2004 GEM Global Electric Motorcars Factory Service & Work Shop Manual

R 2004 and Earlier Models Tips for Proper Maintenance and Storage of your GEM Quick Reference Guide

Please refer to your Owner’s Manual for more detailed information regarding your vehicle. BASIC VEHICLE OPERATION INSTRUCTIONS: • Disconnect the Charging Cord from the vehicle before operating • Master Disconnect Switch must be in the “ON” position • Turn key clockwise to the “ON” position • Fully release the parking brake • Select driving mode (Road or Turf) • Select vehicle direction (Forward or Reverse) • Press accelerator pedal and go SERVICE CODES When the wrench icon is illuminated a service code is displayed. [04] Park brake is engaged. Fully release park brake. [06] Pedal depressed with no direction selected. Release pedal and select a direction. [15] Battery voltage is too low. Charge the vehicle for 8 to 10 hours. [16] High voltage on battery pack. Turn headlights on for 30 seconds, then turn key switch to the OFF position and then back to the ON position. *If you see other service codes please contact your dealer. When the battery icon is illuminated the vehicle’s battery state of charge is displayed. If the display reads below 25 the battery pack should be put on recharge as soon as possible. When you turn the key switch off, the hourglass icon will light up for two seconds and will display the accumulated miles or hours on the vehicle.

BATTERY CHARGING GEM vehicles have a battery control and recharge system especially designed for electric vehicle usage. The charging system is designed to maximize the battery pack life while recharging the pack in the shortest amount of time with the available household current (110-volt, 15-amp, A/C outlet). Four of the six batteries are located under the bench seat cushion and two are located under the hood. The following guidelines will ensure that you get the maximum battery life and performance out of your GEM batteries. RECHARGE VEHICLE AFTER EACH USE. NOTE: THE BATTERIES USED IN YOUR GEM WILL PERFORM BETTER WHEN KEPT FULLY CHARGED. THEREFORE, WHENEVER POSSIBLE, RECHARGE THE BATTERIES— NO MATTER WHAT STATE OF CHARGE IS INDICATED. 1. The “Master Disconnect Switch” must be in the “ON” position for the charger to operate and charge the batteries. The Master Disconnect Switch is located under the bench seat cushion. 2. The Battery Charger Receptacle is located either on the hood or on the bench seat pedestal. It accepts a standard, 3 wire, grounded extension cord. The extension cord should not exceed the following: 12-gauge wire 50 feet in length or 14-gauge wire 25 feet in length. 3. Insert the proper extension cord into the Battery Charger Receptacle. 4. Plug the extension cord into a 110- volt A/C, 15-amp breaker outlet. A Ground Fault Interupt (GFI) protected circuit is recommended. TO ENSURE PROPER CHARGING, NO OTHER CARS, APPLIANCES, DOOR OPENERS, ETC. CAN BE PLUGGED INTO THE SAME CIRCUIT. 5. A full recharge cycle can take from 8 to 12 hours (if the state of charge indicator is 30% or less). Please refer to your Owner’s Manual for more detailed information regarding your vehicle.

BATTERY TIPS & STORAGE RECOMMENDATIONS 1. Battery posts must be clean and tight. 2. If corroded, clean posts with a solution of one cup baking soda and one gallon water. 3. When storing or not using your GEM for an extended period of time (two weeks or longer) it is strongly recommended that you first charge the vehicle to 100%, then turn the Master Disconnect Switch to the “OFF” position. 4. Even with the Master Disconnect Switch off, you need to make arrangements to have the vehicle charged at least every 30 days. 5. The Master Disconnect Switch must be in the “ON” position for the charger to operate and charge the batteries. 6. If the batteries appear to be frozen, do not charge them. Contact your local authorized GEM dealer for service. TROJAN BATTERIES 1. The water level in these batteries needs to be maintained at no higher than the bottom neck opening (1/2 inch above the plates) and should be checked at least monthly. 2. If the water level is below the plates, add just enough distilled water to cover the plates, then charge and re-check the water levels. 3. If the water level is below the neck opening, but above the top of the plates, first charge the vehicle, then re-check the levels and add distilled water to just below the neck opening. Overfilling can cause the batteries to boil and spill acid. 4. Check all battery connections monthly to ensure that they are tight and free of corrosion. If corrosion starts to appear, wash the tops and terminals of batteries with a solution of one cup baking soda and one gallon water. Let terminals dry and then spray them with anti-corrosion spray. Please refer to your Owner’s Manual for more detailed information regarding your vehicle.

GEL BATTERIES There is little maintenance needed for the GEL batteries only to keep the batteries charged and the terminals clean and tight. It is recommended that you check the battery terminals at least once a month to check for corrosion. While checking the terminals, make sure that there is a tight connection between the battery cable and the battery terminal. If corrosion starts to appear, wash the tops and the terminals of the batteries with a solution of one cup baking soda and one gallon water. Let terminals dry and then spray them with anti-corrosion spray. If you regularly maintain the batteries, your GEM will run more efficiently. GEM ON-BOARD CHARGER Your GEM contains an on-board 12-amp, 72-volt charger. There is a safety feature built into the charger that will not allow it to engage if the batteries are overly discharged. This safety feature is activated when the charger detects that the combined voltage of all six batteries is 68 volts or less. If the total voltage is below 68-volts and the on-board charger will not activate, it then becomes necessary to employ an alternate charging method. Alternate Charging Method (Requires a 12-volt battery charger - not included) The alternate charging method is designed to charge each battery in the vehicle separately, using a 12-volt battery charger. During the alternative charging method it is not necessary to remove or unhook battery post connections. Turn the Master Disconnect Switch to “OFF” position. Set 12-volt charger (same as you would use to charge any 12-volt battery) to medium amp settings (10 to 40 amps). Charge each battery 10 - 20 minutes. Move quickly from battery to battery, as this is only a residual charge, and it will dissipate in a short period of time. After charging the last battery, remove 12-volt charger leads, turn on the Master Disconnect Switch and plug the vehicle in. If the on-board charger does not recognize the residual charge and activate, it may be necessary to repeat the alternative charge cycle. TIRE INFLATION Maintaining proper tire inflation pressure is essential to safe operation of your vehicle. Improperly inflated tires can also contribute to poor battery range and vehicle handling. Tire inflation pressures should be checked monthly and maintained at 30 PSI for 10” tires and 32 PSI for 12” tires. Please refer to your Owner’s Manual for more detailed information regarding your vehicle.

CLEANING INSTRUCTIONS Windshield or Sunroof We recommend using GEM Windshield Cleaner and Protectant to clean your windshield, sunroof and side windows. Normal dust and dirt can also be removed using a liquid household glass cleaner. Do not use abrasive cleaners on the windshield and sunroof, as they will cause scratches. NOTE: Be very careful when cleaning the acrylic windows as they can be scratched or damaged. Do not use a cleaner with an abrasive, a combination cleaner and wax or any solvent that contains ethyl or methyl alcohol. Also, do not use products containing ammonia, soaps or abrasives. Never use gasoline or cleaning solvent. These products can scratch and/or destroy the surface of the windows. To remove oil, grease or road tar, use isopropyl alcohol, then wash the windows with water. Dry gently with a soft cloth or chamois. Seats and Interior We recommend using GEM Foaming All-Surface Cleaner to clean your seats and interior surfaces. You can use warm water and rub with a clean, damp cloth to remove dirt. Substances such as tar and asphalt will stain if not removed quickly. Use a clean cloth and solvent-type vinyl cleaner. Then wash the area thoroughly with a damp cloth and mild liquid detergent. Finish by rinsing with cool water. NOTE: Do not spray the interior of your vehicle with water. Water contact with the windshield, dash panel or instrument panel could damage the electrical system. Exterior The best way to preserve your vehicle’s ﬁnish is to wash the vehicle regularly. Use mild liquid detergents only (no strong soaps or chemical detergents) and rinse promptly. Dry the ﬁnish with a soft, clean chamois or towel to avoid surface scratches and water spotting. To remove haze, bring back the original shine and protect the exterior surfaces of your vehicle, we recommend using GEM Fiberglass, Plastic and Rubber Restorer. NOTE: To avoid spotting, do not wash the vehicle in direct sunlight. Please refer to your Owner’s Manual for more detailed information regarding your vehicle.

GEM Notes: For more information contact GEM Service at 866.764.0616

R 1302 39th St NW Suite #2 ■ Fargo, ND 58102

2004 GEM Global Electric Motorcars Factory Service & Work Shop Manual

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