# GEM E825 Newbie
**URL:** https://community.electricforum.com/t/gem-e825-newbie/4032
**Category:** GEM Forum
**Created:** [January 22, 2014, 6:23am UTC](https://community.electricforum.com/t/gem-e825-newbie/4032 "2014-01-22T06:23:15Z")
**Posts on this page:** 15
**Page:** 1
### Author:  [@Tony](https://community.electricforum.com/u/Tony)
#### Post date: [January 22, 2014, 6:23am UTC](https://community.electricforum.com/t/gem-e825-newbie/4032/1 "2014-01-22T06:23:15Z")
Hello,
I am the proud owner of a 1999 GEM E825. I was told it needed batteries, so we installed them yesterday. I energized the system and error -16 appears and an obnoxious horn that I did locate next to the master contactor. I am not getting an over voltage. 72 volt registering on my Fluke. The main contactor will not pull in with the 72 volt coil. I assume it is bad. Would this cause the error code -16? Batteries are all wired properly. I am looking for my next step in sorting this one out.
Thanks!
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### Author:  [@arandall](https://community.electricforum.com/u/arandall)
#### Post date: [January 23, 2014, 4:50am UTC](https://community.electricforum.com/t/gem-e825-newbie/4032/2 "2014-01-23T04:50:14Z")
I [U]thought [/U]the earlier GEMS weren’t 72v systems but something less (48v maybe) though I’m not 100% about that. If you installed 6 x 12v batteries in series and it wasn’t a 72v system that would be the problem.
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### Author:  [@Tony](https://community.electricforum.com/u/Tony)
#### Post date: [January 23, 2014, 10:25am UTC](https://community.electricforum.com/t/gem-e825-newbie/4032/3 "2014-01-23T10:25:04Z")
Hi,
Thank you for the response. My Gem has a 72 volt system in it. GE 72 v controller, Zivan NG1 micro upgraded charger and a 72-12v DC to DC converter. The only issue I a seeing at this point is the error -16 and beeping when the key is energized.
Charger is working and system volts are not over 76 volts. I fully charged the new batteries for the 1st time last night. The only schematic I can’t locate, is the GE controller. I believe the issue resides there.
Any thoughts?
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### Author:  [@arandall](https://community.electricforum.com/u/arandall)
#### Post date: [January 23, 2014, 11:35am UTC](https://community.electricforum.com/t/gem-e825-newbie/4032/4 "2014-01-23T11:35:43Z")
Hmm, you’re now a bit outside my area of expertise. The earlier controllers ARE programmable and there [B]may[/B] be a setting to determine what constitutes “overvoltage”. If it’s set too low for some reason, then it would throw the -16 error. The controllers “reboot” whenever you cut and then restore the power (which presumably would have been done (I HOPE!!) when you replaced the batteries.
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### Author:  [@Tony](https://community.electricforum.com/u/Tony)
#### Post date: [January 23, 2014, 8:13pm UTC](https://community.electricforum.com/t/gem-e825-newbie/4032/5 "2014-01-23T20:13:15Z")
I believe I need to replace the GE Controller. It appears the error code is derived from it. I have been rebooting the system and it did not help.
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### Author:  [@arandall](https://community.electricforum.com/u/arandall)
#### Post date: [January 24, 2014, 4:52am UTC](https://community.electricforum.com/t/gem-e825-newbie/4032/6 "2014-01-24T04:52:14Z")
You might first want to call Ride-4-Fun and/or talk to Marlon (you can find him on this newsgroup) about the controller issue first. Both of these parties do a lot with reprogramming controllers and might have additional insights. I believe R4F also rebuilds them if you need to go down that road.
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### Author:  [@eSGEMColo](https://community.electricforum.com/u/eSGEMColo)
#### Post date: [January 24, 2014, 11:56pm UTC](https://community.electricforum.com/t/gem-e825-newbie/4032/7 "2014-01-24T23:56:02Z")
hi Tony… welcome… I just drive my GEM car and haven’t had the problem you are having… not sure if R-4-F is open on Saturday… maybe GEMmechanic will weigh in… if not drop do to the forum and repost your question… on Monday call Lee at [Gem Car Parts Direct | The Nations #1 Source for Gem Car Parts](http://www.GEMcarpartsdirect.com)… 888-677-4961… he can probably get you on the road quickly… I believe Marlon is still recuperating from an accident
Bob
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### Author:  [@Tony](https://community.electricforum.com/u/Tony)
#### Post date: [February 5, 2014, 3:34pm UTC](https://community.electricforum.com/t/gem-e825-newbie/4032/8 "2014-02-05T15:34:59Z")
Hi,
Thanks for the info. I will look into that. I had sent my controller to an electronics specialist and he could not help. Just got it back and would like to have it looked at by someone knowledgable in these.
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### Author:  [@gtmo-gem](https://community.electricforum.com/u/gtmo-gem)
#### Post date: [February 6, 2014, 3:03am UTC](https://community.electricforum.com/t/gem-e825-newbie/4032/9 "2014-02-06T03:03:17Z")
content removed…
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### Author:  [@GEMmechanic](https://community.electricforum.com/u/GEMmechanic)
#### Post date: [February 19, 2014, 1:37pm UTC](https://community.electricforum.com/t/gem-e825-newbie/4032/10 "2014-02-19T13:37:20Z")
Wow, this is my 500th post! It has been a long three years on here. 72 volts is actually a bit low. Fully charged and settled, the batteries should read 75.6 volts,which is 12.6 per battery. If you get a -16, run the lights for a minute to reduce the “surface charge” on the batteries. There are numerous companies that repair GE controllers. RFF is the best known.
Daniel
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### Author:  [@eSGEMColo](https://community.electricforum.com/u/eSGEMColo)
#### Post date: [February 19, 2014, 1:51pm UTC](https://community.electricforum.com/t/gem-e825-newbie/4032/11 "2014-02-19T13:51:49Z")
CONGRATS GEMmechanic on the 500
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### Author:  [@Tony](https://community.electricforum.com/u/Tony)
#### Post date: [February 19, 2014, 7:29pm UTC](https://community.electricforum.com/t/gem-e825-newbie/4032/12 "2014-02-19T19:29:00Z")
I sent the controller in to Flight Systems. It was diagnosed as a bad potentiometer and they refurbed it. Put the controller in last night and it runs! Everything works great! Now I have a new issue ( or I believe it’s an issue). The car runs but the differential sounds very loud. Almost like a metal snow shovel on cement constantly ( if you understand what that sounds like). Breaks are not stuck, sound is in diff for sure.checked the oil and it looks fine. I think I’m going to open the diff this weekend and inspect the bearings.
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### Author:  [@eSGEMColo](https://community.electricforum.com/u/eSGEMColo)
#### Post date: [February 19, 2014, 7:47pm UTC](https://community.electricforum.com/t/gem-e825-newbie/4032/13 "2014-02-19T19:47:37Z")
Tony… glad you’re back on the street… did you check the oil level? maybe you only need to put oil in it… again I just drive my car and can’t fix it
Bob
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### Author:  [@Tony](https://community.electricforum.com/u/Tony)
#### Post date: [March 1, 2014, 10:27am UTC](https://community.electricforum.com/t/gem-e825-newbie/4032/14 "2014-03-01T10:27:25Z")
I replaced the oil with 140 weight to see if it would quiet the trans axle down. To no prevail, I plan on removing motor today and possibly rebuilding front diff. Not sure what to do?
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### Author:  [@Tony](https://community.electricforum.com/u/Tony)
#### Post date: [March 10, 2014, 6:35pm UTC](https://community.electricforum.com/t/gem-e825-newbie/4032/15 "2014-03-10T18:35:17Z")
My issue was a bad motor! Bearings were shot. Rebuilt it and it runs like a champ!