Polaris eM 1400 manual

PMS 419 2014 Owner's Manual for Maint enance and Safety GEM eM 1400[...]

W ARNING Read, understand, and follo w all of the in structions and safety precautions in this manual and on all produ ct labels. Failure to follow the safety precautions could result in serious injury or dea th.[...]

1 WELCOME Thank you for purchasing a GEM by POLARIS , and welcome to our world-wide POLARIS family of recreational and utility vehicle owners. W e believe POLARIS sets a standard of excellence for all recreational and utility vehicles manufactured in the world today . With our many years of experience in design and manufa cturing, we proudly bring [...]

2 POLARIS® and GEM® are registered trademarks of POLARIS Industries Inc. Global Electric Motorcars® is a division of POLARIS. Copyright 2013 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the d esign and quality of product[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Operation . . . . . . . . . . . . . . . . . . . [...]

4 INTRODUCTION The GEM eM 1400 is a utility vehicle. Never operate on public roads. This vehicle does not meet National Highway T raffic Safety Adminis tration (NHTSA) regulations for operation on public streets, roads and highways. Familiarize yourself with all laws and regulations con- cerning the operation of this vehicle in your area. The follo[...]

5 INTRODUCTION Failure to follow the warnings con tained in this manual can result in seve re injury or death. S pecial precautions must be followed when op erating or servi cing a battery-powered vehicle. This vehicle handles differently than other vehicles. A collision or rollover can oc cur quickly , even during ro utine maneuvers, if you fail t[...]

6 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identification numbers an d key number in the spaces provided below . The V ehicle Identification Numb er (VIN) i ndicates the model year , model type and serial number of your vehicle. The VIN is stamped on the left rear frame. The VIN is also on the manufacturer ’ s label[...]

7 SAFETY Safety Labels and Locations W arning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully . If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle . If any label b[...]

8 SAFETY Safety Labels and Locations Age 16 W arning Operating this vehicle if you are u nder the age of 16 increases your chance of severe injury or death. NEVER operate this vehicle if you are under age 16 and NEVER operate this vehicle without a valid driver ’s license. 7175566 Discretionary W arning W ARNING Improper vehicle use can result in[...]

9 SAFETY Safety Labels and Locations Battery Caution CAUTION • Do not drive through water above the floor of the vehicle. Battery damage wil l occur . • Batteries requi re regular main tenance. • Failure to maintain batteries in accordance with the owners manual can result in battery damage, vehicle malfunction, fire and/ or severe injury or [...]

10 SAFETY Personal Protective Equipment Always wear the proper clothing when operating or riding in this vehicle. All riders shoul d wear substantial footwear , long pants and a close-fitting shirt. A hard hat or helmet and approved eye protection are recommended when appropriate for working or riding conditions. GEM recommends wearing approved eye[...]

11 SAFETY Operator Safety • Never modify this vehicle through improper installation or use of non-GEM-ap proved accessories. • Always set the park brake and remove the key when leaving the vehicle unattended . • The voltage in the battery pack is suf fici ent to cause death by electrocution. With the exception of battery inspections and refil[...]

12 SAFETY Operator Safety Gross V ehicle Weight Rating (GVWR) W ARNING! Exceeding the gross vehicle weight rating of your vehicle can reduce stability and handling and could cause loss of control. NEVER ex ceed the GVWR of your vehicle. The maximum payload capacity of your vehicle is the maximum weight you may add to your vehicle without exceeding [...]

13 SAFETY Operator Safety Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover , which may result in serious injury or death. Heed all safety warning s outl ine d in this section of the owner ’s manual. See the OPERA TION section of the owner ’s manual for proper operating procedures. Age Res[...]

14 SAFETY Operator Safety V entilation When Charging Batteries Failure to provide adequate ventilation whi le charging batteries can result in an explosi on. V olatile hydrogen gas is emitted during charging and may accumulate in pockets at the ceiling. • Always ensure a minimum of 5 air changes per hour in the charging area. • Always remove an[...]

15 SAFETY Operator Safety Operating on Public Roads This vehicle does not meet National Highway Traf fic Safety Administration (NHTSA) regulations for operation on public stre ets, roads and highways. Operating this vehicl e on public streets, roads or highways could result in a collision with anoth er vehicle. Never operate this vehicle on any pub[...]

16 FEA TURES AND CONTROLS Component Locations Console Hip Bar Cargo Box Headlights Front Bumper/Brush Guar d T ailgate Latch Releases Receiver Hitch T ailgate T aillight Reflecto r Charge Receptacle[...]

17 FEA TURES AND CONTROLS Console 1. S teering Wheel 2. Indicat or Lights 3. Key Switch 4. Direction Selector 5. Headlight Switch 6. Charge S tatus Indicato r 7. Battery Discharge Indicator 8. Hour M eter 9. Glove Box/S torage Compartment 10. Beverage Holder 1 1. 12V Auxiliary Outlet 12. Park Brake Lever 13. Throt tle Peda l 14. Brake Pedal 5 4 6 1[...]

18 FEA TURES AND CONTROLS Console Battery Discharge Indicator The battery discharge indicator displays the am ount of charge r emoved (used) from fully charged batteries. When the batteries are fully char ged, the gauge will display 100%. The charge status indicator will be solid green (see page 19). A void dischar ging the batteries mor e than 80%[...]

19 FEA TURES AND CONTROLS Console Park Brake Lever T o help prevent the vehicle from rolling, set the park brake when parking the vehicle. When the park brake is set and the park brake indicator is illuminated, motor speed is limited. If the accelerator is applied, this limiting feature prevents operation, which protects the park brake pads from ex[...]

20 FEA TURES AND CONTROLS Console Indicator Panel Light s The indicator lights activate when the key is in the ON position. Indicator St atus Indicates Malfunction S teady Electrical malfunction (flash sequ ence on controller indicates type; see troublesh ooting guide on page 21) Accelerator pedal is pre ssed while key is being turned on (release p[...]

21 FEA TURES AND CONTROLS Malfunction Indicator T roubleshooting Guide The malfunction codes will blink on the controller . The code definitions provided here are for informational purposes only . Tip : If the indicator illuminates due to a minor issue such as a l ow voltage condition or a seque nce fault (reversing direction without releasing the [...]

22 FEA TURES AND CONTROLS Batteries This vehicle is equipped with eight 6-volt batteries that supply the power needed to operate the vehicle. The batteries are located under the seat. See page 55 for battery access instructions. Always observe all battery safety warnings and safe hand ling procedures as outlined on vehicle safety labels and in this[...]

23 FEA TURES AND CONTROLS Batteries Battery Conditioning New batteries cannot initially hold all of t h eir capacity. The approximate capacity of the battery pack increases as the num ber of charge cycles increases. Ambient T emperature Implications o n Batteries 1. Battery range decreases as ambient temperature decreases. This can affect the range[...]

24 FEA TURES AND CONTROLS Main Power Connector NOTICE: Damage to electrical connecti ons and components will occu r if they are unplugged before the main power connector is disconnected. Always disconnect the main power connector before servi cing or unplugging any electrical components. When disconnected, the main power connector disconnects the b[...]

25 FEA TURES AND CONTROLS Brake Pedal Push the brake pedal toward the floor to slow or stop the vehicle. Apply the brakes before turning the key on. Accelerator Pedal The accelerator pedal will function only when the key is ON and the direction selector switch is set to either forward or reverse. T o begin moving or to increase vehicle speed, gradu[...]

26 OPERA TION Failure to operate the vehicle properly can result in a collision, loss of contro l, accident or ro llover , which may result in serious injury or death. Read and un derstand all safety warni ngs outlined in the safety section of this owner ’s manual. Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe oper[...]

27 OPERA TION Driving Procedure 1. Disconnect the charging cable (if connected). 2. All riders should wear substantial footwear , long pants and a close- fitting shirt. A hard hat or helmet and approved eye protectio n are recommended when appropriate for working or riding conditions. 3. Sit in the driver's seat. 4. Apply the brakes. Place the[...]

28 OPERA TION Driving On Slippery Surfaces Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpe cted ly). When operating on slippery surfaces such as ice or loos e gravel, reduce speed and use extra caution to reduce the chance of ski dding or sl iding out of control. Do not op erate on excessive ly slippery su[...]

29 OPERA TION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always travel straight uphill. 2. A void excessively steep hills. 3. Keep both feet on the floor . 4. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces. 5. Proceed at a steady rate of speed. [...]

30 OPERA TION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. 2. Always avoid backing downhill. 3. Back slowly . 4. Apply the bra kes lightly for stopping. 5. A void turning at sharp angles. 6. Never acce[...]

31 OPERA TION Hauling Cargo Hauling cargo improperly can alter ve hicle handl ing and may cause loss of control or brake instability , which can result in serious injury or death. Always follow these precautions when hauling cargo: Never exceed the maximum weight cap acity of the vehicle. When determinin g the weight you are adding to the vehicle, [...]

32 OPERA TION T owing Loads T owing improperly can alter vehicle handling and may cause loss of cont rol or brake instability . Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weig ht on the towing bracket. 2. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. See page 31. T owing a t[...]

33 OPERA TION Dumping the Cargo Box If equipped, use the electric dump box switch to raise the cargo box and dump car go. 1. Select a level site to dump the cargo box. Do not attempt to dump or un load the vehicle while parked on an incline. 2. Apply the brake s. 3. Set the park brake. 4. Place the direction selector in neutral. 5. Dismount the veh[...]

34 OPERA TION T ransporting the V ehicle When transporting the GEM eM 1400 for a long distance or on public streets, always use a trailer with an approved load rating greater than the GEM eM 1400’ s curb vehicle weight of 1700 lbs. (771 kg) plus an y installed accessories or cargo. Follow these guidelines when transporting the GEM eM 1400. 1. Pla[...]

35 WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an a ccessory winch to your vehicle. Improper winch use can result in SEVERE INJU RY or DEA TH. Always follow all winch i nstructions and warnings in this manual. Your winch may have a cable made of either wire rope or spec[...]

36 WINCH GUIDE Winch Safety Precautions 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning. 14. Never attempt to winch loads that weigh more than the winch’ s rated capacity . 15. The winch motor may become hot during winch use. If you winch for more than 45 seconds,[...]

37 WINCH GUIDE Winch Operation Read the W inch Safety Pr ecautions in the preceding pages before using your winch. Tip : Consider practicing the operation and use of yo ur winch before you actually ne ed to use it in the field. Improper winch use can result in SEVERE INJU RY or DEA TH. Always follow all winch i nstructions and warnings in this manu[...]

38 WINCH GUIDE Winch Operation 4. Always use the hook strap when handling the hook. W ARNING! Never put your fingers into the hook. This coul d lead to SEVERE INJURY . A. Attach the hook it self onto the load or use a tow strap or chain to secure the lo ad to the winch cable. Tip : A “tow strap” is NOT intended to stre tch. A “recovery strap?[...]

39 WINCH GUIDE Winch Operation 8. Read and adhere to the following inform ation for winch damping to ensure safe winc h use. A. In order to absorb energy that could be released by a winch cable failu re , always place a “damper” on the wi nch cable. A damper can be a heavy jacket, tarp, or other soft, dense object. A damper can absorb much of t[...]

40 WINCH GUIDE Winch Operation 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’ s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch [...]

41 WINCH GUIDE Winch Cable Care For your safety , always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer . W ARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJUR Y . 1. Always inspect your winch before eac h use. Inspec t for worn or l[...]

42 WINCH GUIDE Shock Loading W ARNING! Y our winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a win ch cable beyond its strength and cause the cable to break. The e nd of a broken winch cable under such high loadi ng can cause SEVERE INJURY or DEA TH to you and other bystanders. W inch[...]

43 WINCH GUIDE Winch Maintenance and Service Safety W ARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJUR Y or DEA TH. Always follow all winch instructio ns and warnings in this manual. 1. Always inspect your winch before eac h use. Inspec t for worn or kinked winch cable. Also inspect for worn or loose parts includ[...]

44 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep yo ur vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace part s as necessary . When inspection reveals the ne[...]

45 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubricat[...]

46 MAINTENANCE T ransaxle T ransaxle Specifications Chart T ransaxle Oil Change This gearbox uses a lifetime fluid. Checking the fluid level and changing the fluid is not r equir ed. Please see your authorized GEM dealer for any transa xle-r elated concerns. Do NOT add fluid to the transaxle unless changing the fluid. If changing the fluid, add onl[...]

47 MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes. See page 25. Brake Fluid Inspect the brake system routinely . Inspect the level of the brake fluid before each operation. W ARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store [...]

48 MAINTENANCE S teering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 44. 1. Position the vehicle on a level surface. 2. Lightly turn the steering wheel left and righ t. There should be 0.8"-1.0" (20-25 mm) of freeplay at[...]

49 MAINTENANCE Ti r e s Operating your vehicle with worn tires, improperl y in flated tires, no n-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance proced ures as outlined in this manua l and on the labels on the vehicle. Alw[...]

50 MAINTENANCE Ti r e s Wheel Removal 1. Apply the brakes. Set the park brake. Turn the key off. 2. Loosen the wheel nuts slightly . 3. Elevate the side of the vehicle by placing a suitable stand under the frame. 4. Remove the wheel nuts and washers. Remove the wheel. Wheel Inst allation 1. Set the park brake. Place the wheel in the correct positio[...]

51 MAINTENANCE Light s Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly . Do not operate this vehicle at night or in low light conditions until the headl ight is replaced. Always make sure lights are adjuste[...]

52 MAINTENANCE Light s Brake Light s When the brake pedal is depressed, the brake light comes on. Check th e brake light before each ride. 1. Turn the key to the ON position. 2. Apply the brakes. If the light doesn't come on, check the wiring, the brake switch or the tail light assembly . Indicator Panel Lamp Replacement 1. Lift the hood. 2. R[...]

53 MAINTENANCE Fuse Replacement If you experience electrical f ailure for a specific component (such as indicator lamps or headlights) a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. The fuse box is located unde r the hood. Spare fu ses are provided in the fuse box. If y[...]

54 MAINTENANCE Batteries Battery posts, terminals and related compone nts contain lead and lea d compounds, che micals known to cause cancer and reproductive harm. Always wash your hands after touching or handlin g the batteries. Charging a damaged battery can result in serio us injury . Never attempt to charge a frozen or bulg ing battery . Discar[...]

55 MAINTENANCE Batteries Battery Charging When not in use, park the vehicle and connect the battery charger . The battery charge receptacle is located on the left side panel below the driver ’ s seat. W ARNING! Failure to provide adequate ventilati on while charging batteries can result in an explosion. Hydroge n gas is emitted during charging an[...]

56 MAINTENANCE Batteries Battery Cleaning Always keep battery terminals and connections free of corrosion. T o clean, remove corrosion with a stiff wire brush. W ash with a solutio n of one tablespoon baking soda and one cup water . Rinse well with tap water and dry off wi th clean shop towels. Coat battery terminals with dielectric grease or petro[...]

57 MAINTENANCE Cleaning and St orage W ashing the V ehicle Keeping your GEM vehicle clean will not only improve its appearance but it can also extend the life of variou s components. NOTICE: High water pressure ma y damage components. GEM recommends washing the vehicle by hand or with a garden hose, us ing mild soap. NOTICE: Certain products, inclu[...]

58 MAINTENANCE Cleaning and St orage Polishing the V ehicle GEM recommends the use of common household aerosol furniture polish for polishing the finish on your GEM vehicle. Follow the instructions on the container . Polishing T ips • A void the use of automotive pro ducts, some of which can scratch the finish of your vehicle. • Always use clea[...]

59 MAINTENANCE S toring the V ehicle Any time the vehicle will be parked for more than a few hours, follow the recommended storage procedures: 1. Make any ne cessary repairs and clean the vehicle. Se e pa ge 57. 2. Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 44. 3. Per[...]

60 SPECIFICA TIONS GEM eM 1400 Dimensions Dry Weight 1500 lbs. (680.4 kg) Ground Clearance 8 in. (20.3 cm) Length 1 14.5 in. (291 cm) Width 56.5 in. (143.5 cm) Height 52.5 in. (133.3 cm) Cargo Box (Inside) 51.5 x 41.75 in. (13 0.8 x 106 cm) Wheelbase 79 in. (200.7 cm) T urning Radi us (GVW) Left: 175 in. (444.5 cm) Right: 159 in. (403.9 cm) T urnin[...]

61 SPECIFICA TIONS TROUBLESHOOTING V ehicle Will Not Operate GEM eM 1400 Brake Syst em Brakes 4-Wheel hydraulic disc w/dual bore front cali pers Park Brake Lever-activated mechanical park brake Suspension Front suspension Independent Macpherson struts w/5 in. (12.5 cm) travel Rear suspension Dual A-Arm w/6 in. (15 cm) travel T ire size 23x8.5-12 T [...]

62 W ARRANTY LIMITED W ARR ANTY POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO- YEAR, 8,000-MILE (12,900-km) or 750-HOUR, whichever comes first, LIMITED W ARRANTY on all component s (except batteries) of your GEM vehicle against defects in material or workmanship. Mileage is unlimite d for the first 6 months of the vehicle warra[...]

63 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND REMEDIES This POLARIS limited warranty ex clud es any failures that are not caus ed by a defect in material or workmanship. THIS W ARRANTY DOES N OT COVER CLAIMS OF DEFECTIVE DESIGN. Thi s warranty also does not cover acts of G od, accidental dama ge, normal wear and tear , a buse or improper handling. [...]

64 W ARRANTY LIMIT A TIONS OF W ARRANTIES AND REMEDIES The exclusive re medy for breach of this warran ty shall be, at POLARIS’ sole option, re pair or replacement of any defective materials, or components or products. THE REMEDIES SET FOR TH IN THIS W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PE RSON FOR BREACH OF THIS W ARRANTY . POLARI[...]

65 W ARRANTY Exported Product s EXCEPT WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W ARRANTY OR SER VICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SO LD OUTSIDE THE COU NTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA TI ON. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not gi[...]

66 MAINTENANCE LOG Use the following chart to record periodic maintenance. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

67 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

68 INDEX A Accelerator Pedal . . . . . . . . . . . . . . . . . . . . . . . . . 25 Auxiliary 12-Volt Terminal Board . . . . . . . . . . . 18 Auxiliary Outlets . . . . . . . . . . . . . . . . . . . . . . . . . 18 Axle Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . 49 B Batteries Accessing . . . . . . . . . . . . . . . . . . . . . . 55 A[...]

69 INDEX P Park Brake Leve r . . . . . . . . . . . . . . . . . . . . . . . . . 19 Parking on an Incline . . . . . . . . . . . . . . . . . . . . . . 30 Parking the Vehicle. . . . . . . . . . . . . . . . . . . . . . . . 30 Periodic Maintena nce Chart . . . . . . . . . . . . . . 44-45 Personal Prote ct ive Eq uipment . . . . . . . . . . . . . . . 10 P[...]

PMS 419 W ARNING Improper vehicle use can result in SEVERE INJURY or DEATH For your nearest GEM dealer , call 855-RIDEGEM (855-743-3436) or visit www .gemcar .com Polaris Sales Inc. 2100 Hwy . 55 Medina, MN 55340 Part No. 9924949 Rev 0 2 Printed in USA A LL RIDERS MUST WEAR APPROVED PROTECTIVE GEAR. NEVER USE ON PUBLIC ROADS. NEVER USE WITH DRUGS O[...]