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A DESCRIPTION ratchet holds the park brake lever in place, maintaining pressure on the cables. 5 - 91 ELECTRICAL Connector Illustration Connector Number Connects To Number of Pins in Connector Taillight Harness GEM Service Manual November 2007... The handle is mounted to the back of the body back panel. Running OVER 22″ tall tires with stock controller (high amp draw). WELL-VENTILATED AREA. Back off nut and tighten to 20 ft-lbs. Box your motor up using a good quality cardboard box, add packing as to protect the motor studs from getting bent and help prevent the armature from coming out of the motor housing. BODY 7 - 6 INSTALLATION OF SCUFF GUARDS • Once all the panel bolts are tightened then the scuff guard can be assembled. 2001 Gem Car Code -27 Problem - GEM Forum. See Dash Panel Upper in Body section. So, how do I know if my GEM car is experiencing a controller problem: The symptoms of bad controller can vary and are not always easily detected by a GEM car owner.
Order New 04-15 Controller. When unit shuts off, record the discharge time. The Polaris Gem electric vehicle has increasingly found use on golf courses as golf carts. Use old mudguard to determine hole locations). 4 - 8 BRAKES DISASSEMBLY INSTALLATION 1.
BRAKES 4 - 3 SPONGY PEDAL THUMP OR CLUNK NOISE A spongy pedal is most often caused by air in the Thumping or clunking noises during braking are system. 4 - 16 BRAKES PARKING BRAKE CABLE ASSEMBLY (6 PASSENGER ONLY) REMOVAL 1. The Clip-In Stake bed is a versatile bed unit designed with a hinged rear Fig. The DC/DC converter has been upgraded and I actually added a digital 12v gauge on my dash so I could watch the volts, it has been steady between 13. If the battery pack is maxed out running the stock motor and you put in a Bandit upgraded motor you could get a larger voltage drop as the Bandit motor will be a higher horse power motor and call more power to achieve greater torque and speed. Three flashes indicate that the battery failed to charge during the allotted time. Check continuity through each pair of motor leads and from each lead to ground. How to reset gem car controller repair. In general the following GEM car problems may be an indication of a controller problem: Error Codes - Frequent occurrence of dashboard error codes.
The tutorial below explains a little about the OBC, how to reset it after charging problems, and what to do if its completely failed. 7 - 17 BODY HOOD LATCH ASSEMBLY OPERATION To unlatch the hood, pull up on leading end of latch handle to release tension on the striker plate, DESCRIPTION allowing disengagement of the striker. The wire harness connector on the steering column has overheated. The Bandit motor has been tested on a dyno machine and if it had a coupler bumper and/or needed a coupler bumper it was tested and determined at that point to use or not. Gem car service manual. I charged the batteries individually until the on board charger would charge them the rest of the way. New batteries need to be charged and discharged 20 to 30 times to achieve the range of which they are capable. 5 - 39 ELECTRICAL PSDM DESCRIPTION The Power Signal Distribution Module (PSDM) is an electrical component that acts as a central hub for all 72 and 12 volt power. Check the fit of the mud flap to the vehicle. There is some type of battery failure, an open circuit or another source of power charging the battery. If it won't show 12. 00 extra added to the Bandit upgrade of $325.
F3 or measure with an Use the Audio System Circuit Diagram to check ohmmeter to determine if it is the wire connection and 12 VDC at PSDM S, open. Now I am NOT getting the -41, but am still getting the random code -27 and the car will trip out. Once the OBC has been reset, you can move on to troubleshooting the golf cart and charging system. This bolt must be horizontal and under the shaft (see Figure 3). A core is required and must be sent to Ride-4-Fun to complete your order. Check under the floor of the cart to inspect the entire length of the accelerator arm for damage and replace if necessary. How to Troubleshoot a GEM Car. When I hooked everything up and drove it, I would sometimes get a stutter and a random code -27 (low 12v). Using reference marks, align steering wheel to steering shaft and place on shaft. Knowledge on how to troubleshoot GEM charging is a very crucial; as you never know when you will encounter these charging faults. 2 Power System DIAGNOSIS AND TESTING The purpose of the power system is to provide primary power for the drive and accessory systems.
You can rectify this by following your manual's instructions. Make sure that the battery pack is not too small and that the voltage is the same as the charger voltage. If you have custom settings, or would like to discuss custom performance settings, Ride-4-Fun can restore these or provide programming options with the rebuilding service. A voltage range from 12. Switch master disconnect OFF, and cover battery terminals to prevent electrical contact. The two, four and six passenger models have a cut out to accommodate the Trunkback/Golfback/Clip- 1.
It's connected directly to the dc buss. A strong sulfur odor or excessive watering requirements of the battery may warn of a battery overcharging or a high battery temperature. All Club Car golf carts newer than 1995 have an OBC or " On Board Computer " in the charge circuit to monitor and control several functions on the golf cart. Five flashes alert you to overheating of the charger during operation. BRAKES 4 - 9 REAR BRAKE ASSEMBLY OPERATION (6 PASSENGER & LONG When pressing on the brake pedal, pressure forces the brake fluid through the brake line from the BACK EXTRA DUTY) master cylinder to each wheel cylinder. It allows you to monitor what's happening in the controller. 7 - 21 BODY SPAT REMOVAL 1. Motor case is striped down to bare metal, field coils are tested and repaired if needed, field and brush studs are inspected and replaced if necessary, motor case bolt threads (rear end side bolt threads) are inspected and chased with tap if needed, motor case bolt threads (end cap for brush rigging) are inspected and chased with tap if needed. Satisfied Customers.
First confirm if the battery connections are faultless, before proceeding. The charger will restart automatically when this fault has been cleared. Raise and support the vehicle on a suitable hoist. To reconnect the OBC back into the system: - Forward/Reverse Switch to Neutral. With master disconnect switch on, measure Proceed to step 10c. 27 12vdc supply low electrical fault check wiring, see manual. 2 - 8 SUSPENSION AND STEERING REAR SUSPENSION REAR SUSPENSION FRAME/AXLE DESCRIPTION (2-4 PASSENGER ONLY) The rear suspension is comprised of a frame that (e2, e4, eS, eL) includes the rear axle, and spring/shock absorbers.
The gray 36 volt GE brand motor is ONLY to be used with 36 volts, stock components and standard tire height. Error 23… Says inspect controller. 5 - 81 ELECTRICAL PIN LOCATIONS FOR FRONT HARNESS CONNECTORS Connector Illustration Connector Connects To Number of Pins in Number Connector PSDM J1 Horn, Motor-Wiper 2, 3, 4, 5, 6, 9, 10, 11 Switch-Brake Pressure, Charger Front Harness Switch-Brake Level Fluid 12 Volt Ground GEM Service Manual November 2007... I am about to order a new pedal in hopes that this solves it, I have looked at all the wiring and the harness and can't find anything.
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