GEM e2 2006 Owner's Manual
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GEM e2 2006 Owner's Manual

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  • Page 1 2006 Owner’s Manual...

  • Page 2: Table Of Contents

    Vehicle Identifi cation and Specifi cations ........6 Things to Know Before You Operate Your Vehicle .....12 Understanding the Features of Your Vehicle ......16 Operation and Maintenance ............45 Warranty and Customer Service ..........71 Word Index .................81 GEM Owner’s Manual - Page 1...

  • Page 3: Introduction

    About this Manual ................4 Cautions, Warnings and Notes ............5 NOTE: This manual is subject to change. For the latest version please visit www.gemcar.com, and click on the GEM Owners link at the bottom of the page. GEM Owner’s Manual - Page 3...
  • Page 4 The GEM company objective is customer safety and product satisfaction. This Owner’s Manual is designed to acquaint you with the proper and safe operation of your GEM vehicle. 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.
  • Page 5 All information and specifications in this Owner’s Manual NOTE: are current at the time of printing. However, due to GEM’s policy of continuous product improvement, we reserve the right to make changes, at any time, without written notice or obligation.

  • Page 6: Vehicle Identifi Cation And Specifi Cations

    Vehicle Identification and Specifications CONTENTS Vehicle Information ..............7 General Specifi cations ..............8 GEM Owner’s Manual - Page 6...

  • Page 7: Vehicle Information

    NOTE: Be sure to record the Vehicle Identifi cation Number in the space provided. Vehicle Identifi cation Number (VIN): __|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__|__| Key # ___________ (Stamped on Key) Optional Rear Accessory # _______________ (Stamped on Key) Date purchased: _____ /_____ /_____ GEM Owner’s Manual - Page 7...
  • Page 8 12’ 6” Wheelbase: 72 inches Curb Weight: 1080 lbs. (EMPTY) GVW: 1850 lbs. (LOADED) Available Cargo Capacity: With Hard Doors: 290 lbs.* Without Hard Doors: 390 lbs.* *Depending on the rear accessory option installed GEM Owner’s Manual - Page 8...
  • Page 9 16’ 6” Wheelbase: 102 inches Curb Weight: 1270 lbs. (EMPTY) GVW: 2200 lbs. (LOADED) Available Cargo Capacity: With Hard Doors: 180 lbs.* Without Hard Doors: 280 lbs.* *Depending on the rear accessory option installed GEM Owner’s Manual - Page 9...
  • Page 10 12’ 6” Wheelbase: 72 inches Curb Weight: 1140 lbs. (EMPTY) GVW: 1850 lbs. (LOADED) Available Cargo Capacity: With Hard Doors: 260 lbs.* Without Hard Doors: 330 lbs.* *Depending on the rear accessory option installed GEM Owner’s Manual - Page 10...
  • Page 11 16’ 6” Wheelbase: 102 inches Curb Weight: 1192 lbs. (EMPTY) GVW: 2300 lbs. (LOADED) Available Cargo Capacity: With Hard Doors: 630 lbs.* Without Hard Doors: 700 lbs.* *Depending on the rear accessory option installed GEM Owner’s Manual - Page 11...

  • Page 12: Things To Know Before You Operate Your Vehicle

    Things to Know Before You Operate Your Vehicle CONTENTS Driving and Alcohol ..............13 Safety Information ..............14 GEM Owner’s Manual - Page 12...
  • Page 13 Things to Know Before You Operate Your Vehicle DRIVING AND ALCOHOL Your ability to drive your GEM vehicle 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.

  • Page 14: Safety Information

    Follow all instructions carefully when dealing with batteries. • The batteries in the GEM vehicle are 12-volt, either fl ooded or gel batteries, specially built for electric vehicle application. Never use anything other than factory approved batteries.
  • Page 15 Only qualifi ed technicians should handle or service this vehicle. CAUTION! When checking the electrolyte level in fl ooded batteries, be careful to never touch the battery terminals. GEM Owner’s Manual - Page 15...

  • Page 16: Understanding The Features Of Your Vehicle

    Understanding the Features of Your Vehicle CONTENTS Instrument Pod ................17 Windshield Wipers ..............29 Foot Pedals ................30 Parking Brake ................31 Main Disconnect Switch .............33 Safety Belts ................34 GEM Owner’s Manual - Page 16...

  • Page 17: Instrument Pod

    1. Turn Signal/Windshield Wiper/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 four pages. GEM Owner’s Manual - Page 17...
  • Page 18 For a left turn, move the lever down until it clicks. For a right turn, move the lever up until it clicks. CAUTION! The turn signal lever is not self-canceling. After completing the turn, return the lever to the center position. GEM Owner’s Manual - Page 18...
  • Page 19 (TRIP must be lit on the display - see page 22). 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 19...
  • Page 20 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.
  • Page 21 Do not leave the key in the ‘ON’ position when not in use. Doing so will discharge the batteries. ZERO SPEED DETECT If the vehicle is moving while the key switch is on and accelerator pedal up, the electric motor will resist vehicle motion. GEM Owner’s Manual - Page 21...
  • Page 22 Understanding the Features of Your Vehicle LCD DISPLAY Figure 4 - LCD Display GEM Owner’s Manual - Page 22...
  • Page 23 Safety Belt Warning Indicator Reverse Indicator Drive-Low Setting Drive-High Setting NOT ACTIVE IN VEHICLE Headlight Indicator Service Required Indicator Right Turn Indicator Speedometer/Error Code Display NOTE: These indicators are defi ned on the next several pages. GEM Owner’s Manual - Page 23...
  • Page 24 If the high motor temperature icon is lit, your motor could be overheating. This is usually a symptom of overworking the motor. Climbing steep grades and hauling heavy loads will overheat the motor and shorten motor life. GEM Owner’s Manual - Page 24...
  • Page 25 Trip Meter/Odometer Switch section on page 19. If the Service icon is lit, an error code will be displayed at the speedometer location. See page 46 for information regarding error codes. GEM Owner’s Manual - Page 25...
  • Page 26 The percent of charge corresponding to each bar is shown below. Color % Full Charge Red (Far Left) Less Than 10 Yellow 10-20 Green 20-30 Green 30-40 Green 40-50 Green 50-60 Green 60-70 Green 70-80 Green 80-90 GEM Owner’s Manual - Page 26...
  • Page 27 The controller will eventually shut the vehicle down be- fore 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. GEM Owner’s Manual - Page 27...
  • Page 28 17 and 20 SERVICE If the Service icon is illuminated, an error code will be displayed at the speedometer location. See page 46 for a description and explanation of common error codes. GEM Owner’s Manual - Page 28...

  • Page 29: Windshield Wipers

    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. GEM Owner’s Manual - Page 29...

  • Page 30: Foot Pedals

    The accelerator pedal (Figure 6), is located on the fl 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. GEM Owner’s Manual - Page 30...

  • Page 31: Parking Brake

    Understanding the Features of Your Vehicle PARKING BRAKE Figure 7 - Parking Brake (models e2, eS, eL) Figure 8 - Parking Brake (model e4) GEM Owner’s Manual - Page 31...
  • Page 32 It may be possible to drive the vehicle with the parking brake lever engaged. Always release the parking brake lever before attempting to move the vehicle. CAUTION! Always engage the parking brake before exiting the ve- hicle. GEM Owner’s Manual - Page 32...

  • Page 33: Main Disconnect Switch

    NOTE: The main disconnect switch must be turned ‘ON’ for operation and charging. The GEM 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.

  • Page 34: Safety Belts

    SAFETY BELTS Figure 10 - Safety Belts (Bench Seat) Figure 11 - Safety Belts (Bucket Seat) 1. Belt 2. Latch 3. Buckle The GEM is equipped with safety belts for both driver and passen- gers. GEM Owner’s Manual - Page 34...
  • Page 35 • 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 matter the size of the person. GEM Owner’s Manual - Page 35...
  • Page 36 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 and not resting on your neck. The retractor will withdraw any slack in the belt. GEM Owner’s Manual - Page 36...
  • Page 37 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. GEM Owner’s Manual - Page 37...
  • Page 38 Safety belt assemblies must be replaced after an ac- cident if they have been damaged. CAUTION! Maximum occupancy is limited to four people for your GEM model e4 vehicle, and two people for your GEM models e2, eS, and eL vehicle. GEM Owner’s Manual - Page 38...
  • Page 39 Using body pressure, move forward and rearward on the seat to assure the seat adjusters are latched securely. Figure 12 - Seat Adjustment Handle 1. Seat Adjustment Handle GEM Owner’s Manual - Page 39...
  • Page 40 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. GEM Owner’s Manual - Page 40...
  • Page 41 Understanding the Features of Your Vehicle CAUTION! Liquids can damage electrical components and the circuit board. Handle liquids with care. Do not spray water directly into the upper or lower dash. GEM Owner’s Manual - Page 41...
  • Page 42 3. Cover Lock - there is a separate key for this lock. Rear accessories options are available from your dealer and they are interchangeable. CAUTION! Use only GEM approved rear accessories. Others may cause damage to the locking system or vehicle, and will void warranty. GEM Owner’s Manual - Page 42...
  • Page 43 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 personal injury. GEM Owner’s Manual - Page 43...
  • Page 44 12-volt accessory plug and is intended for moderately powered accessories such as a cellular phone. It will not operate large current items such as cigarette lighters. WARNING! Damage to electrical components may occur from im- proper use. GEM Owner’s Manual - Page 44...

  • Page 45: Operation And Maintenance

    Operation and Maintenance CONTENTS Basic Operation .................46 What to do in Emergencies ............46 Basic Maintenance ..............48 Care and Cleaning ..............68 Vehicle Maintenance Schedule ..........70 GEM Owner’s Manual - Page 45...

  • Page 46: Basic Operation

    Pedal is depressed when key is turned on. Low voltage on battery pack. Need to charge batteries before operating. Turn lights on for several seconds, then High voltage on battery pack. turn key switch off, and back on again. GEM Owner’s Manual - Page 46...
  • Page 47 Operation and Maintenance NOTE: I f any other codes are present, contact your GEM dealer or customer service 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.

  • Page 48: Basic Maintenance

    - no matter what the state of charge is at the time the charge status is started. The GEM vehicle has a battery control and recharge system especially designed for electric vehicle usage. Two of the six 12- volt fl...
  • Page 49 • Always wear safety glasses or approved eye protection when servicing the vehicle. Wear a full-face shield and gloves when working with or around batteries and electrical connectors. • Always use insulated tools when working with or near batteries. GEM Owner’s Manual - Page 49...
  • Page 50 (+) and the negative cable is attached to the negative post (-). Battery posts are identifi ed on the battery case as positive (+) and negative (-). Cable clamps should be tight on the terminal posts and free of corrosion. GEM Owner’s Manual - Page 50...
  • Page 51 • 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). GEM Owner’s Manual - Page 51...
  • Page 52 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.
  • Page 53 Operation and Maintenance BATTERY CARE Your GEM vehicle is equipped with six 12-volt Gel or fl ooded batteries. Both types are shown in Figure 19. Figure 19 - Gel and fl ooded batteries 1. Gel Battery 2. Flooded Battery CAUTION! Each vehicle is programmed at the factory for a particular bat- tery type.
  • Page 54 Each battery contains two vented caps and six fi ll wells. Figure 20 shows one vented cap removed to show the three fi ll wells. *See Page 57 for fi lling instructions NOTE: Gel batteries do not have fi ll wells, as they are maintenance free. GEM Owner’s Manual - Page 54...
  • Page 55 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 55...
  • Page 56 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 GEM Service at 866.764.0616. GEM Owner’s Manual - Page 56...
  • Page 57 48 and 49. 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. GEM Owner’s Manual - Page 57...
  • Page 58 Make sure the lynch pin is in the proper position and locked. 5. Worn insulation, frayed cables, or damaged cable ends should be replaced immediately by a GEM certifi ed technician. NOTE: After each use, the batteries should be charged. The batteries should never be left discharged.
  • Page 59 24 weeks. NOTE: In the case that the GEM vehicle can not be left plugged in for extended periods of time, the recommended method is to check the water level of fl...
  • Page 60 Customer Service immediately at 866.764.0616. CAUTION: Brake fl uid may cause damage to painted and fi nished surfaces. Use caution when refi lling the brake fl uid reservoir. GEM Owner’s Manual - Page 60...
  • Page 61 Over-infl ation 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. GEM Owner’s Manual - Page 61...
  • Page 62 REPLACEMENT TIRES The tires on your new vehicle provide a balance of many characteristics. They should be inspected regularly for wear and correct infl ation 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.
  • Page 63 Use tires of the recom- mended load capacity for your vehicle and never overload them. NOTE: The vehicle’s tire information can be found on the VIN/Certifi cation label (See page 7, Figure 1). GEM Owner’s Manual - Page 63...
  • Page 64 (X) Tie-down points for transporting your GEM, see pages 47 for transporting vehicle. In the event of a fl at tire, GEM recommends using the GEM dealer network or GEM 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: •...
  • Page 65 CAUTION! Jacking at any location other than the proper jacking points may cause major vehicle body damage. GEM Owner’s Manual - Page 65...
  • Page 66 (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 26 - Fuse Access Panel Figure 25 - Fuse Block GEM Owner’s Manual - Page 66...
  • Page 67 A sticker is attached to the inside of the fuse access panel showing the function and amp rating of each fuse as shown in Figure 27. The ‘Spare’ and ‘Heater Coil’ fuses are used for accessories. Figure 27 - Fuse Decal GEM Owner’s Manual - Page 67...

  • Page 68: Care And Cleaning

    CLEANING THE WINDSHIELD AND SUNROOF GEM recommends using GEM Windshield Cleaner and Protectant to remove normal dust and dirt, available at all GEM dealerships. A liquid household glass cleaner can also be used. Do not use abrasive cleaners on the windshield and sunroof, as they will cause scratches.
  • Page 69 Operation and Maintenance CLEANING THE SEATS To clean the seats of your GEM vehicle, use GEM Foaming All Surface Cleaner available at your local GEM dealer. Rubbing seats with warm water and a clean, damp cloth will also remove dirt. Substances such as tar, asphalt, and other soils will stain if not removed quickly.

  • Page 70: Vehicle Maintenance Schedule

    PROTECTION FROM THE ELEMENTS Covering your vehicle is optional, however, prolonged exposure to UV light may deteriorate the exterior and interior fi nish. It is recommended to protect the vehicle with a GEM Custom Vehicle Cover, available at local dealerships. MONTHLY VEHICLE MAINTENANCE MONTHLY TASKS 1.

  • Page 71: Warranty And Customer Service

    Warranty and Customer Service CONTENTS Warranty ..................72 GEM Customer Service .............77 Change of Address/Transfer of Warranty ........78 GEM Owner’s Manual - Page 71...
  • Page 72 The factory warranty for parts and labor shall include your GEM in its entirety. Battery and tires are excluded from warranty as they are warranted by their respective manufacturers.
  • Page 73 7:00 a.m. - 7:00 p.m. Monday - Thursday CST, 7:00 a.m. - 5:00 p.m. Friday CST. 1.866.764.0616 Changes by GEM in design or equipment made during the course of ownership shall not apply to any GEM vehicle previously manufactured or purchased.
  • Page 74 Warranty and Customer Service This warranty shall not apply to damage or repair costs caused by: 1) Failure to operate, maintain, and service, as specifi ed in the GEM Owner’s Manual. 2) Abuse, misuse, neglect, accident, collision, or operation other than the specifi...
  • Page 75 fi tness to the full extent allowed by law. GEM and its dealers shall not be liable for loss of use, inconvenience, lost time, commercial loss or any incidental, consequential or other damages.
  • Page 76 Global Electric Motorcars, LLC 1301 39th St. N Suite 2 Fargo, North Dakota 58102 Customer Service Hours 7:00 a.m. - 7:00 p.m. Monday - Thursday CST, 7:00 a.m. - 5:00 p.m. Friday CST. 1.866.764.0616 GEM Owner’s Manual - Page 76...
  • Page 77 Make a written list of your vehicle’s problems or the specifi c work you want done. If you’ve had an accident, or work done that is not on your maintenance log, let the service provider know. GEM Owner’s Manual - Page 77...
  • Page 78 Warranty and Customer Service CHANGE OF ADDRESS/TRANSFER OF WARRANTY Change of Address/2nd Owner Address Please copy the form on page 79 and mail to GEM at the address below, to keep records current. Transfer of Factory Warranty/On-Site Please copy the form on page 80 and mail to GEM at the address below.
  • Page 79 Vehicle Identifi cation Number (See page 7, Vehicle Identifi cation and Specifi cations section) ______________________________________________________ Last Name _________________________________________________ First Name _________________________________________________ Street Address _________________________________________________ City State Zip Code _________________________________________________ Phone # _______________________________________________________________ E-mail Address GEM Owner’s Manual - Page 79...
  • Page 80 New Owner Information _________________________________________________ Last Name _________________________________________________ First Name _________________________________________________ Street Address _________________________________________________ City State Zip Code _________________________________________________ Phone # _______________________________________________________________ E-mail Address *Contact GEM Customer Service at 866.764.0616 for transfer fees and information. GEM Owner’s Manual - Page 80...

  • Page 81: Word Index

    Word Index CONTENTS Word Index .................82 GEM Owner’s Manual - Page 81...
  • Page 82 High Motor Temp, 22-24 Change of Address or New Owner Instrument Pod, 17-28 Charge Receptacle, 52 Jacking, 64-65 Charger Connected Indicator, 22- Key(s), 7, 68 23, 26 LCD Display, 22-28 Charging, 48-52 Left Turn Signal Indicator, 22-24 GEM Owner’s Manual - Page 82...
  • Page 83 Service Assistance, 5,77 Service Indicator, 22-23, 28 Shoulder/Lap Belt, 34-38 Specifi cations, 8-11 Speedometer, 22-23, 25 State of Charge, 22-23, 26 Tire or Tires, 8-11, 61-63 Transmission, 8-11 Transporting, 47, 64 Trip/Odometer Switch, 17, 19 GEM Owner’s Manual - Page 83...
  • Page 84 Notes GEM Owner’s Manual - Page 84...
  • Page 85 1301 39th Street N, Suite 2 ■ Fargo, ND 58102 Customer Service: 866.764.0616 www.gemcar.com...

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