SERVICE MANUAL
NO PART OF THIS PUBLICATION MAY BE REPRODUCED, STORED IN A RETRIEVAL SYSTEM, OR TRANSMITTED, IN ANY FORM OR BY ANY MEANS, ELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORDING, 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 previously manufactured.
Litho in U.S.A. Copyright © 2002 Global Electric Motorcars, L.L.C.
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The information contained in this service manual has been prepared for the professional automotive technician involved in daily repair operations. Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle. Information in this manual is divided into groups. These groups contain 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 sure 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 manual. 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 engineering torque range for a given fastener application. These torque values are intended for use in service assembly and installation procedures 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.
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GROUP TAB LOCATOR 0 - INTRODUCTION 2 - SUSPENSION AND STEERING 3 - DRIVETRAIN 4 - BRAKES 5 - ELECTRICAL 6 - WHEELS & TIRES 7 - BODY 8 - WORD INDEX
0-2
INTRODUCTION
USING THIS MANUAL Appropriate service methods and proper repair procedures 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 recommended 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 manual must first establish that he/she compromises neither their personal safety nor vehicle integrity by their choice of methods, tools, or parts.
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
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. Figure 1 - VIN/Certification Label
• Be sure that the Ignition Switch is always in the "OFF" position and that the "KEY" is removed.
1
• 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 is 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 lefthand (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.
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.
INTRODUCTION
0-3
Fasteners and torque specifications references in this Service Manual are identified SAE format.
FASTENER USAGE Description
During any maintenance or repair procedure, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly. If the fastener is not salvageable, a fastener of equivalent specification must be used.
WARNING! Use of an incorrect fastener may result in component damage or personal injury.
NOTE: Nylon lock nuts must always be replaced.
TORQUE SPECIFICATIONS DESCRIPTION Battery Cables to Battery Post Brake line to Wheel/Master Cylinder Brake Master Cylinder to Frame Brake Pedal Assembly to Frame Brake Pedal to Push Rod Brake, Drum Assembly to Steering Knuckle Brake, Parking - Cable Mount to Rear Suspension Control Arm to Frt. Suspension Frame Differential to Frt. Suspension Frame Front Suspension Frame to Frame (Lower) Front Suspension Frame to Frame (Upper) Half Shaft to Drum Brake Assembly King Pin Pinch Bolt Motor to Differential Rack & Pinion to Frt. Suspension Frame Rear Suspension Frame to Frame 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 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
THREAD SIZE
5/16 - 18 5/16 - 18 3/8 - 16 M8 x 1.25 1/2" x 13 M12 x 1.75 5/16" -- 18 M12 x 1.75 3/8 - 16 M16 x 1.5 M6 - 1 1/4 - 20 M8 x 1.25 M12 x 1.75
M12 x 1.75 M12 x 1.75 3/8 - 16 5/16 - 18 M10 x 1.5 M10 x 1.5 M12 x 1.75
Use Loctite® 242 NO NO NO NO NO NO NO NO NO YES YES YES YES YES NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO
INCHFOOTPOUNDS POUNDS 70 --225 225 --225 ----225 ------65 65 225 --------------------225 225 -------
--37 ----30 --90 60 --60 30 74 ------60 60 60 60 60 60 60 60 60 30 --35 50 60
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INTRODUCTION
PARTS AND LUBRICANT RECOMMENDATION
MAINTENANCE SCHEDULES
When service is required, GEM recommends that only GEM replacement parts be used. GEM provides the best engineered products for servicing GEM vehicles.
Perform the following inspections, and corrections as necessary, on a monthly basis. Item
Description - Lubricants and Grease Only lubricants bearing designations defined by The Society for Automotive Engineers (SAE) should be used to service 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 identification 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 highest quality.
1
2
Description
1.
Check all six batteries for proper water levels.
2.
Check battery terminals for tight connections.
3.
Check battery terminals for corrosion.
4.
Check tires for correct PSI and wear.
5.
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.
8.
Check brake lines for leaks.
9.
Check seat belts for proper operation.
10.
Check headlights, horn, turn signals, windshield wiper and brake lights for proper operation.
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HOISTING AND JACKING
0080
Figure 3 - NLGI Symbols 1. Wheel Bearing Lubrication 2. Chassis Lubrication 3. Chassis and Wheel Bearing Lubrication
FWD
Description - Differential 0066
Use SAE 30 weight motor oil.
Description - King Pin Lubricant
Figure 4 - Hoisting/Jacking Locations
Use only grease with NLGI "L" or "LB" symbol.
A vehicle can be lifted with:
Description - Brake Fluid
• A single-post frame-contact hoist • A twin-post, chassis hoist • A ramp-type drive-on hoist.
Use only DOT3 brake fluid from an unopened container when filling the master cylinder to prevent contaminants from entering the brake system.
NOTE: When a frame-contact type hoist is used, verify that the lifting pads are positioned properly.
INTRODUCTION
0-5
WARNING! The hoisting and jack lifting points provided are for a complete vehicle. When a chassis or drivetrain component is 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.
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SUSPENSION AND STEERING
SUSPENSION AND STEERING
Inspection - Pre-Alignment
WHEEL 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 complaints 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 plenty of room to maneuver.
Description Front wheel alignment is essential for proper vehicle handling and passenger safety. Front-end damage or replacement of any steering or front suspension component will require inspection of the alignment to determine if it is still within specifications.
CAUTION! Never attempt to modify suspension or steering components by heating or bending.
RAPID WEAR AT SHOULDERS
RAPID WEAR AT CENTER
UNDER-INFLATION OR LACK OF ROTATION
OVER-INFLATION OR LACK OF ROTATION
CONDITION
Before starting wheel alignment, the following inspection and necessary corrections must be completed. Refer to Suspension and Steering System Diagnosis Chart below for additional information.
1. Inspect tires for size, air pressure and tread wear. 2. Inspect front wheel bearings for wear. 3. 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.
CRACKED TREADS
FEATHERED EDGE
BALD SPOTS
INCORRECT TOE
UNBALANCED WHEEL
SCALLOPED WEAR
1.
EFFECT 2.
UNDER-INFLATION
CAUSE
LACK OF ROTATION OF TIRES OR WORN OR OUTOF-ALIGNMENT SUSPENSION.
OR TIRE DEFECT *
CORRECTION
ADJUST PRESSURE TO SPECIFICATIONS WHEN TIRES ARE COOL ROTATE TIRES
ROTATE TIRES AND ADJUST TOE-IN DYNAMIC OR INSPECT SUSPENSION TO STATIC SEE GROUP 2 SPECIFICATIONS BALANCE WHEELS
* HAVE TIRE INSPECTED FOR FURTHER USE.
Figure 1 - Tire Wear Chart
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