5 - 19 ELECTRICAL
GEM Service Manual November 2007
OPERATION
The GEM vehicle has a battery control and
recharge system specially 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 amp, A/C 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.
• When recharging, 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 110°F 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.
BATTERY CODES
A-January
B-February
C-March
D-April
E-May
F-June
G-July
H-August
I-September
J-October
K-November
L-December
The number after the letter is the year in which the
battery was produced.
2-2002
3-2003
4-2004
5-2005
6-2006
7-2007
8-2008
BATTERY CARBON PILE LOAD TEST
Test batteries at 1/2 CCA for 15 seconds and the
voltage should not drop below 10.5 volts and with
no more that 1/2 (0.5) of a volt difference between
batteries. Trojan: 30XHS or SCS225, liquid lead
acid, CCA 665, CA 820, 130 AH, BCI group size
30H, Test at 330 amps. Deka: 8G31, Gel, sealed,
CCA 550 @ 0 degrees F, CA 780 @ 32 degrees F,
97.6 AH, BCI group 31, Test at 275 amps. Deka:
EV31, liquid lead acid, CCA 650, Test at 325 amps.
110 AH @ 20 amps. Group size 31, test at 300
amps. Deka: 8G8VGC Gel, sealed, CCA 400, 165
AH Test at 200 amps.
POWER BRAKING LOAD TEST FOR GEM CARS
NOTE: DO NOT STALL THE VEHICLE MORE
THEN ONE TIME PER BATTERY TO ALLOW FOR
COOLING TIME OF THE MOTOR AND
CONTROLLER.
2006 and Newer Models
8-Volt Battery Option
e6S & eLXD Models
1. Block wheels, clear, and secure area in front
and around vehicle.
2. Set voltmeter to lowest scale above 15 volts.
3. Hook voltmeter to number 1 battery negative
and positive using correct polarity.
4. Set car to forward or high-speed mode.
5. Depress and hold brake pedal solid. Release
emergency park brake handle.
6. While watching voltmeter, floor and hold
accelerator down.
7. In about 5 seconds motor controller should cut
off power to motor.
8. Let up on accelerator pedal and record the
lowest reading observed on voltmeter at or
before the cut-off.
9. Turn off key.
10. Repeat steps 3 through 9 for batteries
2 through 9.
The batteries recorded voltages should not drop
below 7 volts, and there should not be a difference
of more then 1/2 (0.5) of a volt between any of the
batteries or the low batteries will need to be
replaced.
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