Professional Documents
Culture Documents
Segway® SE Service Manual
Segway® SE Service Manual
Segway® SE Service Manual
Service Manual
i2 SE
i2 SE Patroller
x2 SE
x2 SE Turf
x2 SE Patroller
March 2014
24019-00001 aa
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 serious injury or death.
Trademarks
Segway owns a number of trademarks including, but not limited to, Segway and the Segway "Rider Design" logo that have been
registered in the United States and in other countries. Those trademarks followed by ® are registered trademarks of Segway.
All other marks are trademarks or common law marks of Segway. Failure of a mark to appear in this guide does not mean that
Segway 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 the property of their respective companies.
Contact Information
For support, please contact the company from which you bought the Segway product. For a listing of Authorized Segway Dealers
and Distributors, refer to the Segway website at http://www.segway.com.
Introduction....................................................................................................................... 0–1
Purpose...................................................................................................................................................... 0–1
Audience..................................................................................................................................................... 0–1
Certification............................................................................................................................................... 0–1
Organization...............................................................................................................................................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
InfoKey Controller.......................................................................................................................................1–7
InfoKey Dock...............................................................................................................................................1–7
InfoKey Controller Battery..........................................................................................................................1–8
2 Mats............................................................................................................................... 2–1
Mats............................................................................................................................................................ 2–2
3 Batteries....................................................................................................................... 3–1
Batteries..................................................................................................................................................... 3–2
5 Fenders.......................................................................................................................... 5–1
i2 SE Fender................................................................................................................................................ 5–2
x2 SE Fender............................................................................................................................................... 5–3
x2 SE Fender Frame................................................................................................................................... 5–4
7 Gearbox..........................................................................................................................7–1
Gearbox...................................................................................................................................................... 7–2
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 Light Pipe........................................................................................................................................ 9–10
11 CU Board...................................................................................................................... 11–1
CU Board................................................................................................................................................... 11–2
13 Motor............................................................................................................................13–1
Motor.........................................................................................................................................................13–2
Elastomer Bushing................................................................................................................................... 13–4
14 Powerbase Chassis.....................................................................................................14–1
Powerbase Chassis...................................................................................................................................14–2
C Fasteners....................................................................................................................... C–1
D Tools and Equipment...................................................................................................D–1
E Glossary........................................................................................................................ E–1
WARNING! Warns you about actions that could result in death or serious injury.
CAUTION! Warns you about actions that could result in minor or moderate injury.
Indicates information considered important, but not related to personal injury. Examples
NOTICE
include messages regarding possible damage to the PT or other property, or usage tips.
General
WARNING!
• Failure to follow these safety precautions could lead to electrical shock, serious injury, death, or damage to property.
• To replace parts on the Segway PT, you must read and follow all instructions and warnings in this Service Manual.
• Always power off the Segway PT before performing any maintenance or installing any part or accessory.
• Always unplug the AC power cord before performing any maintenance or installing any part or accessory.
Batteries
WARNING!
• Do not use the battery if the battery casing is broken or if the battery emits an unusual odor, smoke, or excessive
heat, or leaks any substance. Avoid contact with any substance seeping from the battery. Batteries contain toxic and
corrosive materials that could cause serious injury.
• As with all rechargeable batteries, do not 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.
• Observe and follow all safety information on the warning label found on the battery.
• Use only Segway-approved charging devices to charge the batteries.
• Do not attempt to open batteries. 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, burns,
or cause a fire. Attempting to open the battery casing will damage the casing and could release toxic and harmful
substances, and will render the battery unusable.
• Do not submerge the PT, batteries, or powerbases in water. Do not use a power washer or high-pressure hose to clean
a PT. Avoid getting water into any of the connectors. Avoid exposing the Segway PT to heavy downpours or extended
periods of heavy rain. If you suspect the batteries or powerbase have been submerged or experienced water intrusion,
call Segway Technical Support immediately at 1-866-473-4929, prompt #2. Until you receive further instructions, store
the PT upright, outdoors, and away from flammable objects. Failure to do so could expose you to electric shock, injury,
burns, or cause a fire.
• Comply with all local and federal or individual country laws when disposing of and transporting Segway PT batteries.
• Failure to adhere to these warnings could lead to serious injury, death, fire, or damage to property.
Fasteners
WARNING!
• Use only Segway-approved fasteners. Other fasteners may not perform as expected and may come loose.
• Do not tighten or reuse any fastener except the screws used to attach the batteries, wheel nuts, and LeanSteer frame.
Instead, when any other fastener is loose or removed, replace the fastener with a new Segway-approved fastener. See
“Fasteners,” page C–1, for more information.
• Before using a fastener, make certain the fastener is the correct size and type with any necessary washer and thread
lock in place (see 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 frame fasteners.
• Do not attempt to repair any stripped or damaged screw hole. Instead, replace the part. If a replacement part is not
available, do not reassemble.
• Insert fasteners slowly and carefully. Do not cross-thread or over-tighten fasteners. Tighten only 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 in appearance from the comparable factory-installed fasteners.
• Failure to adhere to these warnings could lead to serious injury or death or damage to property.
Eye Protection
WARNING!
• When procedures require the use of safety glasses (such as those in which a mallet or solvent is used), failure to wear
eye protection could result in serious injury.
ESD Procedures
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.
SOLVENTS
CAUTION!
• This manual refers to the use of isopropyl alcohol and ammonia or ammonia-based window cleaner in certain cleaning
procedures. Use of any other type of solvent is not allowed.
Questions
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.
Audience
Chapters 1 – 8 of this manual are written for either customers or Segway
Certified Service Technicians working under agreement with Segway Inc.
Chapters 9 – 14 of this manual are written only for Segway Certified Service
Technicians working under agreement with Segway Inc. See page 8–3 for
more information.
Certification
Becoming a Segway 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, the service
technician becomes certified to repair the Segway PT parts and assemblies
according to the following scheme:
Table 0–1: Certification Levels
Level Parts and Assemblies Certified to Maintain Instructions
1 • Customer Replaceable Parts
−− LeanSteer Frame Chapter 1
−− Mats Chapter 2
−− Batteries Chapter 3
−− Tire/Wheel Assembly Chapter 4
−− Fender Chapter 5
−− Powerbase Trim Chapter 6
−− Gearbox Chapter 7
• Serviceable Powerbase Chapter 8
2 • All Level 1 (see above) See above
• Console Chapter 9
−− Radio Board “
−− Console “
−− Power Board “
−− Interconnect Board “
−− AC Input Filter “
−− Pivot Assembly “
−− Front Light Pipe “
Organization
This manual organizes service instructions into two general categories:
• Instructions intended for both customers and service technicians
(Chapter 1 – Chapter 8)
• Instructions intended for service technicians only
(Chapter 9 – Chapter 14)
The instructions in Chapter 9 – Chapter 14 describe procedures for replacing parts
after having established a Serviceable Power Base (SPB), which is described in
Chapter 8.
Table 0–2: Chapter Descriptions
Chapter Description
page ix Safety information. Read before servicing the Segway PT.
page 0–4 Exploded view of the Segway PT component parts.
Chapter 1 LeanSteer Frame and LeanSteer Stem installation and removal procedures.
Chapter 2 Mat installation and removal procedures.
Chapter 3 Li-ion Battery installation, removal, and troubleshooting procedures.
Chapter 4 Tire/Wheel Assembly installation and removal procedures.
Chapter 5 Fender and Fender Frame installation and removal procedures.
Chapter 6 Powerbase Trim (Fascia) installation and removal procedures.
Chapter 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 Chassis cover installation and removal procedures.
Chapter 11 CU Boards installation and removal procedures.
Chapter 12 Balance Sensor Assembly installation and removal procedures.
Chapter 13 Motor installation and removal procedures.
Chapter 14 Powerbase Chassis replacement procedure.
Appendix A Post-Service Tests to be performed after servicing the Segway PT.
Appendix B Parts Lists for the Segway PT.
Appendix C Fastener descriptions and specifications.
Appendix D Tools and diagnostic equipment necessary to properly service a Segway PT.
Appendix E Definitions of product-specific words used in this manual.
Terminology
Throughout this manual, the term “model x2” refers to both the x2 and x2 Turf
models unless otherwise noted. All i2/x2 procedures are valid in all SE and
Patroller models unless otherwise noted.
Parts Diagram
Handlebar Clamp InfoKey
21861-00001 (Patroller) 21064-00001 (Programmed)
21065-00001 (Unprogrammed)
InfoKey Dock
20533-00001
x2 Fender x2 Components
x2 Fender Frame 20798-00002 (Left)
23489-00001 20798-00001 (Right)
LeanSteer Frame
23512-00001 (Standard) x2 Wheel
(Patroller) 23548-00001 23725-00001
x2 Hubcap
23537-00001
Mat
23554-00001 (Standard)
23578-00001 (Comfort)
Stem Cap
23519-00001
Rear Fascia
23550-00002
i2 Hubcap
20325-00001
i2 Wheel
Battery
20162-00001
20967-00001
WARNING! Qualifications
• Failure to follow these safety precautions could lead to electrical shock,
Customer Replaceable
serious injury, death, or damage to property.
• Read all instructions. Customer Replaceable Kits
• Power off the Segway PT. Handlebar Clamp Kit (20954-00001)
• Unplug the Segway PT. 1 Handlebar Clamp
• The LeanSteer Frame and LeanSteer Stem must be properly attached 3 Fasteners
and secured. Failure to properly attach the LeanSteer components
and/or maintain proper torque on the fasteners could result in Handlebar Kit (20955-00001)
machine malfunction and could cause personal injury or damage to
1 Handlebar
the Segway PT. Using the Segway PT without properly assembling
the LeanSteer components and/or maintaining proper torque on the
fasteners could lead to an unexpected change in steering and could
result in serious injury and/or damage to the Segway PT from loss of
control, collisions, and falls.
• Check the tightness of the fasteners connecting the LeanSteer Stem
to the Pivot Base every time the LeanSteer Stem is removed and
reinstalled.
When to Replace
You need to replace the LeanSteer frame if any part is bent or otherwise broken.
M4 x 20 SHCS
20306-00001
Grip Trim
Handlebar Clamp
18892-00001
20046-00001 (Standard)
Handlebar Tube
20045-00001
Tube Bushing
Handlebar Stop 23511-00001
20041-00001
Washer
20751-00001
Lower LeanSteer Tube
Wedge 23509-00001
20042-00001
#6-19x19mm PHCS
Bolt Trim 23558-00001
23516-00001 (Standard)
M4 x 20 SHCS
20306-00001
Grip Trim
18892-00001
Handlebar Clamp
21861-00001 (Patroller) Handlebar Tube
20045-00001
Handlebar Stop
20041-00001
Tube Bushing
23511-00001
Height Adjust Knob
20753-00001
Washer
20751-00001
#6-19x19mm PHCS
Bolt Trim 23558-00001
23545-00002 (Patroller)
Handlebar
Removal Handlebar
Tool Required: 3 mm hex wrench
1. Make sure the Segway PT is powered off and
unplugged.
2. Using a 3 mm hex wrench, remove the three
fasteners that secure the Handlebar Clamp to the
LeanSteer Frame. See Figure 1–3.
3. Remove the Handlebar and Handlebar Clamp from Handlebar Clamp
the LeanSteer Frame.
20306-00001
Installation 2.0 N-m (18 in-lbf)
Tools Required: 3 mm hex wrench
Torque wrench Figure 1–3: Installing and Removing the Handlebar
LeanSteer Frame
Removal 23517-00001
Tool Required: 5 mm hex wrench 11.0 N-m (8.1 ft-lbf)
LeanSteer Frame
1. Make sure the PT is powered off and unplugged.
2. Using a 5 mm hex wrench, remove the two fasteners LeanSteer
holding the LeanSteer Frame to the LeanSteer Stem Stem
(see Figure 1–5), while supporting the LeanSteer
Frame.
3. Remove the LeanSteer Frame.
Installation
Tools Required: 5 mm hex wrench
Torque wrench
1. Make sure the PT is powered off and unplugged.
2. Place the LeanSteer Frame onto the LeanSteer Stem
(see Figure 1–5).
3. Using a 5 mm hex wrench, install the two fasteners.
Torque to 11.0 N-m (8.1 ft-lbf).
Figure 1–5: LeanSteer Frame
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. Ensure the LeanSteer Frame returns to a straight,
upright position. If it is not vertical, follow the
instructions on page 1–6 to remove and install the
LeanSteer Stem.
6. Check the fasteners to be sure they are tight.
NOTICE
Check the fasteners at least monthly to be sure they
remain tight. If they are loose, tighten the fasteners
to 11.0 N-m (8.1 ft-lbf).
7. Perform post-service tests (page A–1).
LeanSteer Stem
Removal
Tool Required: T-30 6-lobe wrench
1. Make sure the PT is powered off and unplugged.
LeanSteer Stem
2. Remove the LeanSteer Stem Cap (see Figure 1–7).
3. Using a T-30 6-lobe wrench, remove the four
fasteners.
4. Slide the LeanSteer Stem off the pivot base.
LeanSteer
Stem Cap
Installation
Tools Required: T-30 6-lobe wrench Pivot Base
Torque wrench
20539-00001
1. Make sure the PT is powered off and unplugged. 11 N-m (8.1 ft-lbf)
2. Slide the LeanSteer Stem onto the pivot base (see Figure 1–7: LeanSteer Stem
Figure 1–7).
NOTICE
The Standard LeanSteer Stem must be used Standard Patroller
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.
InfoKey Controller
Removal
1. Press the release tab at the bottom of the InfoKey
Dock. See 1 in Figure 1–9.
2. Slide the InfoKey Controller out of the Dock.
See 2 in Figure 1–9.
InfoKey Controller
Installation
1. Make sure the InfoKey Dock is installed (see
page 1–7).
2. Place the InfoKey Controller onto the Dock and slide
into place until the release tab (1 in Figure 1–9) is
engaged.
3. Perform post-service tests (page A–1).
InfoKey Dock
InfoKey Dock
Removal
Tool Required: 3 mm hex wrench 20306-00003
2.0 N-m (18 in-lbf)
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. InfoKey Dock
See Figure 1–10.
3. Remove the InfoKey Dock.
Installation
Tools Required: 3 mm hex wrench
Torque wrench
1. Make sure the PT is powered off and unplugged.
2. Place the InfoKey Dock against the upper LeanSteer
Frame with the release tab oriented toward the
bottom. See Figure 1–10.
3. Using a 3 mm hex wrench, install the fastener
through the hole in the InfoKey Dock and into
the upper LeanSteer Frame. Torque to 2.0 N-m
(18 in-lbf).
4. Perform post-service tests (page A–1).
Figure 1–10: InfoKey Dock
Installation
Tool Required: 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 Controller Battery with the
positive (+) side showing. See Figure 1–12. Figure 1–11: Connect/Disconnect InfoKey Controller to Dock Adapter
4. Using a coin or flathead screwdriver, reattach the
back cover of the InfoKey Controller.
5. Place the InfoKey Controller on the InfoKey Dock
Adapter and rotate clockwise until the InfoKey
Controller clicks into position. See Figure 1–11.
6. Perform post-service tests (page A–1).
When to Replace
It is appropriate to replace a Mat if any worn edges or tears are observed.
Mats
Removal
1. Make sure the PT is powered off and unplugged.
2. Lift the Mat off the Powerbase. See Figure 2–1.
Installation
1. Make sure the PT is powered off and unplugged.
2. 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 the front and rear fascia and the
Powerbase. See Figure 2–1.
5. Visually confirm that the Mat is properly aligned and
all rubber tabs are tucked in prior to riding.
6. Perform post-service tests (page A–1).
Figure 2–1: Mat Installation
When to Replace
Replace batteries as advised by a Segway Service Representative.
Batteries
When replacing a Battery, consider replacing both Batteries,
and always use pairs of Batteries with the same chemistry.
Replacing only one Battery will not necessarily increase the
performance or range of the PT, because the PT is designed to
operate only at the level allowed by the lower-energy Battery.
Redundancy is a critical safety feature built into the Segway
PT that also applies to the Batteries. Therefore, you should
replace Batteries in pairs (except for 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 to confirm that the error condition follows the
Battery.
Removal
Tool Required: 3 mm hex wrench
1. Make sure the PT is powered off and unplugged. Battery
2. Tip the PT onto its side so the Wheel lies flat against
a smooth, clean surface.
3. Using a 3 mm hex wrench, remove the battery
fasteners (4 per battery). See Figure 3–1
4. Pull the Battery straight off the chassis.
5. Repeat steps 3 and 4 for the other Battery.
NOTICE
Consult your local recycling center for proper disposal of
Batteries.
Figure 3–1: Battery Removal
Batteries (cont.)
Installation
Tools Required: 3 mm hex wrench
Torque wrench
CAUTION!
To avoid risk of damage, do not use power tools.
i2 SE Wheel Assembly
NOTICE
Support your Segway PT by means other than resting it
on its wheels. Support of the unit from below the batteries
is recommended. As an alternative, the Segway PT can be
positioned on its side on the opposite wheel. Do not rest the
Segway PT on an exposed gearbox.
Removal
Tool Required: 13 mm socket wrench
i2 Wheel
1. Make sure the PT is powered off and unplugged.
2. Support the PT or turn it on its side.
3. Remove the wheel cap. Push a screwdriver 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
wheel nuts and discard.
20158-00001
5. Remove the i2 SE Wheel Assembly. 30 N-m (22 ft-lbf)
Gearbox Flange
Installation
Tools required: 13 mm socket wrench
Torque wrench
1. Make sure the PT is powered off and unplugged. i2 Hubcap
2. Support the PT or turn it on its side. Figure 4–1: i2 SE Tire/Wheel Assembly
3. Place the i2 SE Wheel Assembly on the gearbox
flange. See Figure 4–1.
4. Using a 13 mm socket wrench, install the three wheel
nuts. Torque to 30 N-m (22 ft-lbf).
5. Install the wheel cap. Press the cap onto the wheel
until it snaps into place.
6. Perform post-service tests (page A–1).
x2 SE Wheel Assembly
Removal
Tool Required: 13 mm socket wrench
1. Make sure the PT is powered off and unplugged.
2. Support the PT or turn it on its side.
3. Using a 13 mm socket wrench, remove the three
wheel nuts and discard. See Figure 4–2. x2 Wheel
Installation
Tools Required: 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 Gearbox Flange
alcohol wipes to clean off all debris.
4. Place the x2 SE Wheel Assembly on the gearbox
flange. See Figure 4–2.
5. Holding the wheel to prevent rotation, use a 13 mm
socket wrench to install the three wheel nuts. Torque Wheel Nuts
to 30 N-m (22 ft-lbf). 20158-00001
30 N-m (22 ft-lbf)
6. Perform post-service tests (page A–1).
Figure 4–2: x2 SE Tire/Wheel Assembly
Installation
Tools Required: Isopropyl alcohol wipes
8 mm hex wrench
20991-00002
Torque wrench
35 N-m (26 ft-lbf)
1. Make sure the PT is powered off and unplugged.
Figure 4–3: x2 SE Turf Tire/Wheel Assembly
2. Support the PT or turn it on its side.
3. Inspect the wheel mounting surfaces; use isopropyl
alcohol wipes to clean off all debris.
4. Place the Spacer over the hub adapter; align the
mounting holes. See Figure 4–3.
5. Place the Wheel against the Spacer, with the valve
stem facing outward; align the mounting holes.
6. Place the wheel trim on the Wheel; align the
mounting holes.
7. Insert four fasteners through the wheel trim, Wheel,
and Spacer. Using an 8 mm hex wrench, thread the
fasteners into the Hub Adapter. Torque to 35 N-m
(26 ft-lbf).
8. Perform post-service tests (page A–1).
i2 SE Tire Tube
Removal
Tools Required: Pen
Bar clamp
2 Tire irons
1. Make sure the PT is powered off and unplugged.
2. Support the PT or turn it on its side.
3. Remove the i2 SE Tire/Wheel Assembly
(page 4–2).
4. Remove the valve stem cap and, using a pen or
other pointy object, release the air from the tire by
pushing down on the valve needle while squeezing
the tire to ensure tire is completely emptied of air.
See Figure 4–5.
Figure 4–5: Deflate the Tire
NOTICE
The i2 SE tire is tightly fitted to the wheel in a
manner similar to a motorcycle tire mounted to a
rim.
NOTICE
Carefully position the clamp to avoid puncturing the
tire. Insert the clamp on the tire wall, centering the
clamp at the tire specification label.
Figure 4–6: Break the Tire Bead
CAUTION!
The rim has sharp edges. Use caution when
handling. Avoid being pinched between the wheel
and the tire.
CAUTION!
Improper placement of the tire iron can result in
pinching.
NOTICE
If the tire becomes overinflated when seating the Figure 4–14: Use a Tire Iron to Lift Remaining Bead
beads, release air until the pressure reaches 15 psi.
i2 SE Fender
Removal
Tool Required: T-20 6-lobe wrench
1. Make sure the PT is powered off and unplugged. i2 Fender
2. Remove the Tire/Wheel Assembly (page 4–2).
3. Using a T-20 6-lobe wrench, remove the four
fasteners holding the 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.
20538-00001
2. Orient and place the Fender on the gearbox. See 1.5 N-m (13 in-lbf)
Figure 5–1.
Figure 5–1: i2 SE Fender
3. Using a T-20 6-lobe wrench, install the four
fasteners. Torque to 1.5 N-m (13 in-lbf).
4. Install the Tire/Wheel Assembly (page 4–2).
5. Perform post-service tests (page A–1).
x2 SE Fender
Removal
Tool Required: 4 mm hex wrench
1. Make sure the PT is powered off and unplugged.
x2 Fender
2. Remove the Tire/Wheel Assembly (page 4–3).
3. Using a 4 mm hex wrench, remove the four fasteners
holding the Fender to the Fender Frame. See
Figure 5–2.
4. Remove the Fender from the Fender Frame.
NOTICE
The Fender and Fender Frame can be removed as a
unit by removing the Fender Frame fasteners (see
page 5–4).
20871-00001
Installation ½ turn – 1 full turn
after seated
Tools Required: 4 mm hex wrench
Figure 5–2: x2 SE Fender
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 Frame.
3. Ensure the grommets are in place on the Fender.
If grommets need to be installed, use a finger to
push the grommets into place. Grommets are
bidirectional and can be installed from either side of
the Fender.
4. Using a 4 mm hex wrench, install the four fasteners
until seated. Tighten one-half to one full turn. See
Figure 5–2.
5. Install the Tire/Wheel Assembly (page 4–3).
6. Perform post-service tests (page A–1).
x2 SE Fender Frame
Removal
Tool Required: 4 mm hex wrench Fender Frame
1. Make sure the PT is powered off and unplugged.
2. Remove the Tire/Wheel Assembly (page 4–3).
3. Remove the Fender (page 5–3).
4. Using a 4 mm hex wrench, remove the three
fasteners holding the Fender Frame to the gearbox.
Gearbox
See Figure 5–3. Discard the fasteners.
5. Remove the Fender Frame.
NOTICE
20553-00002
The Fender and Fender Frame can be removed as a
6.0 N-m (4.5 ft-lbf)
unit (not shown). Fender Frame fasteners should be
discard and replaced with new ones.
Installation
Tools Required: 4 mm hex wrench
Torque wrench
1. Make sure the PT is powered off and unplugged.
Figure 5–3: x2 SE Fender Frame
2. Place the Fender Frame on the Gearbox.
See Figure 5–3.
3. Using a 4 mm hex wrench, install three new Fender
Frame fasteners. Torque to 6.0 N-m (4.5 ft-lbf).
4. Install the Fender (page 5–3).
5. Install the Tire/Wheel Assembly (page 4–3).
6. Perform post-service tests (page A–1).
WARNING! Qualifications
• Failure to follow these safety precautions could lead to electrical shock,
Customer Replaceable
serious injury, death, or damage to property.
• Read all instructions. Customer Replaceable Kits
• Power off the Segway PT. Front Fascia Kit (23876-00001)
• Unplug the Segway PT. 1 Front Fascia
2 Fasteners
When to Replace
You need to replace front or rear fascia if either is physically damaged. Rear Fascia Kit (23876-00002)
1 Rear Fascia
2 Fasteners
Gearbox Cover
This component is installed on i2 models only.
Installation
20553-00001
Tools Required: 4 mm hex wrench
6.0 N-m (4.5 ft-lbf)
Torque wrench Figure 6–1: Gearbox Cover
1. Make sure the PT is powered off and unplugged.
2. Align the holes in the Gearbox Cover with the holes
in the Gearbox. See Figure 6–1.
3a. x2 SE: install Fender and Fender Frame assembly
(page 5–4). Thread three new fasteners through
the holes in the Gearbox Cover.
3b. i2 SE: using a 4 mm hex wrench, install three new
fasteners.
4. Torque to 6.0 N-m (4.5 ft-lbf).
5. Perform post-service tests (page A–1).
Console Cover
Removal
Tools Required: 4 mm hex wrench
T-20 6-lobe wrench Center Console Cover
1. Make sure the PT is powered off and unplugged.
2. Using a 4 mm hex wrench, remove the two fasteners
from the Front Console Cover and slide the Front
Console Cover off. See Figure 6–2.
3. Using a T-20 6-lobe wrench, remove the four
fasteners on the Center Console Cover and lift the
Center Console Cover off. See Figure 6–3.
CAUTION!
Make sure the IEC connector (charge port) remains
clean and dry.
Front Console Cover
20554-00001
Installation Figure 6–2: Front Console Cover 1.5 N-m (13 in-lbf)
Tools Required: T-20 6-lobe wrench
4 mm hex wrench
Torque wrench
20307-00002
1. Make sure the PT is powered off and unplugged. 1.5 N-m (13 in-lbf)
2. Place the Center Console Cover on the console.
3. Using a T-20 6-lobe wrench, install the four
fasteners. Torque to 1.5 N-m (13 in-lbf).
See Figure 6–3.
Center Console Cover
4. Slide the Front Console Cover over the legs of the
Center Console Cover.
5. Using a 4 mm hex wrench, install the two fasteners.
Torque to 1.5 N-m (13 in-lbf). See Figure 6–2.
6. Perform post-service tests (page A–1).
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 of the
powerbase (Figure 6–5) and the rear Fascia onto
the rear of the powerbase (Figure 6–4).
3. Using a 4 mm hex wrench, install the four fasteners.
Torque to 1.5 N-m (13 in-lbf).
4. Install the Console Cover (page 6–3).
5. Install the Fenders.
−− i2 SE (page 5–2) 20554-00001
−− x2 SE (page 5–4) 1.5 N-m (13 in-lbf)
6. Install the Tire/Wheel Assembly.
−− i2 SE (page 4–2) Front Fascia
Figure 6–5: Front Fascia
−− x2 SE (page 4–3)
−− x2 SE Turf (page 4–4)
7. Perform post-service tests (page A–1).
When to Replace
It is appropriate to remove, inspect, or replace the gearbox for reasons that
include the following:
• Excessive wheel wobble that cannot be remedied by either changing
the wheel position on the gearbox, by rotating the mounting position
by 180 degrees, or by replacing the Tire/Wheel Assembly.
The wheel hub has three holes that correspond to the three gearbox
flange studs. The wheel can be mounted to the gearbox in any of three
positions, relative to these holes. Clocking the wheel (i.e. advancing
the wheel to the next of these three possible positions) might minimize
wheel wobble on some units.
• Excessive and progressively worsening noise and/or vibration that
cannot be remedied by removing potential obstructions of the wheel,
by properly inflating the tire, or by replacing the Tire/Wheel Assembly.
Gearbox
Removal
Tools Required: T-45 6-lobe wrench
Rubber mallet Chassis
NOTICE
Gearbox fasteners are installed with thread lock
compound and require significant leverage to loosen
for the duration of thread engagement. Use of new
gearbox fasteners with new thread lock compound is
required for proper installation.
Gearbox (cont.)
Installation
CAUTION!
Machined edges can be sharp. To avoid pinching, keep hands
and fingers clear of mating surfaces while seating gearbox
and spacer to chassis.
NOTICE
Using a vacuum cleaner or similar tool, remove any
foreign material from the motor cavity prior to re-
installation.
Gasket
NOTICE
Although the motor is shown out of position in
Figure 7–5 (to make couplings and roll pins visible),
motor is still in place during this procedure.
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.
NOTICE
The following sections in this Service Manual are intended for use by Segway 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 in any of the following sections are replaced by an
individual other than a Segway Certified Service Technician.
Console Components
Light Pipe
23483-00001
Radio Board
23451-00001
Gap Pad
23699-00001
Console Base
Front Light Pipe 23390-00001
23402-00001
Insulator
23575-00001
AC Input Filter
23405-00001
Interconnect Board
23411-00001
Power Board
23371-00001
Insulator
23598-00001
Figure 9–1: Console Components
Radio Board
Removal
Tools Required: T-20 6-lobe wrench
T-10 6-lobe wrench 20203-00002
1.8 N-m (16 in-lbf)
1. Make sure the PT is powered off, unplugged, and the
batteries have been removed.
Light Pipe
2. Establish a Serviceable Powerbase (page 8–2).
3. Using a T-20 6-lobe wrench, remove the six
20567-00001 (self-tapping)
fasteners holding the Light Pipe in place. Discard the
20973-00001 (non-tapping)
fasteners.
1.6 N-m (14 in-lbf)
4. Remove the light pipe.
5. Using a T-10 6-lobe wrench, remove the six fasteners
holding the Radio Board in place. Discard the
fasteners. Radio Board
6. Remove the Radio Board.
7. Using ESD best practices, place 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 Board. Press it onto the
Interconnect Board. Figure 9–2: Light Pipe and Radio Board
3. Using a T-10 6-lobe wrench, install six new fasteners.
Torque to 1.6 N-m (14 in-lbf).
NOTICE
Original fasteners are self-tapping. Replace with
non-tapping fasteners.
Console
20540-00005
Removal 11.0 N-m (8.1 ft-lbf)
Tool Required: T-27 6-lobe wrench 20540-00006
1. Make sure the PT is powered off, unplugged, and the
batteries have been removed. 20540-00005
2. Establish a Serviceable Powerbase (page 8–2).
3. Remove the Radio Board (page 9–3).
4. Using a T-27 6-lobe wrench, remove the four
fasteners holding the Console in place. See
Figure 9–3. Discard the fasteners.
5. Tip the Console on its side and disconnect the four
Powerbase harnesses. See Figure 9–4.
6. Remove the Console.
Installation
Tools Required: T-27 6-lobe wrench
Torque 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 different size/shape and fits into only
one of the connectors.
3. Tip the Console upright, being careful not to pinch
the harnesses.
4. Using a T-27 6-lobe wrench, install the three shorter
fasteners to the front and rear of the Console. Install
Figure 9–3: Console Fasteners
the longer fastener in the center. Torque to 11.0 N-m
(8.1 ft-lbf).
5. Install the Radio Board (page 9–3).
6. Reassemble the PT from the Serviceable Powerbase
(page 8–2).
7. Perform post-service tests (page A–1).
Figure 9–4: Console Harnesses
Power Board
Removal
Tool Required: T-10 6-lobe wrench
1. Make sure the PT is powered off, unplugged, and the Insulator
batteries have been removed.
2. Establish a Serviceable Powerbase (page 8–2).
3. Remove the Radio Board (page 9–3).
4. Detach the Console from the Powerbase
(page 9–4).
5. Remove the insulator covering the Power Board. See Power Supply Harness
Figure 9–5.
6. Disconnect the Power Supply Harness from the
Power Board. Press down on the tab while gently
pulling the connector out of the socket.
7. Using a T-10 6-lobe wrench, remove the eight
fasteners holding the Power Board in place. Discard
the fasteners. See Figure 9–6.
8. Remove the Power Board. Lift the board out of Figure 9–5: Power Board Insulator
the Console Base, leaving the Interconnect Board
behind.
9. Using ESD best practices, place the Power Board in
an ESD bag for return shipment to Segway. 20567-00001 (self-tapping)
20973-00001 (non-tapping)
1.6 N-m (14 in-lbf)
Installation
Tools Required: T-10 6-lobe wrench
Torque Wrench
1. Install the Power Board. Press the board onto the
Interconnect Board. Power Board
2. Using a T-10 6-lobe wrench, install eight new Thermal
fasteners. Torque to 1.6 N-m (14 in-lbf). Gap Pad
NOTICE
Original fasteners are self-tapping. Replace with
non-tapping fasteners.
Interconnect Board
Removal
1. Make sure the PT is powered off, unplugged, and the
batteries have been removed. Interconnect Board
2. Establish a Serviceable Powerbase (page 8–2).
3. Remove the Radio Board (page 9–3).
Pivot Harnesses
4. Detach the Console from the Powerbase
(page 9–4).
5. Remove the Power Board (page 9–5).
6. Disconnect the two Pivot Assembly Harnesses. For
each harness, press down on the tab while gently
pulling the connector out of the socket.
Pivot Assembly
7. Remove the Interconnect Board.
8. Using ESD best practices, place the Interconnect
Board in an ESD bag for return shipment to Segway. Figure 9–7: Interconnect Board
Installation
1. Orient the Interconnect Board so the notched side
protrudes through the hole in the Console Base, and
the Pivot Harness connectors are toward the Pivot
Assembly. See Figure 9–7.
1. Install the Interconnect Board.
2. Connect the Pivot Harnesses to the Interconnect
Board.
3. Install the Power Board (page 9–5).
4. Install the Console onto the Powerbase
(page 9–4).
5. Install the Radio Board (page 9–3).
6. Reassemble the PT from the Serviceable Powerbase
(page 8–2).
7. Perform post-service tests (page A–1).
AC Input Filter
Removal
23591-00001
Tools Required: 4 mm hex wrench 20567-00001 (self-tapping) 3.0 N-m (27 in-lbf)
T-20 6-lobe wrench 20973-00001 (non-tapping)
T-10 6-lobe wrench 1.6 N-m (14 in-lbf)
1. Make sure the PT is powered off, unplugged, and the
AC Input Filter AC Input
batteries have been removed.
Socket
2. Establish a Serviceable Powerbase (page 8–2).
3. Remove the Radio Board (page 9–3).
4. Detach the Console from the Powerbase Insulator
(page 9–4).
5. Disconnect the Power Supply Harness from the
AC Input Filter. Press down on the tab while gently
pulling the connector out of the socket. See
Figure 9–10.
6. Using a 4 mm hex wrench, detach the ground lug
Console Base
from the Console Base. See Figure 9–10.
23559-00001
7. Using a T-20 6-lobe wrench, remove the two 1.0 N-m (9 in-lbf)
fasteners holding the AC Input Socket in place. Figure 9–8: AC Input Filter
Discard the fasteners. See Figure 9–8.
8. Using a T-10 6-lobe wrench, remove the five
fasteners holding the AC Input Filter in place.
Discard the fasteners.
9. Remove the AC Input Filter.
10. Using ESD best practices, place the AC Input Filter in
an ESD bag for return shipment to Segway.
11. Remove the insulator.
NOTICE
Original fasteners are self-tapping. Replace with
non-tapping fasteners.
Pivot Assembly
Removal
Tool Required: T-30 6-lobe wrench
Pivot Assembly
1. Make sure the PT is powered off, unplugged, and the
batteries have been removed.
2. Establish a Serviceable Powerbase (page 8–2).
3. Remove the Radio Board (page 9–3).
4. Detach the Console from the Powerbase
(page 9–4).
5. Remove the AC Input Filter (page 9–7).
6. Remove the Power Board (page 9–5).
7. Remove the Interconnect Board (page 9–6). Gasket
8. Using a T-30 6-lobe wrench, remove the four
fasteners and discard. See Figure 9–11.
9. Remove the Pivot Assembly.
Installation
Tools Required: T-30 6-lobe wrench
Torque wrench
1. Install the gasket into the groove on the underside of 20205-00001
the Pivot Assembly. 11 N-m (8.1 ft-lbf)
2. Thread the Pivot Assembly harnesses through the
hole in the Console Base and position the Pivot
Assembly on the Console Base.
Figure 9–11: Pivot Assembly
3. Using a T-30 6-lobe wrench, install four new
fasteners. Torque to 11 N-m (8.1 ft-lbf).
4. Install the Gap Pad. See Figure 9–12.
5. Install the Interconnect Board (page 9–6).
6. Install the Power Board (page 9–5).
7. Install the AC Input Filter (page 9–7).
8. Install the Console onto the Powerbase
(page 9–4).
9. Install the Radio Board (page 9–3). Gap Pad
10. Reassemble the PT from the Serviceable Powerbase
(page 8–2).
11. Perform post-service tests (page A–1).
Figure 9–12: Gap Pad
Installation
Tools 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-10 6-lobe wrench, install the two fasteners.
Torque to 1.6 N-m (14 in-lbf).
NOTICE
Original fasteners are self-tapping. Replace with
non-tapping fasteners.
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.
• 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
seal between cover and chassis could result in malfunction leading to
injury or property damage.
When to Replace
Under most circumstances, the chassis cover is removed to service the
Powerbase and is reused to cover the Powerbase during assembly. It is
appropriate to replace the chassis cover with a new one if any of the following
symptoms are present:
• The edge gasket or the bolt gasket is torn.
• The chassis cover is bent or warped.
• A rider detect button is damaged.
Chassis Cover
Removal
Tool Required: T-27 6-lobe wrench Chassis Cover 20540-00001
6.0 N-m (4.5 ft-lbf)
1. Make sure PT is powered off, unplugged, and the
batteries have been removed.
2. Establish 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 harnesses down through the holes in the
Chassis Cover.
7. Remove the Chassis Cover.
Rear
NOTICE
Do not install the two front-center fasteners. These
will be installed when the Console is installed.
7. Install the Console (page 9–4). Figure 10–3: Feed Harnesses Through Holes in Chassis Cover
WARNING! Qualifications
• Failure to follow these safety precautions could lead to electrical shock,
Certified Service Technician
serious injury, death, or damage to property.
• Read all instructions. Technician Replaceable Parts
• Power off the Segway PT. CU Board (23244-00001)
• Unplug the Segway PT. 1 CU Board
• Remove batteries 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 procedures could result in personal
injury or damage to property.
When to Replace
Replace a CU Board when diagnostic testing determines the board is defective.
For diagnostic procedures, contact a Segway Service Representative.
CU Board
Removal
Tools Required: Small flathead screwdriver
T-10 6-lobe wrench
1. Make sure the PT is powered off, unplugged, and the
batteries have been removed.
2. Establish a Serviceable Powerbase (page 8–2).
3. Remove the Radio Board (page 9–3).
Balance Sensor Connector Tab
4. Remove the Console (page 9–4).
Assembly (BSA)
5. Remove the Chassis Cover (page 10–2).
6. Disconnect the two CU motor harnesses from the
motors (one per motor). Using a small flathead
screwdriver, gently lift the tab on the connector, Heat Sink
then carefully pull on the connector to unseat it. See
Figure 11–1.
7. Disconnect the BSA harness and CU harness from
Motor
the CU board by squeezing the plastic tab on the
Harnesses
connector and gently pulling on the connector. See
Figure 11–2.
8. Using a T-10 6-lobe wrench, remove the 14 screws
that hold the CU Board to the Chassis. Discard the
fasteners. See Figure 11–3. CU Board
9. Grasp the CU Board by the edges of the heat sinks Heat Sink
and lift it from the Chassis. Figure 11–1: Motor Harnesses Locations
10. Using ESD best practices, place the CU Board in an
ESD bag for return shipment to Segway.
CU Harness
BSA Harness
CU Board (cont.)
Installation
Tools Required: T-10 6-lobe wrench 20567-00001 (self-tapping)
Torque wrench 20973-00001 (non-tapping)
1. Make sure the PT is powered off, unplugged, and the 1.6 N-m (14 in-lbf)
batteries have been removed.
2. Inspect and verify that the Chassis is clear of debris.
Make sure the mating surface (underside of heat
sinks) is clean.
3. Holding the CU Board by the edges, position the
board in the Chassis.
4. Using a T-10 6-lobe wrench, install 14 new fasteners.
Torque to 1.6 N-m (14 in-lbf). See Figure 11–3.
NOTICE
Original fasteners are self-tapping. Replace with
non-tapping fasteners unless the Powerbase
Chassis requires replacement.
NOTICE
Rotate each harness as you insert the connector so
that the smaller gauge wires are beneath the larger
gauge wires. Make sure the tab locks in place over
the mating connector.
CAUTION!
Make sure the BSA harness and CU motor harness
are seated in the notches in the Chassis and cable Figure 11–4: CU Board Motor Harness
router. If cables get pinched when the Chassis Cover
is installed, the PT could malfunction causing injury
or damage to property.
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.
When to Replace
Replace the BSA when diagnostic testing determines the component is
defective. For diagnostic procedures, contact a Segway Service Representative.
NOTICE
Original fasteners are self-tapping. Replace with
non-tapping fasteners unless the Powerbase
Chassis requires replacement.
Figure 12–2: BSA Harnesses and Fasteners
4. Connect the BSA harnesses to the CU Boards. See
Figure 12–2.
5. Install the Chassis Cover (page 10–2).
6. Install the Console (page 9–4).
7. Install the Radio Board (page 9–3).
8. Reassemble the PT from the Serviceable Powerbase
(page 8–2).
9. Perform post-service tests (page A–1).
When to Replace
It is appropriate to replace a Motor if any of the following symptoms are present:
• Motor is a source of noise.
• Motor is loose.
• Motor is cracked or damaged.
• The elastomer bushing is damaged.
Motor
Removal
Tools Required: Small flathead screwdriver
T-25 6-lobe wrench
1. Make sure the PT is powered off, unplugged, and the
batteries have been removed.
2. Establish a Serviceable Powerbase (page 8–2).
3. Remove the Radio Board (page 9–3).
4. Remove the Console (page 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 flathead screwdriver, gently lift
the tab on the connector, then carefully pull on the
connector to unseat it. See Figure 13–1.
8. Using a T-25 6-lobe wrench, remove the two
fasteners attaching the Motor to the Chassis. See Figure 13–1: CU Motor Harnesses
Figure 13–2.
9. Pull the Motor straight out of the Chassis.
Motor (cont.)
Installation
Tools Required: Cotton swabs
Ammonia
Isopropyl alcohol Motor with Coupling
T-25 6-lobe wrench
Torque wrench
1. Clean the Motor well.
2. Completely remove the thread lock compound
from the Motor fastener holes in the Chassis. Use
cotton swabs to thoroughly clean excess thread
lock compound from the internal threads. First 20536-00001
use ammonia or ammonia-based window cleaner, 5.0 N-m (3.7 ft-lbf)
then isopropyl alcohol, to remove the thread lock
compound.
3. Slide the Motor into the Chassis. It will fit only one
way; the fit is snug.
NOTICE
Make sure the Motor harness does not block the
Motor as it is inserted into the Chassis. The Motor
will not seat properly if the connector is pinched
Figure 13–2: Motor
between the Motor and the BSA.
NOTICE
Rotate each harness as you insert the connector so
that the smaller gauge wires are beneath the larger
gauge wires. Make sure the tab locks in place over
the mating connector.
CAUTION!
Make sure the harnesses are seated in the notches
in the Chassis and cable router. If cables get pinched
when the Chassis Cover is installed, the PT could
malfunction causing injury or damage to property.
Elastomer Bushing
Inspection
Check to see if the Elastomer Bushing is worn or damaged.
Presence of excessive particles of elastomer material
indicates that replacement is necessary. See Figure 13–3.
Removal
1. Make sure the PT is powered off, unplugged, and the
batteries have been removed.
2. Pull the Elastomer Bushing off the motor coupling.
Installation
Tools Required: Cotton swabs
Ammonia
Isopropyl alcohol Figure 13–3: Worn Elastomer Bushing
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 the residue.
2. Align the new Elastomer Bushing with the coupling,
making sure the tabs go on first. See Figure 13–4.
CAUTION!
Do not remove the coupling from the Motor. If
damaged, replace the entire Motor assembly.
If the Motor assembly is modified, the PT could
malfunction causing injury or damage to property.
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.
When to Replace
Replace the Powerbase Chassis when diagnostic testing or inspection
determines that the assembly is defective. For diagnostic procedures, contact a
Segway Service Representative.
The Segway PT Chassis is serialized and may only be replaced with
permission from Segway. A new serial number may be issued, and the
serialized replacement Chassis may be shipped to order from Segway Service
Headquarters.
You should replace a Powerbase Chassis under any of the following conditions:
• Stripped screw holes
• Visible cracks
• Ingress of moisture or dirt is evident
• Battery vent is damaged
Powerbase Chassis
The inset in Figure 14–1 shows the numeral 2 and an arrow
stamped on the Chassis to indicate the front of the Chassis.
Disassembly
Rear
1. Make sure the PT is powered off, unplugged, and the
batteries have been removed.
2. Establish a Serviceable Powerbase (page 8–2).
3. Remove both Gearboxes (page 7–2).
4. Remove the Radio Board (page 9–3).
5. Remove the Console (page 9–4).
Front
6. Remove the Chassis Cover (page 10–2).
7. Remove both CU Boards (page 11–2).
Figure 14–1: Powerbase Chassis
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
Use self-tapping fasteners when installing the BSA
into a new Powerbase Chassis.
NOTICE
Use self-tapping fasteners when installing the CU
Boards into a new Powerbase Chassis.
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.
Startup Test
1. Make sure the Wireless InfoKey Controller properly powers on the PT
without any error messages.
Standard Check
1. Check that fasteners 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 sure the LeanSteer
Frame returns to center.
5. Check to make sure that no part is damaged or loose.
Operational Test
1. Check for obstruction under the Mats.
2. Check the LeanSteer Frame for tightness and centered orientation.
3. Turn on and power off the PT twice.
4. Confirm adequate battery levels.
5. Turn on the PT and test the rider detect. Make sure that the display
does not indicate that the rider detect button is on at startup. Tilt the
PT back and press each rider detect button.
6. While holding the PT level, tap the Mat with a foot to enter balance
mode.
7. Step on and ride the PT. Move forward and backward. Turn 360 degrees
to the left and to the right.
WARNING!
• Use only Segway-approved fasteners. Other fasteners may not perform
as expected and may come loose.
• Do not tighten or reuse any fastener except the screws used to attach
the batteries, wheel nuts, and LeanSteer frame. Instead, when any
other fastener is loose or removed, replace the fastener with a new
Segway-approved fastener.
• Before using a fastener, make certain the fastener is the correct size
and type with any necessary washer and thread lock in place (see
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 frame fasteners.
• Do not attempt to repair any stripped or damaged screw hole.
Instead, replace the part. If a replacement part is not available, do not
reassemble.
• Insert fasteners slowly and carefully. Do not cross-thread or over-
tighten fasteners. Tighten only 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 in appearance from the comparable
factory-installed fasteners.
• Failure to adhere to these warnings could lead to serious injury or
death or damage to property.
Table C–1: Fasteners
Part Number Fastener Type Application Qty/PT Drive Torque
Nut, M8 x 1.25 Wheel 6 13 mm 30 N-m (22 ft-lbf)
20158-00001
20537-00002
Self-tapping. For use only when installing a CU Board into a new Powerbase Chassis,
or when installing a Radio Board, Power Board, or AC Input Filter into a new Console.
For use when reinstalling a CU Board into the original Powerbase Chassis,
. or when reinstalling a Radio Board, Power Board, or AC Input Filter into the original Console.
20991-00002
23517-00001
BHCS, M4 x 0.7 x 12, SEMS AC Input Filter, Plug 2 T-20 1.0 N-m (9 in-lbf)
23559-00001