Oxygen LEPTON User manual

Rev.0
CE-DOT
Service manual
Freedom. By Choice.
LEPTON
LEPTON-e

Rev.0 LEPTON Service manual
OXYGEN S.p.A.
2
INDEX
INTRODUCTION.......................................................................................................................4
RECEIVING THE GOODS.......................................................................................................5
STORAGE...................................................................................................................................5
DELIVERY TO THE FINAL CUSTOMER............................................................................6
INSTRUCTIONS FOR FILLING IN THE FORM “READY TO START” ............................6
MOTOR & MECHANICAL TRANSMISSION......................................................................7
REMOVING THE MOTOR ......................................................................................................8
MOUNTING THE ELECTRIC MOTOR..................................................................................9
DRIVE & BATTERY CHARGER, LEAD SEALED BATTERIES VERSION ................11
REMOVING THE DRIVE.......................................................................................................12
MOUNTING THE DRIVE ......................................................................................................12
DRIVE & BATTERY CHARGER NI-ZN BATTERIES VERSION..................................14
REMOVING THE DRIVE.......................................................................................................14
MOUNTING THE DRIVE ......................................................................................................16
BATTERIES ( LEAD SEALED VERSION ).........................................................................18
MOUNTING / REMOVING THE BATTERIES ...................................................................18
BATTERIES ( NI-ZN VERSION ) .........................................................................................20
MOUNTING / REMOVING THE BATTERIES ....................................................................20
BATTERY MANAGEMENT SYSTEM.................................................................................23
AUTONOMY INDICATORS ON THE SCOOTER...............................................................23
BATTERY CHARGER............................................................................................................24
HUMAN INTERFACE ............................................................................................................26
ELECTRONIC KEY INITIALIZATION................................................................................26
THROTTLE..............................................................................................................................28
WIRINGS ..................................................................................................................................30
INSTRUCTIONS FOR USE AND INTERVENTION ON BATTERIES...........................31
BATTERIES MAINTENANCE ..............................................................................................31
BRIEF NOTES ON USE OF LEPTON BATTERIES.............................................................34
ALARM OR ERROR MESSAGES........................................................................................37
ALARM....................................................................................................................................37
ERROR.....................................................................................................................................37
TROUBLESHOOTING GUIDE.............................................................................................38
COUPONS.................................................................................................................................40
OPERATIONS COUPONS OF MAINTENANCE.................................................................40

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LIST AND PROCEDURES OF CONTROLS.........................................................................41
FUSES........................................................................................................................................44
FUSES ON LINE 230 VAC.....................................................................................................45
FUSE INSERTED TO THE BATTERIES POSITIVE POLE................................................46
SERVICES FUSE AND IGNITION FUSE.............................................................................47
FORELOADS <P> AND CLAMPING TORQUES <M> OF ISO METRIC THREAD
SCREWS....................................................................................................................................48

Rev.0 LEPTON Service manual
OXYGEN S.p.A.
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INTRODUCTION
OXYGEN S.p.A. would like to wish you a good job and hopes to be useful to you by
providing this handbook.
Please read carefully the information this document contains; in case of doubts or
remarks about its contents contac us. Generally, in case the information are not
enough for particularly complicated operations on a LEPTON we are at your complete
disposal to supply the assistance you need.
Lepton is a Z.E.V. vehicle (zero emission vehicle), it respects the environment and
the current regulations concerning polluting emissions of the vehicles.
This manual indicates the main points for LEPTON maintenance and it is
supplementary to the Use and Maintenace Manual and to the Warranty Manual. So
before reading this document it is necessary to read the information containerd in the
Use and Maintenance Manual and in the Warranty Manual.
In this manual are examined the components peculiar of the electric scooter, for
interventions on the devices usually used on endothermic scooters such as:
•Tyres
•Shock absorbers
•Fairing
•Lights
•Break levers
•Frame
•Others…
It is necessary to refer to the normal rules of intervention.
WARNING!
Any work carried out on the vehicle during the warranty period by any person other
than authorized OXYGEN personnel shall result in the warranty becoming void.
OXYGEN S.p.A. reserves the right to make any change to its models at any time,
though the essential characteristics described and illustrated herein remain unaltered,
and therefore declines liability for any errors encounterd in the manual as a result of
said changes.

Rev.0 LEPTON Service manual
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RECEIVING THE GOODS
On receiving the Lepton check the packaging is not damaged or broken, otherwise
do not accept it, motivating the refuse and communicating it as soon as possible to
OXYGEN.
When removing the packaging, pay attention to the following instructions:
•Use the proper tools to remove all the metallic clips;
•Remove the carton around the handlebar;
•Open the carton on the side up paying attention not to scratch the fairing of
the scooter and taking off the packaging;
•Remove the nylon cover always paying attention not to scratch the fairing of
the scooter.
After removing the packaging, chek the following parts:
•Plastic fairing, painted and not painted;
•Lights and mirrors;
•Motor and driver;
•Tyres;
•Suspensions;
For Lepton Pb the battery voltage must be higher than 50 Volt. If it is between 46
Volt and 50 Volt make a complete recharge as soon as you can, if lower than 46 Volt
contact OXYGEN at once.
For Lepton Ni-Zn the battery voltage must be higher than 48 Volt. If it is between 44
Volt and 48 make a complete recharge as soon as you can, if lower than 44 Volt it is
necessary to charge and recharge the batteries about 10 times untill a sufficient
autonomy of the vehicle is reached. In case this procedure is not successful contact
OXYGEN as soon as you can.
STORAGE
Keep the Lepton away from heating and from direct irradiation. Besides, do not
keep the Lepton or its spare parts in wet spaces.
IMPORTANT : Every two months at the latest, chek the voltage of the battery pack
and recharge the LEPTON completely. Before this operation chek the battery voltage.
If this is between 46 Volt and 54 Volt recharge completely, if lower than 40 Volt
contact OXYGEN as soon as you can.

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DELIVERY TO THE FINAL CUSTOMER
The vehicle is ready for starting: it is a very important operation and must be made
very carefully.
LEPTON is a product where particolar attention is given to the quality of its
components and to their assembling. Anyway, during packaging, storaging, transport,
moving and receiving of the vehicle, damages to the components might occur.
INSTRUCTIONS FOR FILLING IN THE FORM “READY TO
START”
Before delivering the LEPTON to the Customer it is necessary to make a careful
chek, filling in the form “Warranty/Product Registration Card” contained in the
Warranty Manual.

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MOTOR & MECHANICAL TRANSMISSION
The Electric motor (1 - Figure 1) is attached to the side of the transmission chain-
guard (2 - Figure 1) with 4 screws.
Figure 1
The entire motor is connected to the frame by means of a special splinter bar (3 -
Figure 1) with two screws (4 - Figure 1).
NOTE:
The electric motor cannot be separated from the transmission chain-guard. Doing
so would compromise the correct functioning of the motor and possibly damage the
motor’s control system. Thus, the electric motor must be changed as a unit.

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REMOVING THE MOTOR
•Remove the helmet storage compartment, being careful to disconnect the
battery recharger plug (17 - Figure 5) and the connector of the rear light
system (19 - Figure 5).
•Cut the thermal sheath from the Z10-1 connectors (1 - Figure 5);
•Unscrew the 3 connectors in order to pull out and disconnect the power
cables (1 – Figure 5);
•Disconnect the 3 motor power cables (black/red/green) from the drive power
cables (black/brown/blue);
•Disconnect the ground cable (yellow/green) from the motor case (2 - Figure
5);
•Pull out the signal connection cable with the corresponding connectors from
the hole in the motor flange (4 - Figure 5).
•Unscrew all the screw 3 in (Figure 4) to allow the rotation of the mudguard, in
order to facilitate the dismantlement of the rear wheel;
•Get off the rear wheel;
•After getting off the rear wheel, get off the brake jaw, the ogive of the jaw and
the ogive lever because these will be mounting into the new motor;
•Disconnect the sheath of the rear brake wire;
•Disconnect the rear shock absorber from the motor leaving screwed the
upper parts;
•Disconnect the splinter bar and the motor from the frame (3 – Figure 1) by
unscrewing the two fastening screws (4 - Figure 1).);
•Dismantle all the rear mudguard unscrewing the 2 residual screws (2 –
Figure 4);
•Disconnect the splinter bar of the motor unscrewing the 4 block screws (3 –
Figure 1).

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Figure 2 Figure 3
MOUNTING THE ELECTRIC MOTOR
•Attach the motor to the splinter bar with the appropriate screws (3 - Figure 1);
•Attach the rear mudguard with only 2 screw (2 – Figure 4);
•Attach the splinter bar and the motor to the frame with the 2 appropriate
screws (4 – Figura 1);
•Attach the rear shock absorber to the motor;
•Mount the jaw brakes, the ogive jaw and the ogive brake;
•Connect the sheath of the rear brake wire;
•Connect the cable with the connector to the top of the motor frame(4 - Figure
5);
•Connect the ground cable (yellow/green) (2 - Figure 5);
•Connect with the Z10-1 clamps the motor power cables(Black / Red / Green)
to the cable coming out of the DRIVE (Black / Brown / Blue) (1 - Figure 5);
oRED wire from DRIVE with RED motor wire
oBLACK wire from DRIVE with BLACK motor wire
oBLUE wire from DRIVE with GREEN motor wire
•Cover the Z10-1 clamps with heat-restringent covers employ a phon in order
to covering completely the connectors. In absence of the thermal shealth,
employ a insulating adhesive;
•Mount the rear wheel;
•Fix the rear mudguard (3 – Figure 4);
•Test the motor;
•Group all the motor cables and the main cables with self blocking bands like
under the interventions;

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•Mount the helmet storage compartment supply to connect the battery
recharger plug (17 – Figure 5) and the connector of the rear light system (19
– Figure 5);
•Functionality test .
Figure 4

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DRIVE & BATTERY CHARGER, LEAD SEALED BATTERIES
VERSION
Figure 5

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REMOVING THE DRIVE
•Open the battery compartment and disconnect the positive poles (7 - Figure 5)
and the negative poles (8 - Figure 5) (10 mm2 section) from the battery group;
•Remove the helmet storage compartment, carefully disconnecting the battery
recharger plug (17 - Figure 5) and the connector of the rear light system (19 -
Figure 5);
•Cut all the self-blocking bands ;
•Remove the cooling fan (18 - Figure 5);
•Cut the heat-restringent covers from the Z10-1 terminals (1 - Figure 5)
•Disconnect the 3 motor power cables (Black / Red / Green) from the drive
power cables (Black / Brown / Blue), unscrew the 3 connectors so that you can
pull out and disconnect the power wires;
•Pull out the signal connection cable on the top of the motor flange(4 - Figure 5);
•Disconnect the ground cable (Yellow / Green) from where it is attached to the
motor casing (2 - Figure 5);
•Remove the front shield unscrewing the 4 screws (9 – Figure 5). Disconnect the
3 connectors from the electrical system (10 / 11 – Figure 5) and cut the self-
blocking band. These cables are connected directly with the DRIVE. Pull them
with care following their runway site under the frame, in order to preserve the
cable;
•Disconnect the wires and cables attached directly to the drive:
oRED wire (10 mm2section) from terminal 87 of the switch (12 – Figure
5);
oBLUE wire drive wire from the yellow wire of the scooter’s electrical
system (16 – Figure 5);
•Disconnect the cables from the DRIVE plug to the electric recharge system
(21 – Figure 5) ;
•Remove all the 2 screws of the DRIVE, and remove the DRIVE (0 – Figure
5).
MOUNTING THE DRIVE
•Place the drive near the motor;
•Connect the signal cable from the drive in the appropriate connector on the
top of the motor flange (4 – Figure5);
•Connect the ground cable (Yellow / Green) from DRIVE to the motor casing
(2 - Figure 5);

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•Attach the drive to the frame brackets carefully after having placed all the
wires from the drive inside the frame itself, without blocking the screws;
•Connect the 2 signal cables with the electrical system into the front shield
(10/11 – Figure 5), taking care that this cables should be insert and block to
the frame ( under the footboard, like originally ). Blocking the 2 cables with
self-blocking band;
•Connect the wires attached directly to the DRIVE;
oRED wire (10 mm2section) from terminal 87 of the switch (12 – Figure
5);
oBLUE wire drive wire from the yellow wire of the scooter’s electrical
system (16 – Figure 5);
•Positioning the NEGATIVE pole with the fastening clamp (8 – Figure 5)
across the frame in order to bring near the NEGATIVE pole of the battery
pack with the pin;
•Fixing completely the DRIVE to the frame brackets (0 – Figure 5), then fixing
the cooling fun (18 – Figure 5) with the correct gradient;
•Connect with the Z10-1 clamps the motor power cables(Black / Red / Green)
to the cable coming out of the DRIVE (Black / Brown / Blue) (1 - Figure 5);
oRED wire from DRIVE with RED motor wire
oBLACK wire from DRIVE with BLACK motor wire
oBLUE wire from DRIVE with GREEN motor wire
•Cover the Z10-1 clamps with heat-restringent covers employ a phon in order
to covering completely the connectors. In absence of the thermal shealth,
employ a insulating adhesive. Then grouping the 3 cables and block with
self-blocking bands to the near frame bracket, tacking care that this clamping
will not block the normal oscillation of the rear fork , and the rear fork will not
pull the cables from the motor;
•Functionality test;
•Group all the motor cables and the main cables with self blocking bands like
under the interventions;
•Mount the helmet storage compartment supply to connect the battery
recharger plug (17 – Figure 5) and the connector of the rear light system (19
– Figure 5);
•Mount the front shield;
•Functionality test;

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DRIVE & BATTERY CHARGER NI-ZN BATTERIES VERSION
Figure 5 / a
REMOVING THE DRIVE
•Open the battery compartment, remove the bar (4 – Figure 7). Remove the
plastic protection of the battery pack , disconnect the POSITIVE pole (7 –
Figura 5/a) from the batteries. NOTE: there is a temperature sensor mounting to
an aluminum bar connect with the POSITIVE pole (22 – Figure 5/a). Taking
care to remove the sensor.
•Remove the helmet storage compartment, carefully disconnecting the battery
recharger plug (17 - Figure 5/a) and the connector of the rear light system (19 -
Figure 5/a);
•Cut all the self-blocking bands;

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•Remove the cooling fan (18 - Figure 5/a);
•Cut the heat-restringent covers from the Z10-1 terminals (1 - Figure 5/a);
•Disconnect the 3 motor power cables (Black / Red / Green) from the drive
power cables (Black / Brown / Blue), unscrew the 3 connectors so that you can
pull out and disconnect the power wires;
•Pull out the signal connection cable on the top of the motor flange(4 - Figure
5/a);
•Disconnect the ground cable (Yellow / Green) from where it is attached to the
motor casing (2 - Figure 5/a);
•Remove the front shield unscrewing the 4 screws (9 – Figure 5/a). Disconnect
the 3 connectors from the electrical system (10 / 11 – Figure 5/a) and cut the
self-blocking band. These cables are connected directly with the DRIVE. Pull
them with care following their runway site under the frame, in order to preserve
the cable;
•Disconnect the wires and cables attached directly to the drive:
oRED drive wire (10 mm2section) from terminal 87 of the switch (12 –
Figure 5/a);
oBLUE drive wire from the yellow wire of the scooter’s electrical system
(16 – Figure 5/a);
oBLACK drive wire from the black wire battery (8/a – Figure 5/a)
•Disconnect the cables from the DRIVE plug to the electric recharge system
(21 – Figure 5/a);
•Remove all the 2 screws of the DRIVE, and remove the DRIVE (0 – Figure
5/a).

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MOUNTING THE DRIVE
•Place the drive near the motor;
•Connect the signal cable from the drive in the appropriate connector on the
top of the motor flange (4 – Figure5);
•Connect the ground cable (Yellow / Green) from DRIVE to the motor casing
(2 - Figure 5);
•Attach the drive to the frame brackets carefully after having placed all the
wires from the drive inside the frame itself, without blocking the screws;
•Connect the 2 signal cables with the electrical system into the front shield
(10/11 – Figure 5), taking care that this cables should be insert and block to
the frame ( under the footboard, like originally ). Blocking the 2 cables with
self-blocking band;
•Connect the wires attached directly to the DRIVE;
oRED wire (10 mm2section) from terminal 87 of the switch (12 – Figure
5);
oBLUE wire drive wire from the yellow wire of the scooter’s electrical
system (16 – Figure 5);
•If it’s present, cut the fastening clamp to the BLACK wire from the DRIVE (8
– Figura 5) and remove 10 mm of the plastic coverage. Connect the wire with
the screw contact (8/a – Figure 5/a) coming to the NEGATIVE pole o fthe
battery pack (8 – Figura 5/a);
•Fixing completely the DRIVE to the frame brackets (0 – Figure 5/a), then
fixing the cooling fun (18 – Figure 5/a) with the correct gradient;
•Connect with the Z10-1 clamps the motor power cables(Black / Red / Green)
to the cable coming out of the DRIVE (Black / Brown / Blue) (1 - Figure 5);
oRED wire from DRIVE with RED motor wire
oBLACK wire from DRIVE with BLACK motor wire
oBLUE wire from DRIVE with GREEN motor wire
•Cover the Z10-1 clamps with heat-restringent covers employ a phon in order
to covering completely the connectors. In absence of the thermal shealth,
employ a insulating adhesive. Then grouping the 3 cables and block with
self-blocking bands to the near frame bracket, tacking care that this clamping
will not block the normal oscillation of the rear fork , and the rear fork will not
pull the cables from the motor;
•Connect the POSITIVE pole (7 – Figure 5/a) and the temperature sensor (22
– Figure 5/a) on the POSITIVE pole of the battery pack, take care that the
temperature sensor will not be damaged ( to know the correct fixing power to
practice on the screw contacts of the Ni-Zn batteries, read carefully the

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“OPERATING INSTRUCTION FOR MAINTENANCE FREE SEALED NI-ZN
BATTERIES” manual supplied with the scooter );
•Functionality test;
•Group all the motor cables and the main cables with self blocking bands like
under the interventions;
•Mount the helmet storage compartment supply to connect the battery
recharger plug (17 – Figure 5) and the connector of the rear light system (19
– Figure 5);
•Mount the front shield;
•Functionality test;

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BATTERIES ( LEAD SEALED VERSION )
Figure 6
MOUNTING / REMOVING THE BATTERIES
Four lead sealed batteries connected in series have been placed within the foot
board of the Lepton (1 - Figure 7). It’s important to know that each battery have an
OXYGEN data label.
NOTE: there is an OXYGEN sticker with pertinent numbering information on each
battery. When the batteries are put back in, they must be placed in
numbered sequence.
Remove the case cover (2 - Figure 7) from the scooter to access the batteries. The
case cover is attached in the front with a lock (3 - Figure 7) and a notch in the back.
Press down on the front of the rod that holds the battery (4 - Figure 7), in place to
disconnect it from the fastening clamp (5 - Figure 7)
The batteries are placed in the designated space in a row according to the diagram.
Connect the batteries using the set of rapid contacts supplied. Verify that the pegs are
correctly attached to the terminals of the batteries. Remember that each contact must
be made between a negative and positive pole in the sequence listed.

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Connect:
•the cable with the black cap to the negative pole of the battery group
(identified on the battery with a black sticker).
•the cable with the red cap to the positive pole of the battery group (identified
on the battery with a red sticker).
•the cable with the blue caps to the pegs on the battery group (identified on
the battery with blue sticker).
•the cables with the green caps to the pegs of the battery group (identified on
the battery with green stickers) in sequence.
1
3
4
2
5
Figure 7
Undo the rapid contact cables in the following order:
•the cables with the green caps in sequence
•the cables with the blue caps
•the cable with the red cap
•the cable with the black cap

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BATTERIES ( NI-ZN VERSION )
Figure 7/a
MOUNTING / REMOVING THE BATTERIES
There is an area within the footboard (1 – Figure 7) that accommodates the nickel-
zinc batteries. There are two sets of batteries that in turn contain two 12 V batteries
each (1 / 2 – Figure 7/a), held in a metal frame.
NOTE: There is an OXYGEN sticker with pertinent numbering information on each
battery. When the batteries are put back in, they must be placed in
numbered sequence.
Remove the case cover (2 - Figure 7) from the scooter to access the batteries. The
case cover is attached in the front with a lock (3 - Figure 7) and a notch in the back.
Press down on the front of the rod that holds the battery (4 - Figure 7), in place to
disconnect it from the fastening clamp (5 - Figure 7)
The batteries are placed in positive and negative sets on the second battery pack (2
–- Figure 7/a) (3 – Figure 7/a), and via the two bridges that connect the two cells (4 / 5
– Figure 7/a). The batteries contain a total of 48 volts (Figure 7/a).
WARNING! In some cases the positive (+) and negative (–) poles are reversed in
respect to their placement in the diagram (Figure 7/a) on the
following page, so clean the terminals to certify that the red
(positive) cable is connected to the red terminal and the black
(negative) cable is connected to the black battery terminal.