.Limited Warranty and Customer Service .................................105
.Word Index ............................................................................... 115
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GEM Owner’s Manual - Page 2
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Introduction
CONTENTS
.About this Manual ........................................................................4
.Introduction to Safe Ownership of GEM models .......................... 5
.Cautions, Warnings and Notes ....................................................7
NOTE: This manual is subject to change. For the latest version please
visit www.gemcar.com, and click on About GEM, Current GEM Owners,
and Owners Manuals.
WARNING
Any modicaons or alteraons to this vehicle could seriously aect its road
worthiness and safety and may lead to an accident resulng in serious injury or
death.
WARNING
You can be badly injured working on an electric vehicle. Take your vehicle to your
dealer or call Global Electric Motorcars Customer Service at 866-764-0616 for
your service needs.
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Introduction
ABOUT THIS MANUAL
Thank you for purchasing your GEM car by Polaris Industries Inc.
Your vehicle is designed to operate exclusively on battery power. It is
an emission-free vehicle. The ideal application for a battery-powered
neighborhood electric vehicle (NEV) occurs when the daily driving
pattern is predictable and the distance is relatively short.
Polaris’ objective includes customer safety and product satisfaction.
This Owner’s Manual is designed to acquaint you with the proper and
safe operation of your GEM car. Please take the time to read and
understand the manual before operating your vehicle. Maintenance
schedules and general care instructions are included in the Operation
and Maintenance section.
This manual is applicable to the following GEM line of vehicles: GEM e2
(two passenger), GEM e4 (four passenger), GEM eS (two passenger
short-back), GEM eL (two passenger long-back), GEM eL XD (two
passenger extra duty long-back), and the GEM e6® (six passenger).
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Introduction
If questions arise after reading the manual, you may contact us at 866.764.0616.
Please have your Vehicle Identication Number (VIN) and date of purchase
information available.
NOTE: All information and specications in this Owner’s Manual are current
at the time of printing. However, due to GEM policy of continuous product
improvement, we reserve the right to make changes, at any time, without
written notice or obligation.
INTRODUCTION TO THE SAFE OWNERSHIP OF GEM LINE OF
VEHICLES
GEM battery-electric vehicles are different from vehicles you might be
accustomed to owning. Special precautions should be followed when owning
and operating a GEM car. Please read this Manual and pay particular
attention to the cautions and warnings in this Manual, as well as those placed
on the vehicle in various locations.
In general, GEM battery-electric vehicles are designed to meet U.S. Federal
Government safety requirements for a special class of vehicle known as
“Low Speed Vehicles.” By this very name, and implicit in these safety
requirements, these vehicles are intended only for use at low speed, up to
25 mph, and on public roads (governed by individual state laws) where the
speed limits are correspondingly low.
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Introduction
Specic to GEM car models, the following safe habits should always be
followed:
• GEM battery-electric vehicles are open vehicles. For this reason, safety
belts should always be worn by all occupants to prevent being thrown from
the vehicle during operation. If your GEM car is equipped with doors, these
were designed and are intended only to keep wind and water out of the vehicle
and should not be relied upon to keep occupants in the vehicle or to protect
them in case of collision.
• GEM battery-electric vehicles are not designed to meet any collision or rollover requirements. Therefore, you should always drive your GEM car in a
safe manner while being alert to potential dangerous situations around you.
As with all motor vehicles, never drink alcohol and attempt to drive a GEM car.
Operate a GEM car only on public or private roads where the speed limits are
appropriate for low speed vehicles (individual state laws vary, so check with
your DMV) and the trafc is light. You should never operate a GEM car so that
you are an obstacle and become an annoyance for faster moving trafc.
• GEM battery-electric vehicles are designed to be recharged from a standard
120 VAC-15 amp electrical outlet that is ground-fault protected. Charging from
a circuit of lesser capacity and/or using a cord from the outlet to the GEM car
that is not sufcient in wire gauge could create a re hazard. Please consult this
Manual for the proper extension cord gauge which depends on its length.
• The voltage in a GEM car battery pack (the battery pack is what you charge
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Introduction
and provides the “fuel” to the GEM cars electric drive system) is sufcient to
cause death by electrocution. For this reason, GEM car owners should NEVER
attempt to do any maintenance or repair work on their GEM cars electric drive
system, including the battery pack, unless they have had special training. The
one exception is inspection and relling, if necessary, of the water in ooded type
batteries that can be ordered with the GEM line of vehicles.
In this Owner’s Manual, the above safe ownership and operation habits will be
pointed out to you as the different aspects of owning and operating a GEM car
are explained. Please read, understand and abide by them for years of safe
operation and enjoyment of your GEM car.
WARNINGS, CAUTIONS, NOTICES AND NOTES
The following signal words and symbols appear throughout this manual and
on your vehicle. Your safety is involved when these words and symbols are
used. Become familiar with their meanings before reading the manual.
The safety alert symbol indicates a potential personal injury
hazard.
WARNING indicates a hazardous situation which, if not avoided,
may result in death or serious injury.
CAUTION indicates a hazardous situation which, if not avoided, may
result in minor or moderate injury.
NOTICE indicates a situation that may result in property damage.
NOTE indicates information to help clarify procedures.
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Vehicle Identication and Specications
CONTENTS
.Vehicle Information ......................................................................9
For all model vehicles, the Vehicle Identication Number (VIN) can be
found on the VIN/Certication Label, located on the left rear section of
the 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 Identication Number in the
space provided.
Optional Rear Accessory # _______________ (Stamped on Key)
Date purchased: _____ /_____ /_____
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Vehicle Identication and Specications
GENERAL SPECIFICATIONS
GEM e2 Specications
Motor: GE Heavy Duty 5 hp, shunt DC electric motor
Drive System: Single speed front wheel drive trans axle
Tire: 2-ply street rated tires 12” 165/70R-12
Battery Pack: Six 12-volt lead acid batteries of specic make and
model number
Accessory Power Supply: 12 volt, 30 amp DC/DC converter
*The turning circle is the diameter of a circle required to make a U-turn maneuver
**These weight limits are approximate. The GVWR must never be exceeded. GVWR
is the actual weight of the vehicle plus the weight of the entire payload of passengers
and cargo.
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Vehicle Identication and Specications
GENERAL SPECIFICATIONS
GEM e4 Specications
Motor: GE Heavy Duty 5 hp, shunt DC electric motor
Drive System: Single speed front wheel drive trans axle
Tire: 2-ply street rated tires 12” 165/70R-12
Battery Pack: Six 12-volt lead acid batteries of specic make and
model number
Accessory Power Supply: 12 volt, 30 amp DC/DC converter
*The turning circle is the diameter of a circle required to make a U-turn maneuver
**These weight limits are approximate. The GVWR must never be exceeded. GVWR
is the actual weight of the vehicle plus the weight of the entire payload of passengers
and cargo.
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Vehicle Identication and Specications
GENERAL SPECIFICATIONS
GEM eS Specications
Motor: GE Heavy Duty 5 hp, shunt DC electric motor
Drive System: Single speed front wheel drive trans axle
Tire: 2-ply street rated tires 12” 165/70R-12
Battery Pack: Six 12-volt lead acid batteries of specic make and
model number
Accessory Power Supply: 12 volt, 30 amp DC/DC converter
Charger: 120 volt 15 amp 60 Hz AC input. 72-100 volt 12 amp
*The turning circle is the diameter of a circle required to make a U-turn maneuver
**These weight limits are approximate. The GVWR must never be exceeded. GVWR
is the actual weight of the vehicle plus the weight of the entire payload of passengers
and cargo.
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Vehicle Identication and Specications
GENERAL SPECIFICATIONS
GEM eL Specications
Motor: GE Heavy Duty 5 hp, shunt DC electric motor
Drive System: Single speed front wheel drive trans axle
Tire: 2-ply street rated tires 12” 165/70R-12
Battery Pack: Six 12-volt lead acid batteries of specic make and
model number
Accessory Power Supply: 12 volt, 30 amp DC/DC converter
Charger: 120 volt 15 amp 60 Hz AC input. 72-100 volt 12 amp
*The turning circle is the diameter of a circle required to make a U-turn maneuver
**These weight limits are approximate. The GVWR must never be exceeded. GVWR
is the actual weight of the vehicle plus the weight of the entire payload of passengers
and cargo.
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Vehicle Identication and Specications
GENERAL SPECIFICATIONS
GEM eL XD Specications
Motor: GE Heavy Duty 7 hp vented, shunt DC electric motor
Drive System: Single speed front wheel drive trans axle
Tire: 2-ply street rated tires TR13” P185/70R13 86H
Battery Pack: Nine 8-volt lead acid batteries of specic make and
model number
Accessory Power Supply: 12 volt, 30 amp DC/DC converter
*The turning circle is the diameter of a circle required to make a U-turn maneuver
**These weight limits are approximate. The GVWR must never be exceeded. GVWR
is the actual weight of the vehicle plus the weight of the entire payload of passengers
and cargo.
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Vehicle Identication and Specications
GENERAL SPECIFICATIONS
GEM e6® Specications
Motor: GE Heavy Duty 7 hp vented, shunt DC electric motor
Drive System: Single speed front wheel drive trans axle
Tire: 2-ply street rated tires TR13” P185/70R13 86H
Battery Pack: Six 12-volt lead acid batteries of specic make and
model number (e6 w/S option) Nine 8-volt lead acid gel
batteries of specic make and model number
Accessory Power Supply: 12 volt, 30 amp DC/DC converter
OnboardCharger: 120 volt 15 amp 60 Hz AC input. 72-100 volt 12 amp DC output
Vehicle Width: 55”
Vehicle Length: 162”
Vehicle Height: 70”
Wheelbase: 133”
Turning Circle: 39 feet*
Curb Weight: 1560 lbs.
1860 lbs w/S option
GVWR: 3000 lbs.
*The turning circle is the diameter of a circle required to make a U-turn maneuver
**These weight limits are approximate. The GVWR must never be exceeded. GVWR
is the actual weight of the vehicle plus the weight of the entire payload of passengers
and cargo.
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Things to Know Before You Operate Your Vehicle
CONTENTS
.Driving and Alcohol ....................................................................17
.Safety Information ...................................................................... 18
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Things to Know Before You Operate Your Vehicle
DRIVING AND ALCOHOL
Your ability to drive your GEM car can be seriously impaired with
blood alcohol levels far below the legal minimum. If you are drinking
alcohol, don’t drive. Ride with a designated non-drinking driver, call a
cab, or use public transportation.
WARNING
Driving aer drinking alcohol can lead to an accident resulng in death or serious
injury. Your percepons are less sharp, your reexes are slower, and your judgment
is impaired when you have been drinking. Never drink alcohol and drive.
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SAFETY INFORMATION
WARNING
Your vehicle is baery powered. If handled improperly, baeries can be dangerous.
Follow the precauons provided on pages 18-19 during charging operaons to avoid
personal injury or damage to electrical components in the vehicle.
• Read the Owner’s Manual before operating this vehicle.
• Charge vehicle in a well-ventilated area only.
• Keep children away from the vehicle during charging.
• Batteries can emit explosive hydrogen gases when charging. Keep
sparks and ames away from the battery area of the vehicle. Tools,
wires and metal objects can cause sparks when shorted across the
battery connections. Follow all instructions carefully when dealing
with batteries.
• The batteries in the GEM car are either 12 volt or 8 volt lead acid
batteries. They are connected in a pack conguration to produce
HIGH VOLTAGE DC (72 to 100 volts). These batteries are either
Flooded electrolyte type or Gel electrolyte type and are selected
specically to optimize the operation and performance of your vehicle.
Never use or substitute any battery other than the original
factory approved batteries.
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Things to Know Before You Operate Your Vehicle
• Electrolyte can leak from damaged or defective ooded batteries. Avoid
contact with skin, eyes or clothing.
• Batteries contain acid, which can cause severe burns. If battery uid
comes in contact with your skin, ush the affected areas with water for at
least 15 minutes and then seek medical assistance.
• Internal ingested: 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.
CAUTION
When checking the electrolyte level in ooded baeries, be careful to never touch
the baery terminals.
WARNING
Baery posts, terminals, and related accessories contain lead and lead compounds.
Always wash hands aer handling the baery.
WARNING
Improper handling of high voltage wiring, baeries, or control systems could result
in serious or fatal injury by electric shock. Only qualied technicians should repair
or access high voltage wiring, baery packs, and associated systems.
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ROLL OVER WARNING
Do not attempt sharp turns or abrupt maneuvers or other unsafe driving actions that can cause loss of vehicle control and possible roll over.
Failure to operate this vehicle safely may result in an accident, roll over,
and serious injury or death. Because of its construction, your vehicle
offers less protection than other types of motor vehicles in the event of
an accident.
WARNING
Carrying loads on the roof could damage the roof and aect vehicle handling causing an accident leading to death or serious injury.
Never carry loads on the roof of the vehicle.
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Understanding the Standard
Features of Your Vehicle
CONTENTS
.Instrument Pod ...........................................................................22
1. Turn Signal/Windshield Wiper & Washer/Horn Lever
2. Trip/Odometer Switch
3. Headlight Switch
4. Forward/Reverse Switch
5. Key Switch
6. LCD Display
NOTE: Further explanation of these vehicle features are found on the next nine
pages.
*Left Hand Drive Model Vehicle shown.
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TURN SIGNAL/WINDSHIELD WIPER & WASHER /HORN LEVER
Figure 3 - Turn Signal Lever
The turn signal lever is multi-functional, controlling the turn signals, horn,
wiper, and washer, if so equipped. 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.
*Same for both Left Hand Drive and Right Hand Drive vehicles.
NOTE: The turn signal lever is not self-canceling. After completing the turn,
return the lever to the center (off) position. An audible tone alert will sound
after the turn signal has been on for 45 seconds.
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HORN
Press the turn signal lever inward toward the instrument pod to activate the
horn.
WINDSHIELD WIPER
Push the turn signal lever away from the steering wheel to turn on the
windshield wiper. Pull the turn signal lever towards the steering wheel to
turn off.
WINDSHIELD WASHER
Push the lever again for a momentary wash of the windshield.
TRIP METER/ODOMETER SWITCH/E-METER
The trip switch has three functions: (1) toggling between the odometer
and the trip meter; (2) reset the trip meter; (3) change the function of the
speedometer and odometer from miles-per-hour (MPH) to kilometers-perhour (km/h) and miles to kilometers; (4) toggle between odometer/trip meter
and e-meter, displaying accumulated power consumed from grid, show in
kilowatt hours (KW/HR).
USING THE TRIP/ODOMETER SWITCH/E-METER
1. Pressing the trip switch for less than 2 seconds will toggle between the odometer
and trip meter modes on the display.
2. Pressing the trip switch for 3-9 seconds, while the display is in the trip mode, will
reset the trip meter to zero. (TRIP must be lit on the display- see page 27).
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 kilometers.
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HEADLIGHT SWITCH
Headlight switch turns the headlights and taillights on and off.
FORWARD/REVERSE 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
0-15 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 car is equipped with a reverse warning device that sounds
when the key is on and the vehicle direction switch is in the reverse position.
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NOTICE
Always bring the vehicle to a complete stop before changing the posion of the
forward/reverse 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 accelerate but accessories and lights will remain on for approximately
30 seconds
prevent unauthorized use.
. Remove the key from the ignition when vehicle is not in use to
WARNING
Never turn the key to the “OFF” posion while the vehicle is in moon. This could
lead to loss of speed control and loss of control of the vehicle. This can cause an
accident and may result in death or serious injury.
NOTICE
Do not leave the key in the ‘ON’ posion when not in use. Doing so will discharge
the baeries.
ZERO SPEED DETECT
If the vehicle is moving while the key switch is on and accelerator pedal up (not
depressed), the electric motor will resist vehicle motion. This feature will not
work unless the main contactor is engaged.
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LCD DISPLAY
A
B
C
D
E
F
G
P
O
N
M
H
JI
Figure 4 - LCD Display
K
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LCD Display Indicators
A Left Turn Indicator
B Low Fluid Level/Parking Brake On Indicator
C High Motor Temperature Warning Indicator
D Odometer/Trip Meter
E Charger Connected Indicator
F
G Current Limiting Mode Indicator
H Safety Belt Warning Indicator
I Reverse Indicator
J Drive-Low Setting
K Drive-High Setting
L Headlight Indicator-Low Beam
M Headlight Indicator-High Beam
N
O Right Turn Indicator
P Speedometer/Error Code Display
State of Charge Indicator/Battery Discharge Indicator (BDI)
Service Required Indicator
*Vehicle will not move when the parking brake is engaged and
parking brake lamp is lit.
NOTE: These indicators are dened on the next several pages.
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TURN INDICATORS
The turn signal arrows will ash corresponding to the direction of the turn signal lever.
HIGH TEMPERATURE MOTOR OR MOTOR CONTROLLER
If the motor temperature icon is lit or an error code 41 is displayed in the speedometer/
error code display, your motor or motor controller may be overheating. Climbing steep
grades while hauling heavy loads may overheat the motor or controller and shorten
component life.
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 uid
• Air in the brake system
• Park brake is engaged
WARNING
Worn brake hoses can burst and cause brake failure. You could have an accident
and suer death or serious injury. If you see any signs of cracking, scung, or
worn spots, have the brake hoses replaced immediately.
WARNING
Riding the brakes can lead to brake failure and possibly an accident resulng in death or
serious injury. Driving with your foot resng or riding on the brake pedal can result in
abnormally high brake temperatures, excessive lining wear, possible brake damage, and
reduced driving range. You wouldn’t have your full braking capacity in an emergency.
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NOTICE
If the high motor temperature warning indicator is lit, or code 41 is displayed, pull
over and park the vehicle in a cool locaon as soon as possible. Wait unl motor
temperature is reduced and the high motor temperature icon turns o before
connuing to drive. If this condion persists, contact your service provider.
TRIP METER/ODOMETER/E-METER
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 trip meter, see the
Odometer Switch/Trip Meter section on page 24. The trip meter is
useful for keeping track of specic distances traveled.
SPEEDOMETER/ERROR CODE
The speedometer indicates driving speed in either miles-per-hour
(MPH) or kilometers-per hour (km/h). To switch between MPH and
km/h, see the Trip Meter/Odometer Switch section on page 24. If the
Service icon is lit, an error code will be displayed at the speedometer
location. See page 74 for information regarding error codes.
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CHARGER CONNECTED
The charger connected icon and state of charge/Battery Discharge Indicator gauge turns on
approximately 8-10 seconds after the extension cord is plugged in. After charging is 100%
complete, the charger connected icon will be the only thing lit and the bar graph will not be
illuminated. A green light on the charger itself will also illuminate when the car is 100% charged.
To know if the charging process is complete, all ten bars on the state of charge indicator should
be illuminated when the car is turned on. If the charger cord is plugged in and neither the
charger connected icon nor the state of charge/battery discharge indicators are not illuminated,
the charger may not be charging. If this occurs, make sure the main disconnect switch is in
the ’ON’ position. More information on the charger and charging of the batteries is discussed
on pages 76-81.
STATE OF CHARGE/BATTERY DISCHARGE INDICATOR
The state of charge indicator shows 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 illuminated when
the car is turned on. The far right green bar will be the rst to turn off once the battery pack
voltage begins to drop. The percent of charge corresponding to each bar is shown below.
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
Bar Color % Of Full Charge
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CURRENT LIMITING MODE
The current limiting mode is designed to protect the batteries and motor. If
the current limiting mode icon is illuminated, it is an indication of one of the
following issues:
Battery Pack Under-Voltage
Battery pack 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 state of charge is low and the
current limiting icon is illuminated, pull the vehicle over to a safe location and
charge the vehicle.
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SAFETY BELT
The safety belt icon reminds you to fasten your safety belt. The icon
remains on for 45 seconds.
WARNING
• Riding in the cargo area could result in death or serious injury.
• Do not allow people to ride in any area of your vehicle that is not equipped
with seats and seat belts.
• Be sure everyone in your vehicle is in a seat and using a seat belt properly.
DRIVE HIGH/LOW/REVERSE
The drive High/Low/Reverse corresponds to the position of the
Forward/Reverse switch. More information regarding this switch can
be found on pages 22 and 25.
SERVICE
If the Service icon is illuminated, an error code will be displayed at the
speedometer location. See page 74 for a description and explanation
of common error codes.
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WINDSHIELD WIPER
NOTE:The windshield wiper circuit is protected by a 10 amp fuse
located in the fuse block behind the fuse access panel. If the wiper
is not working check the fuse and if blown, replace it with the same
type and rating.
1
Figure 5- Windshield Wiper
1. Wiper Blade and Arm
CAUTION
A damaged or worn wiper blade may reduce vision and impair you from seeing
well enough to drive safely. A worn wiper blade could damage windshield glass. If
your blade becomes damaged or worn, replace it.
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NOTICE
When replacing a blown fuse, it is important to use only a fuse having the correct
amperage rang. The use of a fuse with a rang other than indicated may result
in an electrical system overload. If a properly rated fuse connues to blow, it
indicates a problem in the circuit that must be corrected.
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FOOT PEDALS
2
1
Figure 6 - Foot Pedals
1. Brake Pedal
2. Accelerator Pedal
BRAKE PEDAL
The brake pedal (Figure 6) is located on the oor to the left of the accelerator
pedal. To slow or stop the vehicle, rmly press the brake pedal.
ACCELERATOR PEDAL
The accelerator pedal (Figure 6), is located on the oor, close to the center
of the vehicle and is used to control your speed. Pressing down on the pedal
will increase speed.
WARNING
Always accelerate slowly to prevent possible injury to yourself or others.
*Left Hand Drive Model shown. (Same for Right Hand Drive Models).
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PARKING BRAKE
1
Figure 7 - Parking Brake (GEM e2, GEM eS, GEM eL, GEM eL XD)
2
Figure 8 - Parking Brake (GEM e4, GEM e6
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1. Parking Brake (models e2, eS, eL, eL XD) Figure 7
2. Parking Brake (models e4, e6®) Figure 8
The parking brake is located to the lower right of the driver seat. To
engage the parking brake, lift up on the handle. To release, press the
button on the end of the brake handle and lower it.
NOTE: The parking brake is adjustable and should be checked
periodically by a trained service technician. Review the vehicle
maintenance schedule on page 104.
WARNING
• Always fully apply the parking break when leaving your vehicle, or it will roll
and may cause death or serious injury.
• Leaving children in a vehicle unaended is dangerous for a number of
reasons. A child or other person could be injured. Children should be warned
not to touch the parking brake or the gear selector lever. Always remove
key from ignion when done with vehicle. A child could operate controls, or
move the vehicle.
• Be sure the parking brake is fully disengaged before driving. Failure to do so
can lead to brake problems due to excessive heang of the rear brakes.
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MAIN DISCONNECT SWITCH AND FUSE PANEL
Figure 9 - Main Disconnect Switch
The main disconnect switch (MDS) (Figure 9), is located inside the fuse
access panel on the lower dash. The switch is clearly labeled ‘ON’ and ‘OF
F’.
The switch is intended to provide an easy way to disconnect all power to the
vehicle during long-term storage. After disconnect is turned off, some power
may remain in the system until all capacitors have discharged.
NOTE: The main disconnect switch must be turned ‘ON’ for operation and
charging. The GEM car is equipped with a battery charger that will monitor
the state of charge of the batteries and will initiate a charge cycle whenever
the batteries fall below a predetermined level. If the car will be left unused for
an extended period of time, leave the MDS on and the car plugged in. The
car will maintain a charge on its own for up to 24 weeks.
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NOTICE
When replacing a blown fuse, it is important to use only a fuse having the correct
amperage rang. The use of a fuse with a rang other than indicated may result in
an electrical system overload. If a properly rated fuse connues to blow, it indicates
a problem in the circuit that must be corrected.
NOTICE
Do not turn o disconnect switch while the vehicle is in moon or undergoing
recharge unless in the case of an emergency where the vehicle operaon or charging requires interrupon.
WARNING
The main disconnect switch will disable the vehicle by disconnecng the baery
pack from the motor. It does not disable the baery pack. HIGH VOLTAGE will be
present at the baery terminals.
HIGH BATTERY VOLTAGE IS ALWAYS PRESENT. DO NOT TOUCH THE BATTERY
TERMINALS.
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CONVENIENCE ITEMS
SEAT ADjUSTMENT - 4 & 6 PASSENGER ONLY
The front seats on the GEM e4 and GEM e6® models are equipped
with manual seat adjustments. The seat adjustment handle is directly
under the front of the seat. Move the handle toward the driver’s side
door, to the left, and move the seat to the desired position. Using body
pressure, move forward and rearward on the seat to assure the seat
adjusters are latched securely.
1
Figure 12 - Seat Adjustment Handle
1. Seat Adjustment Handle
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3
1
2
Figure 10 - Safety Belts (Bench Seat)
1. Belt
2. Latch
3. Buckle
3
2
1
Figure 11 - Safety Belts (Bucket Seat)
The GEM car is equipped with safety belts for both driver and
passengers.
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Research has shown that safety belts save lives. Safety belts can
reduce the seriousness of injuries in a single vehicle accident. Some
of the worst injuries happen when people are thrown from the vehicle.
Safety belts provide protection, and they reduce the risk of injury
caused by striking the inside of the vehicle. Everyone needs to buckle
up all the time, even for short trips.
WARNING
• Always wear your safety belt correctly. Safety belts are designed to go
around the large bones of your body. These are the strongest parts of
your body and can take the forces of a collision best.
• Wearing your safety belt incorrectly could increase your risk of death
or serious injury in an accident. You could suer internal injuries, or
even slide out of part of the belt. Use the instrucons in this manual
to insure you and your passengers are wearing the safety belts
properly.
• Two people should never be belted into a single safety belt. People
belted together can crash into one another in an accident, causing
injury. Never use a lap/shoulder belt for more than one person, no
maer the size of the person.
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WARNING
In a collision, you and your passengers can suer death or serious injury if you
are not properly buckled up. You can strike the interior of your vehicle or other
passengers, or you can be thrown out of the vehicle. Always be sure you and others
in your vehicle are buckled up properly.
PROPER USE OF YOUR LAP AND SHOULDER BELT
1. Enter the vehicle and sit back.
2. The safety belt buckle is located above the back of the seat. Grasp
the buckle and pull out the belt. Slide the buckle up the webbing as
far as necessary to make the belt go around your lap.
3. When the safety belt is long enough to t, insert the buckle into the
latch until you hear a click. Make sure the button on the latch faces
upward or outward so that you are able to unbuckle your safety belt
quickly.
4. Position the lap belt across your thighs, and below your abdomen.
To remove slack in the lap belt portion of the belt, pull up on the
shoulder belt. To loosen the lap belt if it is too tight, tilt the buckle
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
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and not resting on your neck. The retractor will withdraw any slack
in the belt.
6. To release the belt, push the red button on the latch. If necessary,
slide the buckle down the webbing to allow it to retract fully.
WARNING
A frayed or torn belt could rip apart in a collision and lead to death or serious
injury. Inspect the belt system periodically, checking for cuts, frays, or loose parts.
Damaged parts must be replaced immediately. Do not modify or disassemble the
system. Seat belt assemblies must be replaced aer a collision if they have been
damaged (bent retractor, torn webbing, etc.).
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WARNING
Maximum occupancy is limited to six people (including the driver) in the GEM
e6®, four people in the GEM e4 and two people in the GEM e2, GEM eS, GEM eL,
and GEM eL XD. Overloading can result in an accident which could cause death
or serious injury.
WARNING
• A belt that is buckled into the wrong latch will not funcon or protect you
properly. The lap poron of the safety belt could ride too high on your body,
possibly resulng in death or serious injury. Always buckle your safety belt
into the latch nearest you.
• A safety belt that is too loose will not funcon properly. In a sudden stop,
you could jerk too far forward, increasing the possibility of injury. Wear your
safety belt snugly.
• A belt that is posioned under your arm is very dangerous. Your body could
strike the inside surfaces of the vehicle in a collision, increasing the possibility
of injury. A belt worn under the arm can cause internal injuries. Wear the belt
over your shoulder.
• A shoulder belt placed behind you will not protect you from injury during a
collision. The lap and shoulder belts are to be used together
.
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SEAT BELTS AND PREGNANT WOMEN
We recommend that pregnant women use seat belts throughout their
pregnancy. Keeping the mother safe is the best way to keep the
baby safe.
Pregnant women should wear the lap part of the belt across the
thighs and as snug across the hips as possible. Keep the belt low
so that it does not come across the abdomen. That way the strong
bones of the hips will take the force if there is a collision.
SEAT BELT EXTENDER
If a seat belt is too short, even when fully extended and when the
adjustable upper shoulder belt anchorage (if equipped) is in its lowest
position, your dealer can provide you with a seat belt extender. This
extender should be used only if the existing belt is not long enough.
When it is not required, remove the extender and store it.
WARNING
Using a seat belt extender when not needed can increase the risk of death or serious injury in an accident. Only use when the seat belt is not long enough when it
is worn low and snug, and in the recommended seang posions. Remove and
stow the seat belt extender when not needed.
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CHILD RESTRAINT
Everyone in your vehicle needs to be buckled up at all times - babies
and children, too. Every state in the United States and all Canadian
provinces require that small children ride in proper restraint systems.
This is the law, and you can be prosecuted for ignoring it.
Children 12 years and under should ride properly buckled up in a
rear seat, if available. According to crash statistics, children are safer
when properly restrained in the rear seats, rather than in the front.
There are different size and types of restraints for children from
newborn size to the child almost large enough for an adult safety belt.
Always check the child seat owner’s manual to ensure you have the
correct seat for your child. Use the restraint that is correct for your
child.
WARNING
In a collision, an unrestrained child, even a ny baby, can become a missile inside
the vehicle. The force required to hold an infant could become so great that you
could not hold the child, no maer how strong you are. The child and others could
be seriously injured or killed. Any child riding in your vehicle should be in a proper
restraint for the child’s size.
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INFANTS AND CHILD RESTRAINTS
Safety experts recommend that children ride rearward-facing in the
vehicle until they are at least one year old and weigh at least 20 lbs (9
kg). Two types of child restraints can be used rearward-facing: infant
carriers and “convertible” child seats.
The infant carrier is only used rearward-facing in the vehicle. It is
recommended for children who weigh up to about 20 lbs (9 kg).
“Convertible” child seats often have a higher weight limit in the
rearward-facing direction than infant carriers do, so they can be used
rearward-facing by children who weigh more than 20 lbs (9 kg) but are
less than one year old. Both types of child restraints are held in the
vehicle by the lap/shoulder belt. This vehicle is not equipped with a
“latch” child restraint anchorage system. The lap/shoulder belt must
be used to secure both types of child restraints into the vehicle.
WARNING
Improper installaon can lead to failure of an infant or child restraint. It could
become loose in a collision. The child could be seriously injured or killed. Follow
the manufacturer’s direcons exactly when installing an infant or child restraint.
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TIPS FOR GETTING THE MOST OUT OF YOUR CHILD RESTRAINT
• Before buying any restraint system, make sure that it has a label certifying
that it meets all applicable Safety Standards. The manufacturer also
recommends that you try a child restraint in the vehicle seats where you
will use it before you buy it.
• The restraint must be appropriate for your child’s weight and height.
Check the label on the restraint for weight and height limits.
• All passenger seat belts are equipped with cinching latch plates.
• Seat belts are designed to keep the lap portion tight around the child
restraint so that it is not necessary to use a locking clip. If the seat belt
has a cinching latch plate, pulling up on the shoulder portion of the lap/
shoulder belt will tighten the belt (the cinching latch plate will keep the belt
tight, however, any seat belt system will loosen with time, so check the
belt occasionally and pull it tight if necessary).
• In the rear seat, you may have trouble tightening the lap/shoulder belt on
the child restraint because the buckle or latch plate is too close to the belt
path opening on the restraint. Disconnect the latch plate from the buckle
and twist the short buckle-end belt several times to shorten it. Insert the
latch plate into the buckle with the release button facing out.
WARNING
An improperly installed child restraint may fail to secure the child and result in
serious injury or death. Always follow the instrucons that come with the restraint.
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• If the belt still cannot be tightened, or if pulling and pushing on
the restraint loosens the belt, disconnect the latch plate from the
buckle, turn the buckle around, and insert the latch plate into the
buckle again. If you still cannot make the child restraint secure, try
a different seating position.
• Buckle the child into the restraint exactly as the manufacturer’s
instructions tell you.
• When your child restraint is not in use, secure it in the vehicle with
the seat belt or remove it from the vehicle. Do not leave it loose
in the vehicle. In a sudden stop or collision, it could strike the
occupants or seat backs and cause serious personal injury.
NOTE: For additional information refer to www.seatcheck.org or call
1-866-SEATCHECK.
OTHER CHILDREN AND CHILD RESTRAINTS
Children who weigh more than 20 lbs (9 kg) and who are older than
one year can ride forward-facing in the vehicle. Forward-facing child
seats and convertible child seats used in the forward-facing direction,
are for children who weigh 20 to 40 lbs (9 to 18 kg), and who are older
than one year. These child seats are also held in the vehicle by the
lap/shoulder belt.
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The belt-positioning booster seat is for children weighing more than
40 lbs (18 kg), but who are still too small to t the vehicle’s seat belts
properly. If the child cannot sit with knees bent over the vehicle’s seat
cushion while the child’s back is against the seat back, they should
use a belt-positioning booster seat. The child and belt-positioning
booster seat are held in the vehicle by the lap/shoulder belt.
CHILDREN TOO LARGE FOR BOOSTER SEATS
Children who are large enough to wear the shoulder belt comfortably,
and whose legs are long enough to bend over the front of the seat
when their back is against the seat back, should use the lap/shoulder
belt in a rear seat.
• Make sure that the child is upright in the seat.
• The lap portion should be low on the hips and as snug as pos-
sible.
• Check belt t periodically. A child’s squirming or slouching can move
the belt out of position.
• If the shoulder belt contacts the face or neck, move the child closer
to the center of the vehicle. Never allow a child to put the shoulder
belt under an arm or behind their back.
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Not all child restraint systems will be installed as we have described
here. Again, carefully follow the instructions that come with the child
restraint system.
TRANSPORTING PETS
Pets should be restrained in the rear seat in a pet harness, or in a pet
carrier that is secured by seat belts.
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2
3
1
4
Figure 13 - Upper Dash
2. Glove Box Door
3. Package Tray
4. Glove Box Lock
The glove box (Figure 13), is located on the top center of the upper
dash and is equipped with a lock to protect against theft or damage.
The upper dash also contains a package tray and four cup holder
locations. Your ignition key will lock and unlock the glove box. Turn
1/4 turn counter clockwise to unlock.
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Electrical wiring, circuit boards and components are located under
and behind the upper and lower dash.
NOTICE
Liquids can damage electrical components and the circuit board. Handle liquids
with care. Do not spray water directly into the upper or lower dash.
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REAR ACCESSORY OPTIONS
1
2
3
Figure 15 - TrunkBackTM
Figure 17 - Clip-In StakeBack
GEM Owner’s Manual - Page 56
Figure 16 - LinksBack
TM
TM
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1. Release Handle - Your ignition key opens this lock, always lock after
changing optional accessory backs.
2. Cover
3. Cover Lock - There is a separate key for this lock.
Rear accessories options are available from your dealer and they are
interchangeable.
NOTICE
Use only GEM approved rear accessories. Others may cause damage to the
locking system or vehicle, and will void warranty.
CAUTION
DO NOT OVERLOAD
When releasing the back latch, make sure the safety strap is secure prior to turning
the release handle. The rear accessories can fall suddenly and cause injury or
damage to the vehicle if the safety strap is not used.
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As the picture shows on page 56, the release handle is located on the
back panel, just below the rear window opening ledge.
To remove or install rear accessories:
1. Remove contents of rear accessory.
2. Steady it to prevent it from falling.
3. Unlock the release handle with ignition key.
4. Rotate the release handle clockwise to release.
5. Remove the safety strap.
6. Lift off the GEM car.
7. Position the new rear accessory onto the brackets and refasten the
safety strap.
8. Push forward to engage lock. Test to make sure it is secure. This is
a two stage locking system. If not secure, repeat procedure.
9. Lock the release handle with ignition key.
NOTICE
Keep the back latch in a locked posion when operang or transporng the vehicle.
The rear accessory could fall and cause injury if the safety strap is not used.
WARNING
The capacity of the back is not intended for any type of passenger use. Doing so
could result in death or serious injury.
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HAZARD WARNING FLASHERS
Your vehicle’s hazard warning asher is an emergency warning
system. When you activate it, all front and rear directional signals
will ash intermittently. Use it when your vehicle is disabled on or
near the road. It warns other drivers to steer clear of you and your
vehicle. This is an emergency warning system, not to be used when
the vehicle is in motion.
To activate the warning ashers, press the button on the lower switch
bank (below climate controls). To turn the warning ashers off, press
the button again.
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HEATED SEATS
Heated seats provide comfort and warmth on cold days and can
help soothe sore muscles and backs. For 2-passenger vehicles, the
front driver and passenger seats are heated. For 4-passenger and
6-passenger vehicles both front and second row seats are heated.
The front heated seat switches are located on the lower dash. The
rear heated seat switches are located directly below the rear of the
front seat backrests. After keying on the vehicle, you can choose seat
heating levels of High, Medium, Low, or Off. Pressing the switch once
selects High. Each successive switch press decreases the heat level
to Medium, Low, and Off respectively. The heated seat system has an
additional safety feature that automatically shuts off the seats 1 hour
after turning them on.
1 - heated seat switches.
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WARNING
Persons who are unable to feel pain to the skin because of advanced age, chronic
illness, diabetes, spinal cord injury, medicaon, alcohol use, exhauson, or other
physical condions must exercise care when using the seat heater. It may cause
burns even at low temperatures, especially if used for long periods of me.
Do not place anything on the seat that insulates against heat, such as a blanket or
cushion. This may cause the seat heater to overheat.
STEREO SYSTEM
The optional stereo system is mounted in an overhead console for your
convenience and features speakers, FM radio, a CD player and has MP3
capabilities. Refer to your stereo system’s User’s Manual for detailed
operating instructions.
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PUBLIC ADDRESS SYSTEM
The optional Public Address (PA) System features a heavy-duty microphone, speaker,
and a four-tone siren. Refer to your PA system user’s manual for detailed operating
instructions.
CHROME FRONT & REAR BUMPERS
The chrome bumpers are for appearance only and will protect the body panels from
minor dents and scratches in some parking maneuver situations. They will not provide
any protection to the vehicle in front or rear collisions.
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RUGGED BUMPERS
The rugged bumpers will protect the body panels for minor dents and
scratches in some parking maneuver situations. They will not provide
any protection to the vehicle in front or rear collisions.
NOTICE
The bumpers are not designed for pushing or towing purposes. Damage to the
vehicle may result.
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GRAB HANDLE PACKAGE
Grab handles can be added at each seat position to assist you in
entering and exiting your GEM car. The interior grab handles are not
intended to retain passengers in the vehicle. Seat belt must be worn
at all times.
VALET BAR
This removable valet bar mounts above the rear seat giving you the
ability to transport clothing on hangers inside the vehicle.
GEM Owner’s Manual - Page 64
NOTICE
Do not overload. Hanging loads
must never exceed 100 lbs.
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SOFT DOOR OPERATION
From either inside or outside the vehicle, locate the zipper at the
bottom front or mid rear of each door. Unzip the door to open. The
door can be held in the open position using the straps and snaps
located on the pillars/door supports.
ENCLOSED CARGO CARRIER OPERATION
To open, insert key and turn lock, pull out and twist T-handle. To
close, reverse the process.
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FRAMED CANVAS DOOR OPERATION
To open the doors from outside the vehicle, locate the knob and
slide in the direction of the arrows (1). To open doors from inside the
vehicle, locate the mid-center nylon strap (2) and pull towards the
front of the vehicle.
To open windows, locate the zipper and unzip to desired position.
The window can be stored in the open position by securing with the
nylon straps and snaps.
1
2
WARNING
The doors, hard or soft, do not offer structural protection in the event of an accident and do not change the open body characteristics of the vehicle. The doors
only provide protection from the weather. Always use seat belts. Failure to use
standard seat belts puts the driver and passengers at greater risk of serious injury
or death in an accident.
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STEERING COLUMN LOCK OPERATION
To lock, turn the key forward (clockwise) while turning the steering
wheel until you feel the lock/key set into place, then remove the key.
To unlock, insert the key and turn it backwards (counterclockwise).
ADjUSTABLE TILT STEERING COLUMN OPERATION
To operate pull the lever to the left of the column backward toward
the driver to release the tilt column and push it forward away from the
driver to the dashes to lock the tilt in the desired location.
*Left Hand Drive Model Shown.
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DOME LIGHT OPERATION
The dome light is turned on or off by pressing the button (1) located on
the side of the light. The dome light is powered by 4-AA batteries. To
replace the batteries, remove the light cover and install new batteries
per the illustration inside the battery compartment.
1
HEATER/DEFOGGER OPERATION
The heater/defogger unit can be used to provide vehicle passenger
heat, as well as to assist in defogging the windshield. To operate,
move the switch (1) located on the dash of the vehicle to the “On”
position. Adjust the airow to the windshield as needed using the
deectors (2) located on the top of the dash.
1
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WINDSHIELD WASHER OPERATION
The windshield washer can be used with the windshield wipers to
remove dirt and debris from the vehicles windshield. To operate
the washer, rst turn on the windshield wipers, then press in on the
turn signal lever (1). The washer reservoir (2), located in the motor
compartment should be checked for uid levels at regular intervals.
Fill the reservoir with windshield antifreeze (not radiator antifreeze)
rated for -25°F (-31°C). Operate the system for a few seconds to
ush out the residual water. To ll, remove the cap (3) and ll with
windshield washer uid.
3
2
1
WARNING
Commercial windshield washer solvents are ammable. They could ignite and
result in serious injury or death. Care must be exercised when lling or working
around the washer soluon.
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HIGH/LOW BEAM HEADLIGHT OPERATION
The high/low beam headlights (1) are operated by moving the
headlight switch (2) located on the steering column to the low beam,
down position, or the high beam, up position. To turn off the lights,
move the switch to the “Off” center position.
2
1
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ACCESSORY OUTLET
Figure 17 - Accessory Outlet
1. Accessory Outlet
1
The optional accessory outlet (Figure 17) is located on the lower dash,
to the right of the fuse access panel. This outlet will accept a standard
automotive 12-volt accessory outlet and is intended for moderately
powered accessories, such as a cellular phone. It will not operate large
current items, such as cigarette lighters.
NOTICE
Damage to electrical components may occur from improper use.
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ACCESSORY OUTLET CONTINUED
NOTICE
• Do not plug in devices requiring power exceeding 25 was.
Damage to the vehicle electrical system may occur or an
accessory fuse may blow.
• The fuse for the power outlet plug is located in the fuse block
under the access panel in the center of the lower dashboard.
Always use fuses with the same type and rang.
• Power outlets are designed for accessory plugs only. Do not
hang any type of accessory or accessory bracket from the
plug.
Turn lights on for several seconds, then turn key
switch off, and back on again.
Need to charge batteries before operating.
Pedal depressed and no direction is
selected.
Release pedal and insure direction switch is
locked into a position.
06
Operation and Maintenance
BASIC OPERATION
Basic procedure of how to operate the vehicle.
1. Unplug the electrical charge cord from the front of the vehicle.
2. Fasten safety belts and adjust mirrors as necessary.
3. Turn key ‘On’.
4. Depress brake pedal and move direction switch to desired position.
5. Release parking brake.
6. Release brake pedal.
7. Press accelerator pedal and go.
WHAT TO DO IN EMERGENCIES
Error Code Summary and Explanation
Error codes are used in the control system to indicate conditions that
prevent the vehicle from operating. All error codes are accompanied by the
service icon. The chart shown below summarizes the most frequent error
codes and remedies.
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NOTE:If any other codes are present, contact your GEM car Dealer or
Customer Service at 1.866.764.0616 for assistance.
TRANSPORTING YOUR VEHICLE
The best way to transport your vehicle is in an enclosed trailer. If it is necessary
to transport your vehicle on an open trailer, follow these guidelines:
1. Never transport your vehicle while the vehicle is facing rearward on the
trailer.
2. With the vehicle facing forward, pull the trailer at speeds of 65 MPH or
less.
4. If your vehicle is equipped with hard doors, put all windows down.
5. Secure any items that could be affected by airow through the vehicle.
6. Do not secure across any plastic body or oor panel component of the
vehicle. Use tie down points on the frame identied with an “X” as shown
on page 97.
NOTE: GEM is not responsible for damage incurred or lost items due to vehicle
towing.
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NOTICE
TOWING THE VEHICLE IS NOT RECOMMENDED. This vehicle is not designed
for dolly towing. Any vehicle failures resulng from dolly towing will void
warranty.
BASIC MAINTENANCE
WARNING
The main disconnect switch should be turned o before any vehicle maintenance
is started. Failure to do so could result in death or serious injury.
Battery Charging
The Main Disconnect Switch must be ‘On’ before charging the
batteries.
The type of batteries used in the vehicle will perform better when kept
fully charged. Therefore, whenever possible, recharge the batteries.
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The GEM car has a battery control and recharge system specially designed
for electric vehicle usage. Depending on the model and options of your GEM,
it may be equipped with Flooded-wet cell or valve regulated Gel type lead
acid batteries. There are also two possible battery placement congurations.
The standard conguration consists of 6, 12-volt batteries with 2 of the
batteries located under the battery access cover on the bed of the GEM eS,
GEM eL, GEM eL XD, and GEM e6® models (see page 84), or under the
maintenance plate on the rear spat of the GEM e2, GEM e4, and GEM e6®
models, with the other 4 batteries located under the bench seat on all models.
The optional conguration, available on the GEM e6® and the GEM eL XD
models, consists of nine, 8-volt batteries. On the GEM eL XD model, 6 of
these batteries are located under the bench seat, with the remaining 3 located
under the access panel located on the bed. On the GEM e6® model, 3 of
the batteries are located under the middle seat pedestal, with access through
the panel located on the front of that pedestal. 3 more batteries are located
under the rear bench seat, with the nal 3 batteries located under the access
panel on either the rear bed or rear spat. The charging system is designed
to maximize the battery pack life while recharging the pack in the shortest
time with available household current (ground fault protected 110-volt, 15amp, A/C outlet). The following guidelines will insure that you receive the
maximum battery life and performance out of your GEM car. Because of
the high power draw at low states of battery charge, the AC outlet should be
dedicated only to recharging your GEM battery-electric vehicle.
GEM Owner’s Manual - Page 77
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Operation and Maintenance
• New batteries will not perform to their fullest capacity until they have
been discharged and recharged 20 to 30 times. Batteries should be
fully charged before the rst use.
• When recharging, it is preferable to have the battery pack at room
temperature. Do not charge at temperatures of 110°F or higher.
• Batteries should be charged after each use, if possible.
• In the rst few years of life, your batteries should provide a range of
up to 30 miles at 72°F. At 32°F, your range may be reduced to 1215 miles. This is a normal characteristic of electric vehicles. Your
actual range my be affected by road conditions, terrain, weather, and
driving habits.
• Always wear safety glasses or approved eye protecon when servicing the
vehicle. Wear a full-face shield and gloves when working with or around
baeries and electrical connectors.
• Always use insulated tools when working with or near baeries.
Failure to follow these instrucons could result in death or serious injury.
GEM Owner’s Manual - Page 78
WARNING
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Operation and Maintenance
WARNING
• Baery uid is a corrosive acid soluon and can burn or blind you.
• Do not allow baery uid to contact eyes, skin or clothing. If acid splashes
in eyes or on the skin, ush the area immediately with large quanes of
water.
• Baery gas is ammable and explosive. Keep ame or sparks away from the
baery or any other booster source.
• Do not allow baery cable clamps to touch each other.
• Baery posts, terminals and related accessories contain lead and lead
compounds. Wash your hands aer handling.
Failure to follow these instrucons could result in death or serious injury.
CAUTION
It is essenal, when replacing the cables on the baeries that the posive cable is
aached to the posive post (+) and the negave cable is aached to the negave
post (-). Baery posts are idened on the baery case as posive (+) and negave
(-). Cable clamps should be ght on the terminal posts and free of corrosion.
NOTICE
If the baeries are replaced, make sure they are the exact type and make originally
supplied with the vehicle. Using incorrect baeries can result in damage to the
vehicle’s electrical system.
GEM Owner’s Manual - Page 79
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Operation and Maintenance
BATTERY CHARGER
The battery pack should be charged whenever convenient and no matter the
state of charge. If no green bars are lit, the battery pack should be put on charge
as soon as possible. A full recharge cycle (state of charge showing only 1 red
bar) can take 8 hours or more for standard battery pack, and up to 14 hours
for heavy duty battery pack. Most recharge cycles will be shorter.
NOTICE
• Fully charge batteries before storing.
• In hot climates, battery self-discharge will increase.
• In cold climates, batteries could freeze if not properly charged.
• If the vehicle will not be used for 10 or more days, unplug the car, turn
the main disconnect switch ‘OFF’ and arrange for monthly charging,
OR leave the car plugged in and the main disconnect switch ‘ON’, (only
up to 24 weeks).
Baeries can be permanently damaged (and the warranty voided) if allowed
to remain 30 days or more with low charge.
GEM Owner’s Manual - Page 80
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Operation and Maintenance
BATTERY CHARGE RECEPTACLE
1
Figure 18 - Charging Receptacle
Charging Receptacle
The Battery Charge Receptacle (Figure 18), is located on the hood. It accepts a standard,
3 wire, grounded, extension cord and should not exceed the following:
• 12 gauge wire with three wire grounded; 50 feet or less in length.
• 14 gauge wire with three wire grounded; 25 feet or less in length.
NOTE: Never use less than 14 gauge cord or cord longer than 50 feet to charge your
GEM car. Using a GFI type cord on a GFCI protected outlet is not recommended and
may not allow the charger to operate efciently.
WARNING
Use the correct gauge extension cord as dened above. An incorrect gauge extension
cord could result in a re, heat damage or charger failure and result in death or
serious injury.
Insert the proper grounded extension cord into the battery charger receptacle (Figure
18), and then plug into a 110-volt A/C, 15 amp breaker outlet. A GFI (Ground Fault
Interrupt) receptacle is recommended. An optional GEM GFI cord set is available from
your GEM Dealer or Customer Service if you do not have a GFI receptacle at your
regular recharge site.
Periodically check extension cords for cut, abrasive or loose connections. Never leave
extension cords in standing water. Do not drive over extension cords.
GEM Owner’s Manual - Page 81
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Operation and Maintenance
BATTERY CARE
Your GEM car is equipped with either six 12-volt Gel batteries, six 12-volt
Flooded batteries, or nine 8-volt Gel batteries. All types are shown in Figure
19.
Figure 19 - Gel and Flooded Batteries
NOTICE
Each vehicle is programmed at the factory for a parcular baery type. Switching
baery types should only be done by a GEM factory-trained technician.
GEM Owner’s Manual - Page 82
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Operation and Maintenance
Flooded Battery Fill Well
2
Figure 20 - Fill Wells of ooded battery
1. Bottom of Fill Well
2. Fill Cap
Top of Battery
Battery Plates
1
Each battery contains 6 screw out ll caps to expose the uid wells.
Figure 20 shows one cap removed to show the ll wells.
*See Page 86 for lling instructions
NOTE:
free.
Gel batteries do not have ll wells, as they are maintenance
GEM Owner’s Manual - Page 83
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Operation and Maintenance
Battery Location for the GEM e4, GEM eS, GEM eL,
and GEM eL XD Models
Four of the batteries are located under the bench seat and two of the six
batteries are located under the battery access cover in the center of the bed.
The battery access cover, as shown in Figure 21, can be removed by unscrewing
four fasteners
#8 X 3/4” Phillips Flat
Head, Type-A
.
Figure 21 - Short Back Bed Battery Access
GEM Owner’s Manual - Page 84
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Operation and Maintenance
Battery Location for the GEM e2, GEM e4,
and GEM e6® Models (Standard)
On the GEM e2 and GEM e4 models four batteries
are under the seat and two of the six batteries are
located under the maintenance plate located in
the center of the rear spat. It may be necessary
to remove any rear accessory options before
removing the cover.
To keep batteries in good working condition, follow
the maintenance schedule listed below and discussed on pages 86-88.
Monthly Battery Maintenance
1.Checkwaterlevel(oodedonly)
Figure 22 - Spat
Battery Access
2. Wash tops and terminals of batteries and allow to dry
3. Check terminal connections
4. Check battery hold down bar to insure
batteries are tightly secured
5. Check for worn insulation or frayed wires
NOTE: For more information or if a problem exists, contact Global Electric
Motorcars Customer Service at 866.764.0616.
GEM Owner’s Manual - Page 85
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Operation and Maintenance
BATTERY MAINTENANCE
WARNING - HIGH VOLTAGE
The baery pack is at a high voltage. High voltage is always present at the baery
terminals. Never touch the baery terminals when performing monthly baery
maintenance procedures. Failure to follow these direcons may result in death
or serious injury.
1. The water level in the ooded batteries should be checked monthly, or more
frequently with heavy usage. The level should be in between the battery
plates and the bottom of the ll well (see page 83). The battery plates
should be visible when looking into the ll well. If not, use a ashlight. Add
(distilled) water only after charging unless the water level is below the top
of the battery plates. In this case, add just enough distilled water to cover
the plates, charge then recheck the level.
NOTICE
Never charge baeries if plates are exposed above water level.
NOTICE
Baery acid from cleaning baeries can damage driveway or garage oor.
GEM Owner’s Manual - Page 86
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Operation and Maintenance
NOTE: For best battery life, add only distilled water.
2. Make sure the battery caps are rmly in place after maintenance and before
washing. (See step 3)
3. Batteries should be kept clean and free of corrosion. Wash the tops and
terminals of batteries with a solution of baking soda and water (1 cup baking
soda per gallon of water) once per month. Review the instructions on pages
76-80.
NOTE: Do not allow the cleaning solution to enter the battery.
4. Be sure battery terminals are tight. If just cleaned, let terminals dry, and
spray them with battery anti-corrosion spray.
WARNING
Improper handling of high voltage wiring, baeries, or control systems could result
in serious injury or death by electric shock. Only qualied technicians should repair
or access high voltage wiring, baery packs, and associated systems.
GEM Owner’s Manual - Page 87
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Operation and Maintenance
WARNING
If baery cable terminals are damaged or corroded, they should be replaced or
cleaned as necessary. Failure to do so may cause them to overheat during opera-
on, possibly leading to re which may result in death or serious injury.
5. The battery hold down bars should be snug to keep batteries from moving
while the vehicle is in motion, but not so tight as to crack or buckle the battery
case. Make sure the lynch pin is in the proper position and locked.
6. Worn insulation, frayed cables, or damaged cable ends should be replaced
immediately by a GEM factory-trained technician.
NOTE: After each use, the batteries should be charged. The batteries should
never be left discharged.
BATTERY DISPOSAL
Lead-acid batteries are recyclable. Return whole scrap batteries to distributor,
manufacturer or lead smelter for recycling. For neutralized spills, place
residue in acid-resistant 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 ofcials regarding
disposal information. You can also contact Customer Service at 866-764-0616
for information.
GEM Owner’s Manual - Page 88
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Operation and Maintenance
BATTERY CARE DURING STORAGE
To allow for extended storage time, your GEM car has several features
to enhance battery life.
A fully charged vehicle can be stored (with the ignition key in the ‘OFF’
position), for up to 10 days. It will lose some of its charge during this
period.
When storing, or not using, your GEM car for an extended period of
time, (two weeks or longer) it is recommended that you rst check the
water level of your batteries, unless equipped with maintenance free
gel batteries, and leave the vehicle plugged in with the Main Disconnect
Switch in the ‘ON’ position. The charger will monitor the state of charge
of the batteries, and will initiate a charge cycle whenever the batteries
fall to a pre-determined charge level, for up to 24 weeks.
NOTE: In the case that the GEM car can not be left plugged in for
extended periods of time, the recommended method is to check the
water level of ooded batteries, charge the car to 100% and then
turn the MDS to the ‘OFF’ position. When storing your vehicle in this
condition for 30 days or more, it is necessary that arrangements are
made to have the vehicle recharged every 30 days while in storage.
To eliminate battery charge loss due to component current drain, or if
the vehicle will be stored for more than 10 days, the car should be fully
charged and the main disconnect switch must be turned ‘OFF’. The
main disconnect switch can be seen on page 39.
GEM Owner’s Manual - Page 89
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Operation and Maintenance
WARNING - HIGH VOLTAGE
The main disconnect switch will disable the vehicle by disconnecng the baery
pack from the motor. It does not disable the baery pack. HIGH VOLTAGE will be
present at the baery terminals.
HIGH BATTERY VOLTAGE IS ALWAYS PRESENT. DO NOT TOUCH THE BATTERY
TERMINALS.
Failure to follow these direcons may result in death or serious injury.
GEM Owner’s Manual - Page 90
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Operation and Maintenance
BRAKE FLUID LEVEL
1. Reservoir
1
2
2. Cap
3. Maximum Level Mark
4. Minimum Level Mark
The
brake uid reservoir (Figure
3
23) is located under the hood,
above and to the rear of the
4
left front tire. The uid level of
your brake system is a very
important safety component. It
should be checked according
Figure 23 - Brake Fluid Reservoir
to the Vehicle Maintenance
Schedule, on Page 104, by observing the side of the reservoir and
noting its level. The uid level should be at the maximum level mark.
If it approaches the minimum level mark, ll it with DOT3 brake uid
and see your dealer for service or call Customer Service immediately
at 866.764.0616.
NOTICE: Brake uid may cause damage to painted and nished
surfaces. Use caution when relling the brake uid reservoir.
GEM Owner’s Manual - Page 91
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Operation and Maintenance
NOTE: The vehicle is equipped with a four-wheel hydraulic braking
system.
WARNING
Use standard DOT3 brake uid. Use of any other uid may result in loss of braking
ability, leading death or serious injury.
TIRES
Proper tire ination pressure is essential to the safe and satisfactory
operation of your vehicle. Tire ination pressures are provided on your
vehicle’s VIN/Certication Label (See page 9, Figure 1).
Three primary areas are affected by improper tire pressure:
1. Safety
Under-ination increases tire exing and can result in tire failure. Overination causes a tire to lose its ability to cushion shock. Objects on the road
and potholes could cause tire damage that may result in tire failure. Unequal
tire pressure can cause steering problems.
NOTICE
After inspecting or adjusting the tire pressure always reinstall the valve stem cap-if
equipped. This will prevent moisture and dirt from entering the valve stem, which
could damage the valve stem.
GEM Owner’s Manual - Page 92
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Operation and Maintenance
2. Range
Improper ination pressures can cause uneven wear patterns to develop across
the tire tread. These abnormal wear patterns will reduce tread life resulting
in premature replacement. Under-ination increases tire rolling-resistance,
resulting in lower vehicle range.
3. Ride Comfort and Vehicle Stability
Proper tire ination contributes to a comfortable ride. Over-ination produces a
jarring and uncomfortable ride. Both under-ination and over-ination affect the
stability of the vehicle and can produce a feeling of sluggish response or over
responsiveness. Replace valve stem caps after tire maintenance to prevent
dirt from damaging valve stem or preventing the stem from closing properly.
4. Wear
Any accelerated wear of tires may be an indicator of improper alignment or poor
driving habits. If uncertain, consult your GEM service provider.
GEM Owner’s Manual - Page 93
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Operation and Maintenance
WARNING
Improperly inated res are dangerous and can cause accidents.
Overinated or under inated res can aect vehicle handling and can
•
fail suddenly, leading to an accident that may cause death or serious
injury.
• Unequal re pressures from one side of the vehicle to the other can
cause the vehicle to dri to the right or le.
Always properly inate all res.
REPLACEMENT TIRES
The tires on your new vehicle provide a balance of many characteristics. They
should be inspected regularly for wear and correct ination pressure. GEM
strongly recommends that you use tires equivalent to the originals in quality
and performance when replacement 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 dealer or Global Electric
Motorcars Customer Service regarding any questions you may have on tire
specications or capability.
GEM Owner’s Manual - Page 94
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Operation and Maintenance
WARNING
• Do not use a re size other than that specied on your vehicle’s re label.
• Improperly sized res can cause vehicle components to wear out prematurely
and may change your vehicle’s ride, handling, and steering behavior. In
addion, it may aect the accuracy of your speedometer/odometer. Using
res sized other than specied on your vehicle’s re label could cause you to
lose control resulng in serious injury or death.
• Never use a re smaller than the minimum re size listed on your vehicle’s
re label. Using a smaller re could result in re overload and failure.
• Failure to equip your vehicle with res having adequate speed capability can
result in sudden re failure and loss of vehicle control.
• Overloading your res is dangerous. Like under inaon, overloading can
cause re failure. Use res of the recommended load capacity for your
vehicle and never overload them. Failure to follow these direcons may
result in death or serious injury.
NOTE: The vehicle’s tire information can be found on the VIN/Certication
label (See page 9, Figure 1).
GEM Owner’s Manual - Page 95
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Operation and Maintenance
WARNING
Do not use a re, wheel size or rang other than that specied for your vehicle.
Some combinaons of unapproved res and wheels may change suspension dimensions and performance characteriscs, resulng in changes to steering, handling,
and braking of your vehicle. This can cause unpredictable handling and suspension
failure. You could lose control and have an accident resulng in serious injury or
death. Use only the re and wheel sizes with load rangs approved for your vehicle.
GEM Owner’s Manual - Page 96
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Operation and Maintenance
TIRE CHANGING AND jACKING AND TIE-DOWN POINTS
Figure 24 - Jacking and Tie Down Points
(X) Tie-down points for transporting your GEM car, see page 75 for
transporting vehicle.
In the event of a at tire, GEM recommends using the GEM dealer
network or Customer Service to change it, because they have the
proper equipment. Should you choose to change the tire yourself, you
need to observe the following precautions:
• Park the vehicle on a rm level surface; avoiding icy or slippery
areas.
GEM Owner’s Manual - Page 97
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Operation and Maintenance
• Set the parking brake and block both the front and rear of the tire diagonally
opposite the jacking position. For example, if the right front tire is being
changed, block the left rear wheel.
• Use a small oor style jack or low prole scissors jack only.
• Jack the vehicle only from the side of the vehicle, on the main frame rail,
at the point where the tub or oor panel support and the main frame rail
are welded (See page 97, Figure 24). Alternative locations include the rear
frame rail and the center of the front cross member.
Tire Lug Nut Torque Specication:
65 ft-lbs, or 88 N-m 12” & 13” Steel Wheels
95 ft-lbs, or 128 N-m 12” & 14” Aluminum Wheels
WARNING
Geng under a jacked-up vehicle is dangerous and may result in death or serious injury.
The vehicle could slip o 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 rst located on a at solid surface,
and is supported securely by automove jack stands or, take the vehicle to a service center
where a technician can put it on a properly adjusted hoist.
CAUTION
Jacking at any locaon other than the proper jacking points may cause major vehicle body
damage and/or personal or property damage.
GEM Owner’s Manual - Page 98
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Operation and Maintenance
FUSE ACCESS PANEL/FUSE BLOCK
The fuse block (Figure 25) is located inside the fuse access panel
(Figure 26), which is on the lower dash. The ignition key opens
the fuse access panel. To open, turn the key counterclockwise one
quarter turn.
Figure 25 - Fuse Block
Figure 26 - Fuse Access Panel
GEM Owner’s Manual - Page 99
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