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SERVICE MANUAL - GreenTechFusion.com

1. 7 1 control 0 3 5 2 5 7 10 18 3 6 22522255 ea qoe douce dando bod qaod e 7 8 dash use e eX xus 0 3 2 5 13 14 4 8 9 5 8 11 18 19 20 21 22 26 29 7 4 7 8 9 Em SEES REI RPM Ee aor t Ux eus LS 5 4 27 DC DG Converter uu bed pred Rue RU S 5 20 21 23 0 3 4 2 5 3 2 3 5 6 7 5 23 24 6 3 direction SWITCNES ea ea ec CR a ee e DC Pe OUR d T 5 4 directional indicators seda e dp I o c ed RO 5 21 27 28 d ve dde desc Sud aU abico Sed e eut feu t P ae Pat ae 3 2 Drive SY SIC DU 5 2 3 4 6 7 20 27 CNIVEMUAU Wigs wel wala 0 5 3 2 5 23 drumi Drakes di ede Deed ast etos eren den be ERA do PUR Y IUE eh dera 2 8 4 2 3 ELECTRICAL 2 13 3 6 4 10 11 5 2 5 8 11 13 15 17 19 20 21 22 23 29 7 9 WORK INDEX electronic control module
2. Kb E Re 5 4 25 ROOTA TET 7 12 13 R Turn Signal Seat Warning 5 4 25 PP METTI 7 11 eie au BOREAS dickes eae bane ores oes 0 2 2 2 5 13 15 19 6 4 5 7 11 Schott si a qos kad 5 18 19 39 7 2 Seat Adjuster Leu ee uud oce Rcg ORE ia See ee 7 8 4 b 11 12 sgat Dack E 7 3 Seat belt anchor e qe ee ne a ants ds 0 4 Seat Belt oe ak 0 3 7 2 3 seat 0 2 3 3 4 12 5 12 17 24 7 3 4 5 10 11 seatbelts resp ar e PCT 7 1 shock absorber 0 3 2 5 6 7 8 9 16 3 5 6 7 7 4 10 Shoe retalllGl ux wear ee X med rri mac mors ec ard ween we 4 5 7 shoe retention 5 8 3 rante o 4 5 7 SHOES 2252 20 4 2 3 5 6 7 8 Side Rear View 7 12 13 WORK INDEX
3. Sa ee 5 38 xut eR ORC ae eons nie 0 4 5 7 20 21 27 28 29 40 CT TULIT 5 17 27 glor 55256 rrr 7 6 TRO TT ITI TCR 0 4 5 hood Iatchi asserbDly e aro utes PAL eee RA Reb an ear e eun isa UM E Sae eke 7 7 8 HOO Stas ILT Pr 7 6 7 4 9 5 12 29 7 1 6 7 8 9 Horm BURON os adm ca ica ORCHARD DECOR ce ace CORONA RR CO AC RN RR 5 4 25 27 UP RT EMT 0 4 5 4 8 21 25 27 28 29 39 40 2 7 3 7 hydraulic brake lt 4 2 DO OL eeaeee a r ER 3 4 5 INSTRUMENT PANEL HARNESS 55 instrument pod s kh 2 11 13 5 4 6 25 26 27 29 7 9 IntrOdUctlOh ute Cd o Rc e e Ce a RC e e De CR Rp EA RC RO e 4 5 7 6 2 se als cee gre 0 5 2 8 13 14 16 4 7 5 24 po Cnr 0 4 4 5 7 PDT 2 15 16 4 11 12 E E E EN E E E E TE AES 2 6 4 2 Key 4 0 8 0 ars eae 3 2 309r on DENE 9 93 3 PEU ao
4. 0 6 2 2 3 10 4 3 25 ane FUR Ge RUPEE 2 17 18 4 2 3 5 6 7 8 Wheel SIZE 1 0 2 Wheels Pik hee ee 2 3 4 5 6 8 10 13 14 4 2 4 9 10 11 12 6 1 4 5 7 9 Windshield Wiper 5 5 4 25 E REOR 5 8 22 27 28 VOKO 0 3 2 5 7 10 16 17 18 Zivan Chafe uus uud ACH E CR eS Ra 5 18 19 42 ZIVAN HARNESS nome Te a i ct eo OR de aa ie Eo dus edet dd 5 45 SERVICE MANUAL COMMENTS What features do you find most useful What errors have you found Please include page number What topics are hard to locate confusing or not covered completely What comments or suggestions do you have Your Name Dealership Address Manual Name All comments become property of Global Electrical Motorcars L L C Please fax to 701 232 9528 mail to Global Electric Motorcars L L C 3601 7th Avenue NW Fargo ND 58102
5. 7 8 Error Codes iR hb i a bn etur Dad tratos du 5 4 6 8 20 22 26 27 fasteners forward 0 3 2 5 8 7 1 Fault Code Display iu v Ea SEA RE REX Lead 5 26 Foot Brake Pedal e tese doe sore Gok os pod X ac rgo doa Ab Past ar duc qd 5 11 frame 0 8 4 2 5 7 8 9 13 14 15 3 6 7 4 8 9 12 5 7 19 7 8 4 5 6 7 9 10 11 12 front drum Drakes ea aces ER CC are Roe one aa DC n e o 2 17 18 4 2 4 FRONT HARNESS RIERERu rari mark e eer ed RE 5 38 39 40 front SUSPENSION eere 1 Re ea 0 3 2 2 5 7 18 3 6 7 6 7 FUSE BOX 5 29 DUIS Sis acts Ar aves ects Ae Sacto 5 3 8 20 27 28 29 42 44 45 46 0566 6S CGA BERGE OR 3 2 Gross Front and Hear Axle 0 2 31056 Vehicle Weight RAUNO necks eave See wee Se 0 2 half 0 3 2 5 7 16 17 18 3 2 3 4 5 6 7 4 5 6 HEADLIGHT 55 as he quee
6. 4 Lift unit up to free legs from pockets and remove Installation 1 Set unit legs in pockets 2 While supporting unit thread Velcro strap from the underside through bracket on unit then press it onto itself 3 Rock unit forward until latch is engaged LINKSPAK SWIVELPAK LATCH ASSEMBLY Description The pack latch assembly consists of a locking handle connected to a latch by threaded rods and a turnbuckle The handle is mounted to the top of the body back panel The latch is mounted to a plate that in turn is mounted to the bench seat back body back panel support frame 0055 Figure 17 LINKSPAK SWIVELPAK Latch Assembly Locking handle Turnbuckle bracket Turnbuckle Latch assembly Velcro r safety strap 0136 Figure 18 LINKSPAK SWIVELPAK Striker Assembly 1 Velcro r safety strap 2 Latch striker 3 Latch striker bracket BODY 7 11 Operation The keyed locking mechanism in the handle prevents unauthorized unlatching of the pack unit for removal When unlocked turning the handle pulls on the threaded rods and turnbuckle to release the latch Pushing the latch bracket on the pack unit into the latch mechanism causes it to close Adjustment When turning the latch handle there should be little or no play detected before the latching mechanism disen gages the latch bar Excessive play can result in the latch ing mechanism failing to disengage when the
7. 8 Avoid charging at temperatures above 120 F Equalizing NOTE Equalization applies to flooded water based batteries only Equalizing is an overcharge performed on flooded lead acid batteries after they have been fully charged It reverses the buildup of negative chemical effects like stratification a condition where acid concentration 15 greater at the bottom of the battery than at the top Equalizing also helps to remove sulfate crystals that 9 18 ELECTRICAL might have built up on the plates If left unchecked this condition called sulfation will reduce the overall capac ity of the battery It is often recommended that batteries be equalized peri odically from once a month to once or twice per year However equalizing is recommended when low or wide ranging specific gravity 015 15 detected after fully charging a battery The on board charger in your GEM vehicle can perform a short term equalization charge After a full charge unplug the extension cord wait 20 seconds and plug back in CHARGER Description L X 0110 Figure 14 Charger Location Schott Charger shown 1 Motor Controller 2 Battery Charger 3 Printed Wiring Board PWB The Battery Charger is located under the dashboard and is an integral part of the vehicle 9see figure 13 The Battery Charge Receptacle see figure 5 15 locat ed on the front tub below the passenger seat on the tw
8. SQ seers x alates ate ake ee he ey ne oes ee Gea UE 2 8 4 11 12 7 1 4 9 10 cic Prem 5 14 15 17 18 2 14 3 2 3 4 5 6 7 8 5 25 cogi C 2 5 6 7 8 9 3 3 5 6 4 5 6 7 8 5 11 12 7 4 Spring shook aDSOIDOIS dodo case DERE ESSE qase os eue V Rede win seh eos 2 8 Steering 55525583355 each 0 3 2 3 4 5 10 13 14 15 4 9 5 29 7 9 Steering ir iUe Ree PORC ac RUE Uke ea ja 2 3 4 10 11 13 14 15 3 6 Steering shaft 0 3 2 4 5 11 12 13 14 3 6 Steering a aai e ea a aE 2 2 9 10 steering wheel GOVE BOE R AEE HE 2 11 12 Steering Wheel Pullef 24s REX print EErEE 2 11 Steering 0 3 2 4 5 10 11 12 13 14 5 26 29 Storag tiay d I Ree E N 7 9 nuce E E 7 10 SNIUBIDSE RIS RE EMEN Maori dis Get a gene NOU ME 7 4 10 11 12 tachometer os euet aes dL dI 5 4 8 10 42 44 Tall Light Harness o de ek RR hen hon ERROR CR CAO IR CRT A 5 28 46 47 ium eR ee R
9. So dA M 2 3 4 3 2 3 4 5 4 10 11 BRAKE BLEEDING 2 7 16 4 3 4 6 8 9 Drake OUI ce RR E RR cee 4 2 3 4 5 7 11 brake 0 4 2 8 4 2 3 4 5 7 9 Drake HOSES sa ck ove ers te rrr 4 3 brake light 6 4 2 8 9 brake lights e SCR 0 4 5 21 27 0 3 4 2 3 5 7 8 9 16 17 18 4 2 3 5 6 7 8 9 brake pedal 1 sss ERROR LER bebe ed AURA Peu OR AL BRAKE SYSTEM eu ehe emere UR CEN ead e aed 0 4 4 2 3 Bucket S at i ee ede re ue tied RR E 0 ded ee 0 3 7 1 2 5 DUSHINGS 5 Deae A lh diode dolebat Ru Ye dl Hated iua 2 5 6 7 8 Cable molnung DIae el RUE RR EO RU a 4 11 Charge Heceplacle iuo vo EA ORO xd ER EUR 4 10 5 4 18 Charge State se due baw Med Se rp PP PS es 5 4 25 COld ire pressure PCM C 0 2 COL OLS
10. E Global Electric Motorcars LLC DaimlerChrysler Company SERVICE MANUAL NO PART OF THIS PUBLICATION MAY BE REPRODUCED STORED IN A RETRIEVAL SYSTEM OR TRANSMITTED IN ANY FORM BY ANY MEANS ELECTRONIC MECHANICAL PHOTOCOPYING RECORD ING OR OTHERWISE WITHOUT THE PRIOR WRITTEN PERMISSION OF GLOBAL ELECTRIC MOTORCARS L L C Global Electric Motorcars L L C reserves the right to make changes in design or to make additions to or improvements in its products without imposing any obligations upon itself to install them on its products pre viously manufactured Litho in U S A Copyright 2002 Global Electric Motorcars L L C FORWARD The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair oper ations Information describing the operation and use of standard and optional equipment is included in the Owners Manual provided with the vehicle Information in this manual is divided into groups These groups con tain description operation diagnosis testing adjustments removal installation disassembly and assembly procedures for the systems and components To assist in locating a group title page use the Group Tab Locator The solid bar after the group title is aligned to a solid tab on the first page of each group The first page of the group has a contents section that lists major topics within the group If you are not su
11. 3 Attach turnbuckle bracket to handle with screw NOTE End of turnbuckle bracket where threaded eye bolt is attached must be aligned toward latching mechanism 4 Adjust latch mechanism position for proper alignment 5 Adjust turnbuckle for proper play in handle 6 Install bench seat back and cushion LINKSPAK SWIVELPAK LEG POCKET Description The LINKSPAK SWIVELPAK has two legs that fit into pockets mounted on each frame rail 0057 Figure 19 LINKSPAK SWIVELPAK Leg Pocket 1 Mounting bolt 2 Pocket 3 Frame rail Removal 1 Remove Linkspak or Swivelpak 2 Remove 2 bolts attaching pocket to upper rear frame rail 3 Remove pocket Installation 1 Position pocket on upper rear frame rail 2 Install 2 mounting bolts 3 Install Linkspak or Swivelpak MIRROR CENTER REAR VIEW Description The center rear view mirror assembly is mounted in the center of the upper windshield support It is not service able and is replaced as a unit Removal 1 Remove the 2 Phillips head screws at either end of the mounting bracket 2 Remove the Phillips head screw in the center of the mounting bracket 3 Remove the mirror assembly Installation 1 POSITION MIRROR ASSEMBLY ON UPPER WINDSHIELD SUPPORT 2 Install short 3 8 Phillips head screw in center hole of mounting bracket 3 Install 2 long 3 4 Phillips head screws in either end holes of mounting bracket MIRROR SIDE REAR VIE
12. 51 Single 207 30PSI Single THIS VEHICLE CONFORMS TO ALL APPLICABLE U S FEDERAL MOTOR VEHICLE SAFETY BUMPER AND THEFT PREVENTION STANDARDS FMVSS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE 1 2000000000000 XXXX TYPE OF VEHICLE Low Speed Vehicle LSV U S VIN Front 465KG 1 023 LBS Rear 465KG 1 077 LBS Figure 1 VIN Certification Label 0001 Figure 2 VIN Certification Location 1 VIN Certification Label Location Typical 2 passenger model shown NOTE The last six digits of the VIN are also stamped into the rear support for the bench seat cushion FASTENER USAGE Description WARNING Use of an incorrect fastener may result in component damage or personal injury INTRODUCTION 0 3 Fasteners and torque specifications references in this Service Manual are identified SAE format During any maintenance or repair procedure it is impor tant to salvage all fasteners nuts bolts etc for re assembly If the fastener is not salvageable a fastener of equivalent specification must be used NOTE Nylon lock nuts must always be replaced TORQUE SPECIFICATIONS DESCRIPTION Battery Cables to Battery Post THREAD SIZE INCH FOOT Brake line to Wheel Master Cylinder Brake Master Cylinder to Frame 5 16 18 Brake Pedal Assembly to Frame 5 16 18 Brake Pedal to Push Rod 3 8 16 Brake Drum Assembly to Steering Knuckle M8 x 1 25 Brak
13. 72 72 472 CONSTANT TO MAIN POWER TO POWER TO CONTROLLER CONTROLLER 1 1 1 6 J2 PWB 2 J6 1 J6 D M P MM gt See 6 5 2 1 PH11 ORG GRN RED GRN 17 MH5 Y 1 MH19 6 Y IP1 17 foc esas PARK GRN i BRAKE KEY SWITCH CHARGER 0020 ELECTRICAL 5 37 MOTOR CIRCUIT PWB pL M TED IIT AH LCD EUN TEE PH D Mm 1 1 1 1 POWER TO POWER TO POWER TO i START SWITCH DIRECTION SWITCH TURF SWITCH 1 1 i 9 J2 10 J2 15 J2 ER P 2 9 10 MH10 15 MH10 BLU WHT BLU WHT WHT MH19 10 MHS arem 10 Y IP1 14 Y 1 1 BLU ACCELERATOR FOOT PEDAL BLU WHT WHT E 1 START SWITCH FORWARD TURF ee PEDAL UP 1 BLU YEL GRY YEL VIO YEL OR GRN BLK WHT AI Je A Jet 197 MH5 207 MH5 187 MH5 4 6 7 MH198 MH19 OR YEL BLK VIO WHT VIO BLU YEL GRY YEL VIO YEL
14. Batteries power the motor Motor speed is controlled by an accelerator pedal potentiometer The motor is con nected to a differential The power is transferred from the differential through two constant velocity CV drive shafts half shaft to the wheel hubs The half shafts are identical and interchangeable NOTE For instructions on motor and accel erator replacement repair see section 7 During straight ahead driving the differential pinion gears do not rotate on the pinion mate shaft This occurs because input torque applied to the gears is divided and distributed equally between the two side gears When turning corners the outside wheel must travel a greater distance than the inside wheel to complete a turn The difference must be compensated for to prevent the tires from scuffing and skidding through turns To accomplish this the differential allows the axle shafts to turn at unequal speeds HALF SHAFT Description The half shaft assembly consists of a shaft with rubber boots at each end for protection from dirt etc A splined socket on the inboard end of the shaft mates with a splined shaft on the differential Splines on the outboard end of the shaft mate with splines in the front wheel spindle Operation Rotating motion of differential side gear is transferred to front wheel spindle by the half shaft Diagnosis Half shafts must be replaced if they exhibit any of the following symptoms A clicking noi
15. Do not dam age battery case If case is broken or dam aged avoid contact with battery contents Neutralize acid spills with baking soda and water solution Properly dispose of a damaged or worn out battery Check with local authorities for proper disposal methods Do not short circuit battery Severe fumes and fire can result WARNING Explosive Gases Cigarettes flames or sparks could cause battery to explode Always shield eyes and face from battery Do not charge or use booster cables or adjust post connections without proper instructions or training Keep vent caps tight and level WARNING POISON ACID Causes severe burns Batteries con tain sulfuric acid Avoid contact with skin eyes or clothing In the event of accident flush with water and call a Physician immediately 9 14 ELECTRICAL First Aid Treatments External Contact Flush immediately with plenty of water nternal Call a Physician immediately Then drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Eye Contact Flush with water for 15 minutes Get prompt medical attention Inspection There are many tools that may help in properly caring for and maintaining batteries Below is a list of basic items that GEM recommends for this task WARNING Always wear protective clothing gloves and goggles when handling batteries and electrolyte WARNING DO NOT SMOKE NEAR BATTERIES Recommended E
16. KEY is removed Be sure to switch the 72 volt Master Disconnect to OFF Set the Parking Brake and place wood blocks 4 x 4 or larger to the front and rear surfaces of the tires to restrain the vehicle from movement Do not smoke while working on your vehicle Batteries produce hydrogen gas that 1s extremely flammable and will explode upon exposure to any ignition source Remove rings watches loose jewelry and loose clothing when working on your vehicle to avoid injury NOTE The terms right hand RH and left hand LH are relative to one sitting in the driver s seat Therefore right hand refers to the passenger side and left hand refers to the driver s side of the vehicle VEHICLE IDENTIFICATION SAFETY CERTIFICATION LABEL Description A label containing the Vehicle Identification Number VIN and safety certification is located above the bench seat on the underside of the rear roof panel on the driver s side The information on the label includes Vehicle Identification Number Month and year of manufacture Gross Vehicle Weight Rating Gross Front and Rear Axle Ratings Wheel size Tire size Cold tire pressure MANUFACTURED BY U S Patent No Des 419 107 E Global Electric MotorCars L L C Web www gemcar com GVWR 953KG 2 100 LBS DATE 10 8 01 COLD INFLATION PRESSURE GAWR TIRE DIMENSION RIM 165 70R 12 T12x4J _165 70R 12 TA KPA PSI SGL DUAL 207 30
17. Older models use two 2 knurled knob bolts one on each side to secure the hood when closed A hood strap prevents the hood from open ing too far 0051 Figure 8 Hood Front View 1 Turn signal assemblies 2 Headlamp assemblies 3 Hood 0135 Figure 9 Hood Rear View Left turn signal lamp assembly Headlamp mounting bracket s Headlamp assembly s Headlamp wiring harness Hood Hood strap bracket Right turn signal lamp assembly Hood Strap Hood hinge bracket s Removal 1 Open hood 2 While supporting hood remove one of the screws that attach the hood strap to the front suspension frame then pull strap though strap bracket on hood 3 Remove hinge bracket mounting bolts 4 Remove hood Installation 1 While supporting hood attach hinge brackets to front suspension frame with mounting bolts Bolts should be loose enough to allow adjustment of hood for fit but tight enough to hold hood in adjusted position 2 Thread hood strap through bracket on hood then fasten strap ends to front suspension frame 3 Adjust hood latch mounting bracket until latch is properly aligned with striker plate on hood 4 Close hood and latch NOTE Adjustment of hood for proper fit can only be made at the lower hood bracket 5 Move hood brackets forward or back until proper fit of hood is attained then tighten hood bracket mounting bolts LATCH ASSEMBLY OLD Descriptio
18. Remove park brake lever assembly INSTALLATION Two Passenger Short Bed Utility Long Bed Utility Models 1 Position park brake lever assembly 2 Replace mounting bolts through park brake lever brackets 3 Re connect park brake switch wires to proper terminals on switch Yellow green on lowest most rearward terminal white green on center terminal and green on upper most forward terminal 4 Insert adjusting rod into park brake cable equalizer replace adjusting and jam nuts 5 Adjust tension on park brake cables See Park Brake Cable Tension Adjustment below 6 Install lower seat See seat installation in Body section Four Passenger Model 1 Position park brake lever assembly 2 Replace mounting bolts through park brake lever brackets 3 Re connect park brake switch wires to proper ter minals on switch Yellow green on lowest most rear ward terminal white green on center terminal and green on upper most forward terminal 4 Insert adjusting rod into park brake cable equalizer replace adjusting and jam nuts 5 Adjust tension on park brake cables See Park Brake Cable Tension Adjustment below 6 Install parking brake lever boot PARKING BRAKE CABLE ASSEMBLY DESCRIPTION Two cables are attached to the park brake lever by a ten sion equalizer and to the park brake actuator levers on the rear brake assemblies AORN B
19. Suspension Frame 8 x 1 25 NO 225 Steering Column Pinch Bolt 38 16 NO Tie Rod Stud Nut 10 15 NO Wheel Lug Nuts OUTER TIE ROD END Description The tie rod end provides the connection between the steering gear rack tie rod and the knuckle on the front wheel Threads on the tie rod end allow adjustment of overall length and control toe in jam nut maintains the tie rod end position relative to the tie rod Figure 14 Tie Rod End Tie rod Jam nut Knuckle Stud Nut Tie Rod End Removal Remove hub cap and loosen lug nuts Raise front of vehicle and support safely with jack stands Remove lug nuts and wheel Loosen the tie rod jam nut Remove the nut from the bottom of the rod end stud where it attaches to the steering knuckle Use a 2 jaw puller to separate the tapered stud from the knuckle Unthread the outer tie rod end from the tie rod to remove Installation Thread the new end into the tie rod to approximately the same depth as the old one Insert stud on tie rod end into steering knuckle and attach nut Tighten nut to seat stud in knuckle then back off nut Re tighten nut to 35 foot pounds Install wheel and tighten lug nuts just snug Lower vehicle to ground Tighten wheel lug nuts to 50 foot pounds Reset toe in See FRONT WHEEL ALIGNMENT in this section 2 16 SUSPENSION AND STEERING TORQUE SPECIFICAT
20. but must be replaced Operation The shock absorbers dampen jounce and rebound of the vehicle over various road and terrain conditions Diagnosis and Testing Movement between mounting bushings and metal brack ets or attaching components may cause a knocking or rat tling noise from a shock absorber spring unit Tightening the attaching nuts can usually stop these nois es If the noise persists inspect for damaged and worn bushings and or attaching components Replace if any of these conditions exist A squeaking noise from the shock absorber may be caused by the hydraulic valving and may be intermittent This condition is not repairable and the shock absorber must be replaced The shock absorbers are not refillable or adjustable If a malfunction or leak occurs the shock absorber spring unit must be replaced To test a shock absorber hold it in an upright position and force the piston in and out of the cylinder four or five times The action throughout each stroke should be smooth and even CAUTION The shock absorber bushings do not require any type of lubrication Do not attempt to stop bushing noise by lubricating them Grease and mineral oil based lubricants will deteriorate the bushing Removal 1 Raise vehicle off floor and support safely with jack stands 2 Using a 3 4 inch wrench and socket remove mounting bolts and nuts 3 Work shock out of mounts Cleaning and Inspection Check bolts and nut
21. hard pedal fade pedal pulsation pull grab drag noise etc 10 Attempt to stop the vehicle with the parking brake only and note grab drag noise etc Pedal Falls Away A brake pedal that falls away under steady foot pressure is generally the result of a system leak The leak point could be at a brake line fitting hose or wheel cylinder If leakage is severe fluid will be evident at or around the leaking component Internal leakage seal by pass in the master cylinder caused by worn or damaged piston cups may also be the problem cause Low Pedal If a low pedal is experienced pump the pedal several times If the pedal comes back up worn linings drums or rear brakes out of adjustment are the most likely caus es The proper course of action is to inspect and replace all worn component and make the proper adjustments spongy pedal is most often caused by air in system However thin brake drums or substandard brake lines and hoses can also cause a spongy pedal The proper course of action is to bleed the system and replace thin drums and substandard quality brake hoses if suspected Hard Pedal or High Pedal Effort A hard pedal or high pedal effort may be due to lining that 15 water soaked contaminated glazed or badly worn The check valve could also be faulty Pedal Pulsation Pedal pulsation is caused by components that are loose or beyond tolerance limits The primary cause of pu
22. loose Systems with combined PWB and DC to DC Converter If there is 72 V at J4 but there is no 12 V at J1 replace the PWB Replace fuse if open If fuse is not open use Headlight and Front Turn Signal Circuit diagram headlights and taillights share many common circuitry and a voltmeter to isolate problem If connection is not loose use Taillight and Rear Turn Signal Circuit diagram and a voltmeter to isolate problem If the resistance to ground is higher than 100 ohms for either pin 2 3 or 4 check for a loose ground connection Use Taillight and Rear Turn Signal Circuit diagram and a voltmeter to isolate the problem Replace the fuse if open If the fuse is not open use Horn and Wiper Circuit diagram and a voltmeter to isolate the problem Replace the fuse if open If the fuse is not open use Horn and Wiper Circuit diagram and a voltmeter to isolate the problem ACCESSORY SYSTEM COMPONENT REPLACEMENT Fuse Replacement WN BW 8 Turn signal 3A ATC Headlights 10 5 Window Wiper 7 5 Horn 3A ATC Ex 7 LISS Figure 29 Fuse Box 4 Brake 5A ATC 6 Accessory plug 3A ATC Disconnect power as described above Open hood as described in Body Panels and Accessories Section Locate fuse block on upper cross member Locate rubber splashguard on passenger side cross member Remove rivet at bottom of splashguard with a flat sc
23. 1 Mill 400 MH11 WHT 1 MH19 4 MH19 MEMINI UE 1 1 4 1 1 1 1 1 1 1 1 3 4 gt A a a v uM ee 1 MH19 3 MH19 4 MH19 PH2 RED GRN BRN GRN BRN YEL 17 MH5 8 MH5 MH5 17 Y 1 1 e BRN YEL BRN GRN SWITCH IP2 9 IP2 2 ORG GRN BRN GRN BRN YEL 6 IP1 1 FHS 2 FHS 6 MH10 PH7 eke aaa a 6 J2 120 VAC 1 1 PWB i TEMPERATURE 1 0019 MAIN CONTACTOR CIRCUIT BATTERY 6 BATTERY 5 BATTERY 4 fees F P 9 1 1 MASTER DISCONNECT ee BATTERY 3 BATTERY 2 BATTERY 1 400 MH18 Un ejes CONTACTOR MH1 BLK GRN BLK WHT RED WHT jme 25 1 1 1 11 MOTOR CONTROLLER GRN I 1 1 RO Le ere ny EE i 2 J MH20 1 T 13 MH20 GRY WHT WHT WHT GRN 1 MH13 11 12 MH 1 MH MH1 242 A 1 J4 11 J2 12 J2 16 J2 J4 1
24. 1 1 FUSE BLOCK 1 1 1 i 10 AMP i 1 1 1 1 1 1 1 1 ee es ea ee eae ee e eee 1 WHT RED 12 MH5 19 12 15 IP1 WHT RED YEURED HEAD LIGHT SWITCH 4 5 VIO BLU RED BLU GRN BLU 2 1 2 4 2 5 2 2 4 FH1 5 1 VIO BLU RED BLU GRN BLU 1 FH2 4 FH2 3 ZN 1 GRN BLU RIGHT LEFT HEADLIGHTS FRONT FRONT BLINKER BLINKER Be 4 4 Te 0016 9 32 ELECTRICAL HORN HORN HORN AND WIPER CIRCUIT 12 VDC PWB J1 YY RED FUSE BLOCK 1 1 1 7 5 AMP 1 1 1 1 1 1 EUNT a dpud al 1 BLU RED GRY RED 16 MH5 11 MHS 11 16 1 1 BLU RED GRY RED e WIPER ON Nx WIPER PARK ORG BLU YEL BLU WHT BLU 3 13 1 2 14 1 2 ZN 3 FHI 13 T FH1 14 FHA ORG BLU YEL BLU WHT BLU ZN ZN 1 1 FH3 2 WIPER MOTOR 0017 ELECTRICAL 5 33 TAIL LIGHT AND REAR TURN SIGNAL CIRCUIT 12 VDC WHT RED 12 MH5 12 WHT RED HEAD LIGHT SWITCH ane A 6 VIO BLU 2 lcs 2 VIO BLU TAILLIGHTS RIGHT REAR BLINKER 15 MH5 15 I
25. 5 MH20 4 MH20 6 MH20 Ee 5 4 6 72 VDC MOTOR CONTROLLER FROM BATTERY i 15 aM PRESE CUNT OEREN EEES EE E E MH20 MH2 i GRY RED GRY BLK GRY 1 1 i MH7 C 1 Fili FIELD 1 2 Y Y wr 1 1 1 1 1 1 0021 5 38 ELECTRICAL HARNESS AND CONNECTOR DRAWINGS HEAD LIGHT HARNESS Q 2 gt 177 uu oe HEADLIGHT HARNESS CONNECTIONS Connector Number Number of Pins in Connector HH1 4 HH2 Left Headlight HH3 HH4 HH5 HH6 HH7 Ground PIN LOCATIONS FOR HEADLIGHT HARNESS MULTI PIN CONNECTORS Number of Connector Illustration Connector Number Pins in Connector ELECTRICAL 5 39 FRONT HARNESS c 2 lt 2 Ls a Ve DED PE gt SS 2 o amp A 7 7 6 0079 FRONT HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector 14 Ground PIN LOCATIONS FOR FRONT HARNESS MULTI PIN CONNECTORS Number of Connector Illustration Connector Connects Pins in Number To Connector Headlight Harness Over Temperature Sensor Only for Schott Charger 9 40 ELECTRICAL INSTRUMENT PANEL HARNESS IP HARNESS CONNECTIONS Connector Number Connects To Num
26. Assembly Old 7 7 Jti Wow Ee wea x hE SSA 7 7 Hood Latch Assembly New 7 1 Des Sad nana praece 7 8 Dash Upper 2 a Summ bk e t mta aA B odio 7 8 Dash Lower Panel esu ge tuae redd aa Sold edo 7 9 od ey E 7 9 Linkspak Swivelpak 7 10 Linkspak Swivelpak Latch Assembly 7 11 Linkspak Swivelpak Leg Pocket 7 12 Mirror Center Rear View 7 12 Mirror Side Rear VIEW 7 12 BODY 7 1 BODY BODY PANELS Description The GEM body panels are molded of white plastic The hood mud guards and spat come in a variety of colors Color Codes The following chart identifies the available colors and the paint codes to match them PPG PAINT TRAVELER CODE COLOR DESCRIPTION CODE B Yellow B Yellow PPG2696 PB White 1B White 7 PPG91097 C Black C B H Green C Bay Harbor Green PPG
27. Codes The Motor Controller monitors the Drive System when the vehicle is powered up key is in the ON position The Motor Controller reports any problems detected by displaying error codes on the multi purpose Battery Discharge Indicator located in the center of the instrument pod Error Codes are explained in the table below Fault Description Corrective Action Display on the Battery Discharge Insure the key switch is closed If switch is Indicator BDI is blank closed verify voltage is present between Motor Controller connector MH20 pin 2 and the controller negative terminal Refer to the Main Contactor Circuit Diagram Check for an open circuit or loose connection from the Y plug and the BDI If voltage is present T ate are no loose connections replace the 02 Car was turned on while the direction Move the direction switch to neutral and switch was in the forward position then select the desired direction Car was turned on while the direction Move the direction switch to neutral and switch was in the reverse position then select the desired direction Emergency brake switch is open Verify that the emergency brake has been fully released If problem persists the emergency brake switch may be misadjusted or defective Refer to the Main Contactor Circuit Diagram for troubleshooting the emergency brake circuit Note the diagram shows the brake switch when the brake is engaged Start switch failed to close Start swit
28. Corrective Action Battery pack voltage is greater than Check the battery pack Verify that the proper 86 VDC voltage is present enn Step 4 of the Drive System Trouble shooting Chart for instructions on checking battery voltage If the voltage is over 86 VDC try running the headlights for a little while to drain the battery charge If the voltage is below 86 VDC there is a problem with the sensing circuit in the Motor Controller 21 Problem with the accelerator pedal wiring See Accelerator Pedal Diagnosis and Testing Motor field current is too high when the Replace the Motor Controller start switch is closed and the reverse direction is selected A Motor field current is too high when the Replace the Motor Controller start switch is closed and the forward direction is selected 12 VDC Buss voltage is too low Verify 12 VDC is present between Motor Controller less than 9 35 VDC connector MH20 pin 1 and the controller negative terminal when the under load e g headlights are on Refer to the Main Contactor Circuit Diagram If voltage stays above 9 35 VDC under load then replace the Motor Controller If voltage drops below 9 35 VDC check for check for loose connections If no loose connections are found the DC to DC converter may be defective Open thermal protector or transistor over Motor Controller is in thermal cut back allow to temperature cool and the status cod
29. LINKSPAK HANDLE in this section 4 Remove two Tek screws one on each side of panel 5 Remove back panel Installation 1 Position back panel 2 Install two Tek screws one on each side of panel 3 Install Swivelpak Linkspak handle adjust as necessary See SWIVELPAK LINKSPAK HANDLE ADJUSTMENT in this section 4 Install body side panels See BODY SIDE PANEL in this section 5 Install Swivelpak Linkspak See SWIVELPAK LINKSPAK in this section SEATS Description The GEM vehicles utilize bench seats in all models The four passenger model has bucket seats in the driver and front passenger positions and the bench seat in the rear BENCH SEAT Description The bench seat is comprised of a seat cushion and a seat back The cushion is attached to the raised portion of the floor panel by a friction latch consisting of a male probe mounted on the seat cushion that mates to a female grommet mounted to the seat sup port A hand hold is attached to each outboard end of the seat cushion The seat back is attached to the back panel and seat back support by screws through the tail lamp assemblies and at the bottom of the seat back 0008 Figure 5 Bench Seat new style 2 Bench seat cushion 4 Friction latch female 6 Seat cushion 1 Bench seat back 3 Hand hold 5 Friction latch male Removal 1 Old style Remove 2 knurled knob bolts New style Pull up on front edge of seat cushion until friction latch
30. Motor Armature 2 A2 3 Speed Sensor Pigtail 4 Motor Armature 1 A1 5 Motor Field 2 F2 9 24 ELECTRICAL Removal Xg T 4 S N Figure 23 Motor to Differential Attachment 1 Differential 2 Mounting Bolts 3 3 Motor 1 Remove lower bench seat cushion to access the Master Disconnect switch 2 Switch master disconnect to off 3 Raise vehicle off floor and support safely with jack stands 4 Remove both front wheel assemblies for improved access 5 Disconnect power wires from top and rear of motor with 1 2 inch wrench noting connections and locations see figure 22 BOLT HEAD SIZE DESCRIPTION NUT SIZE Motor to Differential Wheel Lug Nuts 6 Disconnect 3 wire pigtail at connector see figure 22 7 Remove 3 bolts from differential side of motor see figure 23 with 7 16 inch wrench or socket taking care to support motor which weighs 30 40 pounds 8 Remove motor noting orientation of power posts for reassembly then pulling straight out Installation 1 Make sure to put a resilient bumper inside motor spline socket The cupped end of the bumper will face outward Be sure bumper is all the way in the spline socket 2 Put a very light coating of Valvoline Special Moly Ep grease or equivalent on the splined differential shaft Too much grease will cause motor problems 3 Install motor Making sure power posts on motor face the same direction as before 4 Install
31. Shaft 2 Inner Boot 3 Differential 4 Pry bar s Cleaning and Inspection Inspect half shafts They must be replaced if they exhib it any of the following conditions and boots for cuts Discard and replace any boots found with cuts Inspect splines on half shaft for wear or damage If worn or dam aged replace the half shaft as it 15 not serviceable Disassembly Secure half shaft in a vise Outboard Boot 1 Usea small flat screwdriver to remove the large and small clamps from the outboard boot PRY APART HERE PRY APART HERE OUTBOARD CV BOOT 0198 Figure 3 Outboard Boot Clamp Removal 2 Push back outboard boot to expose snap ring connecting the spindle to the shaft SNAP RING SLIDE CV BOOT BACK Figure 4 Snap Ring Location 3 4 DRIVETRAIN 3 Using snap ring pliers to release tension from snap ring remove spindle assembly SPREAD SNAP RING APART Figure 5 Spindle Removal 4 Slide damaged boot off the outboard end of the half shaft 5 Clean off grease and inspect spindle and half shaft for damage Replace if damaged Inboard Boot 1 Usea small flat screwdriver to remove the large and small clamps from the inboard boot PRY APART HERE INBOARD CV BOOT 0205 Figure 6 Inboard Boot Clamp Removal 2 Push back inboard boot to expose snap ring connecting inboard joint to the shaft SNAP RING SLIDE CV BOOT BACK 0206 Figure 7 Snap Ring Loca
32. The GEM vehicle has a battery control and recharge sys tem especially designed for electric vehicle usage The charging system is designed to maximize the battery pack life while recharging the pack in the shortest time with available household current 110 volt 15 outlet The following guidelines will insure that you get the maximum battery life and performance out of your GEM electric vehicle New batteries will not deliver their full capabilities until they have been discharged and recharged 20 to 50 times Batteries should be fully charged before first use of new vehicle before releasing vehicle for daily use Whenrecharging it is preferable to have the battery pack at close to room temperature Do not have in direct sunlight on hot pavement or in excess heat of 110f or higher Batteries should be charged after each period of use Lead Acid batteries do not develop a memory and need not fully discharge before recharging WARNING Always wear safety glasses or approved eye protec tion when servicing the vehicle Wear a full face shield when working with batteries Always use insu lated tools when working around batteries or electri cal connectors WARNING Battery fluid is a corrosive acid solution and can burn or even blind you Don t allow battery fluid to contact eyes skin or clothing If acid splashes in eyes or on the skin flush the area immediately with large amounts of water Battery
33. WHEELS DESCRIPTION The GEM 825 uses steel wheels with a 4 bolt pattern and tires in two different sizes as shown in the charts below Wheel Chart Four Passenger Short Bed Utility Long Bed Utility Two Passenger Construction Diameter Offset Bolt Pattern Capacity 2 1 8 4 on 4 circle Tire Chart Two Passenger 205 50 10 4 Load Range Be Y Four Passenger Short Bed Utility Long Bed Utilit 165 70R 12 Steel Belt Radial Rim Width 4 5 Maximum Load 795 Approx Weight 10 Ib Revs Per Mile Max Section Width Overall Diameter TIRES Description Tires are designed and engineered for each specific vehicle They provide the best overall performance for WHEELS amp TIRES 6 1 normal operation The ride and handling characteristics match the vehicle s requirements With proper care they will give excellent reliability traction skid resistance and tread life Driving habits have more effect on tire life than any other factor Careful drivers will obtain in most cases much greater mileage than severe use or careless drivers A few of the driving habits which will shorten the life of any tire are Rapid acceleration Severe brake applications Excessive speeds on turns Striking curbs and other obstacles Radial ply tires are more prone to irregular tread wear It 1s important to follow the tire rotation interval This will help to achieve
34. are not covered by this service manual Operation Standard accessories receive their 12 volt power from the fuse protected DC to DC converter The DC to DC con verter receives 72 volt input power directly from the six batteries and requires no user action for its operation other components of the Accessory System function identical to those devices in a standard automobile The two headlights are 12 volt single filament incandes cent bulbs A rocker switch see figure 8 item 3 located on the instrument pod activates headlights Taillights and brake lights are 12 volt dual filament incandescent bulbs One filament is used for directional indicators and brake lights The taillight filament 15 acti vated when the headlights are turned on There are 4 directional indicators left and right front and left and right rear Turn signal lever see figure 8 item 1 located on the left side of the instrument pod activates the directional indicators The horn provides a single continuous tone when the horn button is pressed Horn button see figure 8 item 2 15 located on the left side of the instrument pod A single speed DC motor powers the wipers The motor automatically returns the wipers to the Parked position when the wipers are turned off A rocker switch see fig ure 8 item 8 on the right side of the instrument pod acti vates the wipers Diagnosis and Testing The purpose of this section is to aid in the isolation
35. autor green ire bU 5 41 42 43 0 3 4 master 0 3 5 2 5 7 9 17 18 4 2 4 5 6 7 8 9 master disconnect 0 2 3 3 6 7 4 10 11 5 2 4 5 8 15 17 19 20 21 22 24 Master Disconnect Switch 3 3 5 2 4 5 8 15 17 19 20 21 22 24 Mirror asse mDly AP 7 12 13 motor forward 0 3 4 3 2 6 7 5 3 4 6 7 8 9 10 11 18 19 20 22 23 25 27 28 29 39 42 43 44 46 6 3 Motor Controller 5 8 4 6 7 8 9 10 11 18 19 20 22 25 42 44 46 MPH Spesd ndi glol See Red CR CIC E EORR CUR ROC 5 26 mud guards 2 5 cs ce eR ERROR CR OCA Ro ECCE ae eae 7 1 6 outboard DOOL 2 2 gad oe Bk EVEN 3 3 4 5 paint COGS P C 7 1 park rx 2 3 8 9 4 2 7 8 10 11 12 park brake 2 8 9 4 2 10 11 12 park brake lever s sake EADIE DO ROC Eee SOR hee AC CR e 4 2 7 10 11 pedal NOUS ICI 5 11 12 pinch DOM we Ke eH wh at ra e ei CE SCR dod ed ORAS 0 3 2 4 5 13 14 16 17 18 Oi C P 0 8
36. container ELECTRICAL 5 17 2 Avoid direct exposure to heat sources such as radiators or space heaters Temperatures above 80 F accelerate the battery s self discharge characteristics Step by step storage procedure 1 Completely charge the battery before storing 2 Remove bench seat cushion rear bench seat cushion for 4 passenger vehicles to access the Master Disconnect switch Switch master disconnect off 3 Store the vehicle in a cool dry location protected from the elements 4 During storage monitor the specific gravity or voltage Batteries in storage should be given a boost charge when they show a 70 charge or less See Table 1 5 Completely charge the battery before reactivating 6 For optimum performance equalize the batteries before putting them back into service Refer to the Equalizing section for this procedure Charging Charge batteries only in well ventilated area Keep sparks or flames away from a charging battery 1 Become familiar with the charger and follow the instructions See charger in the electrical section 2 Batteries should be charged after each period of use 3 Lead acid batteries do not develop a memory and need not be fully discharged before re charging 4 Check electrolyte level refer to the Watering section 5 Tighten all vent caps before charging 6 Do not undercharge the batteries Under charging causes stratification 7 Do not charge a frozen battery
37. handle is turned If the latching mechanism is not properly lined up with the latch bracket on the pack unit it may be difficult or impossible to engage and lock the unit in place To adjust the play in the latch handle 1 Remove bench seat cushion and back See BENCH SEAT in this section 2 Rotate turnbuckle until play 15 sufficiently reduced To adjust latch alignment 1 Remove bench seat cushion and back See BENCH SEAT in this section 2 Loosen the 2 bolts attaching latching mechanism to the mounting plate 3 Adjust latch assembly from side to side until proper alignment is attained 4 Tighten mounting bolts 5 Install bench seat Removal Remove screw that attaches small bracket from turn buckle to shaft handle Remove two 2 screws that attach handle to back panel and remove handle 2 Remove bench seat See BENCH SEAT in this section 3 Remove small screw that attaches the turnbuckle assembly bracket to the handle then dis engage bracket from handle 4 Remove 2 screws attaching handle assembly to body back panel 5 Remove handle 6 Remove 4 self drilling screws attaching the latch mounting bracket to the seat back body back panel support frame remove latch assembly 1 12 BODY Installation 1 Position latch mounting plate on seat back body back panel support frame and install 4 self drilling screws 2 Insert latch handle into body back panel and install mounting screws
38. mounted to the steering knuckles Pivoting action of the knuckles change the direction of the front wheels Diagnosis and Testing CONDITION POSSIBLE CAUSES CORRECTION Tighten bolts to specification 2 Inspect and repair RATTLE OR CLUNK DIFFICULT TO TURN WHEEL WHEEL STICKS OR BINDS STEERING WHEEL DOES NOT WANT TO RETURN TO CENTER POSITION EXCESSIVE PLAY IN STEERING WHEEL VEHICLE PULLS OR LEADS TO ONE SIDE Gear mounting bolts loose Loose or damaged suspension components Loose or damaged steering column Low tire pressure Worn or damaged steering components kingpins tie rod ends Steering column u joints binding Steering gear worn Incorrect tire pressure Lack of lubrication suspension components Worn or loose suspension or steering components Worn or loose wheel bearings Steering gear mounting bolts loose Steering gear worn Steering column u joints worn Incorrect tire pressure Redial tire lead Brakes dragging suspension components Replace steering column 1 Adjust tire pressure Inspect and repair replace as necessary Replace steering column Replace steering gear Adjust tire pressure Inspect and lubricate suspension components Replace steering gear Inspect and repair as necessary Replace drum brake assembly Tighten mounting bolts Replace steering gear Replace steering colum
39. piston to move forward Movement of piston forces brake fluid out of master cylinder into brake lines leading to the four brake assemblies REMOVAL 1 Chock wheels 2 Using a flare nut wrench remove brake lines from master cylinder Take care to capture brake fluid in proper container for disposal 3 Remove two mounting bolts attaching master cylinder to cowl 4 Remove master cylinder and mounting gasket INSTALLATION 1 Position master cylinder and mounting gasket on cowl 2 Attach with two mounting bolts and nuts Tighten to 225 inch pounds 3 Attach brake lines to master cylinder 4 Add DOT3 brake fluid to master cylinder reservoir until FULL line on side of reservoir is reached 5 Bleed brakes See BRAKE BLEEDING in this section TORQUE SPECIFICATIONS DESCRIPTION THREAD SIZE Brake line to Wheel Master Cylinder Brake Master Cyliner to Frame 4 10 BRAKES PARK BRAKE LEVER ASSEMBLY DESCRIPTION The park brake lever is located between the driver and front passenger seats On four passenger models it 15 mounted on top of the front seat tub On all other mod els it is mounted on the front of the bench seat tub 0005 Figure 10 Park Brake Lever 1 Charge Receptacle 2 Park brake lever 0068 Figure 11 Park Brake Lever 4 Passenger 1 Park brake lever OPERATION Pulling up on lever causes the park brake adjuster assem bly to pull on the park brake cables A ratchet holds the
40. screws from the back of the mounting plate 6 Remove the PWB Installation of PWB both versions 1 Reverse procedure to reinstall Use care when positioning the PWB on the converter so they do not bend pins version 1 boards only ELECTRICAL 5 21 DC DC CONVERTER Description 0107 Figure 19 DC DC Converter Version 1 PWB 1 Mounting posts As indicated in the previous section the DC DC con verter 15 located either on the PWB or is mounted direct ly under the PWB In either case the converter serves the same function converting the high voltage delivered by the batteries 72 VDC to lower voltage 12 VDC The lower voltage is used to power all the devices that are part of the Accessory System headlights taillights direc tional indicators brake lights horn and wipers Operation The DC DC converter functions automatically when the Master Disconnect is in the ON position Diagnosis and Testing Diagnosis and testing of the DC DC Converter is covered in the Accessory System Troubleshooting Chart The cir cuit diagrams provided in this manual are also useful in isolation of problems associated with the DC DC Converter Removal Note These replacement instructions apply only to systems that have DC to DC con verters mounted separately and behind the Printed Wiring Board For replacement instructions of the Version 2 PWB which includes the DC to DC converter see the Printed Wiring Board
41. section 9 22 ELECTRICAL Turn off the Master Disconnect Switch Remove upper and lower dash Locate the printed wiring board and remove electrical connections noting connection and orientation Remove four 6 screws from each corner of PWB Gently lift PWB off the converter mounting posts located directly behind the PWB see figure 18 6 Using pliers loosen and remove the four posts and remove the converter Installation 1 Hold the converter in place and install the four mounting posts 2 Set the PWB in place over top of the mounting posts and install the four 6 mounting screws 3 Orient and attach all wires and cables to their proper connections Install the lower and upper dash Turn Master Disconnect Switch to on Und MAIN CONTACTOR Description Lo v 0 0 0 0112 Figure 20 Main Contactor Location 1 Main Contactor The Main Contactor is an electronically controlled switch that provides a high current connection between the battery and the motor controller It is located under the front dash to the right of the battery charger and above the Printed Wiring Board Operation The Motor Controller activates the Main Contactor if the Key Switch is on and the Motor Controller determines high voltage high current power should be supplied to the drive motor The Motor Controller will not activate the Main Contactor if an error condition exist
42. striker 3 Striker mounting bolt bushing 4 Striker bracket adjustable 5 Hood latch mounting bracket 71 8 BODY 0131 Figure 11 Hood Latch Assembly Closed 1 Hood latch 2 Striker bracket adjustable 3 Striker mounting bolt bushing Operation To unlatch the hood pull up on leading end of latch han dle to release tension on the striker plate allowing disen gagement of the striker To latch the hood engage handle on striker plate then press down on leading end of han dle to lock in place Removal 5 Open hood 6 Remove 2 Phillips head screws attaching latch to hood 7 Remove latch 8 Remove upper dash panel See DASH this section 9 Remove bolt attaching mounting bracket to windshield lower support 10 Remove mounting bracket and bushing Disassembly 1 Remove 2 Phillips head screws attaching striker plate to mounting bracket 2 Remove striker Assembly 1 Position striker on mounting bracket 2 Attach with 2 Phillips head machine screws lock washers and nuts Installation 4 Position latch on hood and attach with Phillips head screws lock washer and nuts 5 Install mounting bolt through lower windshield support from inside vehicle 6 Insert bushing then mounting bracket over mounting bolt and attach with locking nut just snug 7 Adjust mounting bracket until striker plate is properly aligned with latch handle on hood CAUTION Striker must be aligned
43. 0035 Figure 12 Park Brake Cables 1 Park brake cables 2 Cable mounting bracket 3 Actuator lever BRAKES 4 11 REMOVAL 1 Chock wheels 2 Remove lower seat See seat removal in Body section 3 Switch master disconnect off and cover battery terminals to prevent electrical contact 4 Release park brake lever 5 Remove cables from the equalizer 6 Remove spat see Spat Removal in Body section exposing rear park brake cable attachments 7 Remove cotter pin and clevis pin from rear brake drum assembly 8 Remove retaining rings from rear mounting points 9 Pull cable back and downward to release 0029 Figure 13 Parking Brake Cable Attachment 1 Cotter pin 2 Clevis pin 3 Actuator lever 4 Cable mounting bracket 5 Cable end 0030 Figure 14 Parking Brake Cable Mounting 1 Mounting bracket 3 Retaining ring 2 Parking brake cable 4 12 BRAKES INSTALLATION 5 Insert park brake cables into equalizer 6 Adjust tension on park brake cables See PARK 1 Install park brake cable into retainer on frame BRAKE CABLE TENSION ADJUSTMENT attach with retaining rings below 2 Position cable end over park brake actuator leveron 7 Uncover battery terminals and switch master rear brake assembly Insert clevis pin to attach disconnect ON insert cotter pin in clevis to retain pin 8 Install lower seat See BENCH SEAT in BODY 3 Install spat See SPAT in BODY section section 4 Install rear shock mou
44. 18 Motor dd Loa a ent btt tu pur E RES 5 19 MERE TUE rr 5 21 Main Contactor Narr ke ERE RO IP E EK S AG Salsa E 5 22 MOIO cats o oM ep Dade aw vee sada ee dicke T 5 23 Battery Discharge Indicater 2 5 25 Aocessory System e be Lux 5 27 Accessory System Component Replacement 5 29 GOL ES ses aa coor ARoTREEODCORAadQUINUIOM LARUM E EEUU 5 30 Head Light and Front Turm Signal Circuit 5 31 Horm and Wiper Circuit a dp ret panna bb 5 32 Tail Light and Rear Turn Signal Circuit 5 33 Brake Light and Warning Circuit au Se gara dos aodio dandi d od 5 34 Battery Charger DIUI ES Pa 5 35 Main Contactor S rasch 5 36 Motor Circuit dos pow rte vi 5 37 Head Cont Harness rassasradacuctdatriENimeX EN 5 38 Front HARNESS siccus MS ew WP
45. 2 The battery has a bad cell Batteries in these conditions should be taken to a spe cialist for further evaluation or retired from service Specific Gravity Open Circuit Corrected to 80 F Voltage 1 277 1 258 1 238 1 217 Percentage of Charge Table 1 State of Charge as related to Specific Gravity and Open Circuit Voltage ELECTRICAL 5 15 Discharge Load Test There are two reasons for using a discharge unit on a bat tery set 1 To determine battery capacity 2 To find defective cells or batteries in a battery set Battery energy is measured in minutes obtained upon discharging a fully charged battery set with a known resistive load at a controlled temperature until a shut off voltage of 10 5 volts per battery is reached NOTE The following procedure is written specifically for a 36 volt 75 amp discharge unit which automatically shuts off at a specified voltage Follow all manufacturers instructions when operating discharge units Two units will be needed to discharge the GEM 72 volt battery set simultaneously Discharge Procedure 1 Fully charge the batteries 2 Turn the Master Disconnect switch to OFF 3 Connect the discharge unit s to the battery set as shown in Fig 1 4 After all the safety procedures specified by the manufacturer have been followed start the unit 5 When unit shuts off record the discharge time If the battery leads are reversed the discharge machine will no
46. 2 5 10 11 13 14 15 3 2 6 5 23 POWER 55 5 8 28 45 46 47 Power SYSIOM bee 5 2 3 4 6 8 10 20 21 22 23 26 eee arae 194 P3973 oes ae eros 2 2 Printed Wiring 5 11 18 19 21 22 5 9 18 19 20 21 22 28 42 43 46 Rack and pinion steering 2 10 14 cosa gaisa thes aace ee a iea aa iea e i aa a ei 6 1 3 5 27 MOAN 06 0 2 2 8 9 4 7 8 rear dr rm Drake sack Diese BAG BA ds ie Bah de Ros Ro dO Rp E 2 8 9 4 2 rear shock absorber mount cover 7 10 rear SUSPENSION iuc a OE EROR Ro re SRO ee e Us 0 3 2 5 6 8 9 4 12 7 10 rear view 0 4 7 12 13 SOL VOIf tose ts ces earns dote t poat Ge ae BAG dete qu diftus cient ea 4 2 3 4 9 Retention MC TTPTITTTPTPT 4 5 cd eroe
47. 20 VAC 0113 Figure 2 Power System The purpose of the Power System is to provide primary power for the Drive and Accessory Systems The Power System consists of the batteries battery charger fuse key switch temperature sensor and power harness not shown in the block diagram Six 12 volt series wired lead acid batteries provide a total power supply voltage of 72 volts Operation The battery charger automatically recharges the battery to 100 charge when plugged into a standard 110 volt 15 amp breaker outlet When the charger is active logic in the Motor Controller prevents the vehicle from being operated The battery charger monitors battery tempera ture by means of a temperature sensor If the battery tem perature reaches above 120 degrees the charger will shut down Diagnosis and Testing Diagnosis and testing of the power system 15 integrated with the Diagnosis and Testing of the Drive system DRIVE SYSTEM Description 72NDC BATTERY POWER VIA MAIN CONTACTOR DRIVE VOLTAGE MOTOR CONTROLLER BATTERY STATUS DATA DISCHARGE INDICATOR KEY SWITCH TACHOMETER TURF MODE amp FORWARD REVERSE ACCELERATOR SWITCHES FOOT PEDAL POSITION 0116 Figure 3 Drive System 9 4 ELECTRICAL The Drive System consists of the Main Contactor Motor Controller DC Motor Battery Discharge Indicator or BDI tachometer accelerator foot pedal direction switches turf switch main wiring harness and other associa
48. 21 Zivan Charger Female Spade RED ELECTRICAL 5 43 PIN LOCATIONS FOR MAIN HARNESS MULTI PIN CONNECTORS Number of Connector Illustration Connector Connects Pins in Number To Connector Motor Controller PWB J2 IP Harness Battery Discharge Indicator 9 44 ELECTRICAL Fuse Block Flasher Module Battery Charger Tachometer Motor Controller ELECTRICAL 5 45 ZIVAN HARNESS 0076 ZIVAN HARNESS CONNECTIONS 72 volt Power Harness Black Fuse Wire 9 46 ELECTRICAL POWER HARNESS 2 7 gt EO S 0015 2 amp 4 PASSENGER POWER HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector PH1 1 2 PH4 B6 Battery 6 Positive Terminal PH5 Parking Brake PH6 1 Battery 1 Negative Terminal PH7 AC Power Cord Male PH8 B4 Battery 4 Positive Terminal PH9 Tail Light Harness PH10 Fuse 400 Amp PH11 PWB J3 PIN LOCATIONS FOR POWER HARNESS MULTI PIN CONNECTORS Number of Connector Illustration Connector Connects Pins in Num
49. 3 motor differential mounting bolts with 7 16 inch wrench or socket Make sure to add one drop of Loctite r to each motor differential bolt Torque bolts to 90 inch pounds 5 Re connect power wires to top and rear of motor with 1 2 inch wrench 6 Replace both front wheel assemblies Tighten wheel lug nuts just snug 7 Lower vehicle to floor 8 Torque wheel lug nuts to 30 foot pounds 9 Return master disconnect switch to ON position 10 Install lower bench seat cushion assembly see BENCH SEAT in BODY section Use Loctite 242 pom pe p pepe Motor Magnet and Speed Sensor Description A small circular magnet is mounted to the motor spindle A sensor attached to a pigtail sits in close proximity to the magnet Access to the magnet and sensor is gained through a small plate in the center of the motor s end panel 0058 Figure 24 Speed Sensor amp Magnet 1 Screw 2 Washer 3 Magnet 4 Speed sensor Operation When the motor s armature rotates the magnet rotates also The sensor detects the magnet s motion and trans mits a signal through its pigtail to the motor controller 0164 Figure 25 Speed Sensor Magnet Location 1 Motor 2 Cover plate mounting holes 3 Washer 4 Magnet bushing underneath 5 Magnet mounting bolt 6 Speed Sensor ELECTRICAL 5 25 Removal 1 Remove 3 small screws attaching cover plate to motor end panel 2 Remove plate and lift out sensor pigtail ass
50. 43844 2001 Model Colors 01 Green Metallic Hes 00 Royal Blue Metallic DBC4830 2100 64 00 Red 0 4451 8 Pf 00 7 00 Metallic DCC4854 00 Green 00 Deep Green Metallic DBC4735 ER _ 99 Bue PPG15231 PPG72302 SEAT BELTS Diagnosis and Service Seat belts should be inspected monthly for the following Description signs of wear The GEM vehicles use automotive type seatbelts at all locations The driver and front passenger positions on the four passenger model have lap belts only GEM vehicles use 3 point automotive seat belts on all models except front bucket seats on four passenger models only two point lap belts are available Frayed edges on web Scores across web Obvious signs of wear on web at buckle Corrosion of any of metal parts or fasteners If any of these signs are present locate and correct cause and replace seat belt assembly 1 2 BODY TWO POINT LAP BELT Description The lap belt assembly consists of a belt retractor assem bly a latch assembly and a mounting bracket The mount ing bracket is attached to the vehicle by the two 2 rear bucket seat mounting bolts Figure 1 Two Point Lap Belt 1 Seat Belt Latch Assembly 2 Bucket Seat 3 Belt and retractor assembly 4 Seat Adjuster Lever Removal 1 From beneath vehicle remove nuts from the four 4 bucket se
51. 77 007 If not follow the steps below 1 Check and record voltage level s 2 Put battery s on a complete charge 3 Take specific gravity readings again If any specific gravity reading is still not within the fac tory specification follow the steps below 1 Check voltage level s 2 Perform equalization charge Refer to the Equalizing section for the proper procedure 3 Take specific gravity readings again If any specific gravity reading is still not within the fac tory specification of 1 277 007 then one or more of the following conditions may exist 1 The battery is old and approaching end of life 2 The battery was left in a state of discharge too long 3 Electrolyte was lost due to spillage or over flow 4 A weak or bad cell is developing 5 Battery was watered excessively previous to testing NOTE Batteries in conditions 1 4 should be taken to a specialist for further evaluation or retired from service Open Circuit Voltage Test For accurate voltage readings batteries must remain idle no charging no discharging for at least 6 hrs prefer ably 24 hrs 1 Disconnect all loads from the batteries 2 Measure the voltage using a DC voltmeter 3 Check the state of charge with Table 1 4 Charge the battery if it registers 0 to 70 charged If battery registers below the Table 1 values the follow ing conditions may exist 1 The battery was left in a state of discharge too long
52. ENT riw be Rex EA xa Ek 5 39 Kula Swan sere ee 5 40 Mam HARNESS Lada CRM SSNS ee KE DS WE ich Rx Cup qaas i 5 42 Power Harness desea DuC a tan d Bas dose a Sees bote dioe ad 5 46 9 2 ELECTRICAL ELECTRICAL ELECTRICAL SYSTEM Description LIGHTS RADIO DC CONVERTER HORN HEATER WIPERS DRIVE VOLTAGE MOTOR CONTROLLER BATTERY STATUS DATA DISCHARGE INDICATOR BATTERIES Py KEY SWITCH TACHOMETER TURF MODE FORWARD REVERSE SWITCHES amp ACCELERATOR FOOT PEDAL POSITION TEMPERATURE Figure 1 Electrical System Diagram 0115 The electrical system of the GEM is show in the block diagram above For purposes of operational description the sys tem 15 divided into three groups the Power System the Drive System and the Accessory System WARNING Always turn off the Master Disconnect Switch and allow a few minutes for the system to discharge before servic ing the electrical system Never wear loose Jewelry rings or watches Always use insulated tools to prevent short ing NOTE The Master Disconnect Switch is located under the bench seat see figure 4 Turn switch counter clockwise to turn off POWER SYSTEM Description 6 BAT 5 ELECTRICAL 5 3 4 MASTER DISCONNECT 2 CHARGER BAT 1 1
53. IONS DESCRIPTION THREAD Use INCH SIZE Loctite POUNDS POUNDS 242 Tie Rod Stud Nut 10 15 NO Wheel Lug Nuts 5 NO KING PIN ASSEMBLY To determine if kingpins are worn Description 1 Raise front of vehicle off floor and support safely with jack stands Two kingpins attach the steering knuckle to the yoke and 2 Grasp the knuckle at top and bottom and rock it up provide the right to left pivoting action of each wheel and down 3 The kingpins must be replaced as set if there is any perceptible motion in relation to the yoke Removal 1 Remove hub cap and loosen wheel lugs 2 Raise vehicle off floor and support safely with jack stands 3 Remove lug nuts and wheel 4 Remove nut and washer from outboard end of half shaft 5 Remove brake line taking care to collect brake fluid in proper container for disposal 6 Remove tie rod ends See OUTER TIE ROD ENDS in this section Remove pinch bolts securing yoke to kingpins Lift and remove knuckle Remove kingpin bearing assembly with special keyed kingpin tool 70112 00580 available from GEM and 9 16 impact socket 0 4 Figure 15 Steering Components Wheel 1 Shock absorber metalation 2 Yoke 1 Insert kingpin bearing assembly in knuckle 3 Kingpins 2 Replace knuckle assembly in yoke 4 Knuckle 3 Tighten bolts securing yoke to kingpins to 65 foot 5 Wheel Brake unit pounds 6 Tie rod end 4 Replace tie ro
54. Motor Controller 51 Motor Controller is not getting 72 volts See the Drive System Troubleshooting Chart step 1 5 Motor Controller motor current sensor Replace the Motor Controller input is too low while running 76 Capacitor 1C voltage is too high during Replace the Motor Controller regenerative braking N 9 8 ELECTRICAL Drive and Power System Troubleshooting Charts The Drive and Power System Troubleshooting Chart A should be used as a guide to isolate electrical problems with the batteries Master Disconnect Switch main contactor and Motor Controller that are not covered by the fault codes Drive and Power System Troubleshooting Chart B should be used to as a guide to isolate problems with the motor motor magnets tachometer and BDI For problems with light horn or wipers refer to the Accessory System Troubleshooting Chart Drive and Power System Troubleshooting Chart A Note DC voltage measurements should be taken with respect to Motor Controller B or chassis ground Action Prior to turning the Key Switch to the On position Proceed to Step 2 Make the necessary verify the following correction and try Vehicle battery charger is not connected operating the vehicle Main disconnect is turned on again Vehicle Directional Switch is in the neutral position neither Forward or Reverse Accelerator pedal is not depressed All conditions met Turn the Key to the On position You shou
55. O SPECIFICATIONS WHEN TIRES ARE COOL ROTATE TIRES CORRECTION HAVE TIRE INSPECTED FOR FURTHER USE Em i UNBALANCED INCORRECT TOE WHEEL SI LACK OF ROTATION OF TIRES UNDER INFLATION OR WORN OR OUT OF ALIGNMENT SUSPENSION OR TIRE DEFECT ADJUST TOE IN DYNAMIC OR TO STATIC SPECIFICATIONS BALANCE WHEELS ROTATE TIRES AND INSPECT SUSPENSION SEE GROUP 2 Figure 2 Tread Wear Chart DIAGNOSIS AND TESTING TIRE NOISE OR VIBRATION Radial ply tires are sensitive to force impulses caused by improper mounting vibration wheel defects or possibly tire imbalance To find out if tires are causing the noise or vibration drive the vehicle over a smooth road at varying speeds Note the noise level during acceleration and deceleration The motor and differential noises will change as speed varies while the tire noise will usually remain constant REPAIRING LEAKS For proper repairing a radial tire must be removed from the wheel Repairs should only be made if the defect or puncture is in the tread area Fig 15 The tire should be replaced if the puncture is located in the sidewall Deflate tire completely before removing the tire from the wheel Use lubrication such as a mild soap solution when dismounting or mounting tire Use tools free of burrs or sharp edges which could damage the tire or wheel rim Before mounting tire on wheel make sure all rust is removed from the rim bead and repaint i
56. ON AND STEERING 2 7 Installation 1 Attach yoke and knuckle assembly to control arm Tighten to 60 foot pounds 2 Attach control arm assembly to front suspension frame Tighten to 60 foot pounds 3 Attach spring shock absorber lower mounting bolt Tighten just snug 4 Attach tie rod end to steering knuckle Tighten to 35 foot pounds 5 Re connect the brake line Tighten to 37 foot pounds 6 Bleed the brakes See BRAKE BLEEDING in BRAKES section 7 Replace wheel tighten lug nuts just snug 8 Replace half shaft washer and bolt tighten just snug 9 Lower vehicle to ground then tighten lug nuts to 50 foot pounds 10 Back off half shaft nut slightly add Loctite 242 and tighten to 74 foot pounds 11 Tighten control arm to front suspension frame mounting bolts to 60 foot pounds 12 Tighten spring shock absorber lower mounting bolt to 60 foot pounds 13 Replace hub cap TORQUE SPECIFICATIONS DESCRIPTION THREAD INCH FOOT SIZE Loctite amp POUNDS POUNDS 37 Brake line to Wheel Master Cylinder Brake line to Wheel Master Cylinder Brake Drum Assembly to Steering Knuckle Control Arm to Frt Suspension Frame Half Shaft to Drum Brake Assembl Shock Absorber Lower Bolt Shock Absorber Upper Bolt Tie Rod Stud Nut Wheel Lug Nuts Yoke to Control Arm Use M12 x 1 75 M12 x 1 75 2 8 SUSPENSION AND STEERING REAR SUSPENSION Description The rear suspension is comprised of a frame that incl
57. P1 YEL RED 4 J 1 1 5 1 1 4 MH5 5 5 BLK BLU GRY BLU a 5 4 PWBJ2 5 PWBJ2 1 PRINTED WIRING BOARD i 1 1 5 JPWBJA 4 APWBJ4 5 PH11 4 PHt1 BLK BLU GRY BLU 3 4 3 T TL1 4T TL1 BLK BLU GRY BLU LEFT REAR BLINKER 0018 5 34 ELECTRICAL RIGHT REAR BRAKE LIGHT BRAKE LIGHT AND WARNING CIRCUIT 4 IP1 4 MH5 BLK BLU 4 MH10 gt 4 PWB J2 5 PWB J4 gt 5 PH11 BLK BLU 3 PH9 gt 3 TL1 BLK BLU LEFT REAR BRAKE LIGHT 7 GRY BLU 5 IP1 5 MH5 GRY BLU 5 MH10 5 PWB J2 4 PWB 2 4 PH11 GRY BLU 4 PH9 4 TL1 GRY BLU 12 VDC PWB J1 MH14 RED 5 AMP ORG RED 7 MH5 7 1 1 ORG RED 7 IP2 7 SEAT BELT ORG RED SWITCH BRAKE BRAKE 3 PWBJ2 OVERTRAVEL MH10 BRN BLU BLU 3 MH5 6 1 10 FH1 1 YN 6 IP2 91 IP2 3 IP1 BRN BLU BLU BRAKE SEAT FAULT BELT BLK 1 1 MH5 BLK 1 MH10 1 0124 BATTERY CHARGER CIRCUIT REI cen SENSOR ELECTRICAL 5 35 BATTERY 6 BATTERY 5 BATTERY 4 MASTER DISCONNECT ee BATTERY 3 BATTERY 2 BATTERY
58. RATION Pressure on the brake pedal forces brake fluid through the brake line from the master cylinder to the wheel cylinder The wheel cylinder has two pistons each of which engage a brake shoe Fluid pressure pushes the pistons out causing the brake shoes to press against the brake drum When the park brake lever is engaged it pulls on the cables to the park brake actuator lever which engages the two brake shoes Movement of the park brake actuator forces the brake shoes to press against the brake drum The friction of the shoes against the drum causes the drum and wheel to stop turning REMOVAL 1 Raise vehicle off floor and support with jack stands See JACKING in INTRODUCTION section 2 Pry off wheel cover with standard screwdriver 3 Remove 19mm wheel lugs 4 Using flare nut wrench remove 17mm brake line from wheel cylinder and allow fluid to drain into suitable container for disposal 5 Remove the four 13mm bolts attaching brake assembly to axle end flange 6 Remove rear brake assembly and support while dis connecting park brake cable 7 Remove cotter pin and clevis pin attaching park brake cable to actuator lever on brake drum 8 Pull park brake cable from actuator lever DISASSEMBLY 1 Remove two Allen head screws holding drum to assembly remove drum 2 Remove spring clips from pins at center of each shoe and remove pins 3 Insert screwdriver between shoe and spring using lower pivot point as a f
59. RIPTION THREAD SIZE Loctite 242 INCH POUNDS POUNDS Use Brake line to Wheel Master Cylinder Brake Drum Assembly to Steering Knuckle M8 x 1 2 5 Half Shaft to Drum Brake Assembl 16x 1 5 Tie Rod Stud Nut M10 x 1 5 No wo 25 15 YES NECI Wheel Lug Nuts M10 x 1 5 2 18 SUSPENSION AND STEERING YOKE Installation Description 1 Attach yoke to control arm with two bolts Tighten to 60 foot pounds The yoke is a single casting that connects the steering 2 Install knuckle assembly Tighten kingpin pinch knuckle to the lower control arm It has two machined bolts to 65 inch pounds See STEERING openings to receive the kingpins of the knuckle assembly KNUCKLE in this section It allows the front suspension to pivot horizontally there 3 Install front drum brake assembly Tighten bolts to by providing steering 225 inch pounds 4 Attach brake line to wheel cylinder tighten to 37 Removal foot pounds then bleed brakes 5 Replace wheel tighten lug nuts just snug 1 Remove hub cap 6 Replace half shaft washer and bolt tighten just 2 Loosen wheel lug nuts snug 3 Loosen half shaft retaining nut 7 Lower vehicle to ground then tighten lug nuts to 50 4 Raise vehicle off floor and safely support foot pounds 5 Remove lug nuts and wheel 8 Back off half shaft nut slightly add Loctite 242 and 6 Disconnect brake line from wheel cylinder tighten to 74 foot pou
60. TATION OF TIRES UNDER INFLATION OR WORN OR OUT OF ALIGNMENT SUSPENSION OR TIRE DEFECT ROTATE TIRES AND INSPECT SUSPENSION SEE GROUP 2 ADJUST TOE IN DYNAMIC OR TO STATIC SPECIFICATIONS BALANCE WHEELS Figure 1 Tire Wear Chart Diagnosis and Testing SUSPENSION AND STEERING 2 3 CONDITION POSSIBLE CAUSES CORRECTION FRONT END NOISE EXCESSIVE PLAY IN STEERING FRONT WHEELS SHIMMY VEHICLE INSTABILITY EXCESSIVE STEERING EFFORT VEHICLE PULLS TO ONE SIDE VEHICLE PULLS TO ONE SIDE WHILE BRAKING EXCESSIVE TIRE WEAR AT CENTER OF TIRE VEHICLE CANNOT REACH TOP SPEED VEHICLE WILL NOT COAST VEHICLE MAKES THUMPING SOUND ON TIGHT TURNS 1 Loose or worn wheel bearing 2 Loose or worn steering or suspension components Loose or worn wheel bearing 2 Loose or worn steering or suspension components Loose or worn steering gear Loose or worn wheel bearing 2 Loose or worn steering or suspension components Tires worn or out of balance 1 Loose or worn wheel bearing Loose or worn steering or suspension components Tire pressure Alignment Loose or worn steering gear Steering column u joints binding Tire pressure Alignment Tire pressure Tire Worn wheel bearings Loose or worn kingpins Weak or broken spring shock absorber assembly Brakes worn or out of adjustment Air in brake lines Loose or worn steering or suspensi
61. TE The use of flare nut wrenches reduces damage to brake fittings Good quality flare nut wrenches are available from reputable automotive tool companies 7 Remove the four 13mm mounting bolts attaching the front brake assembly to the steering knuckle 8 Remove front brake assembly DISASSEMBLY 1 Remove two Allen head screws holding drum to assembly remove drum 2 Remove spring clips from retaining pins at center of each shoe and remove pins 3 Insert screwdriver between shoe and spring using lower pivot point as a fulcrum Remove lower spring 4 6 BRAKES 0026 Figure 6 Lower Spring Removal 4 Remove bolt retaining plate and spacer at lower pad pivot point 5 Remove upper spring 6 Lift pads away from wheel cylinder and off center locating post 7 Remove two bolts attaching wheel cylinder 8 Remove wheel cylinder ASSEMBLY 1 Position wheel cylinder on backing plate and attach with mounting bolts 2 Position shoes over posts on backing plate NOTE Make sure that pads properly engage wheel cylinder pistons 3 Replace upper and lower springs 4 Replace shoe retention pins and clips 5 Replace lower pivot point spacer with narrow side up then replace retainer with rounded side down Attach with bolt and nut 6 Replace drum attach with Allen head screws INSTALLATION 1 Position front brake assembly on steering knuckle attach with four 13mm bolts 2 Using a flare nut wrench attach 17
62. USPENSION amp STEERING section 7 Install motor See MOTOR in ELECTRICAL section 8 Install half shafts Tighten nut just snug See HALF SHAFT in this section 9 Install spring shock absorber upper mounting bolt Tighten just snug 10 Install front wheels tighten lug nuts just snug 11 Lower vehicle to ground 12 Tighten spring shock absorber upper mounting bolt to 60 foot pounds DRIVETRAIN 3 7 13 Add Loctite 242 and torque half shaft nuts to 74 15 Replace hub caps foot pounds 16 Switch master disconnect to ON 14 Tighten wheel lug nuts to 50 foot pounds TORQUE SPECIFICATIONS DESCRIPTION THREAD Use INCH SIZE Loctite POUNDS POUNDS Differential to Frt Suspension Frame 5 16 18 Half Shaft to Drum Brake Assembl M16 x 1 5 Motor to Differential 1 4 20 Shock Absorber Upper Bolt M12 x 1 75 Wheel Lug Nuts M10 x 1 5 BRAKES 4 1 CONTENTS Bana BID oa qa wa qud ga ote sara a a rae pp Ca Pee IS UOS 4 2 Dis a EC CII aot cba ade quee ira da 4 3 Standard Procedure Manual Bleeding 4 3 Pressure e oaea naoi Xe bake L RETIREE 4 4 Front Brake x raTa RI Ra TAA ENTER 4 5 Rear Brake ASSUM oe ea Eee hur 4 7 Br
63. W 0193 Figure 21 Side Rear View Mirror typical LH shown Roof rail Mounting gasket Mirror assembly Screws mounting phillips head Screw cover plate eR Description A driver s side rear view mirror is standard on all vehi cles Passenger side mirrors are optional Side mounted rear view mirrors are attached to the front portion of the roof rail If vehicle 1s ordered with optional hard doors the mirrors are mounted on the doors Damaged mirrors must be replaced as they are not serviceable Removal Using small screwdriver pry out lower screw cover on base of mirror 2 Remove the two 2 phillips head screws attaching mirror to roof rail door 3 Remove mirror assembly and mounting gasket Installation 1 Mount mirror and gasket to roof rail door with phillips head screws 2 Replace screw cover BODY 7 13 1 14 BODY WORK INDEX accelerator TOOL pedal Seu dee we etae ice tr bu gue qoi iw NAT ARAS 5 4 42 accelerator 3 2 5 6 7 8 11 12 19 20 Accelerator 5 11 Accessory 5 2 3 8 21 27 28 29 Accumulated 5 ipe pue ed X Ded RD ACE Ro do aod 5 26 Actuator lever 55555 ten datae d
64. a greater tread life RADIAL PLY TIRES Description Radial ply tires improve handling tread life and ride quality and decrease rolling resistance Radial ply tires must always be used in sets of four Radial ply tires have the same load carrying capacity as other types of tires of the same size They also use the same recommended inflation pressures The use of oversized tires either in the front or rear of the vehicle can cause vehicle drive train failure The use of tires from different manufactures on the same vehicle is NOT recommended The proper tire pressure should be maintained on all four tires TIRE INFLATION PRESSURES Proper tire inflation pressure 15 essential to the safe and satisfactory operation of the vehicle Under inflation will cause rapid shoulder wear tire flexing and possible tire failure Over inflation will cause rapid center wear and loss of the tire s ability to cushion shocks Both under and over inflation affect the stability of the vehicle and can produce a feeling of sluggish response or over responsiveness 6 2 WHEELS 8 TIRES Unequal tire pressures can cause steering problems resulting in loss of control of the vehicle For proper tire pressure specification refer to the VIN Certification Label at the left rear of the roof panel The label also lists proper wheel and tire size for the vehicle See VIN CERTIFICATION LABEL in INTRODUCTION section Tire pressures have been chose
65. ake Fedal Assemb Jack aude werden Side tees beste esau Hd DEAN 4 8 Master Cylinder Assembly 4 9 Park Brake Lever Assembly 4 10 Parking Dhaka able Assemblea sors Gast nar ah ered 4 11 Park Brake Cable Tension Adjustment 4 12 4 2 BRAKES BRAKES BRAKE SYSTEM Figure 1 Hydraulic Brake System DESCRIPTION The GEM E3825 utilizes a hydraulic brake system with drum brakes at all four wheels Although the front drum brake assemblies are interchangeable the rear drum brake assemblies are specific for RH and LH applica tions There is also a mechanical parking brake that acti vates the rear brakes only OPERATION Pressure on the brake pedal activates the brake light switch and causes a piston in the master cylinder to move inward forcing brake fluid into the wheel cylinders via brake lines The pistons in each wheel cylinder are forced out causing the brake shoes to come into contact with the brake drums When the park brake lever is pulled up tension is placed on park brake cables attached to the rear drum brake assemblies thereby activating them DIAGNOSIS 1 Check condition of tires and wheels Damaged wheels and worn damaged or under inflated tires can cause pull shudder vibration and a conditi
66. an inter face and signal conditioning module Signals between many of the GEM circuits pass through the PWB including the turn signal module and blinker fuse module and headlights key switch and battery charger direction turf switches and the motor controller Operation The PWB operates automatically when the Master Disconnect is in the ON position and the Key Switch is on Diagnosis and Testing Because the PWB interacts with many different circuits diagnosis and testing of the PWB 15 split between the Drive and Power System Troubleshooting Charts and the Accessory System Troubleshooting Chart The circuit diagrams provided in this manual are also useful in iso lation of problems associated with the PWB Removal of the Version 1 PWB 1 Turn off the Master Disconnect Switch Remove upper and lower dash Locate printed wire board and remove electrical connection noting connection and orientation Remove four 6 screws from each corner of PWB Remove the PWB Gently lift PWB off the converter pins which are directly behind it WN Un Removal of the Version 2 PWB 1 Turn off the Master Disconnect Switch 2 Remove upper and lower dash 3 Locate the printed wire board and remove electrical connection noting connection and orientation 4 Remove the five 3 8 Tek screws that secure the ECM to the mounting plate and the ECM will fall forward 5 Once you have the ECM forward remove the four Phillips
67. ant Recommendation 0 4 Maintenance SeIsdulBs Fed zx E mec Rx em Awe rs 0 4 HOISTING and Jacking Ys 0 4 0 2 INTRODUCTION USING THIS MANUAL Appropriate service methods and proper repair proce dures are essential for the safe reliable operation of your vehicles as well as the safety of the individual doing the work This service manual provides general directions for accomplishing service and repair work with recom mended techniques Following them will help assure reliability There are numerous variations in procedures techniques tools and parts for servicing your vehicle as well as in the skill levels of the individuals doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions for each Accordingly anyone who departs from the instructions provided in this manu al must first establish that he she compromises neither their personal safety nor vehicle integrity by their choice of methods tools or parts GENERAL WARNINGS The following should be followed whenever you are working on your vehicle Always wear safety glasses for eye protection Use safety stands whenever a procedure requires you to be under the vehicle Be sure that the Ignition Switch is always in the OFF position and that the
68. at anchoring bolts Remove bucket seat assembly Remove seat belt bracket Remove bolt attaching lap belt retractor assembly to seat belt bracket 5 Remove lap belt retractor assembly 6 Remove bolt attaching lap belt latch assembly to seat belt bracket 7 Remove lap belt latch assembly AUN Installation 1 Position lap belt latch assembly at inboard end of seat belt bracket Inboard end of bracket points UP Attach with mounting bolt Tighten to 60 foot pounds 2 Position lap belt retractor assembly at outboard end of seat belt bracket Outboard end of bracket points DOWN Attach with mounting bolt Tighten to 60 foot pounds 3 Install two rear bucket seat mounting bolts through bucket seat assembly then lap belt bracket 4 Position bucket seat assembly and lap belt assembly on front seat support 5 From underneath vehicle attach nuts to mounting bolts Tighten nuts to 190 200 inch pounds TORQUE SPECIFICATIONS DESCRIPTION THREAD SIZE Loctite 242 Use INCH FOOT POUNDS POUNDS Seat Belt Latch Assembly to Bracket Bucket Seat Seat Belt Retractor to Bracket Bucket Seat THREE POINT SEAT BELT Description Three point automotive shoulder lap belts are used with bench seats The seat belt 15 anchored to a flange at the lower outboard end of the seat back support frame The seatbelt passes through a D ring mounted at the upper outboard edge of the seat back support frame in
69. ber To Connector Tail Light Harness PWB J6 ELECTRICAL 5 47 TAIL LIGHT HARNESS 0075 TAIL LIGHT HARNESS CONNECTIONS Connector Number Connects To Number of Pins in Connector Power Harness Left Tail Light Left Rear Blinker Right Tail Light Right Rear Blinker 6 0 WHEELS 4 TIRES CONTENTS TERR Dru ue 6 1 Radial PIV TITO S cro ve eX saad am areata a Ae ye nar pa d E E 6 1 ud adu th 6 1 Peg Ar ges Ou nes Te Dei veda HEU EU E 6 2 Diagnosis and Testing Pressure Gauges 6 2 Diagnosis and Testing Tread Ware Indicators 6 2 Diagnosis and Testing Tire Noise or Vibration 6 3 Repairing Leaks 4g s ER FAN 6 3 hs Grass bak 6 3 Gand oe reet Gee epis tears AL qa Np A PPAR BO bv ep A 6 4 Diagnosis and Testing Wheel Inspection 6 4 AN esi 2 LR 6 4 TIRES AND
70. ber of Pins in Connector Main Harness MH5 20 Front Harness FH1 14 Battery Discharge Indicator Blue Left Turn Indicator Light Red Right turn Indicator Light IP7 8 2 Purple Headlight 010 5 Org Green Ignition Brn Red Horn 4 HE Red Grn Ignition Org Brn Horn pin 3 Black Turn Indicator Blu Yel F R Org Wht F R Gry Yel F R Vio Yel R T White R T Wht Blu Wiper Gry Red Wiper Yel Blu Wiper Wht Red Headlights Turn Signal Module oin ELECTRICAL 5 41 PIN LOCATIONS FOR IP HARNESS MULTI PIN CONNECTORS Number of Connector Illustration Connector Connects Pins in Number To Connector BDI amp Turn signal Module 9 42 ELECTRICAL MAIN HARNESS 4 oa gt W MAIN HARNESS CONNECTIONS Connector Connects Number of Pins Number to in Connector 2 MH1 Controller B Female Spade and Circular Lug GRN MH2 MH3 MH5 MH6 P Harness Battery Discharge Indicator 8 MH7 MH8 MH9 MH10 MH11 MH12 MH13 MH14 MH15 Fuse Block MH16 MH17 MH18 Firewall Chassis Ground 2 Female Spade 1 Circular Lug BLK 19 AccelmaorFoopeda 28 20
71. ccelerator potentiometer and the start switch Testing for accelerator potentiometer and the start switch are described separately below It may be helpful to reference the Motor Circuit electrical diagram while testing these components Accelerator Potentiometer Testing a Remove the upper dash and lower dash as described in Body and Panels Accessories b Disconnect 23 pin connector MH20 located on the top of the motor controller c Using an ohmmeter measure the resistance between pin 9 and pin 7 When the accelerator pedal is in the up position the ohmmeter should read approximately zero resistance ohms Push the accelerator pedal down the resistance between pins 9 and 7 should gradually increase When the accelerator pedal is completely down the resistance ELECTRICAL 5 11 should reach a maximum of approximately 5000 ohms If the resistance does not vary as described replace the accelerator pedal If the resistance is a constant very low resistance possible short circuit or constant high resistance open circuit there could be a problem with the wiring harness between the motor controller and the accelerator pedal module d Using an ohmmeter measure the resistance between pin 9 and pin 8 The resistance between these two pins should remain approximately 5000 ohms regardless of the position of the accelerator pedal If the resistance is very high there is probably a broken wire between the motor controller conne
72. ce a GEM vehicle The National Lubricating Grease Institute NLGI rates lubricating grease for quality and usage All approved products have the NLGI symbol Fig 3 on the label At the bottom of the symbol is the usage and quality identi fication letters The letter G identifies wheel bearing lubricant The letter L identifies chassis lubricant The letter following the usage letter indicates the quality of the lubricant The following symbols indicate the high est quality NATIONAL LUBRICATING GREASE INSTITUTE NATIONAL LUBRICATING GREASE INSTITUTE NATIONAL LUBRICATING GREASE INSTITUTE AUTOMOTIVE AUTOMOTIVE WHEEL BEARING amp CHASSIS WHEEL BEARING amp CHASSIS LUBRICANT LUBRICANT NLGI AUTOMOTIVE WHEEL BEARING amp CHASSIS LUBRICANT GC LB GC LB 0080 Figure 3 NLGI Symbols 1 Wheel Bearing Lubrication 2 Chassis Lubrication 3 Chassis and Wheel Bearing Lubrication Description Differential Use SAE 30 weight motor oil Description King Pin Lubricant Use only grease with NLGI L or LB symbol Description Brake Fluid Use only DOT3 brake fluid from an unopened container when filling the master cylinder to prevent contaminants from entering the brake system MAINTENANCE SCHEDULES Perform the following inspections and correc tions as necessary on a monthly basis Check all six batteries for proper water Description levels 2 Check battery terminals for tight connecti
73. ch may be defective Refer to the Motor Circuit Diagram for troubleshooting the start switch circuit Accelerator pedal was pushed Release the accelerator pedal select a without a direction being selected direction and then push the accelerator pedal Accelerator voltage input is too high on Refer to the Motor Circuit Diagram for power up after initial key switch closure roubleshooting the start switch circuit The accelerator pedal input to the Motor Controller 20 pin 7 should be less than 0 9 VDC before depressing the pedal If the voltage is greater than 0 9 VDC the accelerator pedal may be misadjusted or defective Both the forward and reverse switches Refer to the Motor Circuit Diagram for are closed at the same time troubleshooting the start switch circuit There should be no input voltage present at Motor Controller connector MH20 pins 4 and 5 from the forward or reverse switches if the switch is in the neutral position am ege should only be present at 4 or 5 but not both w are selected en forward or reverse Accelerator pedal was pushed when Release the accelerator pedal select a direction the car was first turned on and then push the accelerator pedal This error code may also be cause by a defective emergency brake microswitch Low battery pack voltage Charge the car see Charger in this section less than 70 VDC for instructions on charging the battery ELECTRICAL 5 7 Error Code Fault Description
74. ctor and accelerator pedal Start Switch Testing a Remove the upper dash and lower dash as described in Body and Panels Accessories b Disconnect 23 pin connector 20 located on the top of the motor controller Disconnect 16 pin connector MHS from 12 of the Printed Wiring Board c Using an ohmmeter measure the resistance between pin 3 of MH20 and pin 9 of MH5 With the accelerator pedal up the circuit should be open high resistance With the accelerator pedal depressed the resistance should be zero ohms start switch is closed If the resistance does not vary as described replace the accelerator pedal Removal Remove upper dash as described in Body Panels and Accessories 2 Unplug foot pedal from wire harness 3 Locate silver pushpins spring loaded on foot pedal cover sides see figure 11 item 1 4 Using small screwdriver or similar tool push one of the pins in and slide the cover out of position Repeat for other side 5 Lift off cover 6 Remove two Tek screws with socket and wrench see figure 12 item 1 Installation 1 Place pedal housing back in its floor position and replace the two Tek screws 2 Make sure the lift spring see figure 12 item 2 is properly seated in place before proceeding with step 3 3 With the pushpins held in slide the pedal cover into position over the housing until the pushpins snap into place 9 12 ELECTRICAL 4 Reattach the foot pedal cable connect
75. d ends Tighten to 35 foot pounds 7 Tie rod end stud nut See TIE ROD ENDS in this section 8 Tie rod end jam nut 5 Replace brake line Tighten to 37 foot pounds 9 Tie rod 6 Bleed brakes See BRAKE BLEEDING in BRAKES section 7 Replace washer and nut on outboard end of half Diagnosis and Testing shaft and tighten just snug m 8 Replace wheel and tire assembly Tighten lugs nuts orn kingpins can produce until just snug Excessive play in steering 9 Lower vehicle to floor e Tendency of the vehicle to wander mE 10 Torque wheel lug nuts to 50 foot pounds Tendency for the vehicle to pull in either direction 11 Back off half shaft nut slightly add Loctite r 242 under braking and tighten to 74 foot pounds Excessive front tire wear 12 Replace wheel cover SUSPENSION AND STEERING 2 17 TORQUE SPECIFICATIONS DESCRIPTION THREAD SIZE Loctite POUNDS POUNDS Brake line to Wheel Master Cylinder aa ee ae a Brake Drum Assembly to Steering Knuckle 8 x 1 25 NO 225 Half Shaft to Drum Brake Assembl M16 x 1 5 yes King Pin Pinch Bolt M6 1 YES Tie Rod Stud Nut 10 15 NO Wheel Lug Nuts STEERING KNUCKLE Description The knuckle is a single casting with legs machined for the upper and lower kingpins It also has a machined surface for mounting the front drum brake assembly Operation The steering knuckle pivots between the arms ofthe yoke on kingpins Steering linka
76. e Parking Cable Mount to Rear Suspension 1 2 x 13 Control Arm to Frt Suspension Frame M12 x 1 75 Differential to Frt Suspension Frame 5 16 18 Front Suspension Frame to Frame Lower M12 x 1 75 Front Suspension Frame to Frame Upper 3 8 16 Half Shaft to Drum Brake Assembly M16 x 1 5 King Pin Pinch Bolt M6 1 Motor to Differential 1 4 20 Rack amp Pinion to Frt Suspension Frame M8 x 1 25 Rear Suspension Frame to Frame M12 x 1 75 Seat Belt D Ring to Frame Seat Belt End to Frame Seat Belt Latch Assembly to Frame Seat Belt Latch Assembly to Bracket Bucket Seat Seat Belt Retractor to Bracket Bucket Seat Seat Belt Retractor to Frame Bench Seat Shock Absorber Lower Bolt M12 x 1 75 Shock Absorber Upper Bolt M12 x 1 75 Steering Column Pinch Bolt 3 8 16 Steering Column to Dash Frame 5 16 18 Steering Wheel to Steering Shaft Tie Rod Stud Nut M10 x 1 5 Wheel Lug Nuts M10 x 1 5 Yoke to Control Arm M12 x 1 75 0 4 INTRODUCTION PARTS AND LUBRICANT RECOMMENDATION When service 1s required GEM recommends that only GEM replacement parts be used GEM provides the best engineered products for servicing GEM vehicles Description Lubricants and Grease Only lubricants bearing designations defined by The Society for Automotive Engineers SAE should be used to servi
77. e end into the spindle on rear of brake assembly Tighten bolts to 225 inch pounds 5 Using flare nut wrench attach 17mm brake line to wheel cylinder Replace 19mm wheel lugs Tighten to 50 ft Ibs Replace wheel cover Bleed brakes See Brake Bleeding instructions in this section ona TORQUE SPECIFICATIONS DESCRIPTION Brake line to Wheel Master Cylinder THREAD SIZE Loctite 242 INCH POUNDS POUNDS Use M8 x 1 2 Brake Drum Assembly to Steering Knuckle Max125 NO 225 Wheel Lug Nuts M10 x 1 5 NO BRAKE PEDAL ASSEMBLY DESCRIPTION The brake pedal assembly is mounted on the dash sup port frame It consists of the brake pedal bracket push rod brake light switch and brake failure light switch 0028 Figure 8 Brake Pedal Assembly OPERATION The brake pedal pivots on a shaft mounted on the brack et Foot pressure causes downward motion of the pedal forcing a push rod against a piston in the master cylinder When foot pressure against brake pedal is released a return spring forces the pedal and push rod back to its original position relieving pressure in master cylinder REMOVAL Remove upper and lower dash panels See DASH PANEL UPPER and DASH PANEL LOWER in BODY section 2 Remove wires from brake light switch uppermost on bracket Blue Brown wire from left terminal Orange and Orange Red combined from right terminal 3 Remove wires from brake fail
78. e E048 5 3 4 6 9 20 21 22 25 29 Rc PUT 2 2 3 10 16 17 18 Med a a 0 8 2 5 6 7 9 10 15 16 17 18 4 5 6 8 latch 0 4 7 2 3 4 7 8 10 11 Latchihiandle oss 7 7 8 10 11 12 Xa acd GR CR 7 7 11 E E 7 10 Ij 0 5 5 13 29 Ligh SWIGIT band RU RO OL 4 2 8 9 5 4 25 29 EInlKSpak Rede C a UN d reo irc A c OR d CORR UR dieto dr MT 7 4 10 11 12 Jove DOX GOOF ESS OS 7 9 lower dashi is ie ERES ed RA RAE SES 2 13 4 8 9 5 8 11 19 20 21 22 29 7 4 8 9 L Turn Signal Brake Warning Light o s sss 9 Seed eee eee ods ERROR RC OR ER EA 5 4 25 TERTII 0 4 2 6 lug 0 8 2 5 7 8 9 14 15 16 17 18 3 3 5 7 4 5 6 8 5 24 6 5 TRO SEPTEM 5 8 10 23 25 WORK INDEX Main Contactor ov Euer Rex eb e e 5 4 6 7 8 9 22 42 MAIN HARNESS imde qm reete tet
79. e should disappear If problem persists after the Motor Controller has cooled replace the Motor Controller Motor armature offset voltage is too high Replace the Motor Controller Motor armature offset voltage is too low Replace the Motor Controller Armature transistor did not turn off properly Replace the Motor Controller Armature transistor did not turn off properly Replace the Motor Controller 46 Look Ahead test for Motor Controller A2 This status code will be displayed if the voltage at voltage is less than 12 596 of battery voltage A2 isless than 12 5 of battery voltage and the current is greater than 52 amps when the controller is in the neutral state This can be cause by a short circuit from motor armature to the frame Test for a short by opening the main disconnect switch and using an ohmmeter measure between Motor Controller A2 and ground there should be a open circuit greater than 5000 ohms If there is a short check the wiring and remove the short If there is not short replace the Motor Controller 41 42 43 44 45 Motor field current is too low during the This status code will be displayed if the current run mode draw in the motor field is less than 1 3 amps and the armature current is greater than 100 amps for more than 1 27 seconds during the run mode Check wiring between the Motor Controller and the motor field connections F1 and F2 If the connections are good replace the
80. e the overall health of the battery Both open circuit voltage and specific gravity readings can give a good indication of the battery s charge level age and health Routine voltage and gravity checks will not only show the state of charge but also help spot signs of improper care such as undercharging and over watering and possibly even locate a bad or weak battery The following steps outline how to properly perform routine voltage and specific gravity testing on batteries NOTE Temperature in the following sec tion refers to electrolyte temperature not ambient temperature Specific Gravity Test For Flooded water based Batteries 1 Do not add water at this time 2 Fill and drain the hydrometer 2 to 4 times before pulling out a sample 3 There should be enough sample electrolyte in the hydrometer to completely support the float The float should be floating freely and not touching the sides of the cylinder 4 Take a reading record it and return the electrolyte back to the cell To check another cell repeat the 3 steps above Check all cells in the battery Replace the vent caps and wipe off any electrolyte that might have been spilled 8 Correct the readings to 80 e Add 004 to readings for every 10 above 80ee e Subtract 004 for every 10 below 80 9 Compare the readings 10 Check the state of charge using Table 1 NINN The readings should be within the factory specification of 1 2
81. eed to Step 9 the Key Switch in the On position Is the voltage approximately 72 VDC Turn off the Main Disconnect Switch Use an ohmmeter All critical inputs Check the parking measure the resistance at Pin 13 of connector MH20 to for contactor operation brake switch and ground with the parking brake released down are good wiring to the parking brake switch See Is the resistance approximately 0 ohms Main Contactor Circuit diagram Turn off the Main Disconnect Switch and the Key Switch Replace the PWB Check the Key switch to On Use an ohmmeter measure the resistance at J2 ground circuit through Pin 6 of the PWB to ground the Battery Charger See the Main Is the resistance approximately 0 ohms Contactor Circuit diagram Measure the voltage on pin 11 of MH5 16 pin connector Check wiring from main Replace PWB on the PWB Is the voltage approximately 72 VDC contactor to PWB See the Main Contactor Circuit diagram 5 10 ELECTRICAL Drive and Power System Troubleshooting Chart B Problem Description Diagnostic Steps Corrective Action BDI does not show MPH Check tachometer for loose Replace motor tachometer indications when the car is moving connections BDI does not show MPH Replace motor magnets indications when the car is moving and tachometer has been replaced Battery charger will not charge battery Battery charger will not charge battery and voltage to battery charger 110 VAC ha
82. elt end through D ring back to front and attach to flange at lower outboard end of seat back support Tighten mounting bolt to 60 foot pounds 5 Install body back panel See BODY BACK PANEL in this section 6 Install body side panels See BODY SIDE PANEL in this section 7 Install bench seat back See BENCH SEAT in this section 8 Install bench seat cushion 9 Install tail light covers BODY SIDE PANEL Description The body side panel is made of molded plastic and is mounted to the floor panel and back panel by rivets old style or phillips head bolts with nuts on the inside new style 0049 Figure 3 Body Side Panel LS Typical 4 passenger shown 1 4 BODY Removal 1 Remove upper and lower dash See DASH 1n this section 2 Remove mudguard See MUDGUARDS in this section Remove spat See SPAT in this section Remove Rear Shock Mount Cover Remove bench seat See BENCH SEAT in this section 6 Old style Drill out center drives on rivets with a 1 8 drill bit Remove rivets New style Holding nuts with fingers or pliers remove phillips head bolts Be sure to retain the nuts gt NOTE Old Style Make sure not to spin riv ets as they will leave marks on panels 7 While supporting the side panel drill out the center drives on side panel rivets and remove 8 Remove front upper attaching screw and three lower attaching screws 9 Remove scuff guard
83. embly 3 Remove small bolt in center of magnet with 5 64 hex wrench 4 Remove magnet and bushing Installation 1 Insert hex socket head bolt through magnet then bushing then attach to motor s armature 2 Position sensor pigtail 3 Install cover plate and attach with mounting bolts BATTERY DISCHARGE INDICATOR BDI Description Figure 26 Instrument Pod 1 Turn Signal Lever Horn Button Light Switch L Turn Signal Brake Warning Light Battery Discharge Indicator BDI Charge Status Light R Turn Signal Seat Belt Warning Light Windshield Wiper Switch Road Turf Switch 10 Vehicle Direction Switch 11 Key Switch The Battery Discharge Indicator is located in cen ter of the Instrument Pod and performs the following function 9 26 ELECTRICAL 1 Battery Discharge Indicator BDI 2 MPH Speed Indicator 3 Accumulated Miles 4 Fault Code Display Operation At key on the BDI will display remaining battery capacity The indicator will then alternate between MPH and battery status The remaining battery capac ity is displayed in 3 digits and the battery icon will light For example 100 means 100 charge When the key is turned off the LED display will show the Odometer reading and the hourglass icon will light NOTE If an error code is displayed it is pre ceded by a minus sign and the tool icon will light For a description and explanation of common fa
84. ence is shown with a minus sign 1 16 Adjusting Toe gt UC Center front wheels Inspect the position of the pinch bolt that joins the steering column shaft to the steering gear This bolt must be horizontal and under the shaft see Figure 3 If necessary turn the steering wheel to put the bolt in this orientation Remove and re center the steering wheel if required Lash the steering wheel in the centered position Loosen the lock nuts on the tie rods Use locking pliers to hold the clamp that secures the small end of the boot to the tie rod Take care not to damage the boot Using a 5 8 wrench rotate the tie rods so that the front wheels have the specified toe in see Figure 4 Tighten the lock nuts 0081 Figure 3 Pinch Bolt Orientation Steering shaft Pinch bolt parallel to steering gear mounting bracket Steering gear t 0034 Figure 4 Tie Rod Adjustment SUSPENSION AND STEERING 2 5 FRONT SUSPENSION Description The front suspension is designed to allow each wheel to adapt to different road surfaces independently wheels are mounted to drum brake assemblies which in turn are mounted to the steering components attached to a control arm which pivots up and down on bushings Spring and shock absorber assemblies at each yoke pro vide cushioning CAUTION Suspension components with rubber urethane bush ings should be
85. f necessary 0063 Figure 3 Tire Repair Area 1 Repairable area ROTATION Tires on the front and rear operate at different loads and perform different steering driving and braking func tions For these reasons they wear at unequal rates and tend to develop irregular wear patterns Rotating the tires at regular intervals can reduce these effects The benefits of tire rotation are 6 4 WHEELS amp TIRES ncrease tread life e Maintain traction levels A smooth quiet ride The suggested method of tire rotation is Fig 3 Other rotation methods can be used but they will not provide all the tire longevity benefits FRONT Figure 4 Tire Rotation Pattern WHEELS Description models use stamped steel wheels Every wheel has raised sections between the rim flanges and rim drop well called safety humps Initial inflation of the tire forces the bead over these raised sections In case of rapid loss of air pressure the raised sections help hold the tire on the wheel The wheel nuts are designed for this specific application Do not use replacement nuts with a different design or lesser quality DIAGNOSIS AND TESTING WHEEL INSPECTION Inspect wheels for Excessive run out Dents or cracks Damaged wheel lug nut holes Air leaks from any area or surface of the rim NOTE Do not attempt to repair a wheel by hammering heating or welding If a wheel is damaged an original equipment re
86. fety feature which does not allow it to turn on if the pack voltage 1s below 68 3 volts If the battery pack goes below this level an alter native charging procedure must followed 1 Turn off Master Disconnect switch under the seat 2 Using an automotive type 12V charger charge each battery individually Set the charger on a medium current level 10 30 Amps Allow enough charge time so the voltage on each battery is at least 10 5 volts 30 minutes to 1 hour per battery 3 After all batteries have been charged remove charger and turn on the Master Disconnect Switch Measure pack voltage according to above diagrams If the pack voltage 15 above the low voltage threshold plug in the on board charger Allow the on board charger to run it s complete cycle MOTOR CONTROLLER Description SRI X ING 0110 Figure 17 Charger Location Schott Charger shown 1 Motor Controller 2 Battery Charger 3 Printed Wiring Board PWB The motor controller shown above is located under the front dash to the left of the battery charger The motor controller is the brains of the GEM vehicle Based on inputs from the accelerator pedal directional 9 20 ELECTRICAL switch and turf mode switch the controller converts bat tery power into the appropriate drive power for the vehi cle s electric motor The controller also generates drive system status information that is displayed on the Battery tro
87. g nuts to 50 foot pounds 10 Re connect park brake cables 16 Test park brake and adjust cable tension See PARK BRAKE CABLES in BRAKES section TORQUE SPECIFICATIONS DESCRIPTION THREAD Use INCH FOOT SIZE Loctite POUNDS POUNDS Brake line to Wheel Master Cylinder Brake Drum Assembly to Rear Axle Brake Drum Assembly to Steering Knuckle Brake Parking Cable Mount to Rear Suspension 1 2 13 NO Rear Suspension Frame to Frame M12 x 1 75 NO Shock Absorber Lower Bolt Mi2x175 NO Shock Absorber Upper Bolt M12 x 1 75 Wheel Lug Nuts M10 x 1 5 STEERING STEERING SHAFT KING KNUCKLE PIN STEERING WHEEL STEERING GEAR TIE ROD END ARM 0036 Figure 6 Steering System 2 10 SUSPENSION AND STEERING Description The steering system is comprised of Steering wheel Steering column Rack and pinion steering gear with integral tie rods Tie rod ends Steering Knuckle Kingpins Yoke Operation The steering column transmits rotation of the steering wheel to the pinion in the steering gear The rotation of the pinion moves the gear rack in the steering gear from side to side This lateral action of the rack pushes and pulls the tie rods that are attached to the steering knuck les steering knuckles pivot on kingpins that are mounted in yokes on the control arms wheel and brake assemblies are
88. g the charg er and turn the power key on If the BDI reads between 25 and 90 the battery pack should be recharged If the BDI reads below 25 the battery pack should be put on charge as soon as possible A full recharge cycle BDI indicating near 096 can take up to 10 hours Most recharge cycles will be much shorter NOTE Recharge cycles are encouraged anytime the reads below 90 CAUTION With an intermittent audible alarm and the Charge Status Indicator flashing means that an alarm situa tion has occurred and there is a problem with the charger NOTE After charging the BDI will read slightly high until the batteries have time to settle which can be approximately an hour Driving the vehicle for over a minute and then cycling the power key off and back on can obtain a more accurate reading CAUTION Fully charge batteries before extended periods of use n hot climates battery self discharge will increase Batteries will freeze if not properly charged Replacement 1 Turn off the Master Disconnect Switch 2 Remove upper and lower dash 3 Disconnect electrical connections noting connection and orientation 4 Remove four mounting bolts from the flange of the charger NOTE The E580 has three bolts with ELECTRICAL 5 19 rubber shock mounts between the flange and the frame 5 Reverse procedure to reinstall Charging When Below Minimum Voltage The on board charger has a sa
89. gas is flammable and explosive Keep flame or sparks away from the bat tery or any other booster source with an output greater than 12 volts Don t allow cable clamps to touch each other Battery posts terminals and relat ed accessories contain lead and lead compounds Wash hands after handling CAUTION It is essential when replacing the cables on the bat tery that the positive cable is attached to the positive post and the negative cable is attached to the negative post Battery posts are marked positive and neg ative and identified on the battery case Cable clamps should be tight on the terminal posts and free of corrosion ELECTRICAL 5 13 Removal and Disposal 1 Disconnect all cables from all six batteries noting connections and locations 2 Remove hold downs or cut battery straps large wire tie and remove from each battery 3 Lift batteries out using proper lifting procedures or battery lifting tools 4 Reverse procedure to reinstall Tighten with battery strap tool if applicable 5 Use ecologically sound procedures to dispose of batteries Battery Safety Improper use and care of batteries can result in serious personal injury or property damage Always observe the following safety precautions Battery produces explosive gases Keep sparks flame or cigarettes away Always wear safety goggles or face shield when working near battery The battery contains toxic materials
90. ge on the contactor check the wire and o y the Motor Controller 0 0 0 0 ile 0 0 0 fuse H i contactor Motor Figure 8 Main Contactor Conttellat and 1 Measuring point B connections can lead to overheating Is the voltage approximately 72 VDC and damage to these circuits Turn the key on drop the brake and measure the Proceed to Step 8 Proceed to Step 11 voltage on the Red White wire connected to the contactor coil Is the voltage approximately 72 VDC Measure the voltage on the Black wire connected Proceed to Step 9 Replace the contactor if to the contactor coil Turn the Key Switch from On to the voltage is on the Off to On black wire changed from 0 to 72 VDC and Does the voltage stay a constant approximately 72 back to 0 when the key was operated and the contactor did not operate Steps 9a through 9c will verify critical inputs to the Replace Motor Troubleshoot circuit s Motor Controller Each must be present before the Controller suggested in step 9a Motor Controller will close the Main Contactor through 9c Are all critical inputs good Measure the voltage at Pin 1 of connector MH20 Proceed to Step 9b Use the Main 23 pin connector on the top of the Motor Controller Contactor diagram to determine where the Is the voltage approximately 72 VDC constant 72 VDC to the Controller has been lost Measure the voltage at Pin 2 of connector MH20 with Proceed to Step 9c Proc
91. ge attached to the knuckle allows the vehicle to be steered Removal Remove hub cap Loosen wheel lug nuts Loosen half shaft retaining nut Raise vehicle off floor and support safely with jack stands 5 Remove lug nuts and wheel 6 Remove half shaft nut 7 Disconnect brake line at wheel cylinder 8 9 Remove front drum brake assembly Mark thread locations of tie rod end at tie rod 10 Remove nut from the bottom of the tie rod end stud where it joins the knuckle M10 x 1 5 11 Use a 2 jaw puller to separate tie rod end stud from knuckle 12 Remove kingpin pinch bolts 13 Lift knuckle up and pull away to remove from yoke Installation 1 Insert upper kingpin into yoke and lift knuckle assembly into place allowing lower kingpin to drop into yoke 2 Tighten kingpin pinch bolts to 65 foot pounds 3 Replace tie rod end stud in knuckle tighten nut to seat stud in knuckle Back nut off then tighten to 35 foot pounds 4 Install front drum brake assembly Tighten bolts to 225 inch pounds 5 Attach brake line to wheel cylinder tighten to 37 foot pounds then bleed brakes 6 Replace half shaft washer and bolt tighten just snug 7 Replace wheel tighten lug nuts just snug 8 Lower vehicle to ground then tighten lug nuts to 50 foot pounds 9 Back off half shaft nut slightly add Loctite r 242 and tighten to74 foor pounds 10 Replace hub cap TORQUE SPECIFICATIONS DESC
92. is disengaged Lift seat cushion up and away to remove Remove tail light lenses Remove 4 Phillips screws attaching seat back to back panel These screws are located at the top of the tail light lamp reflectors two on each side 5 Remove the two TEK screws located on the lower plywood section of the seat back 6 Remove bench seat back AUN Installation 1 Position bench seat back against upper seat support frame 2 Install 2 TEK screws through lower plywood section of seat back into seat back support frame 3 Install 4 Phillips head screws through upper holes of tail lamp reflectors into seat back BODY 7 5 4 Replace tail light lenses 5 Old style Position bench seat cushion and attach with 2 knurled knob bolts New style Position bench seat cushion and push down to attach BUCKET SEAT Description The driver and front passenger seats in the four passen ger model are bucket seats Each seat assembly consists of a seat cushion built in seat back and integral hand hold on outboard side of the cushion The seat is adjustable A handle under the front of the seat cushion releases a latch allowing the seat to move forward or backward on two tracks 0071 Figure 6 Bucket Seat Adjuster 1 Bucket seat 2 Adjuster rails 3 Adjusting lever Removal 1 From beneath vehicle remove nuts from the 4 bucket seat anchoring bolts 2 Remove bucket seat assembly Installation 1 P
93. ite 242 and torque half shaft nuts to 74 foot pounds 12 Install hubcaps 0203 Lisle CV Boot Clamp Pliers P N LIS 30800 Used on large inboard boot clamp Figure 8 Clamp Pliers TORQUE SPECIFICATIONS DESCRIPTION THREAD SIZE Loctite POUNDS POUNDS Half Shaft to Drum Brake Assembl M16 x 1 5 YES Wheel Lug Nuts M10 x 1 5 3 6 DRIVETRAIN DIFFERENTIAL Description The differential consists of a pinion gear and two side gears in a cast aluminum case The drive motor is attached to the pinion gear The side gears are each attached to half shafts Operation Rotation of the motor spindle is transferred to the pin ion gear The pinion gear contacts the side gears forc ing them to rotate transferring power to the half shafts Figure 9 Differential Mounting Bolts 1 Upper mounting bracket 2 Mounting bolts 3 Lower mounting bracket 4 Differential Removal Switch master disconnect to OFF Remove hubcaps Loosen lug nuts on front wheels Raise front of vehicle and support safely with jack stands Remove front wheel lug nuts and front wheels Remove upper bolts from front shocks Make sure front assembly is supported as releasing shocks will cause control arms to drop down 7 Remove half shafts See HALF SHAFT in this section HNN 8 Remove motor See MOTOR in ELECTRICAL section 9 Remove steering shaft from steering gear pinch bol
94. jaw puller to separate the tapered stud from the spindle 5 Remove the pinch bolt that joins the steering column shaft and the steering gear Slide the steering shaft up to disconnect it from the gear 6 Remove the bolts and washers that attach the steering gear to the mounting bracket on the front suspension frame 7 Removal of the steering gear requires the mounting bracket to be opened up to free the gear for removal Have a helper support and remove the gear as the mounting bracket is gently opened with a pry bar Figure 13 Steering Gear Attaching Bolts 1 Bracket 2 Attaching bolts with up to four washers each 2 per side Installation 1 Position steering gear assembly in mounting brack et on front frame support Attach with mounting bolts and tighten to 225 inch pounds 2 Make sure rack and pinion are in centered position Tie rods are equal length 3 Make sure steering wheel is in centered position then insert lower end of steering shaft over pinion stud Tighten pinch bolt to 30 foot pounds 4 Install outer tie rod ends See TIE ROD ENDS in this section 5 Install wheels and tighten lug nuts just snug 6 Lower vehicle to floor 7 Tighten wheel lug nuts to 50 foot pounds 8 Replace wheel cover 9 Check toe in adjust if necessary See FRONT WHEEL ALIGNMENT in this section SUSPENSION AND STEERING 2 15 TORQUE SPECIFICATIONS DESCRIPTION THREAD SIZE Rack amp Pinion to Frt
95. ld see a Proceed to Step 3 Proceed to Step 4 04 on the Battery Discharge Indicator When the parking brake is released did you hear a Clunk sound from under the dash Are any error codes displayed on the Battery Use the DRIVE Proceed to Step 4 Discharge Indicator SYSTEM ERROR CODES to isolate the vehicle fault Remove upper and lower dash and locate the Proceed to step 5 1 If a voltage is Main Contactor and Battery Fuse Measure the present but less voltage at the fuse connection large black wire than 70 VDC marked FUSE charge the batteries present use the Main Contactor diagram and a voltmeter to check all battery connections and main disconnect switch 6 2 If no voltage is Figure 7 Battery Fuse Connection 1 Measuring point Is the voltage approximately 72 VDC Verify the Battery Fuse is not open by measuring Proceed to Step 6 Replace the fuse If the voltage at the fuse connection on the Main the fuse opens again Contactor The voltage should be the same greater contact the GEM than 70 VDC as the voltage measured in step 4 Service Department Is the Battery Fuse okay ELECTRICAL 5 9 Sep Ye Ne Measure the voltage on the output side of the Check the voltage Proceed to Step 7 contactor on the input of the Motor Controller E If the voltage is 8 approximately 72 L VDC Replace the 0 Controller If the voltage is O or significantly less than the volta
96. ller you should see an error code on the Battery Discharge Indicator Use the Drive and Power System Error Codes section starting on page 5 6 ELECTRICAL to help in isolating the fault Discharge Indicator Replacement Operation 1 Turn off the Master Disconnect Switch The controller functions automatically when the Master 2 Remove upper and lower dash Disconnect is in the ON position There are no other 3 Disconnect all cables and connectors noting direct operator interactions with the motor controller connection location and wire orientation module Operation of the motor controller is accom 4 Remove bolts holding controller to fire wall plished by actuation of the devices such as the accelera tor pedal turf and directional switches Installation Diagnosis and Testing 1 Reverse procedure to reinstall The motor controller function is critical to every aspect of the drive system If a fault occurs with the motor con PRINTED WIRE BOARD Description Note Input Voltage Fuses 0118 Figure 18 Printed Wiring Boards 0119 Note Input Voltage Fuses Version 1 Version 2 The GEM 72 volt system may employ one of two Printed Wiring Boards PWBs The latest version see figure 18 Version 2 has an integrated DC DC converter The earlier version see figure 18 Version 1 has the DC DC convert er mounted separately and behind the Printed Wiring Board Both versions of the PWB serve principally as
97. llips head bolts that attach spat to mounting brackets 4 Carefully remove spat INSTALLATION 1 Carefully position spat on vehicle 2 Attach with 4 hex head bolts and 4 Phillips head bolts NOTE The hex head bolts are used where they will be hidden by the rear shock absorber mount cover and the Phillips head bolts are used at all exposed locations 3 If vehicle is equipped with license plate bracket a re connect ground wire to upper license plate mounting bolt b Route power wire over rear suspension frame to connector above rear batteries and connect 4 Replace bench seat cushion 5 Replace rear shock absorber mount cover LINKSPAK SWIVELPAK 00010 Figure 15 SWIVELPAK 1 Latch handle 2 Swivel pak lid 3 Lid lock 0082 Figure 16 LINKSPAK clubs not included DESCRIPTION The LINKSPAK is a unit designed to carry two sets of golf clubs The SWIVELPAK 15 a molded plastic box with a hinged locking lid Both are used on the two and four passenger models They are not available on the short bed or long bed utility models All four have two legs that fit into pockets mounted on each frame rail Each attaches to a locking latch assembly mounted at the top of the body back panel Removal 1 Use key to unlock the latch handle 2 Unlatch unit by turning handle counter clockwise 3 While supporting unit pull Velcro strap at latch mechanism free of itself and pull through bracket on unit
98. lsa tion is out of round brake drums Other causes are loose wheel bearings and worn damaged tires Brake Noises Some brake noise is common with drum brakes during the first few stops after a vehicle has been parked overnight or stored This is primarily due to the formation of trace corrosion light rust on metal surfaces This light corrosion is typically cleared from the metal sur faces after a few brake applications causing the noise to subside Brake Squeak or Squeal Brake squeak or squeal may be due to linings that are wet or contaminated with brake fluid grease or oil Glazed linings and rotors with hard spots can also contribute to squeak Dirt and foreign material embedded in the brake lining will also cause squeak squeal A very loud squeak or squeal is frequently a sign of severely worn brake lin ing If the lining has worn through to the brake shoes in spots metal to metal contact occurs If the condition is allowed to continue drums can become so scored that replacement is necessary Brake Chatter Brake chatter is usually caused by loose or worn compo nents or glazed burnt lining Additional causes of chatter are brake lining not securely attached to the shoes loose wheel bearings and contaminated brake lining Thump or Clunk Noise Thumping or clunk noises during braking are frequently not caused by brake components In many cases such noises are caused by loose or damaged steering suspen sion or engi
99. ment ua sou edP ERRARE RESO ols sen lees Bes WOMEN Ea Pru 2 2 Alignment ua au Coon dy die bes You babe E aie tea eB pas toli da 2 4 Front SUSPENSION 245 a ER ow Rod TUR Cae Rer d d 2 5 Spring Over Shock Absorber Assembly 2 6 Control Arm Assembly with bushings 2 7 Rear SUSUENSION e u S E ROC EO m 2 8 Rear Suspension Frame Axle RIC 2 8 Steerng WEE Gre ROS EI EE No PAT 2 11 Steering Column Assembly 2 13 2 14 Outer Rod rub ones TT LL D TL 2 15 King IN ausus o avi bd CEPR ELA rape tque ewe 2 16 St erind Knuckle esin TT TI E bed Lee 2 17 2 2 SUSPENSION AND STEERING SUSPENSION AND STEERING WHEEL ALIGNMENT Description Front wheel alignment is essential for proper vehicle handling and passenger safety Front end damage or replacement of any steering or front suspension compo nent will require inspection of the alignment to deter mine if it is still within specifications CAUTION Never attempt to modify suspensio
100. mm brake line to wheel cylinder 3 Bleed brakes See Brake Bleeding instructions in this section 4 Install 15 16 drive shaft retaining nut and washer tighten just snug 5 Install wheel Attach with lug nuts tighten just snug 6 Lower vehicle to ground 7 Back off drive shaft retaining nut apply Loctite 242 and re tighten to 74 foot pounds 8 Tighten wheel lug nuts to 50 foot pounds 9 Replace wheel cover TORQUE SPECIFICATIONS DESCRIPTION THREAD SIZE Loctite POUNDS POUNDS Brake line to Wheel Master Cylinder NO O SOS Brake Drum Assembly to Steering Knuckle M8 x 1 25 NO 225 Half Shaft to Drum Brake Assembl M16 x 1 5 ves Wheel Lug Nuts 5 NO REAR BRAKE ASSEMBLY DESCRIPTION The rear brakes consist of a spindle wheel cylinder park brake actuator lever drum and shoes It is mounted on flanges at each end of the rear axle The park brake actu ator lever is connected by cables to the park brake lever Figure 7 Rear Brake Breakdown indicates serviceable part Drum Drum mounting bolt s Wheel cylinder mounting bolt s Wheel cylinder Bleed screw Upper spring Mounting Backing plate Spindle Brake shoe s 10 Brake shoe retention pin s 11 Retention pin clips 12 Lower spring 13 Spacer 14 Lower shoe retainer 15 Spacer retainer mounting bolt and nut gt BRAKES 4 7 OPE
101. n Adjust tire pressure Rotate tires Adjust or repair as necessary STEERING WHEEL Description The steering wheel assembly consists of two parts the steering wheel and the steering wheel cover Operation Splines on the steering wheel mounting hole match to splines on the steering shaft These splines force the wheel and shaft to turn as a unit thereby transmitting turning force to the steering gear Removal 0037 Figure 7 Steering Wheel Puller Remove the mounting screws located on the underside of each side spoke of the steering wheel Remove steering wheel cover Remove attaching nut and washer from steering shaft 4 Mark steering wheel and steering shaft end for reference when re installing 5 Remove the steering shaft rack and pinion attachment bolt 6 Pull steering wheel away from the instrument panel as far as possible 7 Separate the two halves of the puller 8 Slide the U shaped piece of the puller around the steering shaft behind the steering wheel Figure 8 WN SUSPENSION AND STEERING 2 11 Figure 8 Puller U Plate Placement 1 Instrument pod 2 U plate 3 Steering wheel 9 Place the two small bolts through the upper plate of the puller From the upper side of the steering wheel run the two bolts through the steering wheel Figure 9 and thread them into the U shaped plate Thread them in far enough to go through the U shaped plate Figure 10 10 Use app
102. n The old hood latch assembly consists of two 2 adjustable brackets each mounted to either side of the lower windshield support The upper flat portion of each bracket is drilled and tapped to receive a knurled knob bolt that passes through holes located at the upper trail ing edge of the hood Operation To unlatch the hood unscrew each knurled knob bolt until it is free of the bracket mounted on the lower wind shield support Pivot the hood forward To latch the hood thread each knurled knob bolt into the threaded hole on each mounting bracket and tighten Removal 1 Open hood 2 Remove upper dash panel See DASH this section 3 Remove bolts attaching mounting brackets to windshield lower support 4 Remove mounting brackets BODY 7 7 INSTALLATION 1 Install mounting brackets to lower windshield support tightening bolts just snug enough to maintain position but loose enough to allow adjustment of bracket position 2 Adjust mounting brackets until threaded holes are aligned with holes on hood 3 Tighten bolts to secure mounting brackets in place LATCH ASSEMBLY NEW Description The new hood latch assembly consists of an adjustable bracket mounted to the center of the lower windshield support holding a striker plate and an eccentrically piv oting latch handle mounted to the center of the hood trailing edge 0130 Figure 10 Hood Latch Assembly Open 1 Hood latch 2 Latch
103. n ohmmeter Using a voltmeter test for voltage at the following location 72 V at PWB J4 Pin 1 PWB J4 Pin 2 12 V at PWB J1 Verify connectors on J4 and J1 have not come loose Remove the 10 amp fuse in the fuse block and visual inspect or measure with an ohmmeter to determine if it is open Verify tail light harness connection with power harness Disconnect the tail light harness from the rear harness Using an ohmmeter measure resistance from pin 2 3 or 4 to ground The resistance should measure no more than 100 ohms There is probably a loose or broken connection between the signal stat in the IP harness to the PWB and rear harness Check the 3 amp fuse there are 2 one is for the horn The wiper motor has overload protection and may stop working for a short period of time if the windshield is very dry Wait a moments and try operating the wipers again If the wipers fail to operate check the 7 5 amp fuse in the fuse block all skill levels and provide advice for each A basic understanding of electronics and troubleshooting tech Corrective Action If the filament is visibly open or the filament resistance is greater than 100 ohms replace the bulb Systems with separate PWB and DC to DC Converter If there is 72 V at J4 but there is no 12 V at J1 replace the DC to DC converter If there is 12 V at J1 make sure the wire connecting J1 to the fuse block has not come
104. n or steering components by heating or bending Inspection Pre Alignment The steering system should be inspected for wear Any worn or damaged components must be replaced before checking alignment The pressure of all four tires should be set to specification with a high quality tire pressure gauge not the pencil type before checking the alignment or performing a driving inspection Customer com plaints of poor handling or excessive front tire wear should be confirmed by a test drive The test drive should be performed on a smooth level surface with plen ty of room to maneuver Before starting wheel alignment the following inspec tion and necessary corrections must be completed Refer to Suspension and Steering System Diagnosis Chart below for additional information Inspect tires for size air pressure and tread wear Inspect front wheel bearings for wear Inspect kingpins linkage pivot points and steering gear for looseness roughness or binding 4 Inspect suspension components for wear and noise 5 Road test the vehicle RAPID WEAR RAPID WEAR CONDITION Vi SHOULDERS AT CENTER CRACKED TREADS FEATHERED EDGE BALD SPOTS SCALLOPED WEAR SN UNDER Bcc OVER INFLATION OR LACK HOTATION OF ROTATION ADJUST PRESSURE SPECIFICATIONS WHEN TIRES ARE COOL ROTATE TIRES CORRECTION HAVE TIRE INSPECTED FOR FURTHER USE UNBALANCED S LACK OF RO
105. n place by tabs fitting into slots in the floor panel and 3 TEK screws into the dash support frame Figure 13 Lower Dash Panel BODY 7 9 1 Lower dash panel 2 Upper mounting tabs 3 Floor tabs Removal Remove upper dash panel 2 Locate and remove the 3 3 8 Tek screws on the top surface mounting tabs 3 Slowly lift lower dash panel out then up until lower tabs are clear of the slots in the floor pan NOTE Take care not to scratch steering col umn instrument pod covers Installation 1 Insert panel lower tabs into slots in floor pan then slowly lower and rock lower panel forward into place NOTE Take care not to scratch steering col umn instrument pod covers 2 Install the 3 3 8 Tek screws through the mounting tabs into the upper dash support frame 3 Install upper dash panel SPAT Description A Spat 1s an assembly that acts as fenders over the rear wheels of the 2 passenger and 4 passenger vehicles It is color keyed to match hood color 0053 Figure 14 Spat 1 Spat 2 Phillips head mounting bolts 8 1 10 BODY Removal 1 Remove rear shock absorber mount cover 2 If equipped with license plate bracket a Disconnect ground wire attached to upper license plate bracket b Remove bench seat cushion c Follow license plate hot wire to connector located under bench seat cushion above rear batteries and disconnect 3 Remove 4 hex head bolts and 4 Phi
106. n to provide safe opera tion vehicle stability and a smooth ride Tire pressure should be checked cold once a month Tire pressure decreases as the ambient temperature drops Check tire pressure frequently when ambient temperature varies widely Specified tire inflation pressures are cold inflation pres sures The vehicle must sit for at least 3 hours to obtain the correct cold inflation pressure reading or be driven less than one mile after sitting for 3 hours Tire inflation pressures may increase from 2 to 6 pounds per square inch psi during operation Do not reduce this normal pressure build up WARNING Over or under inflated tires can affect vehicle han dling and tread wear This may cause the tire to fail suddenly resulting in loss of vehicle control REPLACEMENT TIRES The original equipment tires provide a proper balance of many characteristics such as Ride Noise Handling Durability Tread life Traction Rolling resistance Speed capability It 15 recommended that tires equivalent to the original equipment tires be used when replacement 1s needed WARNING Do not use a tire size other than that specified Improper size tires can cause vehicle components to wear out prematurely and may change the vehicle s In addition it ride handling and steering behavior may affect the accuracy of the speedometer odome ter Using tire sizes other than specified could cause loss of control resulting in serio
107. nce a month until you get a feel for how thirsty your batter les are WARNING The electrolyte is a solution of acid and water so skin contact should be avoided Important things to remember 1 Do not let the plates get exposed to air This will damage corrode the plates 2 The electrolyte level should not be up inside the fill well This may cause the battery to over flow electrolyte during charging resulting in a loss of capacity as well as causing a corrosive mess 3 Do not use water with a high mineral content Use distilled or de ionized water only Step by step watering procedure Remove the vent caps and look inside the fill wells 2 Check electrolyte level the minimum level is at the top of the plates 3 f necessary add just enough water to cover the plates at this time 4 Replace and tighten all vent caps 5 Put the battery on a complete charge before adding any additional water refer to the Charging section 6 Once charging is completed remove the vent caps and look inside the fill wells 7 Add water until the electrolyte level is about 1 8 below the bottom of the fill well 8 Clean replace and tighten all vent caps Cleaning After time batteries attract dust dirt and grime In addi tion electrolyte expelled from the battery vent caps due to over watering and or overcharging can form a conduc tive path that will cause the batteries to discharge Keeping them clean will help
108. nd of bleed hose to bleed screw and insert opposite end in glass container partially filled with brake fluid Fig 4 Be sure end of hose is immersed in fluid Have a helper pump the brake pedal 4 5 times then hold the brake pedal down Once the pedal is down open the bleeder and let the air out Close the bleeder and then release the brake pedal Repeat steps 4 and 5 until fluid stream is clear and free of bubbles Then move in turn to the left rear right front then left front drum brake assemblies and repeat steps 1 6 PRESSURE BLEEDING I 2 Follow the bleeder unit instructions for attachment and use Always ensure that the brake fluid reservoir in the master cylinder is kept at the MAX fill line while bleeding Bleed the system at all four wheels Start at right rear brake drum assembly Continue on to left rear then right front then left front After bleeding all four wheels apply pressure to brake pedal Pedal should have a firm feel and not contact the floor even under maximum effort If pedal feels mushy or makes contact with the floor repeat steps 1 3 Check bleed screws and hose line connections for leaks Double check brake fluid level in master cylinder reservoir and fill if necessary Test drive vehicle to ensure that the brakes work properly and vehicle does not pull to left or right during braking FRONT BRAKE ASSEMBLY DESCRIPTION The front b
109. nds 7 Remove half shaft nut 9 Replace hub cap 8 Remove front drum brake assembly 9 Remove knuckle assembly 10 While providing support to control arm and yoke remove the two bolts holding yoke to control arm 11 Remove yoke TORQUE SPECIFICATIONS DESCRIPTION THREAD Use INCH SIZE Loctite POUNDS POUNDS Brake line to Wheel Master Cylinder Brake Drum Assembly to Steering Knuckle M8 x 1 2 TeRodStudNut 8 NO WheellugNuts NO YoetoConrlAm 5 NO SPECIAL TOOLS 5 Half Shaft to Drum Brake Assembl M16 x 1 5 0065 Kingpin Tool 0112 00580 DRIVETRAIN 3 1 CONTENTS DOSE EHE Sos oo o RC n e od d ard cedet C Be CR CET CC RU ede rab ie dedica 3 2 aai ead SUI HARI CE edes Voi iaa dee on placed nu 3 2 PAGAL Stine Oe Loa pae ek OA ed OE CERT Vd 3 2 Differential 3 6 41 44 4 9 9 9 3 s s 9 5 m s 3 2 DRIVETRAIN DRIVETRAIN DESCRIPTION The drive train consists of a 72 volt motor a gearbox dif ferential and two constant velocity drive shafts called half shafts DIFFERENTIAL WHEEL MOTOR WHEEL HALF SHAFT HALF SHAFT ACCELERATOR 0044 Figure 1 Drivetrain OPERATION
110. ne components However worn out improp erly adjusted or improperly assembled brake shoes can also produce a thump noise BRAKES 4 3 BRAKE BLEEDING Brakes must be bled to remove air from the system when ever the brake hoses or brake lines are disconnected BLEEDING THE BRAKE SYSTEM NOTE Proper brake bleeding requires an automotive type pressure bleeder or vacu um bleeder Good quality units are available from reputable automotive tool companies WARNING Brake fluid is toxic and must be properly disposed Follow instructions on brake fluid container in the event of accidental contact or ingestion CAUTION Use only DOT3 brake fluid from an unopened con tainer CAUTION Brake fluid will remove paint Immediately clean up any fluid that gets on a painted surface STANDARD PROCEDURE MANUAL BLEEDING Use brake fluid or an equivalent quality fluid meeting DOT 3 standards only Use fresh clean fluid from a sealed container at all times 1 Remove reservoir filler cap and fill reservoir 2 If wheel cylinders were overhauled open all wheel cylinder bleed screws Then close each bleed screw as fluid starts to drip from it Top off master cylinder reservoir once more before proceeding 4 4 BRAKES Figure 3 Bleed Screw Typical 1 Bleed Screw Figure 4 Brake Bleeding Setup 1 Hose 2 Container for waste brake fluid 0024 Starting at the right rear brake drum assembly attach one e
111. nt cover See REAR SHOCK MOUNT COVER in BODY section TORQUE SPECIFICATIONS DESCRIPTION THREAD Use INCH FOOT SIZE Loctite POUNDS POUNDS 242 90 Brake Parking Cable Mount to Rear Suspension 1 2 x 13 BENE PARK BRAKE CABLE TENSION ADJUSTMENT 1 Chock wheels 4 Locate threaded adjusting rod cable assembly at the 2 Remove bench seat cushion See SEATS in end of the lever BODY section 5 Using 1 2 open wrenches back off rear nut to 3 Release park brake release forward adjusting nut 6 Thread forward adjusting nut forward or backward as needed to adjust tension 7 Tighten rear nut against adjusting nut to lock in o place 8 Apply park brake and test by attempting to roll GS vehicle forward by pushing it If vehicle moves repeat tension adjustment procedure 0031 Figure 15 Park Brake Cable Tension Adjustment 1 Park brake cables to rear wheels 2 Jam nuts 3 Adjusting rod cable assembly 4 Tension equalizer ELECTRICAL 5 1 CONTENTS Electrical D MP vr 5 2 POUSSE THREE TEIL En 5 3 DEVESVSIE ace Met Odi ed 5 3 Accelerator Fedal Sa ean lean oan o ead ce abd 5 11 5652 anis ox OY a Gd toos edite 5
112. nted Offset Leak air through welds or Mounting configuration Have damaged bolt holes Failure to use equivalent replacement wheels may Wheel repairs employing hammering heating or affect the safety and handling of your vehicle welding are not allowed Replacement with used wheels is not recommended Their service history may have included severe Original equipment wheels are available through your treatment dealer Replacement wheels from any other source should be equivalent in TORQUE SPECIFICATIONS THREAD Use INCH FOOT DESCRIPTION SIZE Loctite POUNDS POUNDS 242 Wheel Lug Nuts M10 x 1 5 7 0 BODY G CONTENTS Ln COMM TP 7 1 SEIL EB Pale x edu Bion ie ra c PT 7 1 TWOP OIE Lap RT wae 7 2 TUBES GIL Seat Belt 7 3 BOO SINUS MANE pef phas FLU Tag emat 7 3 Hom Baie PADS oho the ee DO DIUINO eu a E rey usb 7 4 SEE pae ELSE 7 5 ARMIN 7 5 M d GIU ea vex dE el adn 7 6 5225 505 dE ineat 7 6 Hood Latch
113. o passenger model and on the rear tub of the four passen ger model It accepts a standard 3 wire grounded exten sion cord and should not exceed the following 2 gauge wire 50 feet in length 14 gauge wire 25 feet in length Operation Insert the proper extension cord into the battery charger receptacle and into a 110 volt A C 15amp breaker out let GFI is recommended When the battery charger 15 active the control circuit prevents operation of the vehicle and the BDI is disabled The indicator light will inform you of the battery charge status Schott Charger 0120 Figure 15 Schott Charger The indicator light on the BDI will blink rapidly during initial charging when the battery charge 15 low The indi cator light will blink slowly as the battery nears the end of its charge cycle and will remain lit when the battery becomes fully charged Zivan Charger 0121 Figure 16 Zivan Charger On vehicles equipped with a Zivan charger light emit ting diodes on the BDI will operate as follows to indicate charging status BLINKING RED shows that the battery is in the initial charge phase RED LED shows that the battery charger has reached 80 of charge YELLOW LED shows that the battery charger has reached 90 of charge GREEN LED shows that the battery has reached 100 of charge To determine the battery charge level unplu
114. of problems with the accessory system Unlike the drive system the BDI does not provide any error codes to aid in troubleshooting problems with accessories The most common problems with the accessory system are open lamp filament or blown fuse For problems that cannot be resolved by lamp and fuse replacement refer to the ACCESSORY SYSTEM TROUBLESHOOTING CHART and the wiring diagrams provided 9 28 ELECTRICAL As was the case with the Drive System the information provided in this section is a guide only There are numer ous variations in the skill level of personnel that service niques is required this vehicle This manual cannot possibly accommodate ETE OU SYSTEM TROUBLESHOOTING CHART EL Problem Description A single bulb headlight taillight or directional indicator does not work The headlamps tail lamps the front and rear directional indicators horns and wipers do not work Headlights and taillights do not work but front and rear directional indicators do work Both rear turn lamps and tail lamps do not work The tail lamps do not work when the headlamps are turned but the rear directional indicators do work The rear directional indicators do not work but the front directional indicators do work Horn does not work Wipers do not work Diagnostic Steps Remove the bulb see bulb removal replacement instructions below examine for open filament or measure the filament with a
115. ok dox ox c o Rex Ro CR Ee RR a 5 21 27 28 temperature SenSOr 4 IUE m hm d 5 3 10 39 Me ROU cL M IEEE 0 3 2 4 5 7 10 14 15 16 17 18 tire pressute i cse eb e Ree RR s 0 2 2 2 3 10 6 1 2 ROTATION State Bok ark arg 6 1 3 4 E LA MU CAL ME ME 0 2 6 2 0 2 4 2 2 3 4 9 10 3 2 4 2 3 6 1 2 3 qm 2 3 4 14 15 6 3 2 4 14 15 6 3 torque specifications 0 3 2 5 6 7 9 12 14 15 16 17 18 3 5 7 4 6 8 9 12 6 5 7 2 tU t SWIECHI aont A 5 4 5 20 25 T rn signal levet o oue RR Po Oed HAM Rl Roa 5 4 25 27 5255 KE 2 13 4 9 5 11 22 26 29 7 7 8 9 Vehicle Direction Switch nh 5 4 25 Vehicle Identification 2 0 2 4 02 o a aa a Ge a ae ete te 0 2 2 2 6 14 6 2 0 2 3 5 4 3 10 5 2 4 5 13 14 15 16 17 25 6 2 4 7 3 wheel
116. on 7 Remove rear shock cover See REAR SHOCK COVER in BODY section 8 Remove spat to expose mounting locations See SPAT in BODY section 9 Make sure to properly support rear frame axle assembly 10 Remove spring shock assemblies with 3 4 inch wrench and socket 11 Remove bolts attaching frame axle assembly to rear of frame 12 Remove frame axle assembly Cleaning and Inspection Inspect frame axle assembly for damage and or worn bushings Bushings are not serviceable Replace the frame axle assembly 1f worn or damaged Installation 1 Move frame axle assembly into position on rear of vehicle frame 2 Install bolts attaching frame axle assembly to rear of frame Tighten just snug 3 Replace spring shock assembly mounting bolts with 3 4 inch wrench and socket Tighten just snug 4 Replace spat See SPAT in BODY section 5 Replace rear shock cover See REAR SHOCK COVER in BODY section SUSPENSION AND STEERING 2 9 6 Re connect license plate wires if so equipped 11 Install wheel and lug nuts Tighten lug nuts just See LICENSE PLATE BRACKET in BODY snug section 12 Lower vehicle to floor 7 Attach rear drum brake assemblies 13 Tighten rear suspension frame to frame bolts to 8 Re connect rear brake lines 60 foot pounds See REAR BRAKE in BRAKES section 14 Tighten spring shock absorber mounting bolts to 9 Bleed brakes 60 foot pounds See BLEEDING BRAKES in BRAKES section 15 Tighten wheel lu
117. on similar to grab 2 If complaint was based on noise when braking check suspension components Jounce front and rear of vehicle and listen for noise that might be caused by loose worn or damaged suspension or steering components 3 Inspect brake fluid level and condition Note that the brake reservoir fluid level will decrease in proportion to normal lining wear NOTE Brake fluid tends to darken over time This is normal and should not be mis taken for contamination 4 If fluid level is abnormally low look for evidence of leaks at drum assemblies hoses and lines and master cylinder 5 If fluid appears contaminated drain out a sample to examine System will have to be flushed if fluid 15 separated into layers or contains a substance other than brake fluid The system seals and cups will also have to be replaced after flushing Use clean brake fluid to flush the system 6 Check park brake operation Verify free movement and full release of cables and lever Also note if vehicle was being operated with park brake partially applied 7 Check brake pedal operation Verify that pedal does not bind and has adequate free play If pedal lacks free play check pedal for being loose or for bind condition Do not road test until condition is corrected 8 If components checked appear OK road test the vehicle 9 During road test make normal and firm brake stops in 10 20 mph range Note faulty brake operation such as low pedal
118. on components Worn wheel bearings Toe out of specification 2 Tires over inflated Toe out of specification 2 Park brake on or cables tensioned too tight Brakes binding Toe out of specification 2 Park brake on or cables tensioned too tight Brakes binding Toe out of specification 2 CV boot cut or torn Replace drum brake assembly 2 Tighten or replace components as necessary Replace drum brake assembly 2 Tighten or replace components as necessary Tighten or replace steering gear Replace drum brake assembly 2 Tighten or replace components as necessary Replace or balance tires 1 Replace drum brake assembly Tighten or replace components as necessary Adjust tire pressure Align vehicle to specifications Replace steering gear Replace steering column Adjust tire pressure Align vehicle to specifications Adjust tire pressure Criss cross front tires Replace drum brake assembly Tighten or replace kingpins as necessary Replace spring shock absorber Adjust or replace brake components Bleed brakes Tighten or replace components as necessary Replace drum brake assembly Reset toe to proper specification 2 Adjust tire pressure to proper specification Reset toe to proper specification 2 Release park brake or adjust park brake cable tension Repair or replace brakes Reset toe to proper
119. one spot trouble signs if they appear and avoid problems associated with grime CAUTION When cleaning do not allow any cleaning solution or other foreign matter to get inside the battery 1 Check that all vent caps are tightly in place 2 Clean the battery top with a cloth or brush and a solution of baking soda and water Rinse with water and dry with a clean cloth Clean battery terminals and the inside of cable clamps using a post and clamp cleaner Clean terminals will have a bright metallic shine Reconnect the clamps to the terminals and thinly coat them with petroleum jelly Vaseline to prevent corrosion 7 Keep the area around the battery clean and dry CAUTION Never hose the batteries down with tap water The sulfuric acid content of the electrolyte will spread to other surfaces and cause corrosive damage BW HNN WARNING Never add acid to a battery Storage Periods of inactivity can be extremely harmful to lead acid batteries When placing a battery into storage fol low the recommendations below to insure that the battery remains healthy and ready for use NOTE Storing charging or operating batter ies on concrete is perfectly OK Avoid temperature extremes when choosing a storage area 1 Avoid locations where freezing temperature is expected Keeping battery at a high state of charge will also prevent freezing Freezing results in irreparable damage to battery s plates and
120. ons 3 battery terminals for corrosion 4 tires for correct PSI and wear Check zerc fittings on each kingpin and grease if needed 6 Check for proper operation of hand brake 7 Check Master cylinder for proper brake fluid levels Check brake lines for leaks Check seat belts for proper operation 10 Check headlights horn turn signals windshield wiper and brake lights for proper operation HOISTING AND JACKING 0066 Figure 4 Hoisting Jacking Locations A vehicle can be lifted with single post frame contact hoist twin post chassis hoist ramp type drive on hoist NOTE When a frame contact type hoist is used verify that the lifting pads are posi tioned properly INTRODUCTION 0 5 WARNING The hoisting and jack lifting points provided are for a complete vehicle When a chassis or drivetrain component 15 removed from a vehicle the center of gravity is altered making some hoisting conditions unstable Properly support or secure vehicle to hoisting device when these conditions exist CAUTION Do not attempt to lift a vehicle with a floor jack positioned under An axle tube Body side panel or sill Front control arm When properly positioned a floor jack can be used to lift a GEM vehicle Support the vehicle in the raised position with jack stands at the locations indicated SUSPENSION AND STEERING 2 1 CONTENTS Wheel Aligi
121. or 5 Replace upper dash as described in Body Panels and Accessories 0122 Figure 10 Accelerator Pedal Assembly Cover 2 Pushpins 3 Housing 0123 Figure 11 Pedal Housing Cover Removed 1 Tek screw locations 2 Lift spring 3 Cable BATTERY Description FRONT BATT 1 BATT 72V 6 GRND MASTER DISCONNECT SWITCH 0114 Figure 12 Battery Layout Six 12 volt lead acid batteries supply 72 volt power for the vehicle Two are located under the front hood Four are located under the front cushion on two passenger models and under the rear seat cushion on four passen ger models The batteries supplied with the GEM electric vehicle are Deep Cycle batteries They are designed to handle dis charges down to 20 30 of their rated capacity without doing any internal damage Since the batteries in the electric vehicle must supply 100 of the energy required for operation they are subject to deep discharges and then must be recharged to restore their capacity In com parison the standard automotive battery is known as a starting lighting and ignition SLI battery It is designed to supply a very high cranking current for a brief period and then maintains the accessory loads on the car NOTE Due to the different operating characteristics of the two types of batteries automotive type batteries should never be substituted in place of a deep cycle battery Operation
122. osition bucket seat assembly over seat belt bracket aligning rear mounting holes of seat over mounting holes of seat belt bracket 2 Insert 4 mounting bolts through bucket seat track seat belt bracket into mounting holes in raised front seat portion of floor panel 3 From underneath vehicle attach lock washers and nuts to mounting bolts 7 6 BODY MUD GUARD Description The mud guards are color keyed to match the hood They are attached to the body side panel to form the trailing portion of the front fenders 0052 Figure 7 Mud Guard Typical 1 Mud Guard LS Removal 1 Remove two screws and speed nuts attaching mud guard to body side panel 2 Remove mud guard Installation 1 With hood closed position mud guard against body side panel so that the mud guard forms a clean line and fit with the fender portion of the hood assembly 2 Using a hand clamp to maintain position of the mud guard 3 If installing a new mud guard drill 2 3 16 holes through mud guard and body side panel Use old mud guard to determine hole locations 4 Attach with Phillips screws and speed nuts HOOD Description The hood assembly forms the hood and upper part of the front fenders The head lamps and turn signal lamps are mounted in the hood The hood is attached by hinges to the front suspension support frame On newer models a latch at the center of the upper edge of the hood holds it secured when hood is closed
123. ottor Tob Pole food ion aaa A 4 7 8 11 12 Adj stertailSi E M 7 5 alignment x2 ers ken ent cei na ade Re VR E Ran etta n 2 2 3 4 14 15 7 11 12 Backing plate siss tiskaj na kiei aiaia e i a a aaa aE aeai aa i g ak a aE ia KA a RE OaE 4 5 6 7 batteries 0 2 4 3 2 4 10 5 3 4 8 10 12 13 14 15 16 17 18 27 7 10 battery charger 5 3 4 8 9 10 18 19 20 22 44 46 7 8 Battery Discharge Indicator 5 4 6 8 20 25 26 40 42 Battery MUG soi sete case 5 13 battery TOmperalullG s craters sp ware E ewe ce ee Re ard 5 3 pn 5 4 6 8 10 18 19 25 26 27 40 41 Belt and retractor assembly EXER FORCE NC Ra oe HOE AN CK RE RS Sed E 7 2 DENCH 2 aos 0 2 3 3 3 4 10 12 5 2 17 24 7 3 4 5 10 11 12 Bleed SCIeWS sucesos e totale pote cte err d Re an CN cR ac Eee Praed dn ROCA oder d 4 3 body back panel oed d Dae tud doe Ake P 7 3 4 10 11 12 body pariels uan dac n o CR OR eos 5 11 12 29 7 1 body side parel AU RR Cea a CR RO I eim E 0 5 7 3 4 6 codes du Dd e uer
124. park brake lever in place maintaining pressure on the cables push button on the end of the park brake cable disengages the ratchet allowing the lever to be returned to its normal position thereby releasing the tension on the cables REMOVAL WARNING Use caution when working near batteries Always switch master disconnect off and cover battery ter minals to prevent electrical shock Accidental contact with battery terminals can result in damage or per sonal injury Two Passenger Short Bed Utility Long Bed Utility Models 1 Chock wheels 2 Remove lower seat See BENCH SEAT in BODY section 3 Switch master disconnect off and cover battery terminals to prevent electrical contact 4 Release park brake 5 Locate threaded adjusting rod cable at the end of the lever 6 Using 1 2 open wrenches remove jam and adjusting nuts from adjusting rod 7 Remove park brake switch connections 8 Locate and remove mounting bolts from park brake lever brackets with 1 2 wrench or socket 9 Remove park brake lever assembly Four Passenger Model 1 Chock wheels 2 Remove parking brake lever boot 3 Release park brake 4 Locate threaded adjusting rod cable at the end of the lever 5 Using 1 2 open wrenches remove jam and adjusting nuts from adjusting rod Remove park brake switch connections From underneath vehicle remove mounting bolts from park brake lever brackets with 1 2 wrench or socket 8
125. placement wheel should be used When obtaining replacement wheels they should be equivalent in load carrying capac ity The diameter width offset and bolt circle of the wheel should be the same as the original wheel WARNING Failure to use equivalent replacement wheels may adversely affect the safety and handling of the vehi cle Used wheels are not recommended The service history of the wheel may have included severe treat ment or very high mileage The rim could fail with out warning WHEEL INSTALLATION The wheel studs and nuts are designed for this vehicle They must be replaced with equivalent parts Do not use replacement parts of lesser quality or a substitute design Before installing the wheel be sure to remove any build up of corrosion on the wheel mounting surfaces Ensure wheels are installed with good metal contact Improper installation could cause loosening of wheel nuts This could affect the safety and handling of your vehicle To install the wheel first position it properly on the mounting surface All wheel nuts should then be tight ened just snug Gradually tighten them in sequence to the proper torque specification see Figure 5 0064 Figure 5 Lug Nut Tightening Sequence CAUTION Never use oil or grease on studs or nuts WHEELS amp TIRES 6 5 WHEELS MUST BE REPLACED IF THEY Load carrying capacity Diameter Have excessive run out Width Are bent or de
126. quipment Wrench Post Cleaner Distilled Water Baking Soda Voltmeter Vaseline Hydrometer Discharge Machine Goggles amp Gloves Batteries should be carefully inspected on a regular basis in order to detect and correct potential problems before they can do harm It is a great idea to start this routine when the batteries are first received Examine the outside appearance of the battery Look for cracks in the container The top of the battery the posts amp connections should be clean free of dirt fluids and corrosion If batteries are dirty refer to the Cleaning section for the proper cleaning procedure Repair or replace any damaged batteries 2 Fluids on or around the battery may be an indication that electrolyte is spilling leaching or leaking out Leaking batteries must be repaired or replaced 3 Check all battery cables and their connections Look closely for loose or damaged parts Battery cables should be intact broken or frayed cables can be extremely hazardous Replace any cable that looks suspicious 4 Tighten all wiring connections to the proper specification see below Make certain there is good contact with the terminals Proper Torque Values for Connection Hardware Flooded 70 to 95 in lbs CAUTION Do not over tighten terminals Doing so can result in post breakage post meltdown and fire Testing Visual inspection alone is not sufficient to determin
127. rake assembly consists of a spindle wheel cylinder drum and shoes It is mounted on the steering knuckle A half shaft drive shaft engages splines on the spindle and 15 attached by a nut and washer s L Figure 5 Front Brake Breakdown indicates serviceable part Drum Drum mounting bolt s Wheel cylinder mounting bolt s Bleed screw Wheel cylinder Upper spring Mounting Backing plate BRAKES 4 5 8 Retention pin clip s 9 Brake shoe retention pin s 10 Lower shoe retainer 11 Spacer retainer mounting bolt and nut 12 Spacer 13 Lower spring 14 Brake shoe s 15 Spindle OPERATION Pressure on the brake pedal forces brake fluid through the brake line from the master cylinder to the wheel cylinder The wheel has two pistons each of which engage a brake shoe This pressure pushes the pistons out causing the brake shoes to press against the brake drum The resulting friction causes the drum and wheel to stop turning REMOVAL 1 Pry off wheel cover with standard screwdriver 2 Loosen wheel lug nuts and drive shaft retaining nut 3 Raise vehicle off floor and properly support See JACKING in INTRODUCTION Section 4 Remove 19mm wheel lugs 5 Remove 15 16 drive shaft retaining nut 6 Using a flare wrench remove 17mm brake line from wheel cylinder and allow fluid to drain into suitable container for disposal NO
128. rame Raise vehicle off floor and support safely with jack stands 7 Loosen pinch bolt attaching steering shaft to steering gear 8 Pull shaft free of steering gear 9 Disconnect wires from instrument pod 10 Remove previously loosened bolts attaching steering column to dash frame 11 Remove steering column BW HNN SUSPENSION AND STEERING 2 13 Cleaning and Inspection Rotate steering shaft in bearing feeling for roughness of action If roughness is detected replace steering shaft Inspect steering shaft u joints and pinion mating surface for wear or damage Replace shaft if necessary Installation 1 Position steering column assembly in dash and loosely attach to dash frame with mounting bolts 2 Make sure that front wheels are straight and that steering wheel is centered then insert steering shaft over pinion gear stud on steering gear NOTE When installing the pinch bolt that connects the steering shaft to the rack and pinion assembly use a 1 8 spacer between the steering wheel and the instrument pod to maintain proper spacing Figure 12 Figure 12 Maintaining Proper Spacing Steering wheel 1 8 spacer Instrument pod Tighten pinch bolt to 30 foot pounds Lower vehicle to floor Re attach wires to instrument pod See INSTRUMENT POD in ELECTRICAL section Tighten steering column to dash support mounting bolts to 225 inch pounds 5 Install steering wheel See STEERING WHEEL in
129. re which Group contains the information you need look up the Component System in the alphabetical index located in the rear of this manual A Service Manual Comment form is included at the rear of this manu al Use the form to provide with your comments and suggestions Tightening torques are provided as a specific value throughout this manual This value represents the midpoint of the acceptable engi neering torque range for a given fastener application These torque values are intended for use in service assembly and installation pro cedures using the correct OEM fasteners When replacing fasteners always use the same type part number fastener as removed Global Electric Motorcars L L C reserves the right to change testing procedures specifications diagnosis repair methods or vehicle wiring at any time without prior notice or incurring obligation GROUP TAB LOCATOR 0 INTRODUCTION 2 SUSPENSION AND STEERING 3 DRIVETRAIN 4 BRAKES 6 WHEELS amp TIRES 7 BODY 8 WORD INDEX U 222 Global Electric Motorcars LLC GEM A DaimlerChrysler Company INTRODUCTION 0 1 CONTENTS General 22524 Fato ce ees 0 2 Vehicle Identification Safety Certification Label oed bee ewer 0 2 Fastener 64 ee ERICRES a E aa e AR PARLE ERA BU 0 3 Parts and Lubric
130. rewdriver pulling out center portion of rivet Lift splashguard to expose fuse block 5 Locate blown fuse using volt ohm meter 6 7 Replace with appropriate size fuse See ECM Use fuse puller to remove fuse Troubleshooting section for appropriate sizes Reverse procedure to reinstall Headlight Replacement 1 2 BW Open hood Remove light from mounting bracket Disconnect ground wire and spade terminal noting connections and orientation Reverse procedure to reassemble Adjust headlight as follows Position the front of the car about five feet away from a wall Turn on headlights and adjust them so the center of the beam on the wall is about one inch lower than the center of the light on the car Front Turn Indicator Lamp Replacement 1 Open hood 2 Remove lock nut from light and disconnect power AU and ground wires Replace light assembly Reverse procedure to reassemble ELECTRICAL 5 29 Rear Turn Indicator Lamp Replacement 1 2 3 4 Remove two Phillips head screws holding lens in place Remove lens Twist bulb counter clockwise to remove noting type of bulb and replace 2057 2067 Reverse procedure to reassemble Wiper Motor Replacement 1 2 6 Open hood and remove upper dash See body panels and accessories Remove wiper arm and blade with 13mm socket or for the style without nut gently pry off arm with a large screwdriver Remove plas
131. rning Light Battery Discharge Indicator BDI Charge Status Light R Turn Signal Seat Belt Warning Light Windshield Wiper Switch Road Turf Switch 10 Vehicle Direction Switch 11 Key Switch 00 10 gt Diagnosis and Testing The purpose of this section is to aid in the isolation of problems with the Drive System and Power System The primary means of troubleshooting the Drive and Power System is via errors codes displayed on the Battery Discharge Indicator see figure 6 item 5 If system problems cannot be isolated by use of error codes refer to the Drive and Power System Troubleshooting Charts in this section NOTE The information provided in this sec tion is a guide only There are numerous variations in the skill level of personnel that service this vehicle This manual cannot possibly accommodate all skill levels and provide advice for each A basic under standing of electronics and troubleshooting techniques is required ELECTRICAL 5 5 WARNING Whenever possible service the vehicle with the Master Disconnect Switch turned off If the Master Disconnect Switch 1s on to measure voltage use extreme caution Dangerous voltage is present Remove all jewelry such as rings watches or neck laces that could contact electrical connections and conduct electricity Severe injury burns or even death could occur if caution is not used 9 6 ELECTRICAL Drive and Power System Error
132. ropriate wrench to turn the large bolt down against the threaded end of the steering shaft 11 Tighten large bolt on puller until the steering wheel comes loose 12 Remove Steering wheel 2 12 SUSPENSION AND STEERING Me pu P gt Ve 0039 0040 Figure 9 Steering Wheel Holes For Puller Figure 10 Wheel Puller Installed 1 Guide holes Installation 1 Using reference marks align steering wheel to steering shaft and place on shaft 2 Replace washer and attaching nut on end of shaft and tighten to press wheel completely on splines Back off nut and re tighten to 225 inch pounds 3 Replace steering wheel cover and attach with mounting screws TORQUE SPECIFICATIONS DESCRIPTION THREAD Use INCH FOOT SIZE Loctite POUNDS POUNDS 242 STEERING COLUMN ASSEMBLY Description The steering column consists of the steering column and steering shaft It is bolted to the dash frame and supports the upper end of the steering shaft and steering wheel The steering shaft is connected to the steering gear by a pinch bolt Figure 11 Steering Shaft Pinch Bolt 1 Pinch Bolt Removal 1 Remove upper dash assembly See UPPER DASH in BODY section 2 Remove lower dash assembly See LOWER DASH in BODY section Remove steering column instrument pod covers Remove steering wheel with wheel puller or appropriate method See STEERING WHEEL in this section Loosen bolts attaching column to dash f
133. s see the Drive and Power System Error Codes chart Removal Turn off the Master Disconnect Switch Remove upper and lower dash Locate main contactor Remove electrical connections noting connection and orientation for each wire 5 Remove screws that mount contactor to the front bulkhead 6 Reverse procedure to reinstall Double check cable connections Installation 1 Reverse procedure to reinstall Double check cable connections ELECTRICAL 5 23 MOTOR Description DIFFERENTIAL MOTOR WHEEL WHEEL HALF SHAFT HALF SHAFT ACCELERATOR 0044 Figure 21 Motor Location Power to the drivetrain 1s supplied by a 72 volt electric motor which is attached to the differential Motor speed RPM 15 monitored by a small magnet and speed sensor mounted to the center rear of the motor see figure 22 Operation Motor activation and speed are controlled by a poten tiometer located in the accelerator pedal in the cab A splined cup in the motor is connected to a splined shaft on the pinion gear in the differential Rotational motion of the motor s cup transmits that motion to the differen tial Diagnosis and Testing Diagnosis and testing of the DC DC Converter is covered in Drive and Power System Troubleshooting Chart B The circuit diagrams provided in this manual are also useful in isolation of problems Figure 22 Motor Electrical Connections 1 Motor Field 1 F1 2
134. s been verified Battery charger will not charge battery voltage to battery charger 110 VAC has been verified and temperature sensor has been verified in step 5 Verify the voltage to battery charger 110 VAC Disconnect the temperature sensor and try charging the batteries again Verify voltage of each battery is greater than 10 5 VDC If there are no loose connections found replace the BDI If voltage was not present connect AC power and try charging the batteries again If they will not charge go to step 5 If the batteries charge after the temperature sensor is disconnected replace the temperature sensor If batteries still do not charge go to step 6 If any battery has an output voltage less than 10 5 VDC turn of the MDS and charge each battery with an offline battery charger for 1 hour The turn the MDS back on and plug extension cord into the vehicle ACCELERATOR PEDAL FOOT PEDAL Description 0004 Figure 9 Foot Controls 1 Foot Brake Pedal 2 Accelerator Pedal The Accelerator Pedal see figure 9 item 2 is locat ed on the floor close to the center of the vehicle and is used to control vehicle speed Operation Pressing down on the pedal will increase speed Letting up on the pedal will reduce power to the electric motor and vehicle speed will slowly decrease Diagnosis and Testing The accelerator pedal module consists has two electrical components the a
135. s for signs of wear and replace if nec essary Installation 1 Work shock into upper and lower mounts 2 Attach with mounting bolts 3 Lower vehicle to the ground 4 Torque mounting bolts to 60 foot pounds TORQUE SPECIFICATIONS DESCRIPTION Shock Absorber Lower Bolt Brake Drum Assembly to Steering Knuckle THREAD SIZE 12 1 75 NO 60 M12 x 1 75 NO 60 INCH Loctite POUNDS FOOT POUNDS CONTROL ARM ASSEMBLY WITH BUSHINGS Description The control arm is a single casting that connects the front suspension to the front frame support assembly It is connected to the front frame support by bolts passing through bushings that allow the control arm to pivot ver tically NOTE The bushings are not serviceable The control arm and bushings must be replaced as a unit Removal Remove hub cap Loosen wheel lug nuts Loosen half shaft retaining nut Raise vehicle off floor and safely support Remove lug nuts and wheel Remove half shaft nut Disconnect brake line taking care to capture brake fluid in a suitable container for disposal 8 Disconnect tie rod end from steering knuckle See TIE ROD END in this section 9 Disconnect spring shock absorber lower mounting bolt 10 Provide support for control arm assembly then remove bolts connecting arm to front frame support l Remove control arm assembly 12 Remove yoke and knuckle assembly SUSPENSI
136. se in turns which indicates that the outboard joint is damaged A thump or clunk when accelerating from coasting which points to a faulty inboard joint Vibration or shuddering during acceleration which may be caused by a damaged inboard or outboard joint a sticking inboard joint or an excessive operating angle Half shaft CV boots must be replaced if they exhibit grease accumulating around the outside of the boot This is caused either by a small hole or a tear in the boot Removal 1 Remove lower bench seat cushion to access the Master Disconnect switch 2 Switch master disconnect off 3 Remove hubcaps 4 Remove nut from outboard end of half shaft with 15 16 inch socket Loosen front wheel nuts Raise front of vehicle and support safely with jack stands Remove front wheel lug nuts and front wheel Remove upper bolt from front shock You will need assistance to remove the inner end of the half shaft that projects from the differential The inner end is held on with a spring clip Using a pair of short pry bars gently force the inner end off the differential Take care to not damage the splined shaft during this procedure 10 Make sure the spring clip is still on splined shaft of differential and is not damaged If damaged replace 11 Remove the outer end of the half shaft from the drum brake assembly HNN N 0133 Figure 2 Shaft Removal DRIVETRAIN 3 3 1 Half
137. sill plate if present 10 Remove side panel 11 If replacing panel remove front and rear trim locks and transfer them to the new side panel Installation 1 Locate side panel on tub making sure to match up holes and attaching back trim lock to back panel 2 Position optional scuff guard over sill area of side panel 3 Attach three lower screws with speed nuts on the back bottom 4 Attach front upper screws to hold body panel to frame 5 Attach side panel to tub with phillips head bolts and nuts 6 Attach side panel to body back panel with phillips head bolts and nuts 7 Attach rear spat See SPAT in this section 8 Attach rear shock mount cover See REAR SPRING SHOCK ABSORBER MOUNT COVER in this section 9 Attach bench seat back See BENCH SEAT in this section 10 Attach bench seat cushion See BENCH SEAT in this section 11 Attach upper and lower dash See DASH this section 12 Attach mudguard See MUD GUARD in this section BODY BACK PANEL Description The body back panel is made of molded plastic The two passenger and four passenger models have a cut out to accommodate the Swivelpak Linkspak latch assembly Figure 4 Body Back Panel with cutout Removal 1 Remove Swivelpak Linkspak See SWIVELPAK LINKSPAK in this section 2 Remove body side panels See BODY SIDE PANEL in this section 3 Remove Swivelpak Linkspak handle See SWIVELPAK
138. specification 2 Release park brake or adjust park brake cable tension Repair or replace brakes Reset toe to proper specification Replace CV boot 2 4 SUSPENSION AND STEERING ALIGNMENT Description FRONT OF VEHICLE TOE IN FRONT OF VEHICLE TOE OUT 0033 TOP VIEW Figure 2 Toe In vs Toe Out Toe is the only available adjustment in the front wheel alignment Toe is the difference between the leading inside edges and trailing inside edges of the front tires It should be measured at a point above the ground equal to one half the overall diameter of the wheel tire assembly The specification 15 1 16 inch toe in Wheel toe position out of specification causes unstable steering uneven tire wear and steering wheel off center Measuring Toe 1 Park vehicle on a level flat surface 2 Center the front wheels 3 Measure distance from the inboard edge of the tread at the rear of the right front tire to the inboard edge of the tread at the rear of the left front tire Measure distance from the inboard edge of the tread at the front of the right front tire to the inboard edge of the tread at the front of the left front tire Subtract the front measurement from the rear measurement If the front measurement is less than the rear the vehicle has toe in and 1s shown with a plus sign 1 16 Ifthe front measurement is greater than the rear the vehicle has toe out and the differ
139. t See STEERING SHAFT in SUSPENSION amp STEERING section 10 Make sure that both the frame and the front sus pension frame are supported separately before going on Supports under the frame and a floor jack under the suspension frame works the best 11 Remove the two bolts attaching the front suspension frame to the body frame lower the front suspension frame to provide clearance for the next steps 12 While supporting the differential remove the top four 4 bolts and upper mounting bracket that connect the differential to the suspension frame mounting plate 13 Next remove the bottom four 4 bolts and lower mounting bracket that connect the differential to the suspension frame 14 Remove the differential by sliding it out the right passenger side Installation 1 Add oil to new differential 160z SAE30 weight 2 Make sure that the spring clips are on the splined differential shafts 3 Position differential between front suspension frame and mounting plate 4 Install mounting brackets and bolts 4 through the lower mounting bracket into the front suspension frame and 4 through the upper mounting bracket and plate Torque differential mounting bolts to 225 inch pounds NOTE Do not over tighten as threads will strip 5 Re attach front suspension frame to body frame See FRONT SUSPENSION FRAME in SUSPENSION amp STEERING section 6 Re connect steering shaft to steering gear See STEERING SHAFT in S
140. t over the inboard joint Position large clamp P N 0613 00198 around large end of boot Use the Lisle Boot Clamp Pliers P N LIS 30800 to secure clamp in place Position small clamp P N 0613 00261 so that raised punch marks face the boot Wrap around small end of boot feed narrow end of clamp into square hole at other end then use channel lock pliers to tighten clamp Special Tools Shock Absorber Lower Bolt M12 x 1 75 Tie Rod Stud Nut 10 15 NO 0202 Lisle CV Boot Clamp Pliers P N LIS 30500 Used on large outboard boot clamp DRIVETRAIN 3 5 Installation 1 8 9 Apply Optimol Olistamoly 2 LN 584 LO grease or equivalent to the splines at the inner and outer end of the half shaft prior to installation Insert the outer end of the half shaft into the drum brake assembly Make sure the spring clip is still on splined shaft of differential and 15 not damaged Install the inner end of the half shaft over the splined shaft on the differential Press inward toward differential until spring clip snaps into place Install upper front shock mounting bolt just snug Install washer and nut on half shaft outer end tighten just snug Install front wheel with lug nuts Tighten wheel lug nuts just snug Lower front of vehicle to ground Tighten spring shock absorber mounting bolts to 60 foot pounds 10 Tighten wheel lug nuts to 50 foot pounds 11 Add Loct
141. t run However an electrical arc could occur and result in an explosion BATTERY 1 Bi B1 we DISCHARGER 1 1 HERE B2 B24 BATTERY 2 BATTERY 3 DISCHARGER 1 HERE 83 E DISCHARGER MASTER 2 HERE DISCONNECT e Q 4 4 5 gt fr lt a BATTERY 4 DISCHARGER 0207 Figure 13 Discharge connection locations 9 16 ELECTRICAL Calculating Battery Capacity Battery capacity is expressed by the percentage of time until shut off voltage is reached In order to determine the accurate capacity of a battery set the manufacturer s rating at a 75 amp discharge rate must be known Also this value is only accurate for mature batteries ones that have 50 70 cycles on them EXAMPLE Manufacturer s rating 56 minutes 75 amp Discharger shuts down after 42 minutes Battery capacity is 42 56 100 75 0 If capacity 15 below 50 batteries may be nearing the end of their life and need to be replaced Testing For Defective Cells During a discharge all cells in a battery set should dis charge at the same rate If one or more of the cells decrease at a faster rate the total discharge time may indicate an unacceptable result Therefore the individual batteries must be compared against the others to see if one or more of the units need to be replaced 1 After discharge unit has shut down from previo
142. ted wiring Operation The Drive System is powered by the 72 VDC generated by the batteries If the Main Contactor is closed the Motor Controller provides drive voltage to the motor based on inputs from the turf mode switch motor tachometer and the accelerator foot pedal position The forward and reverse switch determines vehicle direction The variable speed reversible DC motor supplies mechanical drive power Power and drive system opera tion is monitored by the Motor Controller status infor mation is displayed on the BDI The Basic Operation procedures described in the Owner s Manual must be followed for the Drive System to operate properly If the Drive System does not operate first verify the following steps have been completed Main disconnect switch see figure 5 is in the ON position shown in the off position in the illustration Batteries are charged but the battery charger is not plugged in Parking Brake see figure 6 has been released Key switch see figure 7 item 11 is in the ON position After turning the Key Switch to On the Vehicle Directional Switch see figure 7 item 10 has been placed in either Forward or Reverse Figure 4 Master Disconnect Switch 0005 Figure 5 Parking Brake 1 Charge Receptacle 2 Parking Brake Handle Figure 6 Instrument Pod 1 Turn Signal Lever Horn Button Light Switch L Turn Signal Brake Wa
143. this section 6 Install instrument pod covers See INSTRUMENT POD in ELECTRICAL section 7 Install lower dash panel See LOWER DASH PANEL in BODY section 8 Install upper dash panel See UPPER DASH PANEL in BODY section A 2 14 SUSPENSION AND STEERING TORQUE SPECIFICATIONS DESCRIPTION Steering Column Pinch Bolt 3 8 16 THREAD SIZE INCH POUNDS POUNDS Use Loctite 242 Steering Column to Dash Frame 516 18 NO 225 Steering Wheel to Steering Shaft STEERING GEAR Description GEM uses a rack and pinion steering gear with integral tie rods Operation Teeth on the pinion gear engage teeth on the rack Turning motion of pinion gear causes rack to move either right or left Diagnosis and Testing If excessive play was detected during the driving test out lined in FRONT WHEEL ALIGNMENT this section raise vehicle off ground and support safely with jack stands Grasp lower half of steering shaft and rotate to determine if play is in the steering gear Also check steering gear for loose mounting bolts e If the steering gear mounting bolts are loose tighten to 225 inch pounds If excessive play is found within the steering gear it must be replaced Removal Remove hub cap loosen lug nuts Raise vehicle and support safely with jack stands Remove front wheel lug nuts and remove wheel Remove the tie rod ends with a 17mm socket or wrench Use a 2
144. tic from windshield sill by lifting up and rotating slightly clockwise if applicable Use 3 8 inch socket or wrench to remove Tek screws from wiper bracket Disconnect electrical connection from wiper motor Use 15 16 inch wrench or adjustable wrench to remove capture nut washer and rubber bushing from wiper shaft Remove wiper from windshield sill Reverse procedure to reinstall Instrument Pod Removal 1 2 Remove upper and lower dash See body panels and accessories Remove steering column covers See body panels and accessories 3 Remove steering wheel 4 5 Reverse procedure to install Remove 4 self tapping screws Headlight Switch Removal 4 5 1 Locate bad switch 2 3 Looking at it from the rear push tabs in with a flat Remove wires noting location and orientation screwdriver and press out front side To install new switches from the front insert switch in proper orientation and press firmly Switch will snap into place Reconnect wires and reassemble Key Switch Replacement 1 Note location of wires on back of key switch Red Grn on top and Org Grn in middle and disconnect Remove two Phillips head screws holding key assembly in place Remove key assembly Reverse procedure to reassemble ELECTRICAL 5 31 HEAD LIGHT AND FRONT TURN SIGNAL CIRCUIT 12 VDC PWB J1 Y MH14 RED 1 1 1 1 1
145. tightened with the vehicle at normal ride height It is important to have the springs sup porting the weight of the vehicle when the fasteners are tightened This will maintain vehicle ride com 0074 fort and prevent premature bushing wear Figure 5 Front Suspension System 1 Front suspension frame 2 Control arm 3 Spring shock absorber 4 Knuckle 5 Yoke TORQUE SPECIFICATIONS DESCRIPTION THREAD Use INCH FOOT SIZE Loctite amp POUNDS POUNDS 242 37 Brake line to Wheel Master Cylinder Brake Drum Assembly to Steering Knuckle M x125 NO 225 Control Arm to Frt Suspension Frame Mi2x175 NO Differential to Frt Suspension Frame 546 18 NO 225 Front Suspension Frame to Frame Lower 12 1 75 YES Front Suspension Frame to Frame Upper 38 16 YES Half Shaft to Drum Brake Assembl King Pin Pinch Bolt Rack amp Pinion to Frt Suspension Frame M8x125 NO 225 Rear Suspension Frame to Frame Shock Absorber Lower Bolt Shock Absorber Upper Bolt Steering Column Pinch Bolt Steering Column to Dash Frame Steering Wheel to Steering Shaft Tie Rod Stud Nut Wheel Lug Nuts Yoke to Control Arm M12 x 1 75 2 6 SUSPENSION AND STEERING SPRING OVER SHOCK ABSORBER ASSEMBLY Description The Gem 825 vehicles combine a spring and shock absorber into a single unit They are used on both the front and rear suspension They are not serviceable
146. tion 3 Using snap ring pliers to release tension from snap ring remove joint assembly 4 Slide damaged boot off the inboard end of the half shaft 5 Clean off grease and inspect joint and half shaft for damage Replace if damaged Assembly Outboard Boot 1 Slide new outboard boot P N 0613 00196 onto the outboard end of the half shaft 2 Repack joint with Optimol Olistamoly 2 LN 584 LO grease NOTE Use only Optimol Olistamoly 2 LN 584 LO grease or equivalent which meets grade 1 and 2 standards at all half shaft boot locations Never use ordinary chassis or wheel bearing grease 3 Push the spindle back onto the outboard end of the shaft and tap the joint until the snap ring is fully seated 4 Slide the large end of the boot over the spindle 5 Position large clamp P N 0613 00199 around large end of boot 6 Use the Lisle Boot Clamp Pliers P N LIS 30500 to secure clamp in place 7 Position small clamp P N 0613 00261 so that raised punch marks face the boot Wrap around small end of boot feed narrow end of clamp into square hole at other end then use channel lock pliers to tighten clamp Inboard Boot 1 2 Slide new inboard boot P N 0613 00195 onto inboard end of the half shaft Repack joint with Optimol Olistamoly 2 LN 584 LO grease Push the inboard joint back onto the end of the shaft and tap the joint until the snap ring 15 fully seated Slide the large end of the boo
147. to a retractor assembly mounted to the seat back frame approximately 6 below the D ring A seat belt latch assembly is mounted at the lower center of the seat back RU 5 4 5 2 4 6 95 oh 0047 Figure 2 Three Point Seat Belt Seat belt anchor Buckle assembly D Ring Retractor Locating tab 1 Remove lower seat cushion See SEATS in this section 2 Remove taillight covers 3 Remove seat back assembly See SEATS in this section 4 Remove body side panel See BODY SIDE PANEL in this section 5 Remove body back panel See BODY BACK PANEL in this section 6 Remove bolt attaching D ring to seat back support 7 Remove bolt attaching retractor assembly to seat back support 8 Remove bolt anchoring seat belt end to seat back support BODY 7 3 9 Remove seat belt assembly 10 Remove bolt attaching seat belt latch assembly to seat back support 11 Remove seat belt latch assembly Installation Attach seat belt latch assembly to seat back support with mounting bolt Tighten to 60 foot pounds 2 Attach D ring to seat back support making sure straight portion of D ring faces forward Tighten mounting bolt to 60 foot pounds 3 Attach seat belt retractor assembly to seat back support Tighten mounting bolt to 60 foot pounds WARNING Tab on retractor assembly MUST engage locating hole on seat back support 4 Feed seat b
148. udes the rear axle and spring shock absorbers 0041 Figure 5 Rear Suspension System 1 Rear suspension frame axle 2 Spring Shock Absorber Operation The rear suspension frame pivots up and down on bolts where it is mounted to the rear of the frame Rear drum brakes and wheels are mounted on flanges at each end of the rear axle Spring shock absorber units control the movement thereby maintaining contact of the tires on the road CAUTION Suspension components with rubber urethane bush ings should be tightened with the vehicle at normal ride height It is important to have the springs sup porting the weight of the vehicle when the fasteners are torqued This will maintain vehicle ride comfort and prevent premature bushing wear REAR SUSPENSION FRAME AXLE Description The rear suspension frame is attached to the rear of the vehicle frame by bolts in bushings Operation The rear suspension frame provides a platform for the rear shocks and acts as an axle for the rear wheels and brakes Removal 1 Remove wheel cover and loosen wheel lug nuts 2 Raise vehicle off floor and support safely with jack stands with jack stands 3 Remove lug nuts and wheel 4 Disconnect park brake cables See PARK BRAKE CABLES in BRAKES section 5 Disconnect rear brake lines making sure to collect brake fluid in proper container for disposal 6 Remove rear drum brake assemblies See REAR BRAKES in BRAKES secti
149. ulcrum remove lower spring 4 Remove bolt retaining plate and spacer at lower pad pivot point 5 Remove upper spring 6 Lift pads away from wheel cylinder and off center locating post 7 Remove two bolts attaching wheel cylinder and park brake actuator return spring 8 Remove wheel cylinder spring and park brake actuator lever ASSEMBLY 1 Replace park brake actuator lever 2 Position wheel cylinder on backing plate and attach with mounting bolt furthest from actuator lever 3 Position park brake actuator lever spring making 4 8 BRAKES sure it engages lever and is directly over mounting hole in wheel cylinder then insert last mounting bolt and tighten 4 Position trailing shoe first 5 Position leading shoe NOTE Make sure that park brake actuator lever properly engages the brake shoes NOTE Make sure that pads properly engage wheel cylinder pistons 6 Replace upper and lower springs 7 Replace shoe retention pins and clips 8 Replace lower pivot point spacer with narrow side up then replace retainer with rounded side down Attach with bolt and nut 9 Replace drum attach with Allen head screws INSTALLATION 1 Be sure you have correct RH or LH drum brake assembly 2 Insert parking brake cable into park brake actuator lever 3 Insert clevis pin into park brake actuator lever making sure park brake cable is engaged secure with cotter pin 4 Replace the four 13mm bolts through the rear axl
150. ult codes see the Drive and Power System Error Codes in this section Removal 1 Remove upper dash panel See UPPER DASH in BODY section 2 Remove lower dash panel See LOWER DASH in BODY section 3 Remove RS and LS pod covers See POD COVERS in this section 4 Disconnect 5 way connector at back of BDI see figure 24 item 3 5 Remove 2 white knurled knobs at back of BDI mounting bracket see figure 25 item 4 6 From steering wheel side pull BDI free of pod 0069 Figure 27 Instrument Pod Rear View Instrument Pod BDI BDI mounting bracket 5 way connector Knurled BDI mounting hardware Installation 1 Insert BDI in pod from steering wheel side 2 Install 2 white knurled knobs through bracket into BDI see figure 25 item 4 3 Attach 5 way connector to back of BDI see figure 25 item 3 Install RS and LS pod covers Install lower dash panel Install upper dash panel ACCESSORY SYSTEM Description 72 VDC ELECTRICAL 5 27 DC TO DC CONVERTER HEAD TAIL DIRECTIONAL LIGHTS LIGHTS INDICATORS BRAKE LIGHTS 0117 Figure 28 Accessory System Diagram The standard Accessory System components for the GEM are essential for safe driving and consist of the headlights taillights directional indicators and brake lights horn and wipers Some vehicles are equipped with a radio and heater that are considered optional equipment and
151. ure light switch lowermost on bracket Blue Brown wire from left terminal Orange Red from right terminal 4 Remove four bolts attaching pedal assembly to dash support frame 5 Remove brake pedal assembly BRAKES 4 9 TORQUE SPECIFICATIONS DESCRIPTION THREAD SIZE Loctite 242 Use Brake Pedal Assembly to Frame 5 16 18 NO No INSTALLATION 1 Position brake pedal assembly on dash support frame making sure push rod passes through bellows and properly engages master cylinder piston 2 Attach pedal assembly to dash support frame with four mounting bolts Tighten to 225 inch pounds 3 Re connect wires to brake failure light switch blue wire to left terminal orange red wire to right terminal 4 Re connect wires to brake light switch blue brown wire to left terminal orange and orange red wire to right terminal 5 Install lower dash panel 6 Install upper dash panel MASTER CYLINDER ASSEMBLY DESCRIPTION The master cylinder assembly is located under the hood on the left frame rail next to the steering column A plas tic reservoir on top of the master cylinder holds addi tional brake fluid for proper operation Aw w N 0012 Figure 9 Master Cylinder 1 Reservoir 2 Cap 3 Maximum fluid level line 4 Minimum fluid level line OPERATION Pressure from the brake pedal is transmitted by a push rod to a piston in the master cylinder causing the
152. us test start unit again 2 Take voltage measurements across each battery while the discharger is running 3 If one or two of the batteries differ in voltage from the other s by more than 0 5 volts replace the ones with low voltages 4 Turn discharge unit off EXAMPLE Battery 1 11 0 volts Battery 2 10 2 volts Battery 3 10 3 volts Replace Batteries 2 and 3 NOTE Unless the batteries are relatively new less than 6 months old replace with batteries of similar age and usage NOTE Be sure to charge batteries after completing the discharge test Leaving bat teries in a discharged state causes sulfation to occur which will reduce the life of the bat teries Watering Note This applies to flooded batteries only Flooded means water base batteries Flooded batteries need water More importantly watering must be done at the right time and in the right amount or else the battery s performance and longevity suffers Water should always be added after fully charging the battery Prior to charging there should be enough elec trolyte to cover the plates If the battery has been dis charged partially or fully the electrolyte level should also be above the plates Keeping the electrolyte at the correct level after a full charge will prevent having to worry about the level at other state of charge Depending on the local climate charging methods application etc GEM recommends that batteries be checked o
153. us personal injury or death WARNING Never use a tire smaller than the size specified Using a smaller tire could result in tire overloading and failure WARNING Overloading the tires is dangerous Like under inflation overloading can cause tire failure Use tires of the recommended load capacity and never overload the vehicle DIAGNOSIS AND TESTING PRESSURE GAUGES A quality air pressure gauge is recommended to check tire pressure After checking the air pressure replace valve cap finger tight DIAGNOSIS AND TESTING TREAD WEAR INDICATORS Tread wear indicators are molded into the bottom of the tread grooves When tread depth 15 1 6 mm 1 16 in the tread wear indicators will appear as a 13 mm 1 2 in band Tire replacement is necessary when indicators appear in two or more grooves or if localized balding occurs 0128 Figure 1 Tread Wear Indicators DIAGNOSIS AND TESTING TIRE WEAR PATTERNS WHEELS amp TIRES 6 3 Under inflation will cause wear on the shoulders of the tire Over inflation will cause wear at the center of the tire Excessive toe in or toe out causes wear on the tread edges and a feathered effect across the tread Fig 14 RAPID WEAR RAPID WEAR CONDITION AT SHOULDERS AT CENTER CRACKED TREADS FEATHERED EDGE BALD SPOTS SCALLOPED WEAR pun UNDER INFLATION OVER INFLATION OR LACK OR LACK OF ROTATION OF ROTATION ADJUST PRESSURE T
154. vertically so that latch handle 1s horizontal when locked If striker is too low or too high hood may come unlatched when driving over rough surfaces 8 Tighten mounting bolt to secure latch assembly in place DASH Description The dash consists of an upper panel assembly and a lower panel assembly Inside the dash is located the battery charger and electronic control module ECM DASH UPPER PANEL Description The upper dash panel is constructed of molded plastic It contains cup holders for both driver and passenger sides and a locking glove compartment in the center The panel 15 secured by two 2 Phillips head screws through lower windshield support and by Velcro r strips where it mates with lower dash panel 0009 Figure 12 Upper Dash Panel 1 Molded cup holder s 2 Locking glove box door 3 Storage tray Removal 1 Open hood 2 Remove the two Phillips head screws located immediately below windshield 3 Lift upper dash assembly out taking care to disconnect electrical hookups if any Installation 1 Re connect electrical hookups if any 2 Position upper dash assembly on lower dash assembly 3 Attach upper dash to lower windshield support with two Phillips head screws NOTE Take care not to cross thread bolts or jack nuts on dash panel will strip 4 Close hood DASH LOWER PANEL Description The lower dash panel is constructed of molded plastic It 15 secured i

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