GEM 2881506 User manual

APPLICATION
2016 GEM e4
BEFORE YOU BEGIN
Read these instructions and check to be sure all parts and tools are accounted for.
Please retain these installation instructions for future reference and parts ordering
information.
KIT CONTENTS
This Kit includes:
REF QTY PART DESCRIPTION PART NUMBER
1 1 Solar Harness 2413186
2 1 Framed Solar Assembly 2635958
3 1 Solar Charger - 220W 4015482
4 4 Solar Mount Bracket 5261057
51 Warning Decal 7181565
6 4 Screw - M8 X 1.25 X 15 7520391
7 4 Hexagonal Nut - 0.25 - 20 7547637
8 4 Roll-In Nut - M8 X 1.25 7547806
Instr 9926536 Rev 02 2016-08 Page 1 of 6
P/N 2881506
220W SOLAR KIT

Instr 9926536 Rev 02 2016-08 Page 2 of 6
REF QTY PART DESCRIPTION PART NUMBER
9 4 Washer - 8.4 X 16.0 X1.6 7556305
10 1 Solar Panel Harness, 220W 2413671
11 13 Panduit Strap 7080138
12 2 Screw - M6 X 1.0 X 16 7518637
13 2 Nut - M6 X 1.0 7547339
14 1 T-Slot, Extrusion Cover 5522130–1610
1 Instructions 9926536
TOOLS REQUIRED
• Safety Glasses
• Torx®Set
• Metric Wrench Set
• Metric Socket Set
• Standard Socket Set and Ratchet
IMPORTANT
Your 220W SOLAR KIT is exclusively designed for your vehicle. Please read the installation instructions
thoroughly before beginning. Installation is easier if the vehicle is clean and free of debris. For your safety, and to
ensure a satisfactory installation, perform all installation steps correctly in the sequence shown.
ASSEMBLY TIME
Approximately 50 minutes
INSTALLATION INSTRUCTIONS
1. Place vehicle in “PARK”. Turn key to “OFF”
position and remove from vehicle.
2. Remove rear deck (A) of the vehicle. Disconnect
negative cable (B) from front right battery.
3. Install mounting brackets ronto the solar panel
extrusion. Torque nuts uto following specification.
TORQUE
8 ft. lbs. (11 Nm)
Keep distance 134 mm between bracket and
inside of extrusion for all four brackets as shown.

Instr 9926536 Rev 02 2016-08 Page 3 of 6
4. Drop the roll-in nuts iinto the top of the OPS
slots (two per side).
5. Mount solar panel on the vehicle using bolts y
and washers o. Torque bolts to following
specification.
TORQUE
17 ft. lbs. (23 Nm)
NOTE
220 Watt panel junction box to be toward right side of
vehicle.
Rear bracket to be 118 mm from rear roof cross
brace as shown.
6. Cover solar panels with cardboard packaging from
the kit.
7. Connect the solar panel harness ato the solar
panel connectors.
8. Use Panduit strap sto fasten solar panel
harness ato front bracket ron RH side.
9. Remove the thumb screws (C) from hood under
the charge port and pull the hood forward and
away from the vehicle.

Instr 9926536 Rev 02 2016-08 Page 4 of 6
10.Mount solar charger eto chassis frame (D) using
bolts dand nuts f. Torque nuts to following
specification.
TORQUE
8 ft. lbs. (11 Nm)
11. See the electrical connections of the solar charger
for reference.
12.Route solar panel harness ainto OPS T-slot
channel.
13.Cover solar panel harness with T–slot cover g.
14.Connect solar harness qto contactor assembly
(PN 4012818) (F) with red wire and motor
controller (PN 4015643) (E) with black wire.
15.Connect solar harness qto solar charger euse
panduit straps to hold in place.

Instr 9926536 Rev 02 2016-08 Page 5 of 6
16.Route controller terminal ring (G) from solar
charger along main vehicle harness (H) and fasten
using Panduit strap s.
17.Reconnect battery connections disconnected in
Step 2, connecting solar controller terminal ring
(G) on top of the battery connection.
18.Connect solar panel harness ato solar charger
e.
19.Ensure rear extrusion is free of dust, dirt, and
debris and install decal t.
20.Remove cardboard. Check LED to confirm
functional operation. (Ensure solar panel is in
direct sunlight).
21.Reinstall hood and rear deck.

Instr 9926536 Rev 02 2016-08 Page 6 of 6
LED Information: