USER MANUAL
Contents
1. PRE OPERATION INSPECTION ITEMS 1 FUNCTIONS OF OPERATING SYSTEM 2 5 OPERATING PROCEDURES 5 RULES FOR SAFE OPERATION 6 SAFETY FEATURES 7 MAINTENANCE OF BATTERIES 8 SCHEDULED MAINTENANCE PROCEDURES 9 10 SCHEDULED OILING LUBRICATION PROCEDURES 11 STORING THE VEHICLE 12 TOWING OR TRAILER TRANSPORT 12 MAINTENANCE OF MOTOR 13 MAINTENANCE OF SPEED CONTROLLER 13 TROUBLE SHOOTING GUIDE 14 WARRANTY _ mu Jm o 15 16 NOTES AAA gt a 17 18 EEV Legacy 9 8 11 OPERATING SYSTEM Headlight Switch Turn Signal Horn Switch Steering Wheel Optional harge Indicator Direction Select2. USER MANUAL 2012 Legacy Model ELECTRIC FORWARD Thank you for purchasing the Legacy model by Evergreen Electric Vehicles Your Legacy Model has excellent performance characteristics fashionable design features and internal systems to provide a comfortable and safe ride Your ongoing satisfaction is important to us therefore we strongly recommend you read this user manual completely and discuss any questions you have regarding safety and operation with your local Authorized Evergreen Dealer Please pass this user manual onto the next owner so they might too become familiar with the Legacy model This Vehicle is Produced by Evergreen Electric Vehicles LLC Corporate uarters Grand Junction CO USA Production Facility Rancho Dominquez CA USA USA Parts Content 50 TAA Parts Content 52 NAFTA Compliant EEV Legacy 9 8 11 PRECAUTIONS A The RED warning text shown here appears throughout the user manual Please pay special attention to these safety warnings in order to prevent injury to your property driver occupants and or persons around you during operation Dic Operators of Legacy Electric Vehicles must be over the age of 16 years and have a valid driver s license Contents of this manual are subject to change without notice Copyright 2012 Evergreen Electric Vehicles LLC 743 Horizon Ct Suite 333 Grand Junction CO 81506 970 257 0346 EEV Legacy 9 8 11 CONTENTS OPERATING TEM 1
3. In order to tow the vehicle properly or move the vehicle without using the motor turn the Ignition Switch to the OFF position see Fig 2 Pg 2 this will allow the motor to turn freely Vehicles equipped with AC motors DO NOT have a RUN TOW switch Aisen A If the key ignition switch is in the ON Position during towing the motor will be permanently damaged 12 Page EEV Legacy 9 8 11 AC MOTOR BRAKING The AC Motor will provide additional braking force when the key ignition switch is in the ON position and pressure is removed from the accelerator The controller unit automatically recognizes this and applies braking force through the motor This will assist in slowing down the vehicle When motor braking occurs power is put into the batteries AC MOTOR ROLLAWAY FEATURE When the key ignition switch is in the ON position and all pressure is removed from the accelerator the vehicle can still roll forwards or backwards if this happens a buzzer will sound to warn the driver that the vehicle is moving The motor will slow the vehicles movement to allow the driver to return to the vehicle and properly set the parking brake The motor will not completely stop the vehicle it will only slow its movement down Aia A When the key ignition switch is in the OFF position the Rollaway Feature is disabled and the vehicle can roll away freely and possible at high speeds MAINTENANCE OF MOTOR 1 Do not keep the motor running at to
4. Charge Indicator A drop in charge means battery capacity is diminishing The battery pack should never be drained below 80 capacity Batteries that are over discharged will have a shorter life If the vehicle is not going to be in use for any long duration the batteries should be fully charged before storing the vehicle If possible the batteries should be recharged every 2 weeks and allow the charger to turn off automatically Ain A During recharging the car should be parked in a well ventilated area with the fill caps completely tightened Keep away from any flame or spark to avoid explosions that could result in physical injury or damage of property 10 11 When replacing a battery make sure the new battery is of the same specification as the battery being replaced and is appropriate for the application To extend battery charge turn the run tow switch to the tow position when the vehicle is going to be stored for an extended period of time AGM Batteries do NOT require watering 8 Page EEV Legacy 9 8 11 SCHEDULED MAINTENANCE PROCEDURES Scheduled inspection procedures for electric cars Schedule Inspection Accelerator Pedal Check for normal operation adjust if necessary Accelerator Microswitch Check for normal operation adjust if necessary Batteries WET ONLY Charger after each use check water level DO NOT OVERFILL AGM Batteri
5. MAINTENANCE AS OUTLINED IN THE USER S MANUAL AND SERVICE MANUAL WAS NOT PERFORMED AT THE TIME AND IN THE MANNER SPECIFIED IN SUCH MANUALS l6 Page EEV Legacy 9 8 11 SOLE REMEDY EVERGREEN ELECTRIC VEHICLES liability under this limited warranty or in any action whether based upon warranty contract negligence strict product liability or otherwise shall be the repair or replacement at EVERGREEN ELECTRIC VEHICLES option of the electric car part that EVERGREEN ELECTRIC VEHICLES deems to be defective For the purposes of this warranty REPLACEMENT shall mean furnishing during the applicable limited warranty period a new electric car or factory reconditioned vehicle or part that is either identical or a reasonable equivalent to the original warranty product or part to the purchaser For the purposes of this warranty REPAIR shall mean remedying a defect in the electric car or part thereof the purchaser during the limited warranty period If EVERGREEN ELECTRIC VEHICLES elects to repair the electric car it may provide factory reconditioned parts All parts replaced under warranty shall become property of EVERGREEN ELECTRIC VEHICLES DISCLAIMER THIS LIMITED WARRANTY IS EXCLUSIVE EVERGREEN ELECTRIC VEHICLES ITS AGENTS OR EMPLOYEES MAKE NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS OR TIME LIMITS STATED BY THIS WARRANTY ARE HERE
6. BY DISCLAIMED BY EVERGREEN ELECTRIC VEHICLES AND EXCLUDED FROM THE WARRANTY THE PURCHASER AND EVERGREEN ELECTRIC VEHICLES EXPRESSLY AGREE THAT THE SOLE REMEDY OF THE REPLACEMENT OR REPAIR OF THE DEFECTIVE ELECTRIC CAR OR PART IS THE SOLE REMEDY OF THE PURCHASER EVERGREEN ELECTRIC VEHICLES MAKES NO OTHER REPRESENTATION NOR HAS THE AUTHORITY TO MAKE OR IMPLY ANY REPRESENTATION PROMISE OF AGREEMENT WHICH IN ANY WAY VARIES THE TERMS OF THIS WARRANTY INFORMATION For further information contact EVERGREEN ELECTRIC VEHICLES 743 Horizon Ct Suite 333 Grand Junction Colorado 81506 or visit www evergreenev com AN wanine A Any modification or alteration of any electric car beyond factory specifications including but not limited to those that affect the weight distribution stability or speed of the Legacy Vehicle can cause serious personal injury or death and damage to property 17 Page EEV Legacy 9 8 11 NOTES 18 Page EEV Legacy 9 8 11 ever sreen electric vehicles LLC Take another path www evergreenev com
7. aler or experience mechanic immediately see Fig 6 pg 3 2 Page EEV Legacy 9 8 11 BRAKE PEDAL Is used in deceleration or parking See pre operation inspection items pg 2 Braking force can be measured with a common bathroom scale and should be set at 65 75 lbs Travel distance of the brake pedal should be 2 3 of the distance from resting to the floor see Fig 7 PARKING BRAKE Is used when the car is unattended or stopped on an incline See pre operation inspection items pg 2 f the Parking Brake fails to remain in the down position the Parking Brake is NOT set Repeat the procedure again until the Parking Brake latches firmly into place see Fig 8 A If you casually set the parking brake while descending a slope you should release the parking brake by depressing the service brake pedal It is prohibited to release the parking brake by depressing the accelerator pedal in this situation to prevent personal injury and vehicle damage Fig 6 Fig 7 Fig 8 STEERING WHEEL Controls the driving direction BATTERY CHARGE INDICATOR There are 10 divisions in the indicator The indicator will fall from the higher divisions as the batteries discharge When the battery is too low the red indicator light will flash reminding you to recharge the battery Allowing the batteries 80 or division 2 could cause permanent damage to the batteries It is best practice to charge the batteries after every use See y
8. er 100 rounds or 50 work hours Check all above routine weekly monthly and quarterly items Batteries Check the specific gravity electrolyte level height and charger voltage Brake System Check for normal operation check is service brake system has normal movement check brake pads and shoes clean and adjust as needed Wires amp Connections Check for exposed broken short circuit wires make repairs as needed Forward Reverse Switch Check contacts and wires for secure connections make repairs as needed Front Wheel Alignment Check and adjust as necessary Entire Car Carry out lubrication as per schedule Annual Inspection to be carried out by qualified Mechanic per 200 rounds or 100 work hours Check all above routine weekly monthly quarterly and semi annual items Accelerator Microswitch Check for normal operation remove cap and check for damage Batteries Carry out discharge test Motor Check brushes replace as necessary Front Wheel Bearings Check for smooth movement adjust or lubricate with chassis lubricating oil if necessary Drive Axle Check and fill oil to seal position if needed Entire Car Carry out lubrication as per schedule 10 Page EEV Legacy 9 8 11 SCHEDULED OILING PROCEDURES Schedule Inspection Position Recommended Lubricating Oil Brake Pedal Main Shaft 1 General Purp
9. es do not require water Routine Brake System Check for normal operation adjust if necessary Maintenance Charger amp Socket Check for normal operation during charging check by Owner socket for damage and debris Parking Brake System Check for normal operation adjust if necessary Forward Reverse Switch Check for normal operation Steering amp Electric Wiring Check for normal operation Tires Check air pressure wear amp tear Warning Labels Make sure all labels are legible and present Battery Terminals j Clean terminals and remove corrosion thoroughly Wee i 7 Wires Connections Check for damage make sure they are secure Inspection by Entire Car Owner Check for loose parts tighten as necessary check maximum speed in forward and reverse see dealer if problem Batteries Clean top of batteries with soda water as Monthly necessary Inspection by Brake System Check for normal operation adjust if necessary Owner or Tires Check air pressure wear amp tear and damage Mechanic Accelerator Microswitch Check for damage ensure switch is fixed to the framework Check all above routine weekly and monthly items Quarterly Inspection by Accelerator Pedal Check for normal operation adjust if necessary Owner OF Driving System Carry out lubrication as per schedule Mechanic Entire Car Carry out lubrication as per schedule 9 Page EEV Legacy 9 8 11 Semi Annual inspection to be carried out by qualified Mechanic p
10. f control of the vehicle resulting in serious injury or death DO NOT Operate the vehicle while under the influence of drugs alcohol or any other substance which could impair one s ability to operate the vehicle safely DO NOT Climb hills beyond a 20 grade DO NOT Travel across hills beyond a 14 grade DO NOT Overtake other vehicles at crossroads blind areas or any other area that could inhibit vision or safety DO NOT Drive the vehicle on unauthorized streets or highways DO NOT Change the Forward Reverse switch while the vehicle is in motion DO NOT Travel at unsafe speeds into turns corners or unstable surfaces A The effectiveness of the Brakes may be reduced when the vehicle is driven in wet condition or through water 6 Page EEV Legacy 9 8 11 SAFETY FEATURES The Legacy Electric Vehicle is equipped with the following standard safety features 1 A NS Foldable windshield optional Rear mechanical disc brakes DOT approved wheels and tires Driver amp Passenger side DOT approved 3 point harness seat belt optional Rear amp Side DOT approved reflex reflectors and Tail amp Stop Lamps Driver amp Passenger side view mirrors optional Parking Brake Headlamps Front Rear Turn Signals See Pics 5 amp 8 Aianei A These safety features should NOT be removed for any reason If any of the above listed items are missing they MUST be replaced before operating t
11. he vehicle on public roads or highways 7 Page EEV Legacy 9 8 11 1 MAINTENANCE OF THE BATTERIES The batteries connection wires and bolts should always be kept clean and dry If there is any electrolyte present wipe it off with a clean cotton cloth then wash and rinse with water afterwards re wipe the area with a clean cotton cloth A When washing the outside of the batteries take extra care to ensure no water is able to enter the battery cells as it may result in battery damage Regularly check battery connections to ensure they are in good condition Do not place any objects on the batteries and do not connect the positive pole to the negative pole this will result in a short circuit a dangerous spark or even damage the battery After discharging the batteries regardless of driving period and mileage driven the batteries should be recharged on the same day Delaying recharging the batteries by more than 24 hours can have a negative effect on battery life During use the density of the liquid in the batteries will increase while the volume of liquid will decrease due to evaporation and electrolysis especially in hot weather Check water levels on a regular basis and add DISTILLED water when the water level gets low No impurity should be allowed to enter the battery cells use only DISTILLED water and use of a battery watering system is highly recommended When driving the driver should be aware of the Battery
12. ions limitations and exclusions contained in this warranty to the original owner or leaser Batteries and Battery Chargers are covered by the specific manufacturer s warranties EXCLUSTIONS Excluded from any EVERGREEN ELECTRIC VEHICLES warranty is damage to an electric car or part resulting from a cause other than a defect including but not limited to poor maintenance neglect abuse accident and collision maintenance adjustments unreasonable or unintended use improper installation of accessories installation of parts or accessories that are not original equipment non approved alteration and acts of God Also excluded from an EVERGREEN ELECTRIC VEHICLES warranty are all fuses filters decals except safety decals lubricants routine where items such as charger plug receptacle brake shoes and pads tires belts brushes bushings cosmetic deterioration upholstery and items which deteriorate fade or fail due to exposure or ordinary wear and tear VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE ELECTRIC CAR IS ABUSED OR USED IN AN UNINTEDED MANNER OR SHOWS INDICATIONS THAT IT HAS BEEN ALTERED IN ANY WAY INCLUDING BUT NOT LIMITED TO MODIFICATIONS OF THE SPEED GOVERNOR BRAKING SYSTEM STEERING TRANSAXLE OR OTHER OPERATING SYSTEM OF THE CAR TO CAUSE IT TO PERFORM OUTSIDE EVERGREEN ELECTRIC VEHICLES SPECIFICATIONS THE WARRANTY IS LIKEWISE VOID IF THE CAR INVOLVED SHOWS INDICATION THAT REASONABLE OR NECESSARY
13. ive when the key switch is turned to the 3 position see Fig 4 Pg 2 Turning the barrel switch forward illuminates the front and rear lights Movement up and down activates the turn signals and depressing the button at the end of the lever sounds the horn see Fig 12 STALK CONTROL HEADLIGHT twist RIGHT TURN Fig 12 OPERATING PROCEDURES Turn the Ignition Switch to either 2 ON or 3 ED Position Select Forward or Reverse Gradually press down on the Accelerator Pedal to increase speed Use Turn Indicators where necessary When arrived at destination engage parking break roll the headlight switch to the OFF Position and turn the Ignition Switch to the 13 OFF Position see Fig 2 Pg 2 AN annam A If you press down on the Accelerator Pedal before switching the Ignition Key to the ON position the car oe W e will NOT move If this happens release the Accelerator Pedal then return the Ignition to the OFF position and start over at step 1 The car should begin to operate properly 5 Page EEV Legacy 9 8 11 RULES FOR SAFE OPERATION The operator of the car should have a good understanding of the operating system of the car and its features Always abide by all rules of safe operation DO NOT Let unqualified persons operate the vehicle DO NOT Overload the vehicle with people or weight doing so may cause damage to the motor or harm to the operator or passengers and may also cause loss o
14. or Parking Brake Brake Pedal ignition Key Accelerator Pedal Fig 1 PRE OPERATION INSPECTION ITEMS Your Electric Car received an overall inspection at the manufacturing facility and a final inspection by your local dealer prior to delivery However it is important to acquaint yourself with the controls and operation of the vehicle 1 Perform your own visual inspection to ensure that all parts are secure and appear to be installed properly Any item that may interfere with clear view ability to start and stop the vehicle or use the steering wheel properly to control the direction of travel should be discussed with your local dealer immediately 2 Check all printed warning labels located on the vehicle 3 Check under the seat bottom in the battery area All wire connections on the battery terminals should be tight secure and corrosion free Your new electric car will be delivered with a full charge please consult Page 6 Maintenance of Batteries and Use of Charger 4 Test drive the car for proper braking acceleration an steering control When traveling at a speed of 19 5mph or less the car should stop smoothly and ina straight line within 25 feet The Parking Brake should catch securely and hold the car in place on grades of 15 degrees or less The Parking Brake will release by activating the Accelerator or applying pressure to the Brake Pedal to unlatch the Parking Brake 5 Adjustments to the vehicle speed or braking sho
15. ose Lithium Base Grease Quarterly Inspection by owner Shaft Accelerator Pedal 2 High Quality Spray Lube or qualified mechanic Steering Gearbox 3 General Purpose Lithium Base Grease Front Spindle King Pin 4 General Purpose Lithium Base Grease Annual Inspection to be carried Check Drive Axle amp Fill Oil to 5 out by qualified mechanic per Seal Position Hypoid Gear Oil 200z of 80 90 weight 200 rounds or 100 work hours Check Front Wheel Bearings 6 General Purpose Lithium Base Grease 11 Page m EV Legacy 9 8 11 STORING THE VEHICLE Fully charge the batteries see Maintenance of Batteries pg 10 Turn the Ignition Key to the OFF position and remove key see Fig 2 Pg 2 Turn RUN TOW Switch to the TOW position see Fig 13 DC motor only Store vehicle in an area where the batteries will not freeze If storing longer than 30 days disconnect positive battery terminal noe WN TOWING OR TRAILER TRANSPORT DC Motor amp Contoller In order to tow the vehicle properly or move the vehicle without using the motor turn the Ignition Switch to the OFF position see Fig 2 Pg 2 and turn the RUN TOW switch to the TOW position see Fig 13 This will allow the motor to turn freely uP Rama concn TN contin be RUN Sm TOW pees on Frame Fig 13 AN wanie A If the RUN Position is selected during towing the motor will be permanently damaged AC Motor Contoller
16. our Battery Charger s owner s manual for complete instructions on how to recharge the electric car batteries see Fig 9 3 Page EEV Legacy 9 8 11 CLOCK To set the clock use the buttons below the clock see Fig 10 Clock is not included in all models Fig 10 ui A Legacy vehicles equipped with a clock draw power even when the vehicle is turned off If the vehicle is going to remain unused for 30 or more days between recharging disconnect the main battery cable to avoid excessive discharge reset the clock after batteries are reconnected VIN PLATE Located under the seat in the battery compartment beside the DC DC converter It displays information regarding the vehicle see Fig 11 MFD BY EVERGREEN ELECTRIC VEHICLES LLC GRAND JUNCTION CO 81506 USA PRODUCTION FACILITY RANCHO DOMINGUEZ CALIFORNIA USA DATE MFD COEG GVRW MN KG EES GAWR FRONT MN K ES GAWR REAR GE LBS TIRE SIZE MN SIZE SPEC COLD INF PRESSURE FRONT amp REAR KPA BEEPS RIMS Si MAXIMUM LOAD ME KG MW LBS OCCUPANTS MN THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE ABOVE VW MN TYPE A MODEL MN USA PARTS CONTENT 50 TAA PARTS CONTENT 52 NAFTA COMPLIANT Fig 11 4 Page EEV Legacy 9 8 11 LIGHT amp TURN ASSEMBLY Located on the steering column just below the steering wheel It becomes act
17. p speed for long periods of time 2 Removal of mud sand and other clinging objects should be performed regularly to facilitate heat dissipation 3 Periodically use low pressure air to remove dust from the carbon brushes and the communicator DC motor only Aci A Explosive gas vapors in the air may explode if contact is made with sparks generated by the motor This could cause severe injury and damage to property We highly recommend you contact your local authorized Evergreen Electric Vehicle Dealer or qualified electrician to work on problems related to the motor or electrical system of your Legacy http evergreenev com plugin electric dealer locator html 13 Page EEV Legacy 9 8 11 MAINTENANCE SPEED CONTROLLER The speed controller of the vehicle is responsible for controlling the speed motor braking regenerative braking torque high efficiency and low energy consumption by use of its sophisticated solid state technology For any problems related to this component you should contact your local authorized Evegreen Electric Vehicle Dealer or experience mechanic AN inci A Any changes repairs or modifications to the controller or electrical system outside the parameters set by the factory or the original design could void the warranty and or cause serious damage to the vehicle and or serious bodily injury to the driver passengers or persons around the vehicle We highly recommend you contact your local au
18. thorized Evergreen Electric Vehicle Dealer or qualified electrician to work on problems related to the motor or electrical system of your Legacy http evergreenev com plugin electric dealer_locator html 14 Page EEV Legacy 9 8 11 TROUBLESHOOTING TIPS Symptom Corrective Action Cart will not move Measure Battery voltage should be 48V or higher Charge batteries and clean tighten all interconnects Fuse blown check all fuses Controller flashing fault code contact support with that two digit code Contact Evergreen or your Authorized Dealer if car still does not run Car moves slowly Motor speed encoder disconnected check to make sure it is tight Low battery voltage charge pack Brakes binding check cables Accelerator box out of tolerance check per Evergreen Tech Bulletin Motion is opposite direction switch Reverse field wires For more information please consult your dealer http evergreenev com plugin electric dealer_locator html 15 Page EEV Legacy 9 8 11 EVERGREEN ELECTRIC VEHICLES LIMITED WARRANTY WARRANTY EVERGREEN ELECTRIC VEHICLES LLC hereby warrants its new EVE Electric Car purchased from EVERGREEN ELECTRIC VEHICLES or an authorized distributor dealer or agent shall be free from defects in material and workmanship under normal use and service for 3 YEARS on the frame and 2 YEARS on all remaining parts as terms are defined herein and subject to the provis
19. uld be performed by an experienced mechanic or your authorized Evergreen Dealer only 6 Take time to train all other persons who will operate the vehicle and have them become familiar with this user manual 1 Page EEV Legacy 9 8 11 FUNCTIONS OPERATING SYSTEM see Fig 1 IGNITION KEY When not in use the Ignition key should remain in the OFF Position with the Parking Brake latched see Fig 2 To activate the flow of power to the motor the key should be turned to the ON position see Fig 3 The Legacy has a 3 position that activates the 12 volt system lights horn and any other accessories wired to the DC DC power converter see Fig 4 Off On Headlight Fig 2 Fig 3 Fig 4 DIRECTION SELECTOR Use the FORWARD REVERSE switch to select the desired direction of travel If you want to travel FORWARD turn the switch to the left side If you want to travel BACKWARDS turn the switch to the right side see Fig 5 Fig 5 ACCELERATOR PEDAL This will control your speed Press down slowly to increase speed The car will speed up with continued pressure applied to the pedal eventually reaching full speed The car will slow down as you take pressure off the pedal When the pedal is fully lifted the electronic brake feature will begin to function If the car tends to accelerate too quickly or the electronic brake function does not create resistance stop the car and discuss this with your authorized Evergreen De
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