Segway i2 SE Service Manual Download

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8–1

Segway Personal Transporter SE Service Manual

8 Serviceable Powerbase

This chapter describes the Serviceable Powerbase in a Segway PT.

WARNING!

• Failure to follow these safety precautions could lead to electrical shock,

serious injury, death, or damage to property.

•  Read all instructions.
•  Power off the Segway PT.
•  Unplug the Segway PT.

CAUTION!

• When a repair involves opening the console or chassis cover, best

practice electrostatic discharge (ESD) control procedures must be
followed. Failure to follow ESD procedures could result in personal
injury or damage to property.

Applies to Models

i2 SE, x2 SE, x2 SE Turf

Qualifications

Customer Serviceable

Summary of Contents for i2 SE

Page 1: ...Segway Personal Transporter Service Manual March 2014 24019 00001 aa i2 SE i2 SE Patroller x2 SE x2 SE Turf x2 SE Patroller...

Page 2: ...orter SE Service Manual ii WARNING To replace parts on the Segway Personal Transporter you must read and follow all instructions and warnings in this Service Manual Failure to do so could result in se...

Page 3: ...way does not use the mark nor does it mean that the product is not actively marketed or is not significant within its relevant market Segway reserves all rights in its trademarks All other trademarks...

Page 4: ...Segway Personal Transporter SE Service Manual iv...

Page 5: ...on 0 2 Terminology 0 3 Customer Replaceable Kits and Technician Replaceable Parts 0 3 Related User Materials 0 3 Parts Diagram 0 4 1 LeanSteer 1 1 Handlebar 1 4 LeanSteer Frame 1 5 LeanSteer Stem 1 6...

Page 6: ...e 8 1 Establishing a Serviceable Powerbase 8 2 9 Console 9 1 Console Components 9 2 Radio Board 9 3 Console 9 4 Power Board 9 5 Interconnect Board 9 6 AC Input Filter 9 7 Pivot Assembly 9 9 Front Ligh...

Page 7: ...Manual vii A Post Service Tests A 1 Startup Test A 1 Standard Check A 1 Operational Test A 1 B Parts List B 1 Customer Replaceable Kits B 1 Technician Replaceable Parts B 2 C Fasteners C 1 D Tools and...

Page 8: ...Segway Personal Transporter SE Service Manual viii Contents...

Page 9: ...t charge near flammable materials When charging the batteries heat up and could ignite a fire Keep out of reach of children and pets Exposure to battery voltage could result in death or serious injury...

Page 10: ...nly to the prescribed torque At the factory Segway installs self tapping fasteners intended for one time use only Service replacement fasteners are not self tapping and therefore may differ slightly i...

Page 11: ...gway Certified Service Technician involves a four level certification process The service technician will be required to undergo training at each level Upon satisfactory completion of this training th...

Page 12: ...7 Gearbox installation and removal procedures Chapter 8 Serviceable Power Base definition and description Chapter 9 Console and related components installation and removal procedures Chapter 10 Chassi...

Page 13: ...eded to install the subassembly These kits are listed under the heading Replaceable Kits on the first page of each chapter All parts included in a Replaceable Kit should be replaced When individual pa...

Page 14: ...r Console Trim 23478 00001 Gearbox Cover 20152 00001 Mat 23554 00001 Standard 23578 00001 Comfort LeanSteer Frame 23512 00001 Standard Patroller 23548 00001 InfoKey Dock 20533 00001 InfoKey 21064 0000...

Page 15: ...eners could result in machine malfunction and could cause personal injury or damage to the Segway PT Using the Segway PT without properly assembling the LeanSteer components and or maintaining proper...

Page 16: ...r LeanSteer Tube 20048 00001 Standard Tube Bushing 23511 00001 Handlebar Stop 20041 00001 Lower LeanSteer Tube 23509 00001 Height Adjust Knob 20753 00001 Washer 20751 00001 Wedge 20042 00001 6 19x19mm...

Page 17: ...HCS 23558 00001 End Cap 23541 00001 Washer Plate 23545 00002 Patroller Bolt Trim 23545 00002 Patroller Height Adjust Knob 20753 00001 Washer 20751 00001 Wedge 20042 00001 Tube Bushing 23511 00001 Hand...

Page 18: ...lebar in place against the LeanSteer Frame using the alignment guides See Figure 1 4 3 Position the Handlebar Clamp against the Handlebar 4 Insert the three fasteners through the Handlebar Clamp and i...

Page 19: ...5 mm hex wrench install the two fasteners Torque to 11 0 N m 8 1 ft lbf 4 With the PT powered down OFF lean the LeanSteer Frame fully left and right until it touches each fender see Figure 1 6 5 Ensu...

Page 20: ...be used with the Standard LeanSteer Frame and the Patroller LeanSteer Stem must be used with the Patroller LeanSteer Frame Standard and Patroller components cannot be used together 3 Using a T 30 6 lo...

Page 21: ...ock Removal Tool Required 3 mm hex wrench 1 Make sure the PT is powered off and unplugged 2 Using a 3 mm hex wrench remove the fastener that holds the InfoKey Dock to the LeanSteer Frame See Figure 1...

Page 22: ...uired Coin or flathead screwdriver 1 Make sure the PT is powered off and unplugged 2 Verify that the new battery is type CR2430 available as part of the Segway InfoKey Kit 3 Insert the InfoKey Control...

Page 23: ...lead to electrical shock serious injury death or damage to property Read all instructions Power off the Segway PT Unplug the Segway PT Always ensure that the top of the Powerbase and bottom of the Ma...

Page 24: ...Verify that the top of the Powerbase and the bottom of the Mat are clean dry and free of debris 3 Place the Mat on the Powerbase 4 Fit the Mat s rubber tabs into the slots formed by the gap between t...

Page 25: ...s Do not insert any object into the batteries or use any device to pry at the battery casing If you insert an object into any of the battery ports or openings you could suffer electric shock injury bu...

Page 26: ...or the unusual situation where a Battery is replaced because of damage or defect and the other Battery is relatively new NOTICE To isolate a problem in a specific battery swap front and rear Batteries...

Page 27: ...of the Powerbase See Figure 3 2 4 Ensure the Battery is aligned straight against the Powerbase edge trim and there are no uneven gaps 5 Install the two center fasteners first do not tighten 6 Install...

Page 28: ...Segway Personal Transporter SE Service Manual 3 4 Batteries...

Page 29: ...he following conditions including but not limited to Persistent leak in tire after reinflation Wheel is cracked or bent Tire is flat cracked or excessively worn Excess wear is determined as follows i2...

Page 30: ...ver into the notch on the side of the wheel cap and pry the wheel cap off See Figure 4 1 4 Using a 13 mm socket wrench remove the three wheel nuts and discard 5 Remove the i2 SE Wheel Assembly Install...

Page 31: ...wipes 13 mm socket wrench Torque wrench 1 Make sure the PT is powered off and unplugged 2 Support the PT or turn it on its side 3 Inspect the mounting surfaces use isopropyl alcohol wipes to clean off...

Page 32: ...uired Isopropyl alcohol wipes 8 mm hex wrench Torque wrench 1 Make sure the PT is powered off and unplugged 2 Support the PT or turn it on its side 3 Inspect the wheel mounting surfaces use isopropyl...

Page 33: ...equired Isopropyl alcohol wipes 13 mm socket wrench Torque wrench 1 Make sure the PT is powered off and unplugged 2 Support the PT or turn it on its side 3 Inspect the mounting surfaces use isopropyl...

Page 34: ...to the wheel in a manner similar to a motorcycle tire mounted to a rim 5 Using a bar clamp break the tire bead by positioning the clamp jaws against the inner and outer sidewalls of the tire and tight...

Page 35: ...t 6 inches away from the first tire iron and pry that portion of the tire over the rim See Figure 4 9 9 Pull the first tire iron out and reinsert it under the bead about 6 inches away from the other t...

Page 36: ...5 Use a tire iron to lift the remaining bead over the rim being careful not to pinch or bind the tube or crack the wheel See Figure 4 14 CAUTION To avoid pinching keep hands and fingers away from the...

Page 37: ...precautions could lead to electrical shock serious injury death or damage to property Read all instructions Power off the Segway PT Unplug the Segway PT When to Replace You need to replace a fender f...

Page 38: ...Fender to the gearbox See Figure 5 1 4 Lift the Fender off the gearbox Installation Tools Required T 20 6 lobe wrench Torque wrench 1 Make sure the PT is powered off and unplugged 2 Orient and place t...

Page 39: ...uired 4 mm hex wrench Torque wrench 1 Make sure the PT is powered off and unplugged 2 Orient and place the left Fender on the left Fender Frame Orient and place the right Fender on the right Fender Fr...

Page 40: ...NOTICE The Fender and Fender Frame can be removed as a unit not shown Fender Frame fasteners should be discard and replaced with new ones Installation Tools Required 4 mm hex wrench Torque wrench 1 M...

Page 41: ...nstructions Power off the Segway PT Unplug the Segway PT When to Replace You need to replace front or rear fascia if either is physically damaged Applies to Models i2 SE x2 SE x2 SE Turf Qualification...

Page 42: ...ard them See Figure 6 1 3 Remove the Gearbox Cover Installation Tools Required 4 mm hex wrench Torque wrench 1 Make sure the PT is powered off and unplugged 2 Align the holes in the Gearbox Cover with...

Page 43: ...ge port remains clean and dry Installation Tools Required T 20 6 lobe wrench 4 mm hex wrench Torque wrench 1 Make sure the PT is powered off and unplugged 2 Place the Center Console Cover on the conso...

Page 44: ...scia See Figure 6 4 and Figure 6 5 6 Remove the Fascia Installation Tools Required 4 mm hex wrench Torque wrench 1 Make sure the PT is powered off and unplugged 2 Place the front Fascia onto the front...

Page 45: ...property Machined surfaces of the gearbox can be sharp Use caution when handling the gearbox and spacer to avoid injury When to Replace It is appropriate to remove inspect or replace the gearbox for...

Page 46: ...Fascia page 6 4 10 Using a T 45 6 lobe wrench remove the three gearbox fasteners and discard See Figure 7 1 NOTICE Gearbox fasteners are installed with thread lock compound and require significant le...

Page 47: ...13 4 NOTICE To prevent contamination cover the motor cavity 3 Completely remove the thread lock compound from the gearbox fastener holes Use cotton swabs to thoroughly clean excess thread lock compoun...

Page 48: ...strike the gearbox flange Striking the flange could knock it out of alignment damaging the gearbox NOTICE Do not use the gearbox fasteners to seat the gearbox to the chassis Make sure the gearbox and...

Page 49: ...serious injury death or damage to property Read all instructions Power off the Segway PT Unplug the Segway PT CAUTION When a repair involves opening the console or chassis cover best practice electros...

Page 50: ...nents on the Segway PT LeanSteer Frame page 1 5 LeanSteer Stem page 1 6 Mats page 2 2 Batteries page 3 2 Tire Wheel Assemblies i2 SE page 4 2 x2 SE page 4 3 x2 SE Turf page 4 4 Fenders i2 SE page 5 2...

Page 51: ...Certified Service Technicians only Segway does not recommend that non certified individuals replace any of the components described in the following sections The warranty will be void if components i...

Page 52: ...Segway Personal Transporter SE Service Manual 8 4 Serviceable Powerbase...

Page 53: ...ollow ESD procedures could result in personal injury or damage to property When to Replace Replace a console component when diagnostic testing determines that the component is defective For diagnostic...

Page 54: ...onents Light Pipe 23483 00001 Radio Board 23451 00001 Console Base 23390 00001 Gasket 23393 00001 Insulator 23575 00001 AC Input Filter 23405 00001 Interconnect Board 23411 00001 Pivot Assembly 23502...

Page 55: ...lace the Radio Board in an ESD bag for return shipment to Segway Installation Tools Required T 10 6 lobe wrench T 20 6 lobe wrench 1 Orient the Radio Board on the Console Base 2 Install the Radio Boar...

Page 56: ...ue wrench 1 Orient the Console on the Powerbase so the end with the Pivot Base is toward the front 2 Tip the Console on its side and connect the Powerbase harnesses See Figure 9 4 Each harness is a di...

Page 57: ...es place the Power Board in an ESD bag for return shipment to Segway Installation Tools Required T 10 6 lobe wrench Torque Wrench 1 Install the Power Board Press the board onto the Interconnect Board...

Page 58: ...d 8 Using ESD best practices place the Interconnect Board in an ESD bag for return shipment to Segway Installation 1 Orient the Interconnect Board so the notched side protrudes through the hole in the...

Page 59: ...Figure 9 10 6 Using a 4 mm hex wrench detach the ground lug from the Console Base See Figure 9 10 7 Using a T 20 6 lobe wrench remove the two fasteners holding the AC Input Socket in place Discard th...

Page 60: ...the five fasteners that hold the AC Input Filter in place Torque to 1 6 N m 14 in lbf NOTICE Original fasteners are self tapping Replace with non tapping fasteners 4 Using a T 20 6 lobe wrench instal...

Page 61: ...6 lobe wrench Torque wrench 1 Install the gasket into the groove on the underside of the Pivot Assembly 2 Thread the Pivot Assembly harnesses through the hole in the Console Base and position the Piv...

Page 62: ...Required T 10 6 lobe wrench Torque wrench 1 Slide the gasket onto the Light Pipe with the adhesive side toward the Light Pipe See Figure 9 13 2 Orient the Light Pipe on the Console Base 3 Using a T 1...

Page 63: ...o property The edge gasket must be capable of maintaining a seal between the cover and the chassis Damage to the edge gasket requires replacement of the cover Operating a Segway PT without the proper...

Page 64: ...lish a Serviceable Powerbase page 8 2 3 Remove the Radio Board page 9 3 4 Remove the Console page 9 4 5 Using a T 27 6 lobe wrench remove the ten fasteners and discard See Figure 10 1 6 Feed the harne...

Page 65: ...alcohol to remove the thread lock compound 3 Orient the Chassis Cover so the openings are toward the rear and the warning label is on the right hand side 4 Feed the harnesses up through the holes in...

Page 66: ...Segway Personal Transporter SE Service Manual 10 4 Chassis Cover...

Page 67: ...T Unplug the Segway PT Remove batteries before servicing CAUTION When a repair involves opening the console or chassis cover best practice electrostatic discharge ESD control procedures must be follow...

Page 68: ...en carefully pull on the connector to unseat it See Figure 11 1 7 Disconnect the BSA harness and CU harness from the CU board by squeezing the plastic tab on the connector and gently pulling on the co...

Page 69: ...ss connects to the B side CU board front 6 Connect the two CU motor harnesses to the motors one per motor See Figure 11 4 NOTICE Rotate each harness as you insert the connector so that the smaller gau...

Page 70: ...Segway Personal Transporter SE Service Manual 11 4 CU Board...

Page 71: ...eries before servicing CAUTION When a repair involves opening the console or chassis cover best practice electrostatic discharge ESD control procedures must be followed Failure to follow ESD procedure...

Page 72: ...ce the BSA in an ESD bag for return shipment to Segway pursuant to the terms and conditions of the Segway PTWarranty or other established procedures Installation Tools Required T 10 6 lobe wrench Torq...

Page 73: ...trostatic discharge ESD control procedures must be followed Failure to follow ESD procedures could result in personal injury or damage to property When to Replace It is appropriate to replace a Motor...

Page 74: ...9 4 5 Remove the Chassis Cover page 10 2 6 Remove the Gearbox on the same side of the PT as the Motor you want to remove page 7 2 7 Disconnect the two CU motor harnesses from the motor Using a small...

Page 75: ...all the two fasteners See Figure 13 2 Torque to 5 0 N m 3 7 ft lbf 5 Connect the two CU motor harnesses to the Motor See Figure 13 1 NOTICE Rotate each harness as you insert the connector so that the...

Page 76: ...red Cotton swabs Ammonia Isopropyl alcohol 1 Use cotton swabs to clean all residue from the motor coupling and cavity First use ammonia or ammonia based window cleaner then isopropyl alcohol to remove...

Page 77: ...t in personal injury or damage to property When to Replace Replace the Powerbase Chassis when diagnostic testing or inspection determines that the assembly is defective For diagnostic procedures conta...

Page 78: ...both CU Boards page 11 2 8 Remove the Balance Sensor Assembly page 12 2 9 Remove both Motors page 13 2 Reassembly 1 Install both Motors page 13 2 2 Install the Balance Sensor Assembly page 12 2 NOTICE...

Page 79: ...are in place secure and torqued correctly 2 Check wheels for wear tightness and tire pressure 3 Check that the Mats are intact secure and free of debris 4 Check the LeanSteer Frame for tightness Make...

Page 80: ...Segway Personal Transporter SE Service Manual A 2 Post Service Tests...

Page 81: ...58 00001 x2 Turf Tire Wheel Kit 21162 00001 Tire Wheel 1 20816 00002 Spacer 1 20802 00001 Fastener 4 20991 00002 x2 Turf Hub Adapter Kit 20963 00001 Hub Adapter 1 20749 00001 Fastener 4 20991 00001 x2...

Page 82: ...ox Kit 21367 00001 Gearbox 1 20919 00001 Fastener 3 20537 00002 Gearbox Gasket Kit 20292 00001 Gasket 1 15409 00001 Table B 1 Customer Replaceable Kits cont Part Part Number Light Pipe 23483 00001 Rad...

Page 83: ...Table C 1 p C 2 Since the pre applied thread lock compound is intended for single use only reuse of fasteners is not permitted with the exception of the wheel nuts battery fasteners and LeanSteer fram...

Page 84: ...0001 SHCS M4 x 0 7 x 20 Handlebar Clamp 3 3 mm 2 0 N m 18 in lbf 20306 00003 SHCS M4 x 0 7 x 20 InfoKey Dock 1 3 mm 2 0 N m 18 in lbf 20307 00002 BHCS M4 x 0 7 x 8 Console Cover 4 2 5 mm 1 6 N m 14 in...

Page 85: ...Front Console Cover 2 4 mm 1 5 N m 13 in lbf For use with a Parking Stand 20566 00001 PHCS M3 x 0 5 x 12 SEMS Balance Sensor Assembly OEM 4 T 10 1 6 N m 14 in lbf Front Light Pipe OEM 2 T 10 1 6 N m 1...

Page 86: ...n lbf Radio Board 6 T 10 1 6 N m 14 in lbf Power Board 8 T 10 1 6 N m 14 in lbf AC Input Filter 5 T 10 1 6 N m 14 in lbf For use when reinstalling a CU Board into the original Powerbase Chassis or whe...

Page 87: ...r small Hex adapter 1 4 inch square to 1 4 inch hex Hex bits 2 5 mm 3 mm 4 mm 5 mm 8 mm Hex wrenches 2 5 mm 3 mm 4 mm 5 mm 8 mm Low pressure inflation gauge Mallet Plastic or rubber 24 oz Multi meter...

Page 88: ...Segway Personal Transporter SE Service Manual D 2 Tools and Equipment...

Page 89: ...the PT Harness A group of cables bound together to form one assembly typically with connectors that plug or snap into place InfoKey Controller The InfoKey Controller is a wireless device used to turn...

Page 90: ...Segway Personal Transporter SE Service Manual E 2 Glossary...

Page 91: ......

Page 92: ...24019 00001 aa...

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