PEUGEOT E1A Workshop Manual Download

Page: 5 / 36

SERVICE AND COMMISSIONING PLAN

Page: 5

Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles

SERVICE AND COMMISSIONING INSTRUCTIONS

Heavy duty servicing is aimed at machines used under “harsh” conditions: door-to-door calls, intensive
urban use (courrier service)
Servicing operations

500 Kms
or 3 months

Every 5000 Kms
or months

Every 10000 Kms

Heavy duty service

500 Kms

Every 2500 Kms

Every 5000 Kms

Check:

Diagnostic readout

Throttle control

Functioning of electrical equipment

Front and rear brake control

Tyre pressures

Tyre condition, pressure and wear

Tightness of nuts and bolts

Change:

Front and rear brake lining

Grease cam spindle

Drive belt

10000 km for
heavy duty
service

Check and change:

Motor brushes #
(depending on engine manufacturer)

10000 km for
heavy duty
service

Test machine:

On road

# if necessary

Summary of Contents for E1A

Page 1: ...Réf 755815 WORKSHOP MANUAL DIAGNOSTIC SALES DIVISION NETWORK TECHNICAL INFORMATION ...

Page 2: ...RQUES AND SPECIAL TOOLS 10 Tightening torques 10 Frame 10 Engine 10 Standard 10 Special tools 10 TEP USER INSTRUCTIONS 11 Presentation 11 Functioning 11 Apparatus functions 11 Instructions for use 11 Example of checking the charge with the TEP 96 12 In case of a fault on your TEP96 12 Precautions 12 TEP96 Version 2 0 logic diagram the TEP96 screen order 13 Faults logic diagram 14 Permanent defects...

Page 3: ...e from motor 25 Incident motor traction fault motor does not run lacks performance 26 Incident loss of range 27 Range test 28 ECU AND MOTOR DIAGNOSTIC 29 Incidents 29 Causes 29 Troubleshooting 29 1 Fault diagnosis 29 2 To determine the faulty component 30 3 Checking the motor 31 CHANGING THE ELECTRONIC CONTROL UNIT 32 Important point 32 Method for TEP 96 version 1 5 before July 1998 32 Method for ...

Page 4: ... or Schabmüller Max power output 2 8 kW Engine speed 2100 rpm Torque speed 2000 rpm Frame 1 Manufacturer s plate 2 VIN number Capacities Relay module 0 12 litres Esso Gear oil EZL 848 P N 753054 Dimensions Length 1755 mm Width 695 mm Height without rear view mirror 1100 mm Ground clearance 160 mm Wheelbase 1300 mm Weight Weight 115 kg Tyres Front wheel 2 5 x10 Front tyre 100 80x10 Front tyre press...

Page 5: ...ery 5000 Kms or months Every 10000 Kms Heavy duty service 500 Kms Every 2500 Kms Every 5000 Kms Check Diagnostic readout X X X Throttle control X X X Functioning of electrical equipment X X X Front and rear brake control X X X Tyre pressures X Tyre condition pressure and wear X X Tightness of nuts and bolts X X X Change Front and rear brake lining X Grease cam spindle X X Drive belt 10000 km for h...

Page 6: ...hold until there is a second beep Release the V key a series of 3 beeps indicates the operation is to commence the charge lamp flashes If it does not flash repeat the operations more quickly The commissioning procedure has started and will take 10 to 15 minutes At the end of charging the lamps stay on indicating that water may be added to the battery Note From this point on you may leave the machi...

Page 7: ...es to the mains 3 Disconnect the connector from the mains and reconnect it immediately Repeat operations 2 and 3 until The charge lamp comes on on the instrument panel The multifunction key pad sounds a beep The charger fan starts After 5 minutes charging for ECU electronic control unit Software version 4 2 4 production prior to July 97 Connect the TEP96 to the machine The DISCHARGE value must be ...

Page 8: ...heck the wheel nuts are tight Front wheel 6 m daN Rear wheel 10 m daN Check all nuts and bolts are tight Check brake adjustment and efficiency Check the tyre pressures cold Front wheel 2 5 bar Rear wheel 2 5 bar Check operation of the lights flashers road and pedestrian horn and brake light Check operation of the various instrument panel lamps Check the power reserve Carry out a road test ...

Page 9: ...he 3 Cadmium Nickel batteries is by means of the on board charger fitted with a 220V 10 16A power connector with earth A partial charge may be carried out and each charge of 10 minutes enables approximately 5 km to be covered in ECO mode If the battery temperature is high charging will only commence after the time it takes to cool down which is controlled automatically by the charger and the ECU w...

Page 10: ...t 6 m daN Rear wheel spindle nut 10 m daN arm to chassis mounting 4 6 m daN Shock absorber upper mount 4 3 m daN Shock absorber lower mount 2 5 m daN Steering locknut 7 m daN Engine Arm to engine mount 2 3 m daN Battery terminal nut 1 2 m daN Strap and 200 A fuse 1 2 m daN Engine to casing 1 m daN Drive pulley 4 m daN Driven pulley 4 m daN Standard Nut and bolt 5 mm diameter 0 5 m daN Nut and bolt...

Page 11: ...system functioning parameters Reads off the fault codes recorded by the system Checks the opening status of the maintenance hatch Tests the functions charger keypad ignition switch Runs the maintenance procedures to Change one or more of the traction battery cells Change the ECU Instructions for use Connect the cable to the TEP 96 unit Connect the other end of the cable to the diagnostic plug unde...

Page 12: ...ter Precautions Do not splash liquid on the TEP96 Do not open the casing Important The Exchange battery and Exchange uce functions can only be used with the consent of PEUGEOT MOTOCYCLES If you select one of these menus by mistake answer NO as quickly as possible as you may disturb the ECU memories Do not leave the TEP96 connected too long for example in order to watch the counters as an excessive...

Page 13: ...Contact ON TO OPENING SPECIALS FUNCTIONS REQUEST AGREEMENT PEUGEOT MOTOCYCLES SPECIAL FUNCTIONS Εxchange UCE Εxchange battery Used to display faults Used to check different machine components Throttle Anti theft keypad Ignition key etc Gives the total ampere hours stored by the battery since it was first commissioned Gives the TEP version Gives the ECU version Used to read the different measuremen...

Page 14: ...ht of overcharge Lenght char maintenan Temperature battery Temperature uce Lack water battery The number of Ah requested in the time imparted was not reached Charge cut off Battery temporary overheating over 55 C or sensor problem ECU temporary overheating over 75 C The machine needs battery maintenance The water light flashes on the instrument panel and the variable Ah add water is over 840 Ah Th...

Page 15: ...THER SWITCHES Brake lever Security switch Rolling switch TEST BRAKE LEVER Activate the brake lever TEST BRAKE LEVER Release the brake lever TEST SECURITY SWITCH Turn the switch off TEST SECURITY SWITCH Set button to off TEST ROLLING SWITCH Press down on the rolling switch TEST ROLLING SWITCH Release the Rolling switch TEST ROLLING SWITCH Result SWITCH GOOD TEST SECURITY SWITCH Result SWITCH GOOD T...

Page 16: ...S OF SCOOTER P2 Stand FOLD BACK FOLD DOWN Security ON OFF Plug 230V CONNECTED DISCONNECT The charge connector is connected to the 220 V mains The charge connector is not connected to the 220 V The safety button is in the motor off position The safety button is in the drive position STATES OF SCOOTER P3 Accelerat ACTIVATED RELEASED Maintenance ACTIVE INACTIVE Phase CHARGE OVERCHARGE WATER AUTHORISE...

Page 17: ... diagnostic VARIABLES PAGE 1 Voltage batt 20V Current batt 1A Gauge batt 90 VARIABLES PAGE 2 Charge 88Ah Discharge 12Ah Overcharg 0Ah VARIABLES PAGE 3 Tempera batt 23 C Tempera uce 21 C Tempera motor 0 C VARIABLES PAGE 6 Speed 0Km h Accelerator 0 Stop gauge 0 VARIABLES PAGE 4 Voltage batt 20V Ah add water 350Ah Treshold over 0 VARIABLES PAGE 5 Current batt 1A Armature rate 0 Field rate 0 All varia...

Page 18: ...rge bench Red wire to the cell terminal Blue wire to the cell terminal Tighten the terminals the cell voltage is displayed The cooling fan B runs if the voltage is between 7 5 V and 4 5 V The cell discharges automatically When discharge is finished the fan stops and the discharge time is displayed in minutes on the display A e g T 50 Battery cell discharge On reception of a new uncharged cell The ...

Page 19: ...t under 3 A change the charger CHOOSE A FUNCTION Check for defects Activating tests States of scooter Select States of scooter VARIABLES PAGE 1 Voltage batt Current batt 50A Gauge batt In VARIABLES page 1 Read Current batt value VARIABLES PAGE 1 Voltage batt Current batt 5A Gauge batt In VARIABLES page 1 Read Current batt value Return to main menu Select Reading variables OTHER FUNCTIONS Reading v...

Page 20: ...er 8 V apply procedure charging after prolonged immobilisation see appropriate chapter Change the charger See workshop documentation Machine connected to 220 V mains Check battery voltage On TEP96 test OTHER FUNCTIONS Reading variables Memory battery Check in disjunct All variables Large Amperemeter Large voltmeter Large Speedometer VARIABLES PAGE 3 Tempera batt 55 C Tempera uce 25 C Tempera motor...

Page 21: ...propriate chapter Test 200 A fuse Check 220 230 V mains and charging cable Check battery voltage YES The charge and maintenance lamps flash Charge between 10 and 15 hours See next page On the TEP 96 carry out a keypad test NO CHOOSE A FUNCTION Check for defects Activating tests States of scooter TESTS SWITCHES Accelerator Keyboard Contact key Change keypad Test incorrect 1 Disconnect the charging ...

Page 22: ...ot charge 100 logic diagram Read fault codes No fault there has maybe been a power failure during the procedure recommence the battery maintenance procedure If there is a fault refer to the corresponding logic diagram Close the hatch the lamps flash YES Change the battery hatch switch Recommence a battery maintenance procedure see logic diagram machine does not charge flashing off charge on and fa...

Page 23: ...BATTERY TEMP SENSOR ECU burned out warning check the wiring harness Check steering lock ELECTRIC SCOOTER Voltage bat 20 V CONNECTION DEFECT If switched on ELECTRIC SCOOTER Voltage bat 8 V Out of range Connect the TEP96 Check the 5A and 200A fuses Check the battery ECU and motor connections Carry out a charging after prolonged immobilisation procedure No display Low voltage under 8 V Drive and faul...

Page 24: ...cts Activating tests States of scooter TESTS SWITCHES Accelerator Keyboard Contact key On the TEP96 read faults and test keypad Kpad does not beep Anti theft security 3 incorrect codes entered wait 15 min minimum and enter correct code No fault and keypad test OK CHOOSE A FUNCTION Check for defects Activating tests States of scooter TESTS SWITCHES Accelerator Keyboard Contact key Code refused Code...

Page 25: ...EP96 do actuator test SAFETY BUTTON THROTTLE ECU destroyed important check wiring harness Turn on ignition ECU relay does not click Code accepted all lamps on for 1 second Enter code Drive and fault lamp flash CHOOSE A FUNCTION Check for defects Activating tests States of scooter TESTS SWITCHES Accelerator Keyboard Contact key OTHER SWITCHES Brake lever Security switch Rolling switch The throttle ...

Page 26: ...TEMPERATURE SPEED SENSOR Motor lacks performance 30 Km h maximum Check Motor not running Check Motor runs ok Motor runs unevenly coughs cuts out Check Stop switch Battery ECU and motor connections Motor brushes worn Speed sensor Battery temperature sensor ECU or motor faulty see ECU and motor diagnostic Batt voltage low e g 16V charge Turn on ignition ECU relay clicks relay functioning Code accept...

Page 27: ...ge or low range is experienced the following parameters are essential to determine the possible fault the maximum distance covered with a machine complete charge the type of use short journeys frequent stops the type of route town mountains the rider s weight and load carried accessories windshield top case Before starting work check the following points tyre pressures 2 5 bars look for punctures ...

Page 28: ...connected check the voltage of each cell The difference in voltage between each cell should not be over 0 8 V Ranged stated by customer Over 20 km check Under 20 km with motor cut out check Electrolyte level in cells Tyre pressures 2 5 bar If level is incorrect carry out battery maintenance Carry out a range check Brake adjustment 20 mm play on brake lever If the difference in voltage is under 0 8...

Page 29: ... the fault it may also be destroyed if the motor is faulty The machine charge must be over 50 1 Fault diagnosis Leave the machine on its stand Turn on the ignition enter the code on the keypad Connect the TEP96 and select READ VARIABLES Set the throttle to 100 and take the measurements for each driving mode DIAGNOSTIC OPERATIONS NOMINAL BATT CURRENT ARMATURE RATE EXCIT RATE SPEED 12A 24 43 10 km h...

Page 30: ...the saddle cover Turn on the ignition enter the code on the keypad Stay in handling mode and fully open the throttle Measure the voltages with a multimeter set to the DC voltmeter range Between the MOT and the MOT correct value 5V 1V Between the MOT and EXC correct value 8V 1V If the values are lower the ECU is faulty If the values are higher the motor is faulty in this case the ECU is also faulty...

Page 31: ...e ignition Disconnect the battery and Disconnect the motor power cables from the ECU Measure the resistances with a multimeter set to the ohmmeter range Between the MOT and the MOT correct value 0 3Ω Between the MOT and EXC correct value 0 8Ω Check the insulation of the 3 wires from the motor casing If the resistances are not correct the motor and the ECU must be changed ...

Page 32: ...ation Method for TEP 96 version 1 5 before July 1998 Select the Exchange uce line from the main menu and confirm Method for TEP 96 version 2 0 after July 1998 Select the SPECIAL FUNCTIONS line from the main menu and confirm To access the special functions press on the 2 buttons on the bottom of the TEP 96 for a minimum of 3 seconds Then confirm on the Exchange uce line OTHER FUNCTIONS Reading vari...

Page 33: ...kshop manual 6 After changing it repeat operations 1 and 2 the TEP 96 displays Do you want to copy parameters NO YES press YES to transfer the parameters previously memorised to the new ECU 7 Another screen is displayed asking you to confirm writing in the ECU press YES The ECU now contains the parameters from the old ECU 8 Disconnect the TEP 96 and switch off the ignition for a minimum of 20 seco...

Page 34: ...l 2 After replacement connect the TEP 96 and turn on the ignition 3 Initialise parameters Method for TEP 96 version 1 5 before July 1998 Select the Exchange battery line from the main menu and confirm Method for TEP 96 version 2 0 after July 1998 Select the SPECIAL FUNCTIONS line from the main menu and confirm To access the special functions press on the 2 buttons on the bottom of the TEP 96 for a...

Page 35: ... 6 Disconnect the TEP 96 and switch off the ignition for a minimum of 20 seconds to confirm parameter transfer 7 Turn on the ignition and enter the machine code the power gauge is at 0 the charge and maintenance lights flash showing that the parameters have been initialised 8 At this point battery commissioning must be carried out see battery commissioning and maintenance procedure chapter EXCHANG...

Page 36: ...EF 755814 With a constant concern for improvement Peugeot Motocycles reserves the right to delete modify or add any quoted reference DC PS ATR printed in E U 07 2001 photos non contractual www peugeot motocycles com ...

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