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Segway SE-3 Patroller, Service Manual

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Segway SE-3 Patroller Service Manual Download Page 5

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Contents

Copyright, Trademarks, Patent, and Contact Information ..........................................................................iv

General Safety Precautions ..................................................................................................1

Safety Conventions ........................................................................................................................................ 1
Important Safety Notices .............................................................................................................................. 1

Introduction .......................................................................................................................... 5

Purpose ..........................................................................................................................................................5
Audience .........................................................................................................................................................5
Certification ...................................................................................................................................................5
General Service Procedure ............................................................................................................................6
Related User Materials ...................................................................................................................................6

Battery Module ......................................................................................................................7

Battery Module...............................................................................................................................................8

Body Panels.......................................................................................................................... 11

Exploded View ..............................................................................................................................................12
Storage Tray .................................................................................................................................................13
Bib Panel ....................................................................................................................................................... 14
Glove Box ......................................................................................................................................................16
Front Cowl ..................................................................................................................................................... 17
Light Cluster .................................................................................................................................................18
Side Panel .................................................................................................................................................... 20
Fender .......................................................................................................................................................... 22
Front Fender (Boot) .................................................................................................................................... 24
Front Splash Guard ..................................................................................................................................... 25
Main Splash Guard ...................................................................................................................................... 26

Tire/Wheel Assemblies ...................................................................................................... 27

Front Tire/Wheel ......................................................................................................................................... 28
Rear Tire/Wheel .......................................................................................................................................... 30

Windshield ...........................................................................................................................31

Windshield ................................................................................................................................................... 32

Summary of Contents for SE-3 Patroller

Page 1: ...Service Manual SE 3 Patroller...

Page 2: ...SE 3 Patroller ii Front Tire Wheel page 28 Front Fender page 24 Side Panel page 20 Fender page 22 Rear Tire Wheel page 30 Light Cluster page 36 Front Cowl page 17 Headlight page 34 Windshield page 32...

Page 3: ...dlebar Grip page 76 KeyLock page 49 Glove Box Door page 48 Bib Panel page 14 Accessory Power Outlet page 50 Front Cowl page 17 Light Cluster page 36 Side Panel page 20 Storage Tray page 13 Fender page...

Page 4: ...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 are...

Page 5: ...ification 5 General Service Procedure 6 Related User Materials 6 Battery Module 7 Battery Module 8 Body Panels 11 Exploded View 12 Storage Tray 13 Bib Panel 14 Glove Box 16 Front Cowl 17 Light Cluster...

Page 6: ...ery Compartment 43 Battery Slides 44 Battery Bumpers 45 Bib Panel Components 47 Glove Box Door 48 KeyLock 49 Accessory Power Outlet 50 Brakes 51 Brake Fluid 52 Draining Brake Lines 53 Bleeding Brake L...

Page 7: ...Front Fender Bracket 98 Power Interface 99 Electronics Shield 100 Charger 101 PI Board 102 Fuses 104 Maximum Speed 105 Harnesses 107 Left Right Motor Power Harness 108 Left Right Drive Harness 110 Han...

Page 8: ...troller viii Post Service Tests 127 Drive Disable and Rider Detect Mat 127 Lights Horn and Siren 127 Brake Check 127 Ride Test 128 Charge Test 128 Fasteners 129 Tools and Equipment 135 Glossary 137 Co...

Page 9: ...lly discharged could result in electric shock CAUTION Always wear gloves when handling chemicals such as lubricants corrosion inhibitors greases or oils to reduce the potential for skin damage or irri...

Page 10: ...causing permanent damage Comply with all local and federal or individual country laws when disposing of and transporting Battery Modules Fasteners WARNING Use only Segway approved fasteners Other fast...

Page 11: ...ns WARNING If you have any questions about the instructions in this guide please contact a Segway Service Representative to avoid confusion leading to serious injury or death or damage to property Gen...

Page 12: ...SE 3 Patroller 4 General Safety Precautions...

Page 13: ...rgo training at each level Upon satisfactory completion of this training the service technician becomes certified to repair the SE 3 Patroller parts and assemblies according to the following scheme Le...

Page 14: ...ing In some cases this requires a simple visual inspection as in the case of a cracked or damaged body panel In other cases diagnostic equipment must be used to troubleshoot the problem as when the ve...

Page 15: ...to Replace Replace when troubleshooting determines that the Battery Module is malfunctioning Safety WARNING Always remove the Battery Module before servicing the SE 3 Patroller Failure to remove the...

Page 16: ...latches as shown in Figure 1 3 Use the handle to slide the Battery Module part way out 4 Grasp both the front handle and the top handle of the Battery Module Figure 2 Slide the Battery Module complete...

Page 17: ...igured as in Figure 3 3 Holding the Battery Module by both front and top handles slide it into the opening 4 Twist the latches and fold them back Figure 4 to lock the Battery Module Figure 3 Slide the...

Page 18: ...SE 3 Patroller 10 Battery Module...

Page 19: ...er from touching the wheels When to Replace Replace a Body Panel when it is cracked bent or otherwise broken Safety WARNING Do not operate the SE 3 Patroller without all body panels installed CAUTION...

Page 20: ...ight Side Panel 24130 00001 Light Cluster 23776 00001 Front Fender 23761 00001 Front Cowl 23750 00001 Left Fender 23756 00001 Right Fender 23757 00001 Bib Panel 24117 00001 Left Storage Tray 23758 000...

Page 21: ...ex wrench remove the fastener at the bottom of the Storage Tray 3 Remove the Storage Tray Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Insert...

Page 22: ...nnected to it 5 Disconnect the two quick connect terminals from the back of the Accessory Power Outlet Figure 10 6 Using wire cutters remove the cable tie on the KeyLock See Figure 9 7 Slide the rubbe...

Page 23: ...the connector block and secure with a cable tie See Figure 9 6 Connect the two quick connect terminals to the Accessory Power Outlet Figure 10 Red Black 7 Slide the Bib Panel onto the frame 8 Using a...

Page 24: ...is powered off unplugged and the parking brake is engaged 2 Install the Splash Shield Figure 15 3 Using a 3 mm hex wrench attach the Service Port harness to the back of the Glove Box Figure 14 Orient...

Page 25: ...in Figure 16 4 Lift the Front Cowl off of the frame Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Place the Front Cowl onto the SE 3 so that i...

Page 26: ...emove the following components a Battery Module page 8 b Storage Trays page 13 c Bib Panel page 14 d Glove Box page 16 e Front Cowl page 17 3 Using a 4 mm hex wrench remove the two fasteners as shown...

Page 27: ...re harnesses Connect the left and right directionals to the labeled harnesses The strobe lights can be connected to any of the strobe light harnesses See Figure 19 Right Directional Yellow Green Left...

Page 28: ...Box page 16 e Front Cowl page 17 f Light Cluster page 18 3 Using a 4 mm hex wrench remove the four front fasteners two each side as shown in Figure 20 4 Using a 4 mm hex wrench remove the three side...

Page 29: ...m hex wrench install the three side fasteners as shown in Figure 21 Torque to 5 5 N m 4 0 ft lbf 5 Using a 4 mm hex wrench install the four front fasteners two each side as shown in Figure 20 Loosely...

Page 30: ...e SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Place the Fender on the frame 3 Connect the Tail Light Harness to the Brake Light and Rear Directional Light 4 Using a 4 mm...

Page 31: ...eners 24270 00006 4 0 N m 3 0 ft lbf Outside Fasteners 24270 00004 Inside Fasteners 2x 24270 00004 1x 24270 00006 P Clip 24509 00001 P Clip 24509 00001 23202 00004 5 5 N m 4 0 ft lbf 9 Install the fol...

Page 32: ...wrench remove the four small fasteners two per side 4 Remove the Front Fender Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Place the Front F...

Page 33: ...remove the eight fasteners as shown in Figure 28 4 Remove the Front Splash Guard Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Align the Fron...

Page 34: ...plash Guard out from behind the Side Panel Work from top to bottom until the entire side is released 5 Slide the Main Splash Guard off the vehicle Installation 1 Make sure the SE 3 Patroller is powere...

Page 35: ...depth is less than 2 mm Rear tire tread depth is less than 3 8 mm or tread is worn down flush with the tread wear indicators Tire inflation pressure can dramatically affect range traction and tread we...

Page 36: ...stand to stabilize it while the wheel is off the ground Failure to stabilize the SE 3 Patroller could result in death or serious injury from the vehicle falling over Removal 1 Prepare the SE 3 Patrol...

Page 37: ...o the rotor is toward the left side of the SE 3 5 Slide the axle through the forks and wheel assembly See Figure 33 6 Using a pair of 30 mm socket wrenches fasten the nut onto the axle Torque to 85 N...

Page 38: ...e it is on the jack 4 Using the wheel nut key remove all four Wheel nuts 5 Pull the wheel off the studs Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is en...

Page 39: ...31 Overview The Windshield protects the UI Module When to Replace Replace the Windshield when it is cracked or otherwise broken Contents Windshield Windshield...

Page 40: ...f unplugged and the parking brake is engaged 2 Install four grommets into the holes in the handlebar frame These grommets protect the Windshield from vibration 3 Orient the Windshield on the SE 3 Patr...

Page 41: ...ty When to Replace Replace a light when diagnostic testing indicates that a light is malfunctioning NOTICE When connecting light harnesses make sure the connectors snap firmly into place Lights Conten...

Page 42: ...ners as shown in Figure 38 6 Remove the Headlight Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Slide the Headlight harness through the hole i...

Page 43: ...red off unplugged and the parking brake is engaged 2 Using a 4 mm hex wrench and a 10 mm socket wrench loosen the Headlight Bracket fasteners as shown in Figure 40 Loosen just enough to adjust the hea...

Page 44: ...lights require plastic sleeves to be installed on the fasteners See Figure 43 Install Body Panels 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Install the...

Page 45: ...to the Front Light Harness See Figure 45 3 Orient the light Police Red toward center Blue toward outside Security Locate the heat vent Figure 46 Right light heat vent down Left light heat vent up 4 S...

Page 46: ...e Front Light Harness 3 Orient the light The pigtail is offset where it connects with the light Orient the lights so the pigtail is toward the top on one light and toward the bottom on the other light...

Page 47: ...ight Cluster and connect it to the Front Light Harness NOTICE Connect the left hand light to the connector labeled Left and the right hand light to the connector labeled Right 3 Slide the plastic slee...

Page 48: ...rness through the hole in the Fender 3 Reach into the wheel well and connect the harness 4 Slide the plastic sleeves onto the fasteners then install the fasteners and Figure 51 5 Using a 3 mm hex wren...

Page 49: ...Feed the Rear Directional Light harness through the hole in the Fender 3 Reach into the wheel well and connect the harness 4 Slide the plastic sleeves onto the fasteners then install the fasteners Fi...

Page 50: ...gaged 2 Feed the Rear Strobe Light harness through the hole in the Skid Plate 3 Connect the Rear Strobe Light harness See Figure 55 4 Orient the light Police Red toward center Blue toward outside Secu...

Page 51: ...Battery Bumpers which together position the Battery Module correctly against the PI Board When to Replace Replace the Battery Slides or Battery Bumpers when they are cracked excessively worn or otherw...

Page 52: ...is engaged 2 Remove the Battery Module page 8 3 Using a 2 5 mm hex wrench remove the fasteners from the Battery Slides See Figure 58 4 Remove the Battery Slides Installation 1 Make sure the SE 3 Patro...

Page 53: ...ender Bracket page 98 e Main Splash Guard page 26 3 Using an 8 mm socket wrench remove the lock nuts holding the three brake line P Clips to the front of the frame See Figure 59 4 Slide the P Clips of...

Page 54: ...the Battery Bumpers to the frame Torque to 2 0 N m 1 5 ft lbf 4 Slide the three brake line P Clips onto the threaded studs on the front of the frame See Figure 59 5 Using an 8 mm socket wrench install...

Page 55: ...e Replace the Glove Box Door when it is cracked excessively worn or otherwise broken Replace the KeyLock or Accessory Power Outlet when troubleshooting determines that the component is malfunctioning...

Page 56: ...ve Box Door must be visible Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Align the Glove Box Door on the Bib Panel 3 Insert the four fastener...

Page 57: ...he KeyLock Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Insert the KeyLock through the hole on the right hand side of the Bib Panel See Figur...

Page 58: ...ower Outlet Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Insert the Accessory Power Outlet through the hole on the left hand side of the Bib...

Page 59: ...emains Replace a master cylinder when diagnostic testing indicates it is malfunctioning Replace the brake lines when they are punctured leaking or otherwise malfunctioning NOTICE Avoid spilling brake...

Page 60: ...rk Figure 66 If fluid is below the low mark brake fluid needs to be added Adding Brake Fluid Tools Required Phillips screwdriver Torque wrench 1 Use a Phillips screwdriver to remove the two screws on...

Page 61: ...the other end in an empty container See Figure 67 5 Using a in wrench open the bleed valve Brake fluid will flow out of the bleed valve See Figure 68 6 Pump the brake lever to drain the Master Cylinde...

Page 62: ...istance is required to perform this procedure 1 Make sure the SE 3 Patroller is powered off unplugged and the wheels are chocked CAUTION You can t bleed the rear brake line with the parking brake on C...

Page 63: ...he Master Cylinder to keep the fluid level at the FILL line 13 Using a in wrench tighten the bleeder valve Torque to 4 5 N m 3 3 ft lbf 14 Place the cap on the Master Cylinder Using a Phillips screwdr...

Page 64: ...s injury from the vehicle falling over 3 Remove the Front Fender page 24 4 Using a bar clamp and socket compress the caliper as shown in Figure 73 then remove the bar clamp NOTICE If you don t have a...

Page 65: ...ny component Used crush washers may leak causing a reduction in braking force 3 Carefully slide the Caliper onto the Rotor so the Rotor rests between the two brake pads 4 Using a 6 mm hex wrench insta...

Page 66: ...he five fasteners holding the rotor in place See Figure 77 7 Remove the Rotor Installation 8 Align the Rotor with the flange on the spindle 9 Using a 5 mm hex wrench install the five fasteners holding...

Page 67: ...brake is engaged 2 Orient the Master Cylinder on the handlebar 3 Using a 5 mm hex wrench install the clamp holding the Master Cylinder to the handlebar 4 Using a digital level orient the Master Cylin...

Page 68: ...ing Figure 81 NOTICE Be careful not to lose the retaining ring Since it is under spring tension it can travel a long distance through the air Use your hand to catch or deflect it so it doesn t get los...

Page 69: ...tion the parking brake bracket on top of the brake housing 6 Using a 10 mm socket wrench install the shoulder bolt Figure 83 Torque to 10 N m 7 4 ft lbf 7 Using a 10 mm socket wrench install the nut u...

Page 70: ...e rear brake 5 Using a 6 mm hex wrench remove the two caliper fasteners See Figure 88 6 Remove the Caliper and secure it so it doesn t strain the brake line 7 Remove the Rotor and Spacer See Figure 89...

Page 71: ...Used crush washers may leak causing a reduction in braking force 5 Carefully slide the Caliper onto the Rotor so the Rotor is between the two brake pads 6 Using a 6 mm hex wrench install the two cali...

Page 72: ...ge 14 d Glove Box page 16 e Front Cowl page 17 f Light Cluster page 18 g Front Fender page 24 3 Drain the brake fluid out of the front brake line see page 53 4 Using a 14 mm socket wrench disconnect t...

Page 73: ...w crush washers when attaching a Banjo Bolt to any component Used crush washers may leak causing a reduction in braking force 7 Using a 2 5 mm hex wrench install three P Clips two on the frame and one...

Page 74: ...isconnect one of the Banjo Bolts from its Caliper NOTICE Place the Banjo Bolt in a container to catch any brake fluid that drains out 5 Repeat step 4 for the Banjo Bolt on the other side 6 Using a 2 5...

Page 75: ...the right side of the frame Thread the brake line between the harnesses and the frame See Figure 96 8 Using a 14 mm socket wrench attach the Banjo Bolt to the Caliper See Figure 98 Torque to 28 5 N m...

Page 76: ...SE 3 Patroller 68 Brakes...

Page 77: ...e the Control Cluster or Throttle when troubleshooting determines that it is malfunctioning Replace the Handlebar Grip when it is cracked loose or otherwise broken NOTICE To service Brake Levers see t...

Page 78: ...age 8 3 Using a 4 mm hex wrench remove the four fasteners as shown in Figure 99 4 Disconnect the harness as shown in Figure 100 5 Remove the UI Module Installation 1 Make sure the SE 3 Patroller is po...

Page 79: ...I Housing 5 Remove the UI Housing Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Orient the UI Housing on the frame 3 Insert the UI Harness int...

Page 80: ...dule page 8 b Storage Trays page 13 c Bib Panel page 14 d Glove Box page 16 e Front Cowl page 17 3 Disconnect the wire harness See Figure 103 4 Using a pair of wire cutters remove the two cable ties o...

Page 81: ...l Cluster so the bottom is parallel to the ground 0 5 Using a T15 Torx wrench install the three fasteners Torque to 2 8 N m 2 0 ft lbf NOTICE Tighten the fasteners carefully to make sure the two halve...

Page 82: ...E 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the following components a Battery Module page 8 b Storage Trays page 13 c Bib Panel page 14 d Glove Box page 16 e Fron...

Page 83: ...de it until it bottoms out then pull it back 3 5 mm 4 Using a digital level align the Throttle so that the rear face rider side is at 82 5 Using a Phillips screwdriver tighten the two fasteners on the...

Page 84: ...harp blade 3 Grab the Handlebar Grip near the flange and tear it at the score line you created 4 Tear the Handlebar Grip and pull it off the handlebar Installation 1 Make sure the SE 3 Patroller is po...

Page 85: ...77 Siren The Siren produces both the horn and siren sounds When to Replace Replace when troubleshooting determines that the Siren is malfunctioning Contents Siren Siren...

Page 86: ...d Glove Box page 16 e Main Splash Guard page 26 3 Locate the Siren on the front of the frame See Figure 108 4 Reach behind the Right Side Panel and disconnect the siren harness See Figure 109 5 Using...

Page 87: ...the Siren onto the bracket so the bolt heads go through the slots on the sides of the siren 6 Using a 10 mm socket wrench tighten the nuts on the bracket See Figure 111 Torque to 2 5 N m 1 8 ft lbf 7...

Page 88: ...SE 3 Patroller 80 Siren...

Page 89: ...e by only allowing the SE 3 Patroller to drive while the rider is standing on the Rider Detect Mat When to Replace Replace the Rider Detect Mat when it is excessively worn or when troubleshooting dete...

Page 90: ...ged 2 Remove the following components a Battery Module page 8 b Storage Trays page 13 c Bib Panel page 14 d Glove Box page 16 e Front Cowl page 17 f Light Cluster page 18 g Left Side Panel page 20 3 U...

Page 91: ...to the left side of the PI Board See Figure 113 5 Slide the Rider Detect Mat in place The front should rest under the tab and the rear should line up with the threaded studs 6 Using a 3 mm hex wrench...

Page 92: ...SE 3 Patroller 84 Rider Detect Mat...

Page 93: ...Motor Controller and the couplings that join them together When to Replace Replace when troubleshooting determines that a component is malfuctioning Contents Gearbox Elastomer Bushing Drive Hub Acces...

Page 94: ...s off the ground Failure to stabilize the SE 3 Patroller could result in death or serious injury from the vehicle falling over 3 Using a 8 mm hex wrench remove the three fasteners as shown in Figure 1...

Page 95: ...Using a 6 mm hex wrench install the Caliper Bracket See Figure 117 Torque to 28 5 N m 21 0 ft lbf 7 Using a 4 mm hex wrench install the Fender Bracket See Figure 118 Torque to 4 0 N m 3 0 ft lbf NOTIC...

Page 96: ...Bushing off of the Drive Hub Figure 119 Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Orient the Elastomer Bushing with the tabs toward the Dr...

Page 97: ...e 120 5 Remove the Motor Cavity Lid Securing 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Align the Motor Cavity Lid on the chassis frame 3 Using a 3 mm h...

Page 98: ...mm socket wrench disconnect the motor phase leads See Figure 121 5 Using a 5 mm hex wrench remove the four fasteners as shown in Figure 122 Lift the Motor Assembly out of the motor cavity 6 Make note...

Page 99: ...ur fasteners as shown in Figure 123 Torque to 12 N m 8 9 ft lbf 7 Place an O ring on the motor mount plate 8 Orient the Motor Assembly so the notch on the motor mount plate is toward the rear of the S...

Page 100: ...of the motor cavity See Figure 124 NOTICE Do not remove the four star drive fasteners holding the Motor Controller cover 6 Remove the Motor Controller Installation 1 Make sure the SE 3 Patroller is po...

Page 101: ...ion of the Steering Column with the Windshield Throttle and other controls The Front Fork is the lower portion of the Steering Column it includes the front wheel When to Replace Replace the Handlebar...

Page 102: ...e cutters remove all the cable ties on the handlebar 4 Disconnect the Handlebar Controls Harness along the handlebar page 112 5 Using a 5 mm hex wrench remove both Brake Levers See Figure 129 NOTICE S...

Page 103: ...nesses from catching on the fasteners when turning the Handlebar 7 Using a 5 mm hex wrench install the Brake Levers See Figure 129 Do not fully tighten 8 Rotate the Brake Lever so that it is 11 5 from...

Page 104: ...h Guard page 25 i Front Fender Bracket page 98 j Front Caliper page 56 k Handlebar page 94 3 Jack up the front of the SE 3 Patroller Figure 130 WARNING Make sure the SE 3 Patroller is stable or use a...

Page 105: ...frame Figure 132 5 Install the bearing and seal as shown in Figure 131 6 Spread some Permatex Anti Seize Lubricant P N 24433 00001 on the collar nut threads This lubricant will make it easier to remov...

Page 106: ...ds the brake line to the Bracket 4 Using a 4 mm hex wrench remove the four fasteners as shown in Figure 133 5 Remove the Bracket Installation 1 Make sure the SE 3 Patroller is powered off unplugged an...

Page 107: ...tes that it is malfunctioning Replace fuses when they blow NOTICE If any fuse blows other than FH9 12VAccessory Supply a deeper issue may exist Contact Segway Technical Support see page iv Safety WARN...

Page 108: ...Module page 8 b Storage Trays page 13 c Bib Panel page 14 d Glove Box page 16 3 Using a 3 mm hex wrench remove the four fasteners as shown in Figure 134 and Figure 135 4 Remove the Electronics Shield...

Page 109: ...harger to the PI Board 4 Using a 3 mm hex wrench remove the four fasteners as shown in Figure 136 and Figure 137 5 Remove the Charger Installation 1 Make sure the SE 3 Patroller is powered off unplugg...

Page 110: ...arking brake is engaged 2 Remove the following components a Battery Module page 8 b Storage Trays page 13 c Bib Panel page 14 d Glove Box page 16 e Electronics Shield page 100 f Charger page 101 3 Dis...

Page 111: ...tion 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Orient the PI Board and aluminum plate on the frame See Figure 139 3 Using an 8 mm socket wrench install...

Page 112: ...he Fuse Mini Blade a Press the fuse into the socket Ceramic Cartridge a Press the fuse into the socket b Install the plastic cover 3 Install the Battery Module page 8 4 Perform post service tests page...

Page 113: ...citors on the PI Board to self discharge Touching the PI Board before the capacitors have fully discharged could result in electric shock 3 Ajust the DIP switch See Table 3 4 Install the Battery Modul...

Page 114: ...SE 3 Patroller 106 Power Interface...

Page 115: ...r when diagnostic testing determines that it is malfunctioning Contents Left Right Motor Power Harness Left Right Drive Harness Handlebar Controls Harness User Interface Harness Light Cluster Harness...

Page 116: ...t Motor Power Harness Remove the right Side Panel to access the Right Motor Power Harness h Rider Detect Mat page 82 i Motor Cavity Lid page 89 3 Disconnect the wire harness from the PI Board See Figu...

Page 117: ...ess under the horizontal brace on the frame and connect it to the PI Board See Figure 144 5 Install two cable ties around the harnesses in the motor cavity 6 Install two cable ties around the harnesse...

Page 118: ...nel page 20 NOTICE Remove the left Side Panel to access the left Drive Harness Remove the right Side Panel to access the right Drive Harness h Electronics Shield page 100 i Rider Detect Mat page 82 j...

Page 119: ...5 Feed the harness under the horizontal brace on the frame see Figure 150 and connect it to the PI Board 6 Install two cable ties around the harnesses in the motor cavity 7 Install two cable ties aro...

Page 120: ...ery Module page 8 b Storage Trays page 13 c Bib Panel page 14 d Glove Box page 16 e Front Cowl page 17 f Electronics Shield page 100 3 Disconnect the wire harness from the PI Board See Figure 151 4 Di...

Page 121: ...the harness around the left side of the frame 4 Connect the wire harness to the PI Board See Figure 151 5 Install three cable ties a Harnesses on the steering column b This harness to the User Interfa...

Page 122: ...Shield page 100 g UI Module page 70 3 Disconnect the wire harness from the PI Board See Figure 154 4 Disconnect the wire harness from the UI Board See Figure 155 5 Using wire cutters remove four cabl...

Page 123: ...left side of the frame See Figure 157 4 Connect the harness to the PI Board See Figure 154 5 Install four cable ties a Two around the harnesses on the steering column b One connecting this harness to...

Page 124: ...6 e Front Cowl page 17 f Electronics Shield page 100 3 Disconnect the wire harness from the PI Board See Figure 158 4 Using a pair of wire cutters remove the cable tie connecting the harness to the fr...

Page 125: ...Install two cable ties to hold the harness neatly and tightly behind the Light Cluster 6 Install a cable tie connecting this harness to the frame 7 Install the following components a Electronics Shie...

Page 126: ...el page 20 NOTICE Remove the left Side Panel to access the left Tail Light Harness Remove the right Side Panel to access the right Tail Light Harness h Electronics Shield page 100 3 Disconnect the wir...

Page 127: ...all a fastener to hold the P clip in place Torque to 5 5 N m 4 0 ft lbf 7 Route the harnessunder the horizontal brace on the frame See Figure 165 8 Connect the wire harness to the PI Board See Figure...

Page 128: ...e Box page 16 e Front Cowl page 17 f Light Cluster page 18 g Right Side Panel page 20 h Electronics Shield page 100 i Rider Detect Mat page 82 j Motor Cavity Lid page 89 3 Disconnect the wire harness...

Page 129: ...ght side of the frame and under the horizontal brace on the frame 6 Connect the wire harness to the PI Board See Figure 166 7 Install two cable ties around the harnesses on the side of the frame 8 Ins...

Page 130: ...o cable ties around the frame 5 Using a pair of wire cutters remove the cable tie holding the harness to the top of the frame 6 Remove the Accessory Power Harness Installation 1 Make sure the SE 3 Pat...

Page 131: ...s remove the cable tie holding the harness to the top of the frame 5 Remove the KeyLock Harness Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2...

Page 132: ...Disconnect the Siren Harness from the siren lead 6 Remove the Siren Harness Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Connect the Siren Ha...

Page 133: ...ve Box page 16 e Electronics Shield page 100 3 Disconnect the wire harness from the PI Board See Figure 175 4 Remove the Service Interface Harness Installation 1 Make sure the SE 3 Patroller is powere...

Page 134: ...SE 3 Patroller 126 Harnesses...

Page 135: ...orn Siren Turn Indicators Lights Front Brake Front Brake Fluid Reservoir Figure 176 Left Handlebar Controls Test Desired Result 1 Rear brake left brake lever Both brake lights illuminate 2 Front brake...

Page 136: ...e is no binding of the handlebar cabling or wiring 1 Drive forward 2 Drive backward 3 Turn the handlebar full left and drive in a circle 4 Turn the handlebar full right and drive in a circle Charge Te...

Page 137: ...Instead when any lock nut is loose or removed replace the lock nut with a new Segway approved lock nut Before using a fastener make certain the fastener is the correct size and type with any necessar...

Page 138: ...0 74 ft lbf 20991 00002 M10 x 40 SHCS Gearbox 3 8 mm 67 N m 49 ft lbf 23202 00001 M4 Lock Nut Brake Light P Clip 1 7 mm 1 6 N M 1 2 ft lbf Front Directional Light 2 7 mm 1 6 N m 1 2 ft lbf Front Stro...

Page 139: ...784 00001 M8 Lock Nut Handlebar to Front Fork 2 13 mm 34 N m 25 ft lbf 23786 00001 M6 x 10 BHCS Front Rotor 5 5 mm 7 0 N m 5 0 ft lbf 23789 00001 Lug Nut Tire Wheel Assembly 4 Spline 67 N m 49 ft lbf...

Page 140: ...nt Splash Guard 8 4 mm 5 5 N m 4 0 ft lbf Headlight Bracket 2 4 mm 6 0 N m 4 4 ft lbf Main Splash Guard 8 4 mm 5 5 N m 4 0 ft lbf Side Panel Bracket to Frame 1 4 mm 5 5 N m 4 0 ft lbf Side Panel Brack...

Page 141: ...Strobe Light 2 3 mm 1 6 N m 1 2 ft lbf 24315 00007 M4 x 25 SHCS Side Strobe Light 2 3 mm 1 6 N m 1 2 ft lbf 24315 00008 M4 x 30 SHCS Brake Light 2 3 mm 1 0 N m 0 74 ft lbf 24346 00001 1 4 in P Clip B...

Page 142: ...box 3 N A N A 24435 00003 M6 Split Lock Washer Ring Terminal to Motor Controller 1 N A N A 24436 00004 M6 x 14 HXBT Ring Terminal to Motor Controller 1 10 mm 7 5 N m 5 5 ft lbf 24437 00003 M10 x 30 BH...

Page 143: ...Fuses Mini blade fuses 1 A 2 A 3 A Ceramic cartridge fuses 5 A See Table 2 p 104 for part numbers Heat gun Hand held heat gun that can reach 105 C 220 F Hex adapter 1 4 inch square to 1 4 inch hex Hex...

Page 144: ...spanner wrench Tire pump Air pump with Schrader valve attachment Torque wrenches 1 4 inch drive torque limiting screwdriver 1 6 N m range 1 4 inch drive torque limiting ratchet 5 15 N m range 3 8 inch...

Page 145: ...tal elapsed time during which the motor drives have been powered on Finger Tight Tighten the fastener by hand Using only your fingers tighten it as much as you can without straining Glass Tube Type Fu...

Page 146: ...pe of screw with a cylindrical head and an indentation hex or 6 lobe used for tightening UI Board User Interface Board This is a printed circuit board that connects to a screen and buttons and powers...

Page 147: ......

Page 148: ...24538 00001 ad...

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