TWIKE Operator’s Manual

Chapter 6 Maintenance and Troubleshooting

Service interval: At 5,000 km or at least once per year you should take your TWIKE to an authorized service station for a general service check. In the appendix you will find the service journal.

Do not make repairs yourself. For safety reasons leave them to TWIKE AG trained specialists.  Note that there are lethal high voltages in the area of the battery boxes even when the vehicle is completely turned off!  We reject responsibility for the consequences of unprofessional repairs.

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General Maintenance
 
Body

Do not use solvents or abrasives for cleaning the body. It is made of thermoplastic Luran S and can be cleaned with soapy water or most mild cleaning sprays--or for more persistent marks, with a special TWIKE polish.

Prior to attaching decals, clean the surface with a grease disolving solvent, e.g., isopropanol. If the decal is to be made easily removable wash the surface with a soapy solution instead. When the ambient temperature is too low, place the vehicle in a heated area before attaching the decal to facilitate the process.

The body can be painted if done properly. Small damage can be patched, primed and sprayed.

Interior

Always keep the interior dry.  The luggage area should not be cleaned with liquids. (Water could play havoc on the sensitive electronics underneath!)

The carpet is attached with four snaps and/or Velcro, and can be taken out easily for cleaning or drying.

Seats

The upholstered seats should be commercially drycleaned or cleaned with upholstery (dry) foam and a soft brush.  The pads of the basic version can also be washed in warm water by hand.

Windshield

Keep the part of the windshield where the wiper tracks especially clean. In the plexiglas version dust can cause fine scratches. It is possible to polish these out with a special acrylic polishing compound with care.

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If the windshield too easily fogs up, it can be treated with anti-fog spray (available at auto parts stores).

Cover the windshield in winter to prevent frost (which cannot be easily scraped off without damage to the plexiglas).

The Cabrio-Verdeck (optional) can be difficult to install when it is very cold. Consider warming it up in advance, as the material expands when warm.

Towing and Changing a Tire

Tools for changing a tire:

 - jacking equipment or suitable large object for propping up the vehicle
 - 22mm open end wrench (?)

A towing eye can be found under the nose of the vehicle which can be removed by undoing two 5 mm Allen head screws with the appropriate wrench.  The TWIKE must be towed carefully so that the towing eye is not damaged.  Keep speed to a minimum while towing.

Repairing a flat: Try using a flat-fixing tire spray product first.  If this is not possible, we recommend allowing a bicycle/motorcycle shop repair the flat. The tire contains a tube which can be patched with a normal tire repair set. [In most cases, it is easier to repair a flat with the wheel left on the vehicle than to try to remove the wheel. Removing the wheel may require a gear puller.]

Jacking: So that the body is not damaged, place a foam pad between the jacking equipment and vehicle.  The jack bearing surface must exhibit a diameter of at least 8 cm.  There are three jacking points: in front just under the center of the crosspiece, housing the pedal hub, and in back 10 cm from the rear edge of the battery tub and 25 cm from the left and right side of the tub.  (See illustration, p. 48.)

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If no hydraulic jacking equipment is available, the TWIKE can also be lifted in an emergency by several strong people carefully lifting only from the aluminum profile around the edge of the vehicle. First, position a suitable article(s) to support the TWIKE at the correct jacking points. The front of the vehicle can be lifted by one person with both hands at the front of the wheel arch.

Changing a front tire: Jack up the vehicle in front.  After loosening the locknuts the wheel and axle can be removed by pulling forward.  The locknuts must be replaced as soon as possible afterwards, since their ability to remain secure is compromised after long use and repeated loosening.

Changing a rear tire:  To remove the wheel cover undo the snaps and, from inside the vehicle, unscrew the knurled nut (rescrewing afterwards to avoid losing it).  Jack up the vehicle and loosen the brake. With pliers you remove the safety lock pin (3 mm split pin) from the hub nut, place it in a safe place, and loosen the hub nut with an the open end wrench (22 mm).  The wheel can now be pulled off the axle. [This may require a gear puller. If possible try repairing flats with the wheel on the vehicle.]

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Assembling the wheels: Tighten the axle hub nut but not overtight. Insert the cotter pin and bend the ends so that it cannot slip out. Do not forget to insert the cotter pin!

The TWIKE has two types of wheels: the front fork hung wheel and the rear side hung wheels. Nevertheless, the tires for all wheels have the same dimension.  The [Relfengroessse] 2.25-16 is a standard size for small motorcycles and mopeds.  Each tire manufacturer offers tires in this size.  The handling characteristics, finish quality, and rolling resistance vary greatly from manufacturer to manufacturer.  Tire types listed here are tested by us and fulfill the requirements of the TWIKE.  We cannot provide assurance for other types.
 
 

Mark	Dimensions	Load-Index	Profile
Maloya	2.25-16	at least 39J	Racer
Maloya	2.50-16	at least 39J	Racer

 

The tires are the only parts that regularly wear and, depending on driving style, must be replaced every 3-6,000 km.  Monitor regularly the tire tread and drive only at legally permitted speeds.

Tire pressure (4-5 bar, i.e., 400-500 kPa) should be checked when the tire is cold.  The wrong pressure impairs security, vehicle handling, travelling comfort, energy consumption and tire wear.  Higher pressure due to tire warm up is normal.  Too low a pressure greatly increases rolling resistance.  Tire side rolling becomes worse at low pressures.  The TWIKE "swims" in curves.  The increased rolling friction results in excessive heating of the tire and can cause damage to the bearing surface or a tire blow-out.

Do not drive over sharp edges.  Hidden damage may only later become apparent.  Carefully inspect rims for dents and tires for cuts and tears.

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Winter operation:  The tires can be used in winter. Tire chains are not recommended.  The parking brake (which may incline to freeze) should be avoided in favor of a wheel wedge under a wheel.

Care of the Brakes

The rear wheel brakes are hydraulically activated, i.e., the lines are filled with fluid.  Beside the driver's pedals there is a small container for brake fluid (DOT 4).  Check it regularly for sufficient brake fluid.

Adjusting the mechanical parking brake with the two set screws behind the hydraulic rear wheel brake will also automatically adjust the latter.  Always make sure that the wheels can turn freely.  Dragging brakes cause a marked increase in energy consumption and, consequently, a shorter range.

The play of the front brake can be adjusted at the brake lever.  Make sure that the front wheel can turn freely when the brake is off.

If the brakes do not stop the vehicle evenly, drag, or cause excessive energy consumption they must be adjusted, or, if necessary, the brake linings replaced.

From time to time use the mechanical brakes instead of the regen brakes to keep the former in play and from rusting.

Adjusting the Steering Damper

A certain amount of influence on the steering damper by grooves in the road or side wind is normal.  However, roadway unevenness can shift the steering damper excessively through resonant vibrations, depending on the loading and inclination of the front axle.

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If the steering vibrates excessively in curves or after road bumps, the steering damper absorption should be increased.  The damper is fastened between the steering rod and chassis.

Its effect can be adjusted with the knurled dial in 7 stages: turn clockwise to increase absorption, counterclockwise to decrease it.

If this procedure does not improve the steering problem, the vehicle should be taken to a TWIKE service station for adjustment of the inclination of the front axle.

Electrical System

The front lamps are accessible behind the removable cover panels forward of the pedal assembly:
 
 

Headlight/headlight low beam	12V 55/60W	H4 Halogen
Parking light	12V 5W
Turn signal	12V 21W	BA 15s
Turn signal indicator (German Version)	12V 2W	Glow lamp H

 

The rear lamps (except for the license plate light) are accessible from the outside (the lamp boxes screw on):
 
 

Taillight/stop light	12V 5/21W	BAY 15d
Turn signal	12V 21W	BA 15s
License plate light	12V 5W	Festoon Lamp 5W 10.5 x 39mm
Reverse driving lamp (German Version)	12V 21W	BA 15s
Fog tail light (German Version)	12V 21W	BA 15s

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The glass bulbs of the lamps should not be touched with bare hands.

Fuses

Behind the driver seat is a fuse holder with four spade type fuses.  The positions indicated below refer to the direction of travel:
 
 

	Position	Rating	Application
1	front	15A	accessories
2, 3	middle	15A each	right and left side of vehicle
4	rear	3A	control circuits

 

Accessory Equipment

The 12V source is a DC/DC converter (instead of an automotive battery). You may add to the 12V system a radio with up to about 20W of power consumption.  Adding more to the system could cause problems when lights are on and brakes are activated.

The spade type fuses for the holder are available at any auto parts store.  The negative poles must be grounded to the frame at the screw behind the controller (static frequency changer).  The fuse makes the link with the positive terminal inside the fuse holder which has a free connection.
- Leave the installation of accessories to properly trained specialists.

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Battery Change

The battery is sealed and absolutely maintenance-free.  It should have a life span of several years. If a battery change becomes necessary, this should be done only by a TWIKE service station.

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Appendix

B. Range

Tips for efficient driving:

- Avoid long periods at high speed. Reduce speed. Cutting speed in half reduces wind resistance by 75%.
- When possible accelerate using the first acceleration stage instead of the second. The battery then supplies a smaller current and can deliver more of its theoretical capacity.
- Use the pedals. They can contribute approximately 150 Watts of power per person (see diagram on page 56).
- Choose your route carefully, avoid unnecessary detours and hills.
- Anticipate stops, avoid sudden ones, and do not accelerate unnecessarily.
- Use the Regen brake (instead of the foot and hand brakes) whenever possible. This will return some energy back into the batteries.
- Maintain the correct tire pressure (4-5 bar, 65 psi). Optimally pumped tires roll more easily. Drive only with the tire types tested by us.
- Do not carry unnecessary weight.
- Plan ahead the time and place of battery charging; better to charge in the valley than on the hill.
- During extended stops turn off both the main switch and the Disconnect button. Leaving the computer switched on will cause the system to consume about 20 Watts of power (approx. 0.06 Ah per hour).

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Pedal Drive contribution:

The energy contribution of pedaling goes directly to the rear wheels.  The faster you drive the less is the portion you can contribute with the pedals.  High speed travel requires more energy because of air resistance. Moreover, you will have less time for pedaling since you arrive at your destination more quickly.

The following diagram shows about how much two persons at an even speed can contribute if they each produce about 150 Watts by pedaling:

[Fahrwiderstand = road/wind resistance, Muskelkraft = muscle power, Geschwindigkeit = speed, umgesetzte Energie = required energy]

As you can see one can keep up a speed with the pedal drive of about 20 km/h. Start (i.e., accelerate), especially on hills, with the electric drive.

Note the fact that, when pedaling, the TWIKE does not necessarily become quicker through your contributed power.  Rather what you are doing by pedaling is relieving the motor and saving energy drain from the batteries.  Therefore, pedal as if you were on a home exercise machine.  Each pedal revolution increases range slightly.  Besides, in Winter you can heat the vehicle this way!

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Flatland
 
The following diagram shows the ranges we drove on a single battery charge.  We used the electric drive and kept the speed constant over the major part of the test track.

[Reichweite = range, ebene Geschwindigkeit = level speed]

Upward Gradients

Climbing 100 m  in elevation consumes approximately 0.5 Ah from a full battery pack plus the flatland distance consumption for the distance covered.  Note that energy consumption depends on driving speed.

Downward Gradients

Descending 100 m in elevation can regenerate the energy for an additional 1-2 km in range (approx. 0.15 Ah).

Acceleration

An acceleration maneuver of 0 to 50 km/h requires approximately 0.03-0.08 Ah.

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Energy Consumption from the Battery

[Verbrauch = consumption]

Electrical Energy (Power) of the Battery

[Leistung = power/energy]

Range Display Calculation

(See Chapter 5, page 35.)  While the vehicle is in operation the computer recalculates constantly the range remaining based on the average electrical energy consumption of the distance already covered and the overall capacity of the battery.

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It uses the formula: R = s*(EO/EI), where R = range, s = distance covered, EO = entire energy content of the battery, EI = electrical energy consumed.  The result is not indicated directly, but "smoothed out" first.

In the case of a short intermediate charge the result calculated this way is rendered useless, i.e., it will result in an inflated number since the energy figure is adjusted without being corrected for the distance covered.

The Energy Consumption of the TWIKE

How does driving the TWIKE affect the electrical energy consumption of an average household if one drives it approximately 10,000 km per year?

[Licht = lights, Kuhlgeräte = refrigerator, Kochherd = kitchen range, Boiler = furnace]

The 500 kwh used for the TWIKE is a significant savings in energy over the consumption of fossil energy.  Approximately 7,000 kwh in gasoline is saved per year.

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C. Handling Errors

The objective of the development of the TWIKE was the building of a reliable vehicle.  A series of  continuous stress tests at the TUV in Munich, manufacturer warranties on wheels and tires, as well as extensive safety precautions with the electronics have prevented the majority of the predictable pitfalls usually associated with a radically different vehicle design.

Over 30 software versions for the TWIKE computer and ten pilot series of batteries were tested in the vehicle.  Measurements of radio interference (EMV) were kept and special filters added to insure that the latest standards were met (not wanting to cause the neighbor's TV disturbance).

Design errors and use restrictions have their causes on three levels:

a) Concept level (what do we want to build?):  Application will determine here.  Road performance, energy consumption, and available space are concept dependent.  80% of the costs are specified at this level, too.

b) Construction (how one builds?): The specification of components will determine intallation and maintenance facility.

c) Assembly and service of the TWIKE: This has a large influence on reliability and durability.  Periodic service of the mechanical components and lubrication of moving parts help prevent unnecessary wear, damage and breakdown.
 
We were able to a large extent eliminate errors in the concept and the construction of the vehicle, i.e., in the development and in the structure of production.  Taking into account the goals of maximizing range and efficiency, the TWIKE is the most cost-effective electric vehicle on the market.

Mistakes while assembling and servicing the vehicle in quantity production unfortunately arise and can hardly be foreseen.  We strive to eliminate these errors immediately.  For your assistance in this task we thank you and hope to make your TWIKE "the best electric vehicle of all".  The following list can help you react to irregularities purposefully:

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Starting
 

What you notice	What you can do
The canopy opens while driving or does not securely close	- The outside latch should be in the correct position while driving: pressed shut.  - The latch release handle for the vehicle canopy (inside left) must be in the rear position.  - The latch cylinder is not correctly aligned with the canopy frame
The main switch doesn't function	- Is the Disconnect button depressed? (Turn)  - Was the TWIKE left unused for an extended time? (Charge again)
Code entered incorrectly three times (computer on, but the TWIKE does not move)	- Turn off, wait five seconds, then try entering the code again
Code has been forgotten	- Bad luck: you must contact TWIKE AG.  Note first the value of parameter INSP 18 (duration counter). From this number we can compute a temporary code for you (valid for approximately one hour) that allows you to re-program your own new code.

 

Driving and Braking
 
 

The TWIKE does not react to pressure on the acceleration button, or brakes while accelerating, or accelerates incorrectly (especially after brake application)  (61)	- Because the hand and foot brakes are both in electronic communication with the motor control, if there is any (even slight) brake activity, the motor will stop or hesitate. (Make sure you are not inadvertently braking--especially with the pedals.)  - Are the wheels free? Move the vehicle back and forth.
Regen brake does not operate correctly	- If the vehicle rolls back from a stand-still, you must tap the acceleration key briefly before the regen brake will function properly.  - When the batteries are full or too warm regen brake performance is automatically reduced.
Acceleration and regen braking keys do not correctly affect motor function	- Check key function (parameter 81, see page 43).
On pressing the acceleration key, the motor brakes unexpectedly	- The RPM sensor must be recalibrated at a TWIKE  service station.
The regen brake is too weak	- It can be adjusted for greater effect (see pages 42-43).  - The batteries are either full or too warm and cannot be further charged at the moment.
Acceleration is too weak	- It can be adjusted for greater effect (see page 42).  - The batteries are nearly discharged (recharge immediately).
Steering element has leading oscillations	- Adjust the steering damper to a stiffer setting (see page 51).  - The front fork requires castor angle adjustment.
Pedal drive does not engage correctly	- Let up briefly on the pedals.  - Place Forward/Reverse shifter into the foremost position.
Tire blowout	- Treat with tire puncture repair spray.  - Remove wheel and tire and repair with a bicycle patch repair set.

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 Charging
 
 

Computer does not start when the TWIKE charge cable is plugged in	- Has the TWIKE not been used in a while?  - Make sure charge cable is plugged in at the outlet and circuit is active; the computer should start within the next hour and then begin after some minutes to charge automatically. (If that doesn't happen: turn on lights and other electrical loads for up to two hours until the batteries are empty, then repeat the charging procedure. Contact your TWIKE service station.)
Batteries unexpectedly empty rapidly	- The batteries were not completely charged and/or the TWIKE has not been used in a while.  - It has been driven at a high rate of speed.  - The brakes are dragging and should be adjusted. (To check this: lift the vehicle and try spinning the wheels, they should spin freely.)
The plug does not fit into the plug socket	- Make sure you are using the correct three-pole adaptor and are plugging into the correct type of electrical service.  Caution: Incorrect contacts can lead to serious problems with a charge!
Charging current blows fuse or trips breaker	- Try charging in Normal Mode.  - If the circuit cannot handle the charging current, limit the charging current (see pages 43-44).  - If the circuit is secured with an unsuitable flat steel bar protective switch (10mA): replace or look for another outlet (?).  - Check the charge cable for defects or replace.
When the TWIKE is plugged in, the display does not indicate "CHARGE READY"	- Plug in the charge cable again; switch off the main switch; wait five seconds; it should begin charging.
Charging does not begin immediately  (63)	- The battery is too warm (>40C): wait a while, charging will begin after a period of cooling.
The FWD and JOG indicator lights flash or don't light up	- Is there voltage at the outlet?  - Check the fuse or circuit breaker (or flat steel protective bar switch (?)) and the charge cable.
The charging procedure runs but no charging current flows	- Corroded cord, splices or loose or bad connections may result in a voltage (green FWD indicator light shines) but a voltage less than 150 V.  - Listen, after plugging in, for the audible clicking of the switching relays as they go on and off.  - Try another outlet or extension cord.
Display: "CHARGE INTERRUPTED"	- This announcement appears if there has been an interruption during the charge procedure. Since this can indicate bad contacts, it will not reset automatically. If the interruption was intentional, energize charge cord again to continue to charge.  - Check to see whether a bad contact is present (FWD indicator light flickers); otherwise, restart charge procedure by plugging in, then pressing in the Disconnect button, then turning it so it pops back out.
Display: "CHARGE TEMP TOO HIGH"	- The temperature of the batteries is over 40C. Wait a while until the batteries cool down somewhat. After, at the latest, two hours, the charge should begin automatically.
Display: "CHARGE TEMP TOO LOW"	- The temperature of the batteries is below 0C. If the battery is not yet fully discharged, you can  run the TWIKE until it warms up, then try charging again. If it is, move into a heated garage or space.

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Computer
 
 

The computer switches itself off while driving and starts again	- Possibly, you drove over a curb, bump or pothole which momentarily removed the load from a drive wheel and caused the motor to draw current over a threshold value. For safety reasons overcurrent in the motor will switch it off. It should start within 10 seconds again automatically.
Display: "ELECTRICAL SYSTEM FAILURE" (error 07)	- Possibly the Disconnect button was operated briefly. Press the STOP button.
Display: "BAT UNSYMM VOLT" (Battery voltage unsymmetrical)	- Occurs when the batteries are nearly discharged and the individual battery blocks are at different voltages and battery equalization has not yet taken place.  - If the condition persists, consult a TWIKE service station.
Display: "OVERCURRENT" (error 06 or 18)	- This error can occur when the wheels rev up briefly as when traveling over a bump or on slippery ground. The computer will restart again independently.
Display: "BATTERY COMMON FAILURE" (error 21)	- This error can occur when 12V electrical loads are excessive and 12V accessory voltage fluctuations arise. Press STOP button.
Display: "NO ACCESS" (The computer parameter is not user programmable)	- There are parameters which can be viewed but not changed, e.g., TYPE OF DEVICE.  - Programming mode functions only while in driving mode, not while charging.  - Displayed after charge cord is plugged into the TWIKE.  - Code was incorrectly entered 3x.

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12V Electrical system (lighting, horn, windshield wiper)
 
 

A lamp does not function	- Clean contacts.  - Replace lamp.  - Check cable connections to the lamp.  - Check appropriate fuse.
The lamps on one side of the vehicle do not function or only weakly	- Check middle fuses behind the driver's seat (replacements are available at any auto parts store, see page 52).
Headlights shine in the wrong direction	- Realign headlights.
Horn or windshield wipers do not work	- Check cable connections.  - With main switch off, switch it on, and after five seconds, try horn or wipers again.  - Check appropriate fuses.

 

Interior equipment and mechanics
 
 

The seat is not comfortable	- If your back hurts, is the seat too far back? Adjust it forward.
The seat rattles	- Check the tightness of the socket-head screws of the seat with the appropriate tool.
A puddle forms in the bottom of the vehicle	- Drain holes may be clogged.  - Drill an additional hole.  - Seal where water is entering.
The underside of the vehicle has oil marks	- Oil may be leaking from the bolts on the transmission.  - If oil loss is not negligible, have it checked at a TWIKE service station.

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Conditions and Symptoms

Please read this section so that you are prepared before problems arise:
 
 

Condition/Cause	What you notice and what you can do
3 A fuse in the electrical system has failed (short circuit in a control cable)	Behaves as though the Disconnect button had been pressed (i.e., no electrical function at all).  Procedure: Inspect cable for defects and repair any. Replace blown fuses.  Warning: Never bridge a fuse or replace with a fuse of a higher current rating, otherwise electronics could be damaged!
15 A fuse in the electrical system failed (short circuit in the lighting)	The lighting on one side of the vehicle is dimmer but still shines.  Procedure: Search for a short circuit and repair. Replace fuse.  Warning: Never bridge a fuse or replace with a fuse of a higher current rating, otherwise electronics could be damaged!
Battery fuse failed	Either there is no electrical function anymore, or the error message occurs only with heavy acceleration.  Procedure: Have the battery fuse replaced.
Battery over-discharged        (67)	Even if the Disconnect button is pressed, battery monitoring uses 3-5 Watts. This will discharge a full battery in a approximately 500 hours (i.e., about three weeks). If the TWIKE is left to stand unused too long, the computer will not start automatically.  Procedure: Plug in charge cable. The computer will need a few minutes to initialize the batteries again.  This procedure does not harm the vehicle.
Bad contact in the Disconnect button	Error messages F21 or F07 appear frequently on the display.  FWD indicator light flickers from time to time while charging.  Procedure: Check or have checked connecting terminals at the Disconnect button.
Bad contact in the charge cable	Interruption of the charging procedure (stops and starts again).  Display: "CHARGE INTERRUPTED", though the charge cord has remained plugged in.  The green FWD indicator light flickers.  Procedure: Replace cord (cable) or adaptors if defective.
Bad contact in the display panel (interruption of the connection to the computer)	Sudden and unpredictable switching on and off of the computer.  Confused numbers, black bars or nothing at all appear on the display.  Procedure: Have the display unit repaired or replaced.
Bad contact in the stop light switch	The stop light is on even when both brakes (back pedal (rear) and front) are released.  The TWIKE operates at only 3km/h and hums.  Procedure: Move the brake lever until the light goes out. This may reveal whether the brake switch should be repaired or replaced.
Bad contact at the start button	Unreliable function of controls such as acceleration and regen braking.  Procedure: Check key function (Parameter 81, page 43).
Bad contact at the headlight  (68)	The blue high beam warning lamp and the high beams are on without having been switched on.  Procedure: Check cable connections at the lamp.
Motor RPM sensor defective	When accelerating the TWIKE brakes hard first with motor regen, then accelerates.  Procedure: Replace motor RPM sensor.
Defective wheel bearing	Loud noises while rolling, cracks from the rear axle, play in the wheel when brakes applied.  Procedure: Replace wheel bearings.
Steering incorrectly adjusted	The vehicle veers to one side or the other when steering tiller is released, or tends to oscillate.  Procedure: Adjust steering damper (see page 51). If this does not correct the problem, have the steering checked by a TWIKE service station.

 
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D. Electronics Troubleshooting

Before referring to a service station, you may take the following measures and note results.  This will help specialists locate the error.

Copy this section and make notes.

1. Push Disconnect off, turn main switch off, plug charge cord into controller socket (normal driving set up).

2. Wait two minutes with everything off.

3. Pull up Disconnect (on).

4. Switch lights on, do the parking lights come on, front and rear, left and right?
- Yes / No:..........

5. Switch lights off.

6. Main switch on, wait for the "INPUT CODE" or standard announcement. Do the FWD and STOP indicator lights come on?
- Yes / No:..........

    Will the TWIKE drive?
- Yes / No:..........

7. Use the arrow keys to switch to the text display.
- What is indicated?.............................................

8. Use the arrow keys to switch to the "Voltage and Capacity" display, and/or the "Current and Temperature" display.
- Temperature of battery 1:..........°C
- Temperature of battery 2:..........°C
- Temperature of battery 3:..........°C
- Voltage of battery 1:..........V
- Voltage of battery 2:..........V
- Voltage of battery 3:..........V
- Ah capacity of battery 1:..........Ah
- Ah capacity of battery 2:..........Ah
- Ah capacity of battery 3:..........Ah

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9. Switch on lights.
- Battery 1 current:..........A
- Battery 2 current:..........A
- Battery 3 current:..........A

10. Electrical system function check:
- Windshield wiper (Yes / No):..........
- Horn (Yes / No):..........
- Hazard blinkers (Yes / No):..........
- Turn signals left (Yes / No):..........
- Turn signal right (Yes / No):..........
- (optional) Fog light (Yes / No):..........
- (optional) Backup light (Yes / No):..........

11. Switch off lights. Switch on defroster.
- Current draw:..........A

12. Unplug charge cord from controller in the TWIKE. Does the computer display "CHARGE READY"?
- Yes / No:..........

      With arrow keys switch to "text display".
- What is indicated?...................................

      Does the JOG indicator light come on or blink?
- Yes / No:..........

13. Plug charge cord into an outlet. Do the FWD and JOG indicator lights come on or blink?
- Yes / No:..........

14. Does it switch from Pre-Charge to I-Charge?
- Yes / No:..........

      Wait 3 minutes.
- Current:..........A

15. Press the JOG key. Does the JOG indicator light come on steady (instead of blinking)?
- Yes / No:..........

      Wait 5 minutes.
- Current:..........A

16. Allow charge procedure to continue until the Symm-Charge phase is reached.

17. Test drive.

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E. Frequently Asked Questions About the TWIKE

Can the TWIKE be powered by pedaling alone?

No, in normal traffic pedal energy is not sufficient. The pedal transmission of the TWIKE is designed so that it operates most comfortably when driving between 25-75 km/ h. The lowest gear is still too high for pedaling from a standstill or up a grade.

Can the TWIKE be driven on bicycle paths?

The TWIKE is certified in Switzerland as a motorcycle and may therefore not be driven on bicycle paths. Ask your local authorities for their rules and for possible dispensations for unproblematic distances.

How does the TWIKE handle in snow and ice?

The TWIKE handles quite well on slippery ground due to its light weight and the fact that 75% of the vehicle weight lies on the drive wheels.

How safe is the TWIKE in collisions with other cars, cyclists and pedestrians?

Physics dictates that the small mass of the TWIKE will cause it to be more strongly accelerated in a collision with a heavy vehicle. However, the aluminum space frame is designed to absorb impact energy and by deforming offers passengers some protection.

The soft statement of the vehicle nose ensures that pedestrians and cyclists will suffer minimal injuries in a possible collision (relative to being hit by a car).

Seat belts are available as accessories.

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Will the TWIKE handle steep grades?

The TWIKE is designed to be capable of up to 20% grades.

Can the TWIKE be charged with solar power?

With approximately five square meters of solar cells enough energy can be produced to drive the TWIKE 10,000 km per year. Before you invest in solar panels, however, you should consider producing your hot water with solar collectors. (It would be a more cost-effective way to save energy.)

Also, consider that you already save, even when plugged into the grid, more than 90% of the energy consumed by a normal car going the same distance.

Where may I park the TWIKE?
 
In Switzerland the TWIKE is certified as a motorcycle. As such, it may be parked in motorcycle restricted areas, if other vehicle spaces are not obstructed. Due to its small dimensions the TWIKE may fit into many spaces too constricted for even small cars.

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F. Electrical Units and Comparisons

Sometimes it is useful to understand electrical terms in context. The following table compares some of the terms and measuring units involved in electricity and the TWIKE to mundane, everyday things. Electrical voltage, for example, can be compared to the pressure in a water pipeline.
 
 

Term	Unit	Description
Voltage	Volt (V)	Comparison: change of pressure  In Europe household sockets supply approximately 230V.  The DC voltage of the TWIKE's battery amounts to 310-420 V (in contrast to other electric vehicles, which are operated at 36-150V). Such high voltage is lethal. Therefore battery and electronics are protected and not accessible from the outside in accordance with TUV/VSE guidelines.
Current	Ampere (A)	Comparison: speed of current  Household current in Europe can be rated from 6-16 A, depending on intended load and fuses or breaker. If this current is exceeded at any time the fuse will blow or the breaker trip. Since at household voltages even currents under 100mA are dangerous, today's outlets are equiped with GFCI protection switches. These will compare the current flowing through in both directions and will shut off if the difference is excessive, i.e., it passes through some unintended object.
Power    (74)	Watt (W)	Comparison: quantity per hour  A normal household socket (in Europe) can provide approximately 2,200 W (220V x 10A = 2.2 kilowatts). This is very little in comparison with the potential power output of a gas station. The TWIKE can use the full power output of the socket. The more power available, the more quickly it charges.
Efficiency	(v)	Comparison: losses  Electric drives have efficiencies over 80%, combustion engines a max of 30%. This indicates the utility derived from a given expenditure.
Energy	Joule (J)	Comparison: quantity  1 kilowatt-hour (kwh) = 3,600,000 J (about as much as is contained in two bars of chocolate); this is equivalent to 1,000 watts of power expended for one hour.  Ampere-hour (ah) = measure of energy for a certain voltage. (Ah x Volts = Wh)  The energy stored in a battery can be compared to the contents of a gas tank. A litre of gasoline contains about 12 kwh of energy. The TWIKE battery contains 2 or 3 kwh of energy.
Consumption	Wh/km	Comparison: quantity per unit of use  Power requirement of the TWIKE: 5 kWh measuring from grid per 100 km = 50 Wh/km (approx. 0.10-0.15 Ah/km measuring from the battery)  Utility: 20m covered for every Wh (about 6-10km/Ah)  Every form of transportation consumes energy. Some more, some less. The TWIKE can cover a kilometer on approximately 10 times less energy than an economical car!
Energy Costs	Fr./km	The TWIKE can cover a kilometer for approximately 1-2 Rappen. If one takes into consideration amortization, service, taxes, insurance, parking lot costs, etc. the amount comes to 30-40 Rappen per kilometer (small car: 60-70 Rp./km).

 

G. Operating Check List

When you wish to let someone inexperienced drive the TWIKE, you should go through with them the following points to make sure they understand the essentials. The list will help assure that you cover all aspects of the vehicle.

(75)

TWIKE VEHICLE OPERATION

Name:.................................   TWIKE Chassis No...............

Date / Place:.....................................   Instructor:..............................

1. Entering and Preparing to Drive

Canopy open (lock)................................Open, latch and reopen again...........................�
Seat inclination adjustment.......................4 positions.......................................................�
Entering..................................................Standing surface, support self while sitting.........�
Seat distance adjust................................Legs not quite fully extended.............................�

2. Controls and Instrumentation (driver sitting in the TWIKE)
 
Elements on the chain case
Steering lock...........................................Caution, always check before starting!..............�
Disconnect button...................................Pressing, resetting, effects.................................�
Forward/Reverse shifter..........................Pedal engagement, display................................�

Operating panel
Main switch.............................................Battery indicator light.......................................�
Defroster.................................................Automatically switches off after 1 minute..........�
Hazard flashers...............................................................................................................�
Lights.......................................................Parking lights, if main switch is off....................�

Display.....................................................Code lock......................................................�
Display 1..................................................km/h, A, Ah, tripometer..................................�
Display 2..................................................km/h, range, km, % charge.............................�
Display 3..................................................Text announcements.......................................�
Display 4..................................................Current and temperature.................................�
Display 5..................................................Individual voltages and Ahs.............................�
Display 6..................................................Condition, V, RPM, V%, torque.....................�
PROG-Mode...........................................Parameter inspection and adjustment...............�

Steering tiller.............................................Steering damper.............................................�
Acceleration.............................................Stages 1 and 2................................................�
Regeneration.............................................Stages 1 and 2...............................................�
Turn signals...............................................Left-off-right (not self-canceling)....................�

Pedal brakes (rear wheels)........................Engaging positions..........................................�

Left control handle
Parking brake (rear wheels).......................Awareness / control.......................................�
Hand brake (front wheel)...........................Always use together with pedal brake............�
Headlight flasher, high beam.......................Blue indicator light.........................................�
Windshield wiper.......................................Momentary and continuous operation...............
..................................................................(use only on wet windshield).........................�
Horn..............................................................................................................................�
Pedal gear shifter........................................1 - 5 gears...................................................�
Opening canopy from inside...........................................................................................�

(76)

3. Driving Practice: Manuevering

Driving........................................................Foot and hand brake coordination.................�
Accelerating................................................1 / 2 stages...................................................�
Regen.........................................................1 / 2 stages...................................................�
Steering.......................................................Adjustment...................................................�
Rear brakes.....................................................................................................................�
Front brake.....................................................................................................................�
Cruise control / coasting...............................On / off.........................................................�
Slalom (Parcours 3x) ...................................Stability, tracking..........................................�
Backing up.......................................................................................................................�
Parking.........................................................Forward, reverse, parallel............................�
Pedal drive....................................................Pedaling, switch, free-wheeling,......................
.....................................................................limitations of use..........................................�
Full braking...................................................With and without locking the wheels.............�
Locking brakes 3 x...........................................................................................................�
Starting up hill 2 x..........................................Braking, preventing rollback.........................�
Safety on grades............................................Parking brakes, pedal drive, .......................�
.....................................................................steering lock................................................�

4. Operational Disturbances

Disconnect.....................................................Test on hill without warning..........................�
Display...........................................................Error messages F 07, F 21, F 06................�
Steering, take off (?).......................................By hand, automatically................................�
Ruckeln (?).....................................................Tricks / characteristics................................�

5. Driving Practice II

10 km stretch..................................................Repeat, if necessary....................................�

6. Theory

Battery charging..............................................Normal, Quick............................................�
Energy consumption and cost..........................1 kWh = 20 km = 1 day of refrigeration.......�
Driving and energy management.......................Range.........................................................�
Temperature concerns.....................................Driving, charging.........................................�
Flat tires..........................................................Repair spray, jacking up, changing tire.........�
Water / humidity..............................................Controller, battery area...............................�
Breakdown triangle..........................................Behind the seat under the carpet.................�
Allen wrench....................................................Tow hook, seat adjustment.........................�
Fuses...............................................................Lights, electrical system, accessories..............
........................................................................(extra fuse).................................................�

7. Cleaning

Windshield.......................................................Polycarbonate, acrylic Plexiglas,....................
........................................................................(laminated safety glass, German versions)....�
Body................................................................Lösungsmittel (?), polish.............................�
Side windows...................................................Squeegee (?), credit card...........................�

(77)

H. TWIKE Log Book (copy as necessary)

Keeping a log is useful for tracking use and energy consumption of your TWIKE.

If you keep a log, we would appreciate occasional feedback so that we can better understand the needs of our customers!
 
 (78)

TWIKE Log Book  No.______________
 
 

Date	km	Energy	Distance Covered / Event

 (79)

Service-Journal
 
 

km	Work completed	TWIKE Service  station stamp	Date
0	Acquisition and license
1,000	First Inspection  Procedure P400, Required time 2.25h  - Test mechanics, electronics  - Transmission oil  - Brakes  - Steering angle (rake)
5,000	Quick Service  P 408, 2.25h  - Canopy lock  - Seat mechanics  - Chassis and steering
10,000	Complete Service  P 409, 3.50h  - Brakes  - Transmission  - Batteries  - Canopy lock  - Seat mechanics  - Chassis and steering
15,000	Quick Service
20,000	Complete Service
25,000	Quick Service
30,000	Complete Service

 
(80)
 
 

km	Work completed	TWIKE Service  station stamp	Date
35,000	Quick Service
40,000	Complete Service
45,000	Quick Service
50,000	Complete Service
55,000	Quick Service
60,000	Complete Service
65,000	Quick Service
70,000	Complete Service
75,000	Quick Service
80,000	Complete Service
85,000	Quick Service
90,000	Complete Service
95,000	Quick Service
100,000	Complete Service

 

(81)

Notes

(82)

Notes

(83)

Index 

5

5 - speed gear

A

acceleration 57
acceleration key (button) 18
accessories 8
arrow keys 32

B

Basic Version Tech Data 54
battery 54
    capacity 30, 33
    change 53
    technology 30
    voltage 8, 38
    warning lamp 16, 42
body 46
brakes 54
    fluid 50
    performance 19
    care 50
    front 19, 23
    parking 19, 22
    rear wheel 22

C

Cabrio-Verdeck 9, 11, 47
canopy 20, 61
care 46
carpet 46
changing a tire 47
charge phases
    cooling 27
    I-charge 27
    post-charge 28
    pre-charge 27
    preservation (float) 28
    symmetry 28
    U-charge 28
charging 26, 34
    current 34
    energy quantity 26
    errors 63
    quick charge 28, 43
    normal charge 27, 44
    opportunity charge 26, 29, 30, 59
time 34
chassis 54
code 16, 41, 61
computer keys 31
computer (on board) 31, 65
control handle (left) 19
cruise control 18

D

defroster 17
Disconnect button 20
discharge current 33
display 32
downward grades 57
drive power 18
driving instruction 76

E

electronics 70
energy capacity 28
energy consumption 26, 54, 58, 59
ENTER 32
equipment 8
errors 60

F

folders 9
forward/reverse 21
frame number 9
fuses 52
FWD 21, 27, 32

G

gear shifter 5-speed 19

H

heaters 17
highbeam 17, 19
horn 19

I

info poster 9
INSP 39
interior 46

J

jacking up 47
JOG 28, 32

L
 
lamps 17, 51
LANGUAGE 41
latches 11, 12
left control handle 19
liability 45
liability insurance 7
licensing 7
life span 30
lights 17, 51
    fog tail light 17
    hazard 17
    headlight flasher 19
    highbeam 19
    parking 17
lock 10
log book 78

M

main switch 16, 61
maintenance and self-help 45
maneuvering 21
maximum speed 54
measuring units 74

O

odometer 35
operating panel 16

P

parameters 39
parking brake 50
payload 54
pedal drive 19, 21, 56
plug socket 8
PROG 32, 40

R

radio 9
range 28, 35, 54, 55, 57, 58
regen 18, 23, 42
regen brake 23
regen brake button 18
repairs 45
REV 21, 32
reverse 21
right control handle 18

S

seat 9
    adjustment 12
    inclination 11
    upholstered 46
seat belts 9
seat inclination cube 11
self-discharge 28
service 45
service journal 80
shift 32
shoes 22
speed 17, 33, 35, 54
standard display 33
starting on grades 24
steering 18, 50, 54
steering damper 18
steering wheel lock 13
summer 19, 30

T

temperature 29
text display 36
tires
    blowout 47
    chains 50
    changes 47
    pressure 49
    size 49
    types 49
total kilometers 35
tow hook 47
towing and changing tire 47
trip odometer 28, 33, 41
turn signals 18

U

upward grades 57

V

vehicle identification plate 9
vehicle operation 75

W

weight unloaded 54
windshield 17, 46
    heating 17
    side windows 11
    wipers 19
winter 29, 30, 47, 50 

(84-85)

TWIKE - MEMO
 
Expert Tips

Press latch in after opening canopy.
Check steering arm lock.
Check forward/reverse shifter.
Before driving off completely release hand brake.
Manually cancel turn signals after use.
Press in Disconnect button if vehicle is not to be used within one hour.
Quick charge mode is toggled on and off by pressing JOG key.

Driving Tips

Starting
Fold seat forward and adjust inclination block.
Charge cable properly plugged into controller and stowed behind (but not under) driver seat.
When entering only step on the crossbar.
Check canopy catch for correct alignment and insertion.
Twist and let pop out Disconnect button.
Turn on main switch at operator panel.
Enter security code to unlock computer.
Operate pedal brake.
Undo parking brake by raising left control handle.

Driving
Accelerate with upper button on right steering handle.
Always be prepared to apply brakes.
If possible use the regen button (below accelerator button) to make planned stops.
The vehicle cannot be steered if you lock the front wheel.
To engage pedal drive put shifter into forward-most position.
5- speed pedal gear shifter is on the left control handle.

Parking
Push left handle forward and down to engage parking brake.
Switch off main switch.
Grasp handle on canopy, pull down slightly while pushing red latch forward, and then let up on canopy.

Charging
Charge cable is behind the driver's seat.
Plug into a suitable electrical outlet (unroll cable completely).
After a few minutes, check to see if charge procedure has started correctly.
If necessary, charge can be interrupted.

ISBN 3-9521088-0-4
 
 

©TWIKE AG
http://www.twike.ch

Translation Copyright © Victor Muñoz