scootelec_service_repair_manuel.pdf

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SALES DIVISION
NETWORK TECHNICAL INFORMATION
WORKSHOP
MANUAL
SERVICE AND REPAIR
CONTENTS
CHARACTERISTICS ............................................................................................................................... 3
Machine markings .................................................................................................................................... 3
Characteristics ......................................................................................................................................... 3
Frame....................................................................................................................................................... 3
Capacities ................................................................................................................................................ 3
Dimensions............................................................................................................................................... 3
Weight ...................................................................................................................................................... 3
Tyres ........................................................................................................................................................ 3
Motor markings ........................................................................................................................................ 3
SERVICE AND COMMISSIONING INSTRUCTIONS.......................................................................... 4
Check: ...................................................................................................................................................... 4
Change:.................................................................................................................................................... 4
Check and change: ................................................................................................................................... 4
Test machine: ........................................................................................................................................... 4
Battery commissioning and maintenance procedure ................................................................................. 5
Commissioning ......................................................................................................................................... 5
Charging after prolonged immobilisation ................................................................................................. 6
Procedure: ............................................................................................................................................... 6
Checks before handing over to the customer:............................................................................................ 7
SPECIAL IMPORTANT POINTS............................................................................................................ 8
TIGHTENING TORQUES AND SPECIAL TOOLS............................................................................... 9
Tightening torques.................................................................................................................................... 9
Frame: .................................................................................................................................................. 9
Motor: .................................................................................................................................................. 9
Standard: .............................................................................................................................................. 9
Special tools:............................................................................................................................................ 9
BODY........................................................................................................................................................ 10
To remove lower body fairings
Step 1.....................................................................................................
10
To remove the footboard
Step 2
.............................................................................................................. 10
To remove the saddle
Step 3
................................................................................................................... 10
To remove the saddle cover and lock
Step 4
........................................................................................... 11
ELECTRICITY........................................................................................................................................ 12
To remove the charger
Step 5
................................................................................................................. 12
Removal of the 200 Amp fuse
Step 6
....................................................................................................... 12
To remove the ECU
Step 7
..................................................................................................................... 13
Setting the throttle sensor ....................................................................................................................... 13
To remove the batteries .......................................................................................................................... 14
Cell fitting order..................................................................................................................................... 15
MOTOR.................................................................................................................................................... 16
To remove the power unit ....................................................................................................................... 16
To remove the brushes ............................................................................................................................ 17
Removal of the motor mounting rod and the stand .................................................................................. 18
To remove the transmission system ......................................................................................................... 19
To remove the motor............................................................................................................................... 20
To remove the speed sensor .................................................................................................................... 20
Relay module removal ............................................................................................................................ 21
MISCELLANEOUS OPERATIONS....................................................................................................... 23
Keypad removal...................................................................................................................................... 23
Page: 2
Reproductions or translations, even partial, are forbidden without the written consent of Peugeot Motocycles
CHARACTERISTICS
CHARACTERISTICS
Machine markings
Model code
Characteristics
Motor
Characteristics
Dimensions
Direct current and
separate excitation
Energy recovery
motor brake
Leroy Somer or
Schabmüller
2.8 kW
2100 rpm
2000 rpm
Length
Width
Height without rear
view mirror
Ground clearance
Wheelbase
Weight
Weight
Tyres
Frame
1
2
Manufacturer’s plate
VIN number
Front wheel
Front tyre
Front tyre pressure
Rear wheel
Rear tyre
Rear tyre pressure
Motor markings
Motor type
EA1
2.5"x10"
100/80x10
2.5 bar
2.5"x10"
110/80x10
2.5 bar
115 kg
1755 mm
695 mm
1100 mm
E1A
Capacities
Relay module
0.12 litres
Esso Gear Oil (EZL
848) P/N 753054
Marque
Max. power
output
Motor speed
Torque speed
1300 mm
Page: 3
Reproductions or translations, even partial, are forbidden without the written consent of Peugeot Motocycles
SERVICE AND COMMISSIONING INSTRUCTIONS
SERVICE AND COMMISSIONING INSTRUCTIONS
Heavy duty servicing is aimed at machines used under “harsh” conditions: door-to-door call, intensive urban
use (courier service)
Servicing operations
500 Kms
Every 5000 Kms
Every 10000 Kms
or 3 months
or months
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
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
10000 km for
heavy duty
service
10000 km for
heavy duty
service
X
X
Check and change:
Motor brushes #
(Leroy Somer only)
Test machine:
On road
# if necessary
X
X
Page: 4
Reproductions or translations, even partial, are forbidden without the written consent of Peugeot Motocycles
SERVICE AND COMMISSIONING INSTRUCTIONS
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 any other source will destroy the battery and result loss of warranty.
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 « V » on the keypad (a minimum of 2 seconds) and do not release it until the 2 confirmation beeps
are given.
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 1à to 15 minutes.
At the end of charging, the
lamps stay on indicating that the 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: 5
Reproductions or translations, even partial, are forbidden without the written consent of Peugeot Motocycles

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