ASSY, DRIVE LINE - 72 VOLT 46 IN WIDE -
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1 ASSY, DRIVE LINE - 72 VOLT 46 IN WIDE ASSY, HALF SHAFT - LH TRI POD ASSY, HALF SHAFT - RH (LONG) TRI POD BUMPER, RESILIENT - DIFF TO MOTOR KEEPER, GEARBOX DIFF DIFFERENTIAL BREATHER VENT WASHER, AXLE SHAFT PIN, COTTER 1/8 X 1.25 LG ZC NUT, HEX - CASTLE - M16 x ZNC BOLT, HEX - 5/16-18 UNC X 1.0 GR 5 ZINC PLATED BOLT, HEX - 1/4-20 UNC X 1.0 GR 8 ZN YL ZINC PLATED WASHER, LOCK - 5/16 ZINC PLATED ASSY, GEAR BOX DIFFERENTIAL W/BREATHER VENT : MOTOR, ELECTRIC - 72 VOLT, 5 HP, HEAVY DUTY ASSY, SENSOR - SPEED 1 = ADD LOCTITE 242 OR EQUIVALENT Page 58 GEM Parts Catalog Section 6 - Drive Line Components November 2007
2 ASSY, DRIVE LINE - 72 VOLT 46 IN WIDE ASSY, HALF SHAFT - LH TRI POD ASSY, HALF SHAFT - RH (LONG) TRI POD BUMPER, RESILIENT - DIFF TO MOTOR KEEPER, GEARBOX DIFF DIFFERENTIAL BREATHER VENT WASHER, AXLE SHAFT PIN, COTTER 1/8 X 1.25 LG ZC NUT, HEX - CASTLE - M16 x ZNC BOLT, HEX - 5/16-18 UNC X 1.0 GR 5 ZINC PLATED BOLT, HEX - 1/4-20 UNC X 1.0 GR 8 ZN YL ZINC PLATED WASHER, LOCK - 5/16 ZINC PLATED ASSY, GEAR BOX DIFFERENTIAL : MOTOR, ELECTRIC VENTED 7 HP, WITH THERMAL PROTECTION ASSY, SENSOR - SPEED 1 = ADD LOCTITE 242 OR EQUIVALENT November 2007 GEM Parts Catalog Section 6 - Drive Line Components Page 59
3 ASSY, ACCELERATOR PEDAL ASSY, PEDAL - ACCELERATOR NUT, HEX - NYLOCK 1/4-20 UNC GR5 ZN BOLT, HEX - 1/4-20 UNC X 2.25 GR5 ZN ZINC PLATED BOLT, HEX - 1/4-20 UNC X 3.75 LG GR 5 ZNC PLT WASHER, FLAT - 1/ ID X OD X THK ZN 6 November 2007 GEM Parts Catalog Section 7 - Electrical Page 61
4 1 2 ASSY, CONVERTER - 72V/12V 30 AMP (SURE POWER) NUT, KEPS - 1/4-20 UNC ZINC PLATED GR 5 ZINC PLATED CONVERTER, 72V/12V - 30AMP ASSY, CHARGER - 72 V 12 AMP WITH SERIAL CHARGER, 72 V - 12 AMP W/SERIAL NUT, KEPS - 1/4-20 UNC ZINC PLATED CORD, EXTERIOR CHARGING INLET 1 Page 62 GEM Parts Catalog Section 7 - Electrical November 2007
5 ASSY, EXTERIOR CHARGING INLET, 15A/125VAC, NEMA ASSY, EXTERIOR CHARGING INLET HOUSING CORD, EXTERIOR CHARGING INLET DECAL, EXTERIOR CHARGING INLET - 10TH ANNIVERSARY DECAL, EXTERIOR CHARGING INLET - EMBLEM STANDARD DECAL, EXTERIOR CHARGING INLET - FILLER 1 November 2007 GEM Parts Catalog Section 7 - Electrical Page 63
6 * ASSY, CONTROL - ELECTRIC MOTOR 5 HP NUT, KEPS - 1/4-20 UNC ZINC PLATED GR 5 ZINC PLATED 6 * CONTROL, ELECTRIC MOTOR - 5 HP 72 V 12 IN WHL *(When ordering a replacement controller, please specify the vehicles battery type, odometer reading and wheel/tire type and size.) ASSY, CABLE MA1 TO CA ASSY, CABLE MA2 TO CA ASSY, CABLE MF2 TO CF ASSY, CABLE MF1 TO CF1 1 *FOR e6 & elxd MODELS SEE PAGES 65 AND 77 Page 64 GEM Parts Catalog Section 7 - Electrical November 2007
7 PSDM RED +72 MAIN CONTACTOR RED MC * MAIN CONTACTOR BLACK MC+ * PSDM BLACK -72 CONTROLLER RED POS MASTER DISCONNECT SWITCH RED DSW * PSDM BLACK NEG PSDM +72 ASSY, CABLES ASSY, CABLE 72+ MC+ 1 * ASSY, CABLE MC- TO POS 1 * ASSY, CABLE NEG TO 72 GND ASSY, CABLE +72 TO DSW 1 *DOES NOT APPLY TO e6 & elxd MODELS. SEE PAGE 77. November 2007 GEM Parts Catalog Section 7 - Electrical Page 65
8 ASSY, WIRE HARNESS - 2-PASS ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - CONTROLLER ASSY, WIRE HARNESS - TAILLIGHT ASSY, REAR HARNESS AND CABLE (SHORT) ASSY, WIRE HARNESS - PARK BRAKE ASSY, WIRE HARNESS - TURN SIGNALS ASSY, WIRE HARNESS - STEERING COLUMN 1 * ASSY, WIRE HARNESS - HEADLIGHT NY 1 ASSY, WIRE HARNESS - 4-PASS ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - CONTROLLER ASSY, WIRE HARNESS - TAIL LIGHT ASSY, REAR HARNESS AND CABLE ASSY, WIRE HARNESS - PARK BRAKE ASSY, WIRE HARNESS - TURN SIGNALS ASSY, WIRE HARNESS - STEERING COLUMN 1 * ASSY, WIRE HARNESS - HEADLIGHT NY 1 ASSY, WIRE HARNESS - 6-PASS ASSY, WIRE HARNESS - MAIN - e ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - CONTROLLER ASSY, WIRE HARNESS - PARK BRAKE ASSY, WIRE HARNESS - TAIL LIGHT ASSY, WIRE HARNESS - TURN SIGNALS ASSY, WIRE HARNESS - STEERING COLUMN 1 * ASSY, WIRE HARNESS - HEADLIGHT NY 1 ASSY, WIRE HARNESS - SHORT BACK ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - CONTROLLER ASSY, REAR HARNESS AND CABLE (SHORT) ASSY, TAIL LIGHT HARNESS W/ GND - LNG BK ASSY, WIRE HARNESS - PARK BRAKE ASSY, WIRE HARNESS - TURN SIGNALS ASSY, WIRE HARNESS - STEERING COLUMN 1 * ASSY, WIRE HARNESS - HEADLIGHT NY 1 ASSY, WIRE HARNESS - LONG BACK ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - CONTROLLER ASSY, REAR HARNESS AND CABLE (SHORT) ASSY, TAIL LIGHT HARNESS W/ GND - LNG BK ASSY, WIRE HARNESS - PARK BRAKE ASSY, WIRE HARNESS - TURN SIGNALS ASSY, WIRE HARNESS - STEERING COLUMN 1 * ASSY, WIRE HARNESS - HEADLIGHT NY 1 *NO PICTURE AVAILABLE Page 66 GEM Parts Catalog Section 7 - Electrical January 2008
9 ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - CONTROLLER 1 November 2007 GEM Parts Catalog Section 7 - Electrical Page 67
10 ASSY, WIRE HARNESS - TAILLIGHT ASSY, REAR HARNESS AND CABLE (SHORT) 1 Page 68 GEM Parts Catalog Section 7 - Electrical November 2007
11 ASSY, REAR HARNESS - PARKING BRAKE ASSY, WIRE HARNESS - TURN SIGNALS ASSY, WIRE HARNESS - STEERING COLUMN 1 November 2007 GEM Parts Catalog Section 7 - Electrical Page 69
12 ASSY, WIRE HARNESS - STEERING COLUMN 1 Page 70 GEM Parts Catalog Section 7 - Electrical November 2007
13 ASSY, WIRE HARNESS, MAIN - e2, el, es ASSY, WIRE HARNESS, MAIN 1 November 2007 GEM Parts Catalog Section 7 - Electrical Page 71
14 ASSY, WIRE HARNESS - e6 ITEM PART NO. DESCRIPTION QTY ASSY, WIRE HARNESS, MAIN ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - MAIN - e6 1 Page 72 GEM Parts Catalog Section 7 - Electrical November 2007
15 ASSY, WIRE HARNESS - e6s ASSY, WIRE HARNESS - FRONT ASSY, WIRE HARNESS - CONVERTER ASSY, WIRE HARNESS - MAIN ASSY, TAIL LIGHT HARNESS W/ GND - LNG BK 1 November 2007 GEM Parts Catalog Section 7 - Electrical Page 73
16 ASSY, WIRE HARNESS - elxd ASSY, WIRE HARNESS, MAIN 1 Page 74 GEM Parts Catalog Section 7 - Electrical November 2007
17 ASSY, PSDM TO DASH SUPPORT ASSY, PSDM PLATE NUT, KEPS - 1/4-20 UNC ZINC PLATED CONTACTOR, MAIN - 100A MODULE, POWER & SIGNAL DISTRIBUTION PSDM SWITCH, DISCONNECT - 100A DECAL, FUSE BLOCK - VIN FUSE, ATC FUSE, ATC FUSE, CARTRIDGE - 10 AMP SLO-BLO CAPS, FUSE HOLDER FUSE, CERAMIC TUBE - 30A SLO- BLO ASSY, PSDM 1 November 2007 GEM Parts Catalog Section 7 - Electrical Page 75
18 ASSY, BATTERY CABLE ASSY, CABLE B3+ TO FUSE ASSY, CABLE B1+ TO B ASSY, CABLE B2+ TO B ASSY, CABLE FUSE TO B ASSY, CABLE B4+ TO B ASSY, CABLE B5+ TO B6-1 Page 76 GEM Parts Catalog Section 7 - Electrical November 2007
19 ASSY, CABLES - e6 & elxd ASSY, CABLE - MA1 TO CA ASST, CABLE - MA2 TO CA ASSY, CABLE - POS TO MC ASSY, CABLE NEG TO 72 GND ASSY, CABLE MF2 TO CF ASSY, CABLE MF1 TO CF1 1 November 2007 GEM Parts Catalog Section 7 - Electrical Page 77
20 ASSY, BATTERY INTERCONNECTS - elxd 8V ASSY, CABLE 5/16 RING - B1+ TO B ASSY, CABLE 5/16 RING - B2+ TO B ASSY, CABLE 5/16 RING - B3+ TO FUSE ASSY, CABLE 5/16 RING -FUSE TO B ASSY, CABLE 5/16 RING - B4+ TO B ASSY, CABLE 5/16 RING - B5+ TO B ASSY, CABLE 5/16 RING - B6+ TO B ASSY, CABLE 5/16 RING - B7+ TO B ASSY, CABLE 5/16 RING - B8+ TO B9-1 * WASHER, CONICAL ID , OD , H , T *NOT SHOWN Page 78 GEM Parts Catalog Section 7 - Electrical November 2007
21 ASSY, BATTERY LEAD ACID FLD-REAR HLD DWN BRACKET, BATTER HOLD DOWN BRKT, BATTERY HOLD DOWN KNOB, 3/ PRONG HOOK, J THREADED 1/4-20 UNC X 4" HOOK, J THREADED 3/8-16 UNC X 5-1/2" NUT, HEX - NYLOCK 1/4-20 UNC GR NUT, 3/8-16 FIN. HEX NUT, 18-8 STAINLESS WASHER, FLAT - 1/ ID X OD X THK ZN WASHER, CONICAL - ID 0.380, OD.750, H 0.059, T 0.040, ZN WASHER, LOCK - 3/8 EXTERNAL/INTERNAL STAR ZP BATTERY, 12 VOLT DEKA FLOODED EV31 6 November 2007 GEM Parts Catalog Section 7 - Electrical Page 79
22 OPTIONS, BATTERIES 8V, GEL BATTERIES, GEL 8V BATTERIES, GEL 8V 9 Page 80 GEM Parts Catalog Section 7 - Electrical November 2007
23 ASSY, BATTERY HOLD DOWN 8-VOLT KNOB, 1/ PRONG CHANNEL, HOLD DOWN - BATTERY HOOK, J THREADED 1/4-20 UNC WASHER, FLAT - 1/ ID X OD X THK ZN 6 November 2007 GEM Parts Catalog Section 7 - Electrical Page 81
24 ASSY, BATTERY HOLD DOWN e6s KNOB, 1/ PRONG CHANNEL, HOLD DOWN - BATTERY SPACER, BATTERY - e6s SPACER, BATTERY HOOK, J THREADED 1/4 20 UNC WASHER, FLAT - 1/ ID X OD X THK ZN 6 Page 82 GEM Parts Catalog Section 7 - Electrical November 2007
25 ASSY BATTERY HOLD DOWN e6 LT KNOB, 1/ PRONG CHANNEL, HOLD DOWN - BATTERY HOOK, J THREADED 1/4-20 UNC WASHER, FLAT - 1/ ID X OD X THK ZN 4 November 2007 GEM Parts Catalog Section 7 - Electrical Page 83
26 ASSY, BATTERY LEAD ACID GEL-REAR HLD DWN WELDMENT, REAR BATTERY HANDLE KNOB, 1/ PRONG BRKT, BATTERY HOLD DOWN HOOK, J REAR PIVOT TUBE HOLD DOWN ZINC PLATED PIN, LYNCH 3/16" ZINC PLATED HOOK, J THREADED 1/4-20 UNC X 4" O-RING, 3/32 C/S X 7/32 ID X 13/32 OD NUT, HEX - NYLOCK 1/4-20 UNC GR5 ZN NUT, 3/8-16 FIN. HEX NUT, 18-8 STAINLESS WASHER, FLAT - 1/ ID X OD X THK ZN WASHER, CONICAL BATTERY, 12 VOLT-GEL DEEP CYCLE 6 Page 84 GEM Parts Catalog Section 7 - Electrical November 2007
27 ASSY, COLUMN STEERING 2&4 PASS HARNESS, INSTRUMENT PANEL COWL, RH COWL, LH COWL, FRONT SCREW, MACHINE TORX PAN HEAD #6-19 X SCREW, MACHINE-TORX PAN HD M4 X 0.7 X 16mm LG SWITCH, DRIVE MODE SWITCH, TURN SIGNAL SWITCH, LIGHT SWITCH, TRIP DISPLAY LCD DRIVER PLUG, SCREW COVER KEY SW KIT W/T-HANDLE 1 November 2007 GEM Parts Catalog Section 7 - Electrical Page 85
28 ASSY, COLUMN STEERING L&S BACK HARNESS, INSTRUMENT PANEL COWL, RH COWL, LH COWL, FRONT SCREW, MACHINE TORX PAN HEAD #6-19 X SCREW, MACHINE-TORX PAN HD M4 X 0.7 X 16mm LG SWITCH, DRIVE MODE SWITCH, TURN SIGNAL SWITCH, LIGHT SWITCH, TRIP DISPLAY LCD DRIVER PLUG, SCREW COVER KEY SW KIT 1 Page 86 GEM Parts Catalog Section 7 - Electrical November 2007
29 C B A ASSY, INSTRUMENT POD ASSY, HARNESS - INSTRUMENT PANEL COWL, FRONT COWL, RH COWL, LH BELLOWS, STEERING COLUMN TIE, CABLE W/#10 MOUNT HOLE 9 BLACK SCREW, MACHINE TORX PAN HEAD #6-19 x SCREW, MACHINE TORX PAN HEAD M4 X 7 X 16mm LG SWITCH, DRIVE MODE SWITCH, TURN SIGNAL SWITCH, TRIP DISPLAY LCD DRIVER PLUG, SCREW COVER 2 NOTE: A. HEADLIGHT SWITCH IS SUPPLIED WITHIN HEADLIGHT OPTION. B. IGNITION SWITCH IS SUPPLIED WITH LOCK SET. C. CABLE TIE IS USED TO SECURE HARNESS TO FRAME. November 2007 GEM Parts Catalog Section 7 - Electrical Page 87
30 ASSY, HORN SCREW, HEX - WHSD 1/4 X 0.75 ZN HORN, ECE ASSY, FUSE -BATTERY ASSY, FUSE HOLDER FUSE, BATTERY - 250A WASHER CONICAL ID 0.317, OD 0.625, H 0.059, T SCREW PHILLIPS FLAT HEAD X Page 88 GEM Parts Catalog Section 7 - Electrical November 2007
31 ASSY, TAIL LIGHTS - CAR TIE, CABLE W/#10 MOUNT HOLE 9" BLACK SCREW, HEX - WHSD 1/4 X 0.75 ZN SCREW, PHIL TRUSS HEAD-#10 X 13/4 LG STEEL ZINC PHIL TRUSS KIT, TAIL LIGHT ASSY, TAIL LIGHT HARNESS - LG UTILITY LIGHT, TAIL, SEALED - UTILITY BED GROMMET, RUBBER - TAIL LIGHT - UTIL BED HARNESS, LIGHT - TAIL - UTIL BED 1 November 2007 GEM Parts Catalog Section 7 - Electrical Page 89
32 ASSY, WIPER MOTOR WINDSHIELD WIPER BUSHING, RUBBER OD X ID X SPACER, SPECIAL NYLON SCREW, HEX - WASHER HEAD SELF DRILL 1/ MOTOR, WIPER - DIN GROMMET, SBR RUBBER - 5/8" ID X 1/8" GROOVE FOR 7/8" HOLE 1 * STARRED PARTS ARE SUPPLIED WITH ITEM #4 Page 90 GEM Parts Catalog Section 7 - Electrical November 2007
33 ASSY, COOLING PACKAGE ASSY, FAN HEATSINK, CONTROLLER - ALUMINUM PLATE, HEATSINK MOUNT BRACKET, FAN THERMAL GREASE, TYPE 120 SILICONE NUT, KEPS - 1/4-20 UNC ZINC PLATED NUT, KEPS ZINC PLATED BOLT, HEX - 1/4-20 UNC X 1.0 GRADE SCREW, HEX - WHSD X 1/2 #2 POINT STL BLK ZINC WASHER HD SELF DRILLING SCREW, MACH GENERIC SST 4 November 2007 GEM Parts Catalog Section 7 - Electrical Page 91
34 1 2 3 ASSY, SCOOP - DUAL SCOOP, WIND - RH SCOOP, WIND - LH BOLT, HEX - 1/ ZN WASHER HD SELF DRILLING 8 Page 92 GEM Parts Catalog Section 7 - Electrical November 2007
35 ASSY, COOLING PACKAGE CLAMP, P - 3/8 WIRE STL/BLK VINYL COATED NUT, KEPS - 1/4-20 UNC ZINC PLATED BOLT, HEX - 1/ UNC X 0.5 LG, GR 5 ZINC PLATED SCREW, HEX - WHSD X 1/2 #2 POINT STL BLK ZINC WASHER HD SELF DRILLING SCOOP, MOTOR AIR 1 November 2007 GEM Parts Catalog Section 7 - Electrical Page 93
36 ASSY, LICENSE PLATE BRACKET AND LIGHT, REAR - COMPLETE SCREW, PHIL PAN HEAD - #8 X 3/8 SELF THREAD 18-8 SST PHIL TRUSS BASE, LICENSE PLATE LAMP LENS, LICENSE PLATE LAMP BRACKET, PLATE - LICENSE REAR NUT, KEPS - 1/4-20 UNC ZINC PLATED BOLT, TORX - TRUSS HD - 1/4-20 X S.S NUTS ARE PART OF SUB ASSEMBLY P/N Page 94 GEM Parts Catalog Section 7 - Electrical November 2007
37 ASSY, LICENSE PLATE MOUNT - FRONT NUT, KEPS UNC ZINC PLATED GR 5 ZINC PLATED SCREW, MACHINE #12-24 x 1 HEX SLOT HEAD BRACKET, LICENSE PLATE - FRONT 1 November 2007 GEM Parts Catalog Section 7 - Electrical Page 95
38 KIT, REVERSE LAMP ASSY, BASE - REVERSE LAMP SCREW, PHIL PAN HEAD - #8 X 1.5 LG SST PHIL TRUSS LENS, REVERSE LAMP BULB, REVERSE LAMP 1 Page 96 GEM Parts Catalog Section 7 - Electrical November 2007
39 ASSY, LICENSE PLATE REAR ASSY, WIRE HARNESS LICENSE LAMP GROUND ASSY, WIRE HARNESS - LICENSE LAMP POWER BRACKET, LICENSE PLATE NUT, HEX - NYLOCK 1/4-20 UNC GR5 ZN NUT, KEPS ZINC PLATED GR 5 ZINC PLATED BOLT, TORX - TRUSS HD - 1/4-20 X S.S SCREW, MACH PAN HEAD PHIL 8-32 X 3/4 ZN KIT, LICENSE PLATE LAMP KIT, LICENSE PLATE LAMP - CHROME OPTION 1 November 2007 GEM Parts Catalog Section 7 - Electrical Page 97
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ASSY, DRIVE LINE - 72 VOLT 46 IN WIDE - 1 0113-01093 ASSY, HALF SHAFT - LH 1 2 0113-01094 ASSY, HALF SHAFT - RH (LONG) 1 3 0313-00168 BUMPER, RESILIENT - DIFF TO MOTOR - - 1 4 0313-00417 KEEPER, GEARBOX
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