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Oxygen LEPTON Service Manual

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

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  • Page 1 Rev.0 Service manual CE-DOT LEPTON LEPTON-e Freedom. By Choice.

  • Page 2: Table Of Contents

    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...
  • Page 3 Rev.0 LEPTON Service manual 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...

  • Page 4: Introduction

    Rev.0 LEPTON Service manual 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.

  • Page 5: Receiving The Goods

    • 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.

  • Page 6: 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.

  • Page 7: Motor & Mechanical Transmission

    Rev.0 LEPTON Service manual 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).

  • Page 8: Removing The Motor

    Rev.0 LEPTON Service manual 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);...

  • Page 9: Mounting The Electric Motor

    Rev.0 LEPTON Service manual 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);...
  • Page 10 Rev.0 LEPTON Service manual • 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 OXYGEN S.p.A.

  • Page 11: Drive & Battery Charger, Lead Sealed Batteries Version

    Rev.0 LEPTON Service manual DRIVE & BATTERY CHARGER, LEAD SEALED BATTERIES VERSION Figure 5 OXYGEN S.p.A.

  • Page 12: Removing The Drive

    Rev.0 LEPTON Service manual REMOVING THE DRIVE • Open the battery compartment and disconnect the positive poles (7 - Figure 5) and the negative poles (8 - Figure 5) (10 mm 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);...
  • Page 13 Rev.0 LEPTON Service manual • 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 –...

  • Page 14: Drive & Battery Charger Ni-Zn Batteries Version

    Rev.0 LEPTON Service manual 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 –...
  • Page 15 Rev.0 LEPTON Service manual • 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;...

  • Page 16: Mounting The Drive

    Rev.0 LEPTON Service manual 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);...
  • Page 17 Rev.0 LEPTON Service manual “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 –...

  • Page 18: 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.
  • Page 19 Rev.0 LEPTON Service manual 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).

  • Page 20: Batteries ( Ni-Zn Version )

    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.
  • Page 21 Rev.0 LEPTON Service manual Figure 7/b Figure 7/c Figure 7/d Figure 7/e REMOVING THE NICKEL-ZINC BATTERIES 1. Remove the cover of the case to access the batteries (2 – Figure 7). The case is secured by a lock at the front (3 – Figure 7), and a notch at the back.
  • Page 22 Rev.0 LEPTON Service manual The second battery unit is dislodged simply by sliding it toward the front of the scooter (2 – Figure 7/a). NOTE: Do not attempt to lift and remove this unit by holding it by the bridge illustrated in Figure 7/e.

  • Page 23: Battery Management System

    BATTERY MANAGEMENT SYSTEM AUTONOMY INDICATORS ON THE SCOOTER The LEPTON scooter has a series of visual LCD indicators on the control panel that indicate the scooter’s charge remaining in terms of kilometers. This calculation is based on an algorithm that estimates remaining energy and average use.

  • Page 24: Battery Charger

    Rev.0 LEPTON Service manual BATTERY CHARGER The scooter has a high frequency battery charger incorporated in the drive. The battery charger can be connected to any 110-Volt outlet and is programmed exclusively for charging the type of batteries used in the scooter automatically.
  • Page 25 It is not true that energy can be added to a completely charged battery. Furthermore, the lead-acid AGM batteries can be ruined electronically if over charged. The electrolyte water is converted into hydrogen and oxygen and produces considerable heat, and the battery could explode. OXYGEN S.p.A.

  • Page 26: Human Interface

    LEPTON Service manual HUMAN INTERFACE ELECTRONIC KEY INITIALIZATION LEPTON scooter is equiped with an electronic key ( Figure 9). The key includes the DRIVE identification code (TRANSPONDER key ). Every key can authorize only the LEPTON connected with this DRIVE identification code.
  • Page 27 LEPTON Service manual Figure 11 If you loose or damage the electronic key so that the LEPTON cannot start, you need to initialize the DRIVE in order to use a new different electronic key. The new key is supplied directly by OXYGEN.

  • Page 28: Throttle

    Rev.0 LEPTON Service manual THROTTLE The LEPTON throttle acts a resistence value variations of the potentiometer. This resistence value is read by the DRIVE, that gives the required electric power to run with the scooter. The potentiometer is inside the front shield (Figure 11/a) and is connected with the throttle by a retrieval spring wire.
  • Page 29 Rev.0 LEPTON Service manual Figure 11/b If the LEPTON throttle does not achieve the maximun speed, you need to check the correct tension of the connection wire (Figure 11/a): • Dismantle the front shield; • You have to turn a throttle at the maximum rotation point, then check that the maximum position of the throttle coincides to the maximum position of the potentiometer braket;...

  • Page 30: Wirings

    Rev.0 LEPTON Service manual WIRINGS LEPTON has three kinds of wirings: • Power wiring: (batteries-DRIVE, motor-DRIVE, relè-DRIVE) particular care must be used when replacing or reparing them because of their high voltage. In particular, uncorrected connections might cause localized heating thus compromizing the safety of the vehicle and the correct functioning of LEPTON’S main components.

  • Page 31: Instructions For Use And Intervention On Batteries

    Rev.0 LEPTON Service manual INSTRUCTIONS FOR USE AND INTERVENTION ON BATTERIES BATTERIES MAINTENANCE • All of the materials used in the lead-acid AGM batteries are resistant to the corrosive action of the acid. • Lead-acid AGM batteries are virtually maintenance free if used in the proper manner.
  • Page 32 Keep the batteries away from heat and open flames. • If the battery fluid contains a higher concentration of hydrogen and oxygen than normal, it could burst into flames. • Do not touch the battery while it is charging or discharging.
  • Page 33 Rev.0 LEPTON Service manual Working on the Batteries • Only OXYGEN service technicians can work on the batteries. • Handle the batteries with care to avoid damaging them. • Check the battery connections. • Use the proper tools when working on batteries.

  • Page 34: Brief Notes On Use Of Lepton Batteries

    Rev.0 LEPTON Service manual BRIEF NOTES ON USE OF LEPTON BATTERIES The battery is influenced by the way of use. The battery is a “variable” tank. If you take as a reference an internal combustion vehicle you know that the higher the average speed, the more the driving is unsteady (strong accelerations), the heaviest the loads (people and goods), the greatest the kilometric consumption.
  • Page 35 If the curve are not correct the batteries might be damaged for an excess of a defect of recharge. So it is important to recharge the LEPTON batteries with the battery charger provided or expressly approved by OXYGEN.
  • Page 36 If this procedure is not respected, irreversible damages might occur to the batteries. WARNING: Ni-Zn LEPTON can recover its initial performance by making a series of repeated charges and discharges (circa 10).

  • Page 37: Alarm Or Error Messages

    Rev.0 LEPTON Service manual ALARM OR ERROR MESSAGES The LCD strip on the instrument panel shows any breakdowns or malfunctions. They are subdivided into Alarm and Error categories. ALARM The Alarm category indicates temporary breakdowns or malfunctions that allow the rider to continue travelling, even if the conditions are not optimal.

  • Page 38: Troubleshooting Guide

    Rev.0 LEPTON Service manual TROUBLESHOOTING GUIDE ALARM DESCRIPTION ALARM CONDITIONS CAUSES TYPE Exceeding of the fixed Real values of temperature motor temperature Motor temperature Break of temperature sensor ALL 4 first high level Problems with electronic card of control Value of voltage over 70V...
  • Page 39 Rev.0 LEPTON Service manual ALARM DESCRIPTION ALARM CONDITIONS CAUSES TYPE Wrong sequence of Wrong wiring of Hall Sensor on the configuration of Hall Sensor motor or break of wiring Tuned of motor Break of Hall Sensor ERR 12 Problems with electronic card of...

  • Page 40: Coupons

    For further information read carefully the Warranty Handbook. Oerations made by any person other than authorized OXYGEN personnel shall result in the warranty becoming void. OPERATIONS COUPONS OF MAINTENANCE n°...

  • Page 41: List And Procedures Of Controls

    Rev.0 LEPTON Service manual LIST AND PROCEDURES OF CONTROLS REAR SHOCK ABSORBER Wavering functionality and oil leak Stroke FORK Wavering functionality and oil leak Stroke ENGINE SUPPORT Wavering functionality Blocking screws STAND Functionality WHEELS BEARING Stroke and damages Sliding Noises...
  • Page 42 Rev.0 LEPTON Service manual TYRES Correct pressure Check tyres TRANSMISSION BELT Check usury Check tension BATTERIES Check integrity shell Check contacts screws block Check the single tension module Check connection and stroke among the batteries o Rapid contacts (LEAD-Acid model);...
  • Page 43 Rev.0 LEPTON Service manual VEHICLE TEST Manageabling and stability Front brake Rear brake Check functionality residual energy Check motor brake Check throttle (free movement). Chek noises and waver running VEHICLE DOCUMENTATION Control the presence of vehicle documentations (Owner’s manual, Warranty,… )

  • Page 44: Fuses

    Rev.0 LEPTON Service manual FUSES In the LEPTON there are some protections to the main circuits which are composed of fuses; they are connected in series to these circuits to protect the electronics of the vehicle and the batteries Before working on these devices, pay attention to the following precautions: BE SURE THAT WHEN REPLACING ANY ONE OF THE FUSES THE LEPTON IS OFF OR THAT THE RECHARGE PLUG IS NOT INSERTED;...

  • Page 45: Fuses On Line 230 Vac

    5X20, inserted inside the two cases (Figure 12); you reach the fuses by lifting the saddle of the LEPTON. These fuses work in case of short-circuits inside the LEPTON with reference to the power circuit of the battery charger, or in case the cooling fan of the DRIVER is damaged or in short-circuit.

  • Page 46: Fuse Inserted To The Batteries Positive Pole

    This fuse, under the helmet holder, is connected to the POSITIVE POLE of the series of batteries under the footrest tunnel of the LEPTON. It is a belt fuse of 70 A (Figure 13) and prevents possibile short-circuits of the batteries.

  • Page 47: Services Fuse And Ignition Fuse

    LEPTON Service manual SERVICES FUSE AND IGNITION FUSE These two fuses, under the helmet holder, protect respectively the power circuit of the LEPTON services ( lights, alarms, etc..) and the control circuit of ignition of the LEPTON. Figure 14...

  • Page 48: Foreloads

    And Clamping Torques Of Iso Metric Thread Screws

    This paragraph collects the set of rules in force of ISO metric thread screws. If there are no other explanations than OXYGEN instruction and user manuals, it is necessary to refer to what is scheduled in the following table about foreloads and clamping torques.
  • Page 49 Rev.0 LEPTON Service manual Table 1. : Foreloads P and clamping torques M of ISO metric thread screws. d x p 10.9 12.9 mm² N·m N·m N·m N·m N·m 3x0,5 5,03 4x0,7 8.78 5x0,8 14.2 11.5 10.4 20.1 10.4 13.8 15.3...
  • Page 50 Rev.0 LEPTON Service manual d x p 10.9 12.9 mm² N·m N·m N·m N·m N·m 27x2 1200 1700 1990 30x3.5 1500 2130 2500 30x2 1060 1670 2370 2780 OXYGEN S.p.A.
  • Page 51 Rev.0 LEPTON Service manual OXYGEN S.p.A. Via Ponticello, 44 - 35129 Padova Tel. +39 (0) 49 8282311 - Fax. +39 (0) 49 8079871 Sito internet: www.oxygenworld.net - E-mail: info@oxygenworld.net OXYGEN S.p.A.

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