Page 1
Réf: 755815
WORKSHOP
MANUAL
DIAGNOSTIC
SALES DIVISION
NETWORK TECHNICAL INFORMATION
Page 2
CONTENTS
Page: 2
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
CHARACTERISTICS ............................................................................................................................... 4
Machine markings: ................................................................................................................................. 4
Characteristics:........................................................................................................................................ 4
Frame:..................................................................................................................................................... 4
Capacities:............................................................................................................................................... 4
Dimensions:............................................................................................................................................. 4
Weight:.................................................................................................................................................... 4
Tyres:....................................................................................................................................................... 4
Engine markings:.................................................................................................................................... 4
SERVICE AND COMMISSIONING INSTRUCTIONS.......................................................................... 5
Check:...................................................................................................................................................... 5
Change:................................................................................................................................................... 5
Check and change:.................................................................................................................................. 5
Test machine:.......................................................................................................................................... 5
Battery commissioning and maintenance procedure............................................................................... 6
Commissioning:....................................................................................................................................... 6
Charging after prolonged immobilisation ............................................................................................... 7
Procedure:............................................................................................................................................... 7
Checks before handing over to the customer:.......................................................................................... 8
SPECIAL IMPORTANT POINTS............................................................................................................ 9
TIGHTENING TORQUES 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:.............................................................................................................................. 14
Intermittent defects:............................................................................................................................ 14
Intermittent or permanent faults:......................................................................................................... 14
Actuators logic diagram:....................................................................................................................... 15
States logic diagram:............................................................................................................................. 16
Variables logic diagram: ....................................................................................................................... 17
6Volt BATTERY CELL DISCHARGE BENCH INSTRUCTIONS FOR USE.................................... 18
Characteristics:...................................................................................................................................... 18
Presentation: ......................................................................................................................................... 18
Protection:............................................................................................................................................. 18
Instructions for use: .............................................................................................................................. 18
Battery cell discharge:........................................................................................................................... 18
Precautions:........................................................................................................................................... 18
TROUBLESHOOTING LOGIC DIAGRAM......................................................................................... 19
Page 3
CONTENTS
Page: 3
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
Incident: the machine does not charge 100%:....................................................................................... 19
Incident: the machine does not charge:................................................................................................. 20
Incident: problems during the maintenance charge:............................................................................ 21
Incident: when the ignition is turned on, the machine does not start:.................................................. 23
Incident: impossible to enter immobiliser code: .................................................................................... 24
Incident: no drive 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 TEP 96 version 2.0. after July 1998:................................................................................... 32
BATTERY REPLACEMENT PROCEDURE (3 cells)........................................................................... 34
Important point: .................................................................................................................................... 34
Method for TEP 96 version 1.5. before July 1998:................................................................................ 34
Method for TEP 96 version 2.0. after July 1998:................................................................................... 34
Page 4
CHARACTERISTICS
Page: 4
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CHARACTERISTICS
Machine markings:
Model code E1A
Characteristics:
Engine
Characteristics Direct current and
separate excitation
Energy recovery on
motor braking
Marque Leroy Somer 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 pressure 2.5 bar
Rear wheel 2.5"x10"
Rear tyre 110/80x10
Rear tyre pressure 2.5 bar
Engine markings:
Engine type EA1
Page 5
SERVICE AND COMMISSIONING PLAN
Page: 5
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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 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
heavy duty
service
Check and change:
Motor brushes #
(depending on engine manufacturer)
10000 km for
heavy duty
service
X
Test machine:
On road X X X
# if necessary
Page 6
SERVICE AND COMMISSIONING PLAN
Page: 6
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Battery commissioning and maintenance procedure
Remark: the maintenance procedure is identical to the commissioning procedure
Important:
It is essential to use distilled water supplied by PEUGEOT MOTOCYCLES under P/N: 973582
The use of distilled water from another sources will destroy the battery.
It is forbidden to pour in distilled water before the end of charging.
Commissioning:
Ensure you have 3 litres of PEUGEOT distilled water, P/N: 973582.
• Connect the charge cable to the 230 V – 10/16 A mains.
• The charge lamp comes on with a beep, the battery lamp flashes
• Press key “V” on the keypad there is a beep and 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 machine connected to the mains for a period of 72 hours. Beyond this
time, you will have to repeat the procedure from the start.
• Disconnect the charging cable, the lamps stay on. You now have a maximum of 30 minutes to
add water to the battery.
• Open the maintenance cover with a Torx screwdriver and slowly pour in the distilled water (P/N:
973582) until the water runs out of the overflow under the scooter.
• Close and tighten the maintenance cover, the lamps go off indicating the end of
commissioning.
• Wait for a minimum of 15 seconds before turning on the ignition.
Page 7
SERVICE AND COMMISSIONING PLAN
Page: 7
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Charging after prolonged immobilisation
After not being used for a few months, the battery voltage may drop below 8 volts and it is impossible to put
the machine on charge.
In this case, the battery needs to be “woken up” by one or more connections / disconnections to and from the
mains socket.
Procedure:
1. Connect the charging connector to the mains.
Important:
• The charge lamp does not come on on the instrument panel.
• No beep on the multifunction keypad.
• The fan does not run.
This is normal.
Do not turn on the scooter lights.
Do not connect the TEP96.
2. Leave the connector connected 5 minutes 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 between 0 and 110 Ah
If the number of discharged Ah is over 110, use the TEP96 to carry out a “Exchange battery” procedure
Press the two buttons (A) for 3
seconds
OTHER FUNCTIONS
♦ Reading variables
♦ Memory battery
♦ Check in disjunct.
♦
All variables
♦ Large Amperemeter
♦ Large voltmeter
♦ Large speedometer
*VARIABLE (PAGE 2)*
Charge =0.0Ah
Discharge = 65.2Ah
Overcharg = 0.0Ah
OTHER FUNCTIONS
♦ Ιdentity UCE
♦ Ιdentity TEP
♦ SPECIAL FUNCTIONS
TO OPENING SPECIALS
FUNCTIONS
REQUEST AGREEMENT
PEUGEOT MOTOCYCLES
SPECIAL FUNCTIONS
♦ Exchange UCE
♦ Exchange battery
A
Page 8
SERVICE AND COMMISSIONING PLAN
Page: 8
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Checks before handing over to the customer:
Check 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
SPECIAL IMPORTANT POINTS
Page: 9
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SPECIAL IMPORTANT POINTS
The scoot'elec is fitted with a coded immobiliser. This system prevents the machine from being started if the
user has not entered the secret code number. See manual.
Charging of the 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 (which means that the charging time will be prolonged
by the same time).
The lamp will flash until the charge is triggered automatically. See manual.
Page 10
TIGHTENING TORQUES AND SPECIAL TOOLS
Page: 10
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TIGHTENING TORQUES AND SPECIAL TOOLS
Tightening torques:
Lower body fairing 0.2m.daN
Footboard 0.4 m.daN
Speedo casing 0.1 m.daN
Saddle cover 0.6 m.daN
Front panel 0.1 m.daN
Rear panel 0.1 m.daN
Side fairings 0.1 m.daN
Rear mudguard * 0.8/0.1 m.daN
Mud flap * 0.6/0.8m.daN
Saddle locking plate 1.2 m.daN
Frame:
Front wheel spindle nut 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 6mm diameter 1 m.daN
Nut and bolt 8mm diameter 2.2 m.daN
Nut and bolt 10mm diameter 3.5 m.daN
Nut and bolt 12mm diameter 5.5 m.daN
Special tools:
Description Item no..
Steering column spanner 754086
Discharge bench 753012
TEP 96 753011
Optional charger 5409
* depending on size of bolt
Page 11
PEUGEOT ELECTRONIC TESTER (TEP 96) USER INSTRUCTIONS
Page: 11
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TEP USER INSTRUCTIONS
VERSION 1.5 AND 2.0
Presentation:
Unit with a display window, and connecting cable
Functioning:
Powered by the machine over the cable, the TEP 96 contains no batteries.
It dialogs with the ECU (Electronic Control Unit).
Apparatus functions:
Reads off the 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 under the machine saddle
Read off the indications in the window
Buttons (A) are used to scroll through the menu or to change from one page to another
Button (B) is used to return to the menu or answer no
Button (C) is used to confirm or answer yes
Page 12
PEUGEOT ELECTRONIC TESTER (TEP 96) USER INSTRUCTIONS
Page: 12
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Example of checking the charge with the TEP 96:
Connect the TEP96 to the machine diagnostic plug
Connect the scooter charge cable to the 220/230V mains
In the main menu, you have 3 read lines to check the charge
1/ Check for defects
Used to read the following defects : Lenght of charge or Lenght of overcharge
2/ States of scooter
Used to consult the following states : Phase = CHARGE or Phase = OVERCHARGE
3/Reading variables/all variables
Used to read the following variables :.Current batt = +42A to +50A for the charge phase
or Batt. current = +4A to +6A for the overcharge phase
In case of a fault on your TEP96:
Test the continuity of the connection cable with an ohmmeter
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 excessively
long connection may disturb certain of the ECU measurements or counters.
It may be necessary to disconnect the TEP96 and turn off the ignition for 20 seconds to confirm certain
operations.
CHOOSE A FUNCTION
Check for defects
Activating tests
States of scooter
FLEETING DEFECTS
Lenght of charge
STATES OF SCOOTER P3
Accelerat =
Maintenance =
Phase = CHARGE
CHOOSE A FUNCTION
Check for defects
Activating tests
States of scooter
OTHER FUNCTIONS
♦ Reading variables
♦ Memory battery
♦ Check in disjunct.
♦
All variables
♦ Large Amperemeter
♦ Large voltmeter
♦ Large Speedometer
* VARIABLES (PAGE 1) *
Voltage batt. = 19,1
Current batt. = 45A
Gauge batt. = 45%
Page 13
PEUGEOT ELECTRONIC TESTER (TEP 96) USER INSTRUCTIONS
Page: 13
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TEP96 Version 2.0 logic diagram (the TEP96 screen order) :
⇓
All variables
♦ Large Amperemeter
♦ Large voltmeter
⇑ Large Speedometer
MAIN MENU
MAIN MENU
CHOOSE A FUNCTION
⇓ Check for defects
♦ Activating tests
♦ States of scooter
ELECTRIC SCOOTER
Voltage bat.= 20V
Switch on
ELECTRIC SCOOTER
Please wait…
ELECTRIC SCOOTER
Voltage bat.= 20 V
CONNECTION DEFECT
(If switched on )
ELECTRIC SCOOTER
Voltage bat.= 8 V
Out of range
OTHER FUNCTIONS
♦ Reading variables
♦ Memory battery
♦ Check in disjunct.
OTHER FUNCTIONS
♦ Ιdentity UCE
♦ Ιdentity TEP
⇑ SPECIAL FUNCTIONS.
PERMANENT DEFECTS
Lenght of charge
See faults logic
diagram
TESTS SWITCHES:
♦Accelerator
♦Keyboard
♦Contact key
See actuators
logic diagram
See states logic
diagram
STATES OF SCOOTER P1
Pin cod = LOCKED
Mode = HANDLING
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
measurements:
-Batt. voltage
-Batt. current.
-Temperatures
-etc…
Gives the last 3 reasons
for setting to safety mode
by the ECU
Do not use this line
without the consent of
Peugeot Motocycles
The ECU gives the
machine mode:
-Immobiliser
-Driving mode
-Safety
-Charging
MEMORY BATTERY
Total charge = 35379Ah
Tot discharge = 2639Ah
Tot overcharge =160Ah
MEMORY BATTERY
Defect add water = NO
Rolling number = 11590
Time bat 50°C = 0h20
IDENTITY ECU
Serie number : 1960
Date product :a98 ,s15
Soft version : 4.2.5
CHECK IN DISJUNCTION
Last-2 : voltage bat
Last-1 : voltage bat
Last: : voltage bat
See variables
logic diagram
0 A
19.1 V
45 Km/h
* IDENTITY TESTER
Version : V2.0
Date : 01/07/98
Serie num : 33862
CONSOLE IDENTITY
Octets sum = 107
U bat calcul = 19.8V
Page 14
PEUGEOT ELECTRONIC TESTER (TEP 96) USER INSTRUCTIONS
Page: 14
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
Faults logic diagram:
List of faults recorded by the ECU during use of the machine
Permanent defects:
Intermittent defects:
Intermittent or permanent faults:
PERMANENT DEFECTS :
Charger
Opening of the hatch
Charge batter (sill)
The battery hatch was left open when there was no battery
maintenance
Batt. voltage was over 27 V during a charge
3 times during charge phase, the number of Ah requested
was reached without the voltage exceeding the threshold for
switchover to the 24.7 V overcharge phase
INTERMITTENT DEFECTS :
Lenght of charge
Lenght 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. This counter is reset to 0
after a battery maintenance
INTERMITTENT OR
PERMANENT :
Keyboard
Sensor tempe uce
Sensor tempe battery
Sensor speed
Accelerator
Measurment tens batt
Sensor current batt
Circuit engine
Uce (relaying)
Uce (program)
Keypad circuit cutoff
Battery temperature false reading or harness cut
Throttle sensor false reading or wiring harness cut
Speed sensor false reading or bad sensor earth insulation
or wiring harness cut
ECU internal faults
ECU internal temperature sensor false reading
Page 15
PEUGEOT ELECTRONIC TESTER (TEP 96) USER INSTRUCTIONS
Page: 15
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Actuators logic diagram:
Testing the machine actuators is used to check they are functioning at the time of diagnostic
TESTS SWITCHES :
⇓ Accelerator
♦ Keyboard
♦ Contact key
TEST ACCELERATOR
0%← ACTIVATE→100%
* TEST KEYBOARD *
Press down on a key
Of the scooter
* TEST KEYBOARD *
KEY READ : 1
(Voltage = 1.75 V)
TEST CONTACT KEY
Switch off
TEST CONTACT KEY
Switch on
TEST CONTACT KEY
Result :
CONTACT GOOD
OTHER 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
TEST BRAKE LEVER
Result :
CONTACT BRAKE GOOD
OTHER SWITCHES
♦ Gauge
⇑ Batt. hatch cover
* TEST OF THE GAUGE *
Check gauge = 0%
And press down on : •
* TEST OF THE GAUGE *
Check gauge = 50%
And press down on : •
* TEST OF THE GAUGE *
Check gauge = 100%
And press down on : •
TEST BATTERY HATCH
Open the hatch
TEST BATTERY HATCH
Shut the hatch
TEST BATTERY HATCH
RESULT:
CONTACT OF HATCH
GOOD
Page 16
PEUGEOT ELECTRONIC TESTER (TEP 96) USER INSTRUCTIONS
Page: 16
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
States logic diagram:
List of the machine accessory states having an effect on ECU functioning
STATES OF SCOOTER P1
Pin cod = LOCKED
UNLOCKED
Mode = ECONOMICAL
NOMINAL
HANDLING
Contact = ON
OFF
Machine waiting for code
The code is entered and the machine is in drive mode
Drive mode, Max sp. 30 km/h
Drive mode, Max sp. 45 km/h
Drive mode, Max sp. 7 km/h
Machine power on
Machine power off
STATES 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 AUTHORISED
ROLLING
Machine undergoing battery maintenance charge
Machine undergoing normal charge
Machine being charged with a current of 50 A
Machine is undergoing maintenance charge and hatch
opening authorised for filling battery with
demineralised water
Machine is in utilisation mode. Service, economy or
nominal
Machine being charged with a current of 5 A
Page 17
PEUGEOT ELECTRONIC TESTER (TEP 96) USER INSTRUCTIONS
Page: 17
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Variables logic diagram:
Display of functioning parameters read by the ECU at the time of 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 variables
♦ Large Amperemeter
♦ Large voltmeter
⇑ Large Speedometer
Page 18
CELL DISCHARGE BENCH USER INSTRUCTIONS
Page: 18
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6Volt BATTERY CELL DISCHARGE BENCH INSTRUCTIONS FOR USE
Characteristics:
Operating voltage 6 Volts
Discharge current 100 amperes
Ventilated discharger
Presentation:
Liquid crystal display (A) on front panel
Fan (B) at rear
2 connection cables (C) + red wire / - blue wire
Protection:
Against polarity inversions (display off)
Against connection of cells in series (display off)
Heat protection, discharge stopped temporarily
(display flashes)
Instructions for use:
Disconnect and remove the 3 cells
Connect the cell to the discharge 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 other 2 cells must be discharged, one after the other in order to equalise and have the same voltage as
the new cell.
After refitting the cells, carry out the battery replacement procedures on the TEP96 and commissioning the
battery with the TEP96 (see corresponding chapters).
Precautions:
Do not use the discharge bench with batteries from another source
Do not splash water, petrol or oil on the discharge bench
Keep the discharge bench away from inflammable materials
Page 19
TROUBLESHOOTING LOGIC DIAGRAM
Page: 19
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TROUBLESHOOTING LOGIC DIAGRAM
Incident: the machine does not charge 100%:
Charge indicator needle does not move to maximum
With or without the following fault codes: “Lenght of charge” or “Lenght of overcharge”
Important: for this test, the machine should not be at the end of charge nor in an atmosphere of over 60°C,
if so, the measurements will be false.
SCOOTER STATUS*
THROTTLEERAT=
MAINTENANCE CHGE=
PHASE= CHARGE
Current batt. under 40 A, change the
charger
Current batt. 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 variables
♦ Memory battery
♦ Check in disjunct.
STATES OF SCOOTER P3
Accelerat =
Maintenance =
Phase = CHARGE
In “STATES OF SCOOTER P3” read
Phase = OVERCHARGE
Select “All variables”
⇓
All variables
♦ Large Amperemeter
♦ Large voltmeter
⇑ Large Speedometer
Machine connected to 220 V
mains Charge lamp on and
charger fan running or not
In “STATES OF SCOOTER P3”
read Phase = CHARGE
STATES OF SCOOTER P3
Accelerat =
Maintenance =
Phase = CHARGE
Page 20
TROUBLESHOOTING LOGIC DIAGRAM
Page: 20
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
Incident: the machine does not charge:
With or without the following fault codes: BAT. TEMPERATURE or BATTERY TEMP SENSOR
Test
200 A
fuse
Test the
220-230 V
mains and
charging
cable
Charge lamp on and
charger fan not
running
Charge lamp off and
charger fan not
running
Charge lamp on, fault
lamp flashing and
charger fan not
running
Voltage over 12V,
change the charger (see
workshop
documentation)
Voltage under 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 = ?°C
If after 2 hrs the battery temperature is not under 55°, check the battery temperature functions and
change it if necessary (sensor fault, or sensor information error).
No fault but battery temperature safety
triggered (room too hot, external
temperature too high)
in this case leave the machine connected
and the charge to finish
Battery
voltage over
55°c
Page 21
TROUBLESHOOTING LOGIC DIAGRAM
Page: 21
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
Incident: problems during the maintenance charge:
With or without the following fault codes: CHARGE TIME, MAINTENANCE CHARGE TIME, BAT
TEMPERATURE or BATTERY TEMP SENSOR
Voltage over 12V,
change the charger (see
workshop
documentation)
Voltage under 8 V apply
procedure: charging after
prolonged immobilisation
(see appropriate 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 cable
2. Test drive for 2 or 3 km to slightly discharge
the battery
3. Repeat the procedure from the start
Test OK
NOCharge lamp is on and
maintenance lamp flashes
Machine connected
to 220 V mains
YES
Press the “V” key
on the keypad for a
minimum of 2
seconds
Page 22
TROUBLESHOOTING LOGIC DIAGRAM
Page: 22
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
Disconnect
the charging
cable and
open the
maintenance
hatch and
slowly add
demineralised
water
On the TEP96, check the
charge current see
machine does not 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
flashingoff
charge on and
fault warning
flashing
on
After this charge, the charge and
maintenance lamps are:
From previous page
NO
Page 23
TROUBLESHOOTING LOGIC DIAGRAM
Page: 23
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
Incident: when the ignition is turned on, the machine does not start:
With or without the following fault codes: CHARGE TIME, MAINTENANCE CHARGE TIME, BAT
TEMPERATURE or 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 fault lamps do not
flash
Turn on the ignition
Display read
connection fault if
ignition on
Does the horn work?
YES NO
Page 24
TROUBLESHOOTING LOGIC DIAGRAM
Page: 24
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
Incident: impossible to enter immobiliser code:
With or without the following fault codes: KEYPAD
Kpad beeps
Enter the code
Drive and fault lamps flash
Turn on ignition
CHOOSE A FUNCTION
⇓ Check for defects
♦ 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 accepted
all lamps on 1
second
OK
On TEP96 read faults
and test actuator
keypad”
This is not the machine
code
Change
keypad
Test incorrect
Test OK
Page 25
TROUBLESHOOTING LOGIC DIAGRAM
Page: 25
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
Incident: no drive from motor:
No fault code
Check the battery
voltage if under
14.5 V charge
On the TEP96 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 grip
position parameter
value should return to
0%
Page 26
TROUBLESHOOTING LOGIC DIAGRAM
Page: 26
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
Incident: motor traction fault: (motor does not run, lacks performance)
With or without fault codes: BATTERY TEMP SENSOR, BAT 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 accepted all lamps on for
1 second
Enter code
Drive and fault lamps flash
Page 27
TROUBLESHOOTING LOGIC DIAGRAM
Page: 27
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
Incident: loss of range:
Reminder: The scoot’elec has a range of 35 to 40 km at a stabilised speed of 45 k/h with a rider weighing 70
kg, and over a flat route covered without interruption
If a drop in range 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)
- adjustment of brakes: 20 mm travel on lever
All these points may result in a loss of between 10 and 20 km of range
After these checks, do a range test
Page 28
TROUBLESHOOTING LOGIC DIAGRAM
Page: 28
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
Range test:
Under the following conditions:
Scooter charged 100%, run it within a maximum of 8 hours after the end of charging
The route should be covered without interruption, on flat roads with a minimum of stops and until the
reserve light comes on (the reserve you to cover another 5 km)
Electrolyte
leak on one
of the cells
With power gauge under
25 % and the cells
disconnected,
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 V, the battery
is OK
If the difference in
voltage is over 0.8
V, the weakest
battery must be
changed
Carry out a range check.
If range is still low, discharge the 3 cells using the
discharge apparatus and compare the discharge times of
each cell.
If a cell has a discharge time far below that of the others
change it.
Page 29
ECU AND MOTOR DIAGNOSTIC
Page: 29
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
ECU AND MOTOR DIAGNOSTIC
Incidents:
Machine on its stand:
- Motor not running
- The motor runs if helped by turning the rear wheel by hand
- The motor revs hard (E.g.: 67 km/h maximum speed on the TEP96)
- The motor power cables are hot
Causes:
ECU destroyed
Motor destroyed (in this case, the ECU is also faulty)
Troubleshooting:
Important:
Do not fit another ECU to find 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
-21 A
100 %
24 %
52 km/h
If the readings are different and disparate, the motor or the ECU is faulty.
OTHER FUNCTIONS
♦ Reading variables
♦ Memory battery
♦ Check in disjunct.
⇓
All variables
♦ Large Amperemeter
♦ Large voltmeter
⇑ Large Speedometer
* VARIABLES (PAGE 1) *
Voltage batt = 19.1V
Current batt. = -12A
Gauge batt. = 45%
Page 30
ECU AND MOTOR DIAGNOSTIC
Page: 30
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2/To determine the faulty component:
Remove the saddle and 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
ECU AND MOTOR DIAGNOSTIC
Page: 31
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
3/Checking the motor:
Cut off the 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
ELECTRONIC CONTROL UNIT REPLACEMENT
Page: 32
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
CHANGING THE ELECTRONIC CONTROL UNIT
Important point:
- Only do this job if the ECU is being changed
- Before starting any work, the memory of the ECU to be replaced must be copied into the TEP 96
1. Connect the TEP 96 and turn on the ignition.
2. Parameter memorisation
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 variables
♦ Exchange uce
⇑ Exchange battery
OTHER FUNCTIONS
♦ Ιdentity UCE
♦ Ιdentity TEP
⇑ SPECIAL FUNCTIONS
TO OPENING SPECIALS
FUNCTIONS
REQUEST AGREEMENT
PEUGEOT MOTOCYCLES
SPECIAL FUNCTIONS
Exchange uce
Exchange battery
Page 33
ELECTRONIC CONTROL UNIT REPLACEMENT
Page: 33
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
3. A “Copy from UCE to TEP In process…” screen is briefly displayed (1 second ) indicating
memorisation of the parameters in the TEP 96
4. Following this screen the TEP 96 displays “Do you want to copy parameters ? NO/YES“
press NO to save the ECU parameters and return to the main menu
5. Disconnect the TEP 96, turn off the ignition, and change the ECU refer to the scoot’elect workshop
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 seconds to confirm parameter
transfer
9. Turn on the ignition again, enter factory code 1111 and do a road test
* EXCHANGE UCE*
Copy from UCE to TEP
In process…
* EXCHANGE UCE*
NO : •
Are you replace
It by a new ? YES : •
* EXCHANGE UCE*
Do you want to NO : •
copy precedents
parameters ? YES :
•
* EXCHANGE UCE*
Do you want to NO : •
copy precedents
parameters ? YES :
•
Page 34
BATTERY REPLACEMENT PROCEDURE
Page: 34
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
BATTERY REPLACEMENT PROCEDURE (3 cells)
Important point:
This operation may only be carried out after battery replacement consent from PEUGEOT MOTOCYCLES
If one or two of the cells is to be replaced, discharge the remaining cell(s) separately using the discharge
bench (see discharge bench user manual)
1. To change the battery, see the scoot’elect workshop manual
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
minimum of 3 seconds.
Then confirm on the “Exchange battery” line.
OTHER FUNCTIONS
♦ Reading variables
♦ Exchange ecu
⇑ Exchange battery
OTHER FUNCTIONS
♦ Ιdentity UCE
♦ Ιdentity TEP
⇑ SPECIAL FUNCTIONS.
TO OPENING SPECIALS
FUNCTIONS
REQUEST AGREEMENT
PEUGEOT MOTOCYCLES
SPECIAL FUNCTIONS
Exchange uce
Exchange battery
Page 35
BATTERY REPLACEMENT PROCEDURE
Page: 35
Reproductions or translations, even parrtial, are forbidden without the written consent of Peugeot Motocycles
4. A “Parameters to initialize ? NO/YES” screen is displayed, press YES
5. Another screen is displayed asking you to confirm writing in the ECU, press YES
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)
* EXCHANGE BATTERY *
NO : •
Are you replace
It by a new YES : •
* EXCHANGE BATTERY *
NO : •
Parameters to
Initialize ? YES : •
Page 36
RECOMMENDED
REF: 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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