GEM eL 2005 User manual

2005 Owner’s Manual

GEM Owner’s Manual - Page 1
Introduction
CONTENTS
 About this Manual ........................................................................2
 Cautions, Warnings and Notes ....................................................3

GEM Owner’s Manual - Page 2
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).
Introduction

GEM Owner’s Manual - Page 3
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.
Introduction

GEM Owner’s Manual - Page 4
Vehicle Identification and Specifications
CONTENTS
 Vehicle Information ......................................................................5
 General Specifications .................................................................6

GEM Owner’s Manual - Page 5
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.
0001
1
0023
Vehicle Identification and Specifications
Vehicle Identification Number (VIN):
__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|
Key # ___________
Optional Pak # _______________
Date purchased: _____ /_____ /_____

GEM Owner’s Manual - Page 6
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)
Vehicle Identification and Specifications

GEM Owner’s Manual - Page 7
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)
Vehicle Identification and Specifications

GEM Owner’s Manual - Page 8
GENERAL SPECIFICATIONS
GEM eS Specifications
Motor: 72-volt shunt GE motor
Transmission: Front wheel drive direct -
couple Dana Spicer differential
Speed Control: GE solid state controller with:
* Motor thermal protection
* Battery under-voltage protection
* Regenerative brakes
* Top speed regulation
Tire: 12” Two-ply street rated tires
Battery Pack: Six 12-volt flooded or gel batteries
Secondary Power Supply: Dual output 30A DC/DC converter
On Board
Charger: Proprietary 72-volt DC charger
110-volt AC house current
Width: 55 inches
Length: 108 inches
Height: 70 inches
Turning Radius: 12’ 3”
Wheelbase: 72 inches
Curb Weight: 1140 lb.(EMPTY)
GVW: 1850 lb.(LOADED)
Vehicle Identification and Specifications

GEM Owner’s Manual - Page 9
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)
Vehicle Identification and Specifications

GEM Owner’s Manual - Page 10
ThingstoKnowBeforeYouOperateYourVehicle
CONTENTS
 Driving and Alcohol ....................................................................11
 Safety Information ......................................................................12

GEM Owner’s Manual - Page 11
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.
ThingstoKnowBeforeYouOperateYourVehicle
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.
WARNING!

GEM Owner’s Manual - Page 12
ThingstoKnowBeforeYouOperateYourVehicle
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.
WARNING!
SAFETY INFORMATION
• 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 13
The battery packs contain high voltage that could cause serious
or fatal injury if not handled properly. Only qualified techni-
cians should handle or service this vehicle, after consulting the
service manual.
WARNING!
• 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.
ThingstoKnowBeforeYouOperateYourVehicle

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

GEM Owner’s Manual - Page 15
Understanding the Features of Your Vehicle
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
Figure 2 - Instrument Pod
NOTE: Further explanation of these vehicle features are found on the next
few pages.
4
3
1
6
2
5

GEM Owner’s Manual - Page 16
Turn Signal/Windshield Wiper/Horn 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.
Understanding the Features of Your Vehicle
Figure 3 - Turn Signal Lever
The turn signal lever is not self-canceling. After
completing the turn, return the lever to the center
CAUTION!

GEM Owner’s Manual - Page 17
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 18
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 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 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 19
Understanding the Features of Your Vehicle
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.
Do not leave the key in the “ON” position when not in
use. Doing so discharge the batteries.
CAUTION!
Always bring the vehicle to a complete stop before chang-
ing the position of the vehicle direction switch.
CAUTION!
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.