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Segway Personal Transporter SE Service Manual

10–3

Chassis Cover (cont.)

Installation

CAUTION!

Make sure the motor and BSA harnesses are seated in the
appropriate notches so that the harnesses are not pinched
when the Chassis Cover is installed. Pinched harnesses
could cause the PT to malfunction, risking personal injury or
property damage.

Tools Required:

Cotton swabs

Ammonia
Isopropyl

alcohol

T-27 6-lobe wrench

Torque

wrench

1. Make sure the PT is powered off, unplugged, and the

batteries have been removed.

2. Completely remove thread lock compound from the

Chassis Cover fastener holes. Use cotton swabs to
thoroughly clean excess thread lock compound from
the internal threads. First use ammonia or ammonia-
based window cleaner, then isopropyl 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 the

Chassis Cover. See

5. Viewed from the rear of the Chassis, the harnesses

should fit through the holes in the Chassis Cover as
follows:

− Left side: 10-pin white connector

Connector with purple wires

− Right side: 12-pin connector

Connector with orange wires

6. Using a T-27 6-lobe wrench, install ten new

fasteners. See

. Torque to

6.0 N-m

(4.5 ft-lbf)

.

NOTICE

Do not install the two front-center fasteners. These
will be installed when the Console is installed.

7. Install the Console (

).

8. Install the Radio Board (

).

9. Reassemble the PT from the Serviceable Powerbase

).

10. Perform post-service tests (

).

Chassis Cover

Figure 10–2: Cable Connections

Figure 10–3: Feed Harnesses Through Holes in Chassis Cover

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Содержание i2 SE

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 91: ......

Страница 92: ...24019 00001 aa...

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