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GEM eM 1400 Owner's Manual

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GEM eM
1400
™
2015 Owner's Manual
for Maintenance and Safety

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  • Page 1 GEM eM 1400 ™ 2015 Owner's Manual for Maintenance and Safety...
  • Page 2 WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death.
  • Page 3 WELCOME Thank you for purchasing a GEM by POLARIS, and welcome to our world-wide POLARIS family of recreational and utility vehicle owners. We believe POLARIS sets a standard of excellence for all recreational and utility vehicles manufactured in the world today. With our...
  • Page 4 POLARIS®, GEM® and eM™ are trademarks of POLARIS Industries Inc. Global Electric Motorcars® is a division of POLARIS. Copyright 2014 POLARIS Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS Introduction ........4 Safety .

  • Page 6: Introduction

    INTRODUCTION The GEM eM 1400 is a utility vehicle. Never operate on public roads. This vehicle does not meet National Highway Traffic Safety Administration (NHTSA) regulations for operation on public streets, roads and highways. Familiarize yourself with all laws and regulations con- cerning the operation of this vehicle in your area.
  • Page 7 INTRODUCTION WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. Special precautions must be followed when operating or servicing a battery-powered vehicle. This vehicle handles differently than other vehicles. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.

  • Page 8: Vehicle Identification Numbers

    Passenger/Tire Pressure Warning Label in the rear cargo box. See page 7. To order an extra or replacement key for your vehicle, please contact GEM customer service. See page 1. Be prepared to provide your key number and VIN. Remove the spare key and store it in a safe place.

  • Page 9: Safety

    If any label becomes illegible or comes off, contact your GEM dealer to purchase a replacement. Replacement safety labels are provided at no charge. The part number is printed on the label.
  • Page 10 • With more than one passenger, or a passenger under age twelve or who cannot comfortably reach the floor and hand holds. • With non-GEM approved accessories - they may seriously affect stability. ALWAYS: • Wear your seat belt, if equipped. Vehicle rollover could cause severe injury or death.
  • Page 11 • Tampering with or unauthorized modification of this unit could result in serious personal injury, will void the warranty, and can result in permanent damage to the vehicle. • Refer to your Owner’s Manual or contact your local GEM dealer with Battery Compartment any questions.
  • Page 12 A hard hat or helmet and approved eye protection are recommended when appropriate for working or riding conditions. GEM recommends wearing approved eye protection bearing markings such as VESC 8, V-8, Z87.1 or CE. Never operate or ride in this vehicle while barefoot or while wearing sandals or tennis shoes.
  • Page 13 • Always follow proper procedures for turning. Make turns slowly, especially when the ground is wet, greasy, bumpy or sloping. Never turn the steering wheel abruptly when driving at high speed. • Always have this vehicle checked by an authorized GEM dealer if it has been involved in an accident.

  • Page 14: Equipment Modifications

    Never install any accessory that grounds to the vehicle chassis. The chassis is a floating ground to protect against electrical short circuits and hazards. Do not install any non-GEM-approved accessory or modify the vehicle for the purpose of increasing speed or power. Any modifications or installation of non-GEM-approved accessories could create a substantial safety hazard and increase the risk of bodily injury.

  • Page 15: Protective Apparel

    A hard hat or helmet and approved eye protection are recommended when appropriate for working or riding conditions. GEM recommends wearing approved eye protection bearing markings such as VESC 8, V-8, Z87.1 or CE. Never operate or ride in this vehicle while barefoot or while wearing sandals or tennis shoes.
  • Page 16 SAFETY Operator Safety Ventilation When Charging Batteries Failure to provide adequate ventilation while charging batteries can result in an explosion. Volatile hydrogen gas is emitted during charging and may accumulate in pockets at the ceiling. • Always ensure a minimum of 5 air changes per hour in the charging area. •...

  • Page 17: Driving Through Water

    • Insulate any tools used within the battery area to prevent sparks or battery explosion caused by shorting the battery terminals or wiring. Remove the batteries, or cover the exposed terminals with an insulating material. FOR MORE INFORMATION ABOUT SAFETY PLEASE CONTACT GEM CUSTOMER SERVICE. See page 1.

  • Page 18: Features And Controls

    FEATURES AND CONTROLS Component Locations Cargo Console Charge Receptacle Tailgate Latch Releases Tailgate Taillight Reflector Receiver Hitch Headlights Front Bumper/Brush Guard...
  • Page 19 FEATURES AND CONTROLS Console 1. Steering Wheel 2. Indicator Lights 3. Key Switch 4. Direction Selector 5. Headlight Switch 6. Charge Status Indicator 7. Battery Discharge Indicator 8. Hour Meter 9. Glove Box/Storage Compartment 10. Beverage Holder 11. 12V Auxiliary Outlet 12.

  • Page 20: Hour Meter

    FEATURES AND CONTROLS Console Battery Discharge Indicator The battery discharge indicator displays the amount of charge removed (used) from fully charged batteries. When the batteries are fully charged, the gauge will display 100%. The charge status indicator will be solid green (see page 19). Avoid discharging the batteries more than 80%.

  • Page 21: Key Switch

    FEATURES AND CONTROLS Console Park Brake Lever To help prevent the vehicle from rolling, set the park brake when parking the vehicle. When the park brake is set and the park brake indicator is illuminated, motor speed is limited. If the accelerator is applied, this limiting feature prevents operation, which protects the park brake pads from excessive wear.
  • Page 22 FEATURES AND CONTROLS Console Indicator Panel Lights Indicator Panel The indicator lights activate when the key is in the ON position. Indicator Status Indicates Electrical malfunction (flash sequence on controller indicates type; see troubleshooting guide on page 21) Malfunction Steady Accelerator pedal is pressed while key is being turned on (release pedal to extinguish lamp) Charger is plugged in (vehicle will not operate when...
  • Page 23 Throttle input error Voltage protection Controller or motor out of temperature range Software fault Charge Status Indicator Troubleshooting Guide The code definitions provided are for informational purposes only. Please see your GEM dealer for diagnosis and repair. # of Code Definition Solution...
  • Page 24 • Never connect an auxiliary battery to the factory-installed DC-to-DC converter. If more than 10 amps are needed for accessories, always install the GEM-approved auxiliary accessory battery kit.
  • Page 25 FEATURES AND CONTROLS Batteries Battery Conditioning New batteries cannot initially hold all of their capacity. The approximate capacity of the battery pack increases as the number of charge cycles increases. # of Charge Cycles: Percent of Full Capacity: 100% Ambient Temperature Implications on Batteries 1.
  • Page 26 FEATURES AND CONTROLS Main Power Connector NOTICE: Damage to electrical connections Main Power and components will occur if they Connector are unplugged before the main power connector is disconnected. Always disconnect the main power connector before servicing or unplugging any electrical components.

  • Page 27: Brake Pedal

    FEATURES AND CONTROLS Brake Pedal Push the brake pedal toward the floor to slow or stop the vehicle. Apply the brakes before turning the key on. Accelerator Pedal The accelerator pedal will function only when the key is ON and the direction selector switch is set to either forward or reverse.

  • Page 28: Operation

    OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.
  • Page 29 OPERATION Driving Procedure 1. Disconnect the charging cable (if connected). 2. All riders should wear substantial footwear, long pants and a close- fitting shirt. A hard hat or helmet and approved eye protection are recommended when appropriate for working or riding conditions. 3.

  • Page 30: Driving On Slippery Surfaces

    OPERATION Driving On Slippery Surfaces WARNING Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces. Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1.

  • Page 31: Driving Uphill

    OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. Avoid excessively steep hills. 3. Keep both feet on the floor. 4. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces.

  • Page 32: Driving In Reverse

    OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5.

  • Page 33: Hauling Cargo

    MPH (8 km/h) when towing loads in rough terrain, while cornering, or while ascending or descending a hill. The GEM eM 1400 has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels.

  • Page 34: Towing Loads

    Total Hitch Maximum Load Weight Load Weight Vertical Towing (Level Ground) (15° grade) Weight Speed GEM eM 1400 1250 lbs. 850 lbs. 150 lbs. 10 MPH (567 kg) (386 kg) (68.1 kg) (16 kph) Towing the Vehicle NOTICE: When towing the vehicle, the key MUST be in the OFF position or severe motor damage will occur.

  • Page 35: Dumping The Cargo Box

    OPERATION Dumping the Cargo Box 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. 3. Set the park brake. 4. Place the direction selector in neutral. 5.

  • Page 36: Transporting The Vehicle

    OPERATION Transporting the Vehicle When transporting the GEM eM 1400 for a long distance or on public streets, always use a trailer with an approved load rating greater than the GEM eM 1400’s curb vehicle weight of 1700 lbs. (771 kg) plus any installed accessories or cargo.

  • Page 37: Winch Guide

    WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 38 WINCH GUIDE Winch Safety Precautions 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning. 14. Never attempt to winch loads that weigh more than the winch’s rated capacity. 15.
  • Page 39 WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
  • Page 40 WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY. Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable.
  • Page 41 WINCH GUIDE Winch Operation 8. Read and adhere to the following information for winch damping to ensure safe winch use. In order to absorb energy that could be released by a winch cable failure, always place a “damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, dense object.
  • Page 42 WINCH GUIDE Winch Operation 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

  • Page 43: Winch Cable Care

    WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. 1.
  • Page 44 WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.

  • Page 45: Winch Maintenance And Service Safety

    WINCH GUIDE Winch Maintenance and Service Safety WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. 1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware.

  • Page 46: Maintenance

    Perform these operations more often for vehicles subjected to severe use. D Have an authorized GEM dealer perform these services. WARNING! Improperly performing the procedures marked with a “D” could result in component failure and lead to serious injury or death. Have an authorized GEM dealer perform these services.
  • Page 47 Change every two years D Toe adjustment Inspect periodically; adjust when parts are replaced D Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. D Have an authorized GEM dealer perform these services.
  • Page 48 Transaxle Oil Change This gearbox uses a lifetime fluid. Checking the fluid level and changing the fluid is not required. Please see your authorized GEM dealer for any transaxle-related concerns. Do NOT add fluid to the transaxle unless changing the fluid. If changing the fluid, add only the recommended fluid capacity as stated in the specifications chart above.

  • Page 49: Brake Fluid

    MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 25. Brake Fluid Inspect the brake system routinely. Inspect the level of the brake fluid before each operation. WARNING! After opening a bottle of brake fluid, always discard any unused portion.

  • Page 50: Steering Wheel Inspection

    3. If there is excessive freeplay or strange noises, or the steering feels rough or “catchy,” have the steering system inspected by an authorized GEM dealer. Spring Adjustment Adjust the rear shock absorber springs by rotating the adjustment cams either clockwise or counter-clockwise to increase or decrease spring tension.

  • Page 51: Tire Tread Depth

    Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use GEM-approved size and type of tires for this vehicle when replacing tires. Tire Tread Depth Always replace tires when tread depth is 1/8"...

  • Page 52: Wheel Removal

    Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your GEM dealer. 2. Attach the wheel nuts and washers and finger tighten.

  • Page 53: Headlight Lamp Replacement

    MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Do not operate this vehicle at night or in low light conditions until the headlight is replaced.
  • Page 54 MAINTENANCE Lights Brake Lights When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. 1. Turn the key to the ON position. 2. Apply the brakes. If the light doesn't come on, check the wiring, the brake switch or the tail light assembly.

  • Page 55: Fuse Replacement

    The fuse box is located under the hood. Spare fuses are provided in the fuse box. If you sus- pect that a fuse or relay may not be working properly, please see your GEM dealer. Fuse...
  • Page 56 MAINTENANCE Batteries WARNING Battery posts, terminals and related components contain lead and lead compounds, chemicals known to cause cancer and reproductive harm. Always wash your hands after touching or handling the batteries. WARNING Charging a damaged battery can result in serious injury. Never attempt to charge a frozen or bulging battery.

  • Page 57: Battery Charging

    MAINTENANCE Batteries Battery Charging When not in use, park the vehicle and connect the battery charger. The battery charge receptacle is located on the left side panel below the driver’s seat. WARNING! Failure to provide adequate ventilation while charging batteries can result in an explosion. Hydrogen gas is emitted during charging and will rise and accumulate at the ceiling.

  • Page 58: Battery Cleaning

    Contact local and/or state environmental officials regarding disposal information. You can also contact GEM Customer Service for information. See page 1.

  • Page 59: Cleaning And Storage

    NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. The best and safest way to clean your GEM vehicle is with a garden hose and a pail of mild soap and water.
  • Page 60 MAINTENANCE Cleaning and Storage Polishing the Vehicle GEM recommends the use of common household aerosol furniture polish for polishing the finish on your GEM vehicle. Follow the instructions on the container. Polishing Tips • Avoid the use of automotive products, some of which can scratch the finish of your vehicle.

  • Page 61: Removal From Storage

    MAINTENANCE Storing the Vehicle Any time the vehicle will be parked for more than a few hours, follow the recommended storage procedures: 1. Make any necessary repairs and clean the vehicle. See page 57. 2. Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 44.

  • Page 62: Specifications

    SPECIFICATIONS GEM eM 1400 Dimensions Dry Weight 1500 lbs. (680.4 kg) Ground Clearance 8 in. (20.3 cm) Length 114.5 in. (291 cm) Width 56.5 in. (143.5 cm) Height 52.5 in. (133.3 cm) Cargo Box (Inside) 51.5 x 41.75 in. (130.8 x 106 cm) Wheelbase 79 in.

  • Page 63: Troubleshooting

    SPECIFICATIONS GEM eM 1400 Brake System Brakes 4-Wheel hydraulic disc Park Brake Lever-activated mechanical park brake Suspension Front suspension Independent Macpherson struts w/5 in. (12.5 cm) travel Rear suspension Dual A-Arm w/6 in. (15 cm) travel Tire size 23x8.5-12 Tire pressure...

  • Page 64: Warranty

    25% of the cost of an approved GEM battery at a GEM dealer REGISTRATION At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to GEM within three days. Upon receipt of this registration, GEM will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement.
  • Page 65 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle, component, or part that has been altered structurally, modified, neglected, improperly maintained, or used for purposes other than for which it was designed, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts.
  • Page 66 If you purchase from a private party: If you purchase a GEM vehicle from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local GEM dealer in your country to ensure that you receive safety information and notices regarding your product.
  • Page 67 This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or in different countries. If any of the above terms are void because of federal, state, local law, all other warranty terms will remain in effect. GEM Customer Service Phone: 855-RIDEGEM (855-743-3436) Web: www.gemcar.com...

  • Page 68: Maintenance Log

    MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...
  • Page 69 MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS OR HOURS...

  • Page 70: Index

    INDEX Accelerator Pedal......25 Equipment Modifications ....12 Auxiliary 12-Volt Terminal Board .
  • Page 71 INDEX Park Brake Lever ......19 Tire Pressure ......7 Parking on an Incline .
  • Page 72 • With more than one passenger, or a passenger under age 12 or who cannot comfortably reach the floor and hand holds. • With non-GEM approved accessories - they may seriously affect stability. ALWAYS: • Wear your seat belt, if equipped. Vehicle rollover can cause severe injury or death.

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