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Service Manual SE-3 Patroller

1. 24367 00002 24400 00001 Service Manual 135 Fasteners Part Number 24404 00001 24409 00003 24409 00008 24434 00003 24434 00005 24435 00003 24436 00004 24437 00003 136 Fastener Type SEGWAY Application Quantity Drive Torque M20 Lock Nut Front Axle 85 N m 63 ft Ibf po L U E Xx M5 x 12 SHCS Ul Module 1 8 N m 1 3 ft Ibf M5 x 35 SHCS Battery Bumpers 2 0 N m L5 ft lbf M6 Flat Washer Ring Terminal to Motor Controller MIO FlatWasher Geam de NANA M6 Split Lock Washer Ring Terminal to Motor Controller M6 x 14 HXBT Ring Terminal to Motor Controller 7 5 N m 5 5 ft Ibf O fo M10 x 30 BHCS Front Fender Boot 5 5 N m 4 0 ft Ibf SE 3 Patroller SEGWAY Fasteners Part Number Fastener Type Application Quantity Drive Torque 1 4 in P Clip Steel Front Brake Line 24440 00001 M4 x 8 SHCS Electronics Shield 2 5 N m 1 8 ft Ibf 24491 00002 gen M4 x 10 SHCS 2 5 N m 18 ff 24491 00003 q 1 2 in P Clip Steel Fender Tail Light Harness 24509 00001 Q Service Manual 137 Fasteners SEGWAY 138 SE 3 Patroller Tools and Equipment This appendix lists the tools and equipment recommended for servicing and diagnosing a Segway SE 3 Patroller Table 7 Tools and Equipment Description Air compressor if complete 2 gallon cap
2. Red Black Slide the Bib Panel onto the frame Using a 4mm hex wrench install the eight fasteners as shown in Figure 13 Torque the top two fasteners to 4 0 N m 3 0 ft Ibf Torque the lower six fasteners to 5 5 N m 4 0 ft Ibf Check the Glove Box Lock Plate alignment see Figure 19 When the Glove Box lock is turned there should be some friction between the pawl and the Lock Plate The weather stripping around the Glove Box Door should compress slightly Torge the Lock Plate fastener to 1 6 N m 1 2 ft Ibf Install the following components a Storage Trays page 15 b Battery Module page 8 Perform post service tests page 129 Service Manual Body Panels Figure 16 Accessory Power Outlet Figure 17 KeyLock Connector Block Figure 18 KeyLock Terminals 17 Body Panels 18 Glove Box The Gove Box fastens to the frame at the opening and rests on studs on the frame at its other end Tools Required 3 mm hex wrench 4 mm hex wrench Torque wrench 20553 00001 Removal A 1 Make sure the SE 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 15 c Bib Panel page 16 3 Using a 4 mm hex wrench remove the three fasteners and Lock Plate as shown in Figure 19 4 Gently lift the Glove Box off of the Frame 5 Using a 3 mm hex wrench remove the two fasteners connecting th
3. Table 3 Fuse Information Location Type Rating Part Number FHI 106 SE 3 Patroller SEGWAY Maximum Speed You can set the maximum speed of the SE 3 Patroller by using a DIP switch located on the PI Board Tools Required None Procedure Al Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the Battery Module page 8 AA WARNING Wait 2 minutes after removing the Battery Module before touching the Pl Board This is how long it takes for the capacitors on the PI Board to self discharge Touching the Pl Board before the capacitors have fully discharged could result in electric shock 3 Ajust the DIP switch See Table 4 4 Install the Battery Module page 8 Validation 1 Bring the SE 3 Patroller to a large open space such as an empty parking lot 2 Drive the SE 3 Patroller until it reaches maximum speed 3 Look at the speedometer Verify that the displayed speed is the desired maximum speed Service Manual Power Interface Figure 151 DIP Switch Table 4 DIP Switch Settings Switch 1 Switch 2 Max Speed 107 Power Interface SEGWAY 108 SE 3 Patroller Harnesses Overview Harnesses connect the various electrical components together When to Replace Replace a Harness when it is severed frayed or when diagnostic testing determines that it is malfunctioning Contents Left Right Motor Power Harness Left Right Drive
4. Front Splash Guard 24077 00001 Main Splash Guard 24076 00001 Figure 5 Body Panels Expoded View 12 SE 3 Patroller SEGWAY Threaded Inserts The body panels have threaded inserts that provide a location to attach fasteners These inserts occasionally come loose and need to be replaced Tools Required 6mm hex wrench Locking pliers 23 64 inch or 9 12 mm drill bit Power drill 5 minute epoxy P N 24750 00001 Cotton swab Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Screw the fastener part way into the threaded insert l Fi R the Threaded Insert 3 Use locking pliers to securely grip the fastener Be Remove the Threaded Inse Figure 6 Remove both the fastener and the insert by pulling forcefully with the pliers 4 Discard both the fastener and threaded insert Alternate Removal Methods If removal using locking pliers is not possible try the following removal techniques in order 1 Use a reverse drill bit or screw removal bit and spin the insert out 2 Useaslide hammer attached to the fastener head to pull the insert out 3 Use a fastener socket and C clamp to push the insert out Figure 7 Figure 7 Use a Clamp to Remove the Insert Table 2 Replacement Inserts Fastener Location Insert Location Replacement Insert Figure Storage Tray Side Panel Flanged Figure 12 p 15 Bib Panel Front Cowl Bib Panel Flanged Figure 13
5. NOTICE Make sure there is enough slack in the brake lines to turn the handlebar full left and right Using a 14 mm socket wrench connect the Banjo Bolt to the Caliper See Figure 102 CAUTION Always use new crush washers when attaching a Banjo Bolt to any component Used crush washers may leak causing a reduction in braking force Using a 2 5 mm hex wrench install three P Clips two on the frame and one on the Front Fender Bracket See Figure 100 Torque to 2 5 N m 1 8 ft Ibf NOTICE Make sure there is enough slack in the brake line to turn the wheel full left and right Install brake fluid and bleed the brake line see page 56 Install the following components Front Fender page 26 Light Cluster page 20 Front Cowl page 19 Do w Glove Box page 18 Bib Panel page 16 Storage Trays page 15 gt pop g Battery Module page 8 10 Perform post service tests page 129 Service Manual Brakes Figure 101 Front Caliper Banjo Bolt Hollow Screw 4 28 5 N m 21 0 ft Ibf Crush Washer 23958 00001 Crush Washer 23958 00001 Figure 102 Brake Line Fasteners 67 Brakes SEGWAY Rear Brake Line Tools Required 2 5 mm hex wrench 8 mm socket wrench 14 mm socket wrench Wire cutters Torque wrench Removal Ax 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the following components Battery Module page 8 a
6. Figure 145 Charger Right Side 103 Power Interface SEGWAY PI Board The Power Interface Board PI Board is the heart of the SE 3 Patroller It controls the motors controls and lights it communicates with the User Interface Board UI Board and it controls the charging circuitry Tools Required 8 mm socket wrench Torque wrench Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 93S 1NdLNO 2 Remove the following components Battery Module page 8 Oo 2 Storage Trays page 15 Bib Panel page 16 Glove Box page 18 Electronics Shield page 102 Charger page 103 gt pop 3 Disconnect all harnesses connected to the PI Board 23202 00003 4 Using an 8 mm socket wrench remove the four 6 0 N m 4 4 ft Ibf nylock nuts as shown in Figure 146 Figure 146 PI Board and Charger 5 Remove the PI Board and aluminum plate A CAUTION Use ESD best practices to avoid damaging the PI Board electronics Figure 147 Pl Board on the Frame 104 SE 3 Patroller SEGWAY Power Interface Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Orient the Pl Board and aluminum plate on the frame See Figure 147 3 Using an 8 mm socket wrench install the four nylock nuts as shown in Figure 146 Torque to 6 0 N m 4 4 ft Ibf 4 Connect all the harnesses See Figure 148
7. NOTICE When connecting light harnesses make sure the connectors snap firmly into place Contents Headlight Headlight Alignment e Accessing the Light Cluster e Front Strobe Light Side Strobe Light Front Directional Light Brake Light Rear Directional Light e Rear Strobe Light 35 Lights SEGWAY Headlight The Headlight rests on an adjustable bracket behind the Windshield Tools Required 3 mm hex wrench Wire cutters Torque wrench Removal A 1 Make sure the SE 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 15 e c Bib Panel page 16 P 24315 00006 d Glove Box page 18 16 N m 1 2 ft N e Front Cowl page 19 f Windshield page 34 Figure 44 Headlight 3 Disconnect the harness See Figure 45 Remove the two cable ties 5 Using a 3 mm hex wrench remove the two fasteners as shown in Figure 44 6 Remove the Headlight Installation A 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 in the Headlight_ bracket Connector 3 Using a 3 mm hex wrench attach the headlight to the bracket as shown in Figure 44 Torque to 1 6 N m 1 2 ft Ibf 4 Connect the Harness See Figure 45 5 Install two cable ties 6 Align the Headlight page 37 7 Install the following c
8. Using a 4 mm hex wrench install the three side fasteners as shown in Figure 27 Torque to 5 5 N m 4 0 ft Ibf Using a 4 mm hex wrench install the four front fasteners two each side as shown in Figure 26 Loosely install theses fasteners on both Side Panels before tightening Torque to 4 0 N m 3 0 ft Ibf Using a 4 mm hex wrench install the bracket fastener as shown in Figure 28 Torque to 5 5 N m 4 0 ft Ibf Install the following components Light Cluster page 20 Front Cowl page 19 ao 2 Glove Box page 18 Bib Panel page 16 Storage Trays page 15 gt peop Battery Module page 8 Perform post service tests page 129 Service Manual Body Panels 24270 00004 5 5 N m 4 0 CS 24270 00004 4 0 N m 3 0 ft Ibf Bracket 24031 00001 Figure 29 Side Panel Bracket 23 Body Panels 24 Fender The Fender attaches to the frame and gearbox bracket Tools Required 4mm hex wrench 10 mm socket wrench Wire cutters Torque wrench Removal A 1 Make sure the SE 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 15 c Bib Panel page 16 3 Using a 4 mm hex wrench remove the six outside fasteners and P clip Figure 30 4 Using a 10 mm socket wrench remove the lock nut and P clip on the back of the upper inside fastener 5 Using a 4 mm hex wrench remove
9. Flat Washer 24434 00003 Figure 134 Hardware Stack Ring Terminal SE 3 Patroller Steering Column Overview The Steering Column is made up of two components the Handlebar and the Front Fork The Handlebar is the upper portion 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 or Front Fork when it is cracked bent or otherwise broken Contents Handlebar Front Fork e Front Fender Bracket 95 Steering Column 96 Handlebar Tools Required 5 mm hex wrench 6 mm hex wrench 13 mm socket wrench Wire cutters Torque wrench UltraLube corrosion inhibitor Digital level Cutting tool box cutter or utility knife Heat gun Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the following components a Battery Module page 8 a Storage Trays page 15 Bib Panel page 16 Glove Box page 18 Front Cowl page 19 Light Cluster page 20 3 Using wire cutters remove all the cable ties on the handlebar 9 29 4 Disconnect the Handlebar Controls Harness along the handlebar page 114 5 Using a 5 mm hex wrench remove both Brake Levers See Figure 137 NOTICE Secure the Brake Levers so that they don t fall or otherwise stress the brake line 6 Score the heat shrink tub
10. on the end of the brake line to the Caliper Torque to 28 5 N m 21 0 ft Ibf See Figure 83 CAUTION Always use new crush washers when attaching a Banjo Bolt to any component Used crush washers may leak causing a reduction in braking force Carefully slide the Caliper onto the Rotor so the Rotor rests between the two brake pads Using a 6 mm hex wrench install the two fasteners holding the Caliper in place See Figure 82 Torque to 28 5 N m 21 ft Ibf Bleed the Brake Line page 56 Install the Front Fender page 26 Perform post service tests page 129 Service Manual Brakes Hollow Screw 28 5 N m 21 0 ft Ibf Crush Washer 23958 00001 Crush Washer 23958 00001 Figure 83 Brake Line Fasteners 59 Brakes 60 Front Rotor Tools Required 5mmhex wrench 30 mm socket wrench 2 Torque wrench Vehicle jack Removal Ax 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Place a vehicle jack under the center front of the skid plate Raise the SE 3 Patroller until the front wheel is off the ground Figure 80 3 Remove the following components a Front Fender page 26 b Front Caliper page 58 NOTICE Do not disconnect the caliper from the brake line 4 Using a 30 mm socket wrench remove the axle and slide it out See Figure 84 5 Slide the wheel assembly out of the front fork 6 Using a 5 mm hex wrench remove the five f
11. 3 Patroller is stable or use a jack 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 4 Using an SKF HN 8 9 spanner wrench remove the two collar rings as shown in Figure 139 5 Remove the Front Fork as shown in Figure 140 98 SEGWAY Place jack here Figure 138 Front Lifting Point 23782 00001 SS 45 N m 33 fbf L i Seal gt die gt Bearing 23790 00001 gi I Front Fork 23777 00001 Figure 139 Front Fork Collars SE 3 Patroller SEGWAY Installation A L 9 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Jack up the front of the SE 3 Patroller Figure 138 AA WARNING Make sure the SE 3 Patroller is stable or use a jack 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 Check both bearings If necessary pack some UltraLube Marine amp Trailer Bearing Grease P N 24431 00001 into the bearings Slide the Front Fork up into the frame Figure 140 Install the bearing and seal as shown in Figure 139 Spread some Permatex Anti Seize Lubricant P N 24433 00001 on the collar nut threads This lubricant will make it easier to remove the collar nuts in the future Using a SKF HN 8 9 spann
12. 5 Install the following components Charger page 103 Electronics Shield page 102 Glove Box page 18 Bib Panel page 16 Storage Trays page 15 oa po oO Battery Module page 8 6 Perform post service tests page 129 Battery Connector Figure 148 Pl Board Components and Connectors Service Manual 105 Power Interface SEGWAY Fuses Tools Required None Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the Battery Module page 8 UI Supply 14 lie Directional Li ZA WARNING PR Supp Wait 2 minutes after removing the Battery Module before touching the PI Board This is how long it takes for the capacitors on the PI Board to self discharge er Touching the Pl Board before the capacitors have fully discharged could result in electric shock 3 Remove the Fuse Mini Blade a Pull on the fuse to remove Ceramic Cartridge AY a Remove the plastic cover b Pull on the fuse to remove 96 10000 69 2 Installation A 1 Make sure the SE 3 Patroller is powered off N f unplugged and the parking brake is engaged _ Left Drive Logic 2 Install the Fuse Mini Blade a Press the fuse into the socket Figure 150 Ceramic Cartridge Fuses Ceramic Cartridge a Press the fuse into the socket b Install the plastic cover 3 Install the Battery Module page 8 Perform post service tests page 129
13. Figure 77 56 SE 3 Patroller SEGWAY 10 11 12 13 14 15 16 17 18 Squeeze the brake lever While the brake lever is being squeezed open the bleeder valve See Figure 78 As brake fluid drains out of the bleeder valve the brake lever will move toward the handlebar Before the brake lever touches the handlebar close the bleeder valve Release the brake lever Repeat steps 8 11 until the brake lever is firm A CAUTION Do not let the Master Cylinder run dry This could introduce air into the brake line Keep adding brake fluid to the Master Cylinder to keep the fluid level at the FILL line Using a in wrench tighten the bleeder valve Torque to 4 5 N m 3 3 ft Ibf Place the cap on the Master Cylinder Using a Phillips screwdriver install the two fasteners Torque to 1 5 N m 1 1 ft Ibf Using a 5 mm hex wrench loosen the fasteners holding the Master Cylinder to the handlebar Rotate the Master Cylinder so that it is 11 5 from horizontal then tighten the fasteners again See Figure 79 Torque to 10 N m 7 4 ft Ibf Install the following components Front install the Front Fender page 26 Rear install a Rear Wheel page 32 Perform post service tests page 129 Service Manual Figure 79 Aligning the Master Cylinder Brakes 57 Brakes 58 Front Caliper Tools Required 4 inch bar clamp 6 mm hex wrench 14 mm socket wrench Torque wrench Vehicle j
14. Glossary SEGWAY Socket Head Cap Screw SHCS A type 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 the user interface of the SE 3 Patroller 142 SE 3 Patroller 24538 00001 ae
15. Light Cluster forward and lift it off the frame SEGWAY 24270 00006 4 0 N m 3 0 ft Ibf Unpopulated ight Cluster me 23776 00001 Figure 24 Light Harnesses with Cable Ties SE 3 Patroller SEGWAY Body Panels Installation Ax 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Slide the Light Cluster onto the frame NOTICE You may need to loosen the fasteners holding the Side Panels to the floating bracket See Figure 26 p 22 Be sure to torque the fasteners after installing the Light Cluster 3 Using a 4 mm hex wrench install the two fasteners as shown in Figure 23 Torque to 4 0 N m 3 0 ft Ibf 4 Connect the wire 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 25 Right Directional Yellow Green Left Directional Black White Brown White 5 Install two cable ties around the light harnesses to keep them neat and safe from sharp corners See Figure 24 6 Install the following components a Front Cowl page 19 b Glove Box page 18 Directional Light Order Not Important Directional Light d Storage Trays page 15 Figure 25 Light Harness Connectors e Battery Module page 8 7 Perform post service tests page 129 Service Manual 21 Body Panels Side Panel The Side Panels attach to a floating bracket at the
16. Panel page 16 Glove Box page 18 Front Cowl page 19 Electronics Shield page 102 3 Disconnect the wire harness from the PI Board See Figure 159 4 Disconnect the wire harness from the Control Cluster Headlight Throttle and both Brake Levers See Figure 160 5 Using a pair of wire cutters remove three cable ties moan p Figure 159 Handlebar Controls Harness to Pl Board a This harness to the frame b This harness to the User Interface Harness c Harnesses on the steering column 6 Remove the Handlebar Controls Harness Figure 160 Connectors on Steering Column 114 SE 3 Patroller SEGWAY Installation A L Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Connect the wire harness to the Control Cluser Headlight Throttle and both Brake Levers Right Brake Lever Grey Red Black Black Orange Black Left Brake Lever Grey _ Grey White Black Brown Black Route the harness around the left side of the frame Connect the wire harness to the PI Board See Figure 159 Install three cable ties a Harnesses on the steering column b This harness to the User Interface Harness c This harness to the frame Install the following components Electronics Shield page 102 Front Cowl page 19 ao g Glove Box page 18 Bib Panel page 16 Storage Trays page 15 gt peop Battery Module page 8 Perform post service tests page 129
17. Service Manual Harnesses Figure 161 Handlebar Controls Harness on the Steering Column 115 Harnesses SEGWAY User Interface Harness This harness connects the PI Board and the UI Module Tools Required Wire cutters Removal A 1 Make sure the SE 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 15 c Bib Panel page 16 d Glove Box page 18 e Front Cowl page 19 f Electronics Shield page 102 g Ul Module page 72 Figure 162 UI Harness to Pl Board 3 Disconnect the wire harness from the PI Board See Figure 162 4 Disconnect the wire harness from the UI Board See Figure 163 5 Using wire cutters remove four cable ties a Two holding the harness to the steering column b One connecting this harness to the Handlbar Controls Harness c One connecting the harness to the frame 6 Carefully push the rubber grommet out of the hole in the back of the Ul Housing See Figure 164 NOTICE Do not use any sharp or pointed tools You could puncture the grommet thereby allowing water to enter the Ul Housing Figure 163 Harness to Ul Board 7 Remove the User Interface Harness 116 SE 3 Patroller SEGWAY Installation A L y Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Insert the harness into the Ul Housing and carefully press
18. Slide an O ring onto the fasteners from underneath then slide a washer and a nut onto the fasteners 5 Using a 2 5 mm hex wrench and a 7 mm socket wrench install the fasteners Torque to 1 6 N m 1 2 ft Ibf 6 Close the Glove Box Door and verify that the latch works properly 50 SEGWAY 20307 00005 1 6 N m 1 2 ft Ibf a Glove Box Bonz 24120 00001 O ring f 24423 00001 0 20450 00001 Lock Nut 23202 00001 1 6 N m 1 2 ft Ibf 0 Y MEA Figure 68 Glove Box Door SE 3 Patroller SEGWAY KeyLock Tools Required Loctite 425 KeyLock nut tool Removal Al 5 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Remove the following components a Battery Module page 8 b Storage Trays page 15 c Bib Panel page 16 Press the tab on the side of the connector block and pull it off the back side of the KeyLock See Figure 70 Unscrew the plastic nut on the back of the KeyLock See Figure 69 Remove the KeyLock Installation Al Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Insert the KeyLock through the hole on the right hand side of the Bib Panel See Figure 69 Apply 1 drop of Loctite 425 P N 24620 00001 to the threads of the KeyLock See Figure 71 NOTE Loctite 425 is specially formulated for plastics Do not use any other threadlock compounds they
19. filling the brake fluid reservoir e Do not use brake fluid taken from old or already opened containers e Do not mix different fluids e Failure to follow these warnings could result in damage to the brake system which could cause serious bodily injury or death if the brake system fails to engage Tools Required Gloves Ya in tubing Empty container Phillips screwdriver Ya in wrench 5 mm hex wrench Torque wrench Digital level Procedure NOTICE Assistance is required to perform this procedure Figure 77 Bleeding the Front Brake Line A 1 Make sure the SE 3 Patroller is powered off unplugged and the wheels are chocked ZA CAUTION You can t bleed the rear brake line with the parking brake on Chock the wheels and ensure the SE 3 doesn t move Figure 78 Bleeding the Rear Brake Line 2 Access the Caliper Front remove the Front Fender page 26 Rear remove a Rear Wheel page 32 3 Using a 5 mm hex wrench loosen the fasteners holding the Master Cylinder to the handlebar 4 Rotate the Master Cylinder until it is level then tighten the fasteners again 5 Using a Phillips screwdriver remove the cover of the Master Cylinder 6 Pour brake fluid DOT 4 only into the Master Cylinder until it reaches the FILL line NOTICE Be careful not to drip brake fluid on the SE 3 Patroller 7 Fitone end of the tubing over the bleeder valve on the Caliper Place the other end in an empty container See
20. front of the steering column Tools Required 4mm hex wrench Torque wrench Removal A 1 Make sure the SE 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 15 c Bib Panel page 16 d Glove Box page 18 e Front Cowl page 19 f Light Cluster page 20 3 Using a4 mm hex wrench remove the four front fasteners two each side as shown in Figure 26 4 Using a 4 mm hex wrench remove the three side fasteners as shown in Figure 27 5 Using a 4 mm hex wrench remove the bracket fastener as shown in Figure 28 6 Lift the Side Panel off of the frame Pull the bottom out then lift up 22 SEGWAY Side Panel 2 as gt P 24270 00004 4 0 N m 3 0 in Ibf Figure 26 Front Fasteners a A Side Panel sg a u Left 24129 00001 E Right 24130 00001 gt 24270 00004 5 5 N m 4 0 ft Ibf Figure 27 Side Fasteners SE 3 Patroller SEGWAY Installation Al Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged If the Side Panel Bracket is not already installed install it now Using a 4 mm hex wrench install the four fasteners as shown in Figure 29 Torque to 4 0 N m 3 0 in Ibf Place the Side Panel onto the frame so that the bracket rests on the frame Align the holes in the Side Panel with the holes in the frame
21. may react with the plastic causing it to deform or crack NOTE Please allow 24 hours for the Loctite to fully cure before operating the SE 3 Patroller Screw the plastic nut back onto the Keylock until it is finger tight Verify the alignment of the KeyLock In the OFF position the key slot should be vertical Using the KeyLock nut tool P N 24630 00001 tighten the plastic nut Torque to 0 8 N M 0 6 ft Ibf Slide the connector block onto the back of the KeyLock until it snaps in place Install the following components a Bib Panel page 16 b Storage Trays page 15 c Battery Module page 8 Perform any post service tests page 129 Service Manual Bib Panel Components KeyLock 23969 00001 Figure 69 KeyLock Tab Figure 70 KeyLock Closeup Figure 71 Apply Loctite 425 Figure 72 KeyLock Nut Tool 51 Bib Panel Components 52 Accessory Power Outlet Tools Required None Removal A 1 Make sure the SE 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 15 c Bib Panel page 16 3 Unscrew the plastic nut on the back of the Accessory Power Outlet See Figure 73 4 Remove the Accessory Power Outlet Installation A 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
22. of wire cutters remove the cable tie connecting the harness to the frame moan p Figure 166 Light Cluster Harness to PI Board 5 Using a pair of wire cutters remove the cable ties around the harness inside the Light Cluster 6 Disconnect the wire harness from the lights See Figure 167 7 Remove the Light Cluster Harness Right Strobe Lights Left Directional Light Order Not Important Directional Light Figure 167 Light Cluster Harness Connectors 118 SE 3 Patroller SEGWAY Harnesses Installation Ax 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Connect the wire harness to the lights See Figure 167 amp Figure 168 3 Route harness around the left side of the frame Connect the wire harness to the PI Board See Figure 166 5 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 Shield page 102 b Front Cowl page 19 c Glove Box page 18 d Bib Panel page 16 Figure 168 Directional Light Connectors e Storage Trays page 15 f Battery Module page 8 8 Perform post service tests page 129 Figure 169 Light Cluster Harness Routing Service Manual 119 Harnesses SEGWAY Tail Light Harness This harness connects the Pl Board to the rear directional lights and
23. off unplugged and the parking brake is engaged 2 Remove the following components a Front Fender page 26 b Front Splash Guard page 27 c Front Fender Bracket page 100 3 Using a 4 mm hex wrench remove the eight fasteners as shown in Figure 35 4 Starting at the top bend one side of the Main Splash 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 A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Slide the Main Splash Guard on the frame 3 Starting at the top bend the Main Splash Guard to fit behind the Side Panels Work from top to bottom 4 Using a 4 mm hex wrench install the eight fasteners as shown in Figure 35 Torque to 5 5 N m 4 0 ft Ibf 5 Install the following components 28 a Front Fender Bracket page 100 b Front Splash Guard page 27 c Front Fender page 26 SEGWAY w Main Splash Guard 24076 00001 Some components not shown Figure 35 Main Splash Guard SE 3 Patroller Tire Wheel Assemblies Overview Contents The SE 3 Patroller has three wheels one front wheel and two rear wheels For Front Tire Wheel general tire care information refer to the Segway SE 3 Patroller User Manual Rear Tire Wheel When to Replace Replace a Tire Wheel Assembly under any of the following conditions including but n
24. page 95 Power Interface page 101 Harnesses page 109 Introduction SEGWAY General Service Procedure Before performing any service on the SE 3 Patroller you must first determine which components may be damaged or malfunctioning 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 vehicle turns on but won t drive No matter what the problem is the general service procedure is the same 1 Identify identify the symptoms 2 Diagnose determine which components may be malfunctioning 3 Replace replace the malfunctioning component s 4 Verify operate the vehicle to verify the problem has been solved It may be the case that there are multiple problems affecting an SE 3 Patroller Try to isolate the problems and solve them one at a time Reusing Fasteners Before reusing any fastener check if it has any threadlock residue on it If so you must remove the old threadlock and apply new threadlock before reusing the fastener For more detailed instructions see page 131 Related User Materials The following additional materials may be needed for reference during service Segway SE 3 Patroller User Manual Please check the Segway website www segway com for updates to the User Manual or contact Segway to confirm you have on hand the most recent service publication
25. smoothly when being installed or removed Tools Required 2 5 mm hex wrench T h 20709 00001 mm en 1 0 N m 0 74 ft Ibf Removal gt A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged E 2 Remove the Battery Module page 8 3 Using a 2 5 mm hex wrench remove the fasteners from the Battery Slides See Figure 64 4 Remove the Battery Slides Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Figure 64 Battery Slides 2 Align the Battery Slides in the battery compartment 3 Using a 2 5 mm hex wrench install the fasteners Torque to 1 0 N m 0 74 ft Ibf 4 Install the Battery Module page 8 46 SE 3 Patroller SEGWAY Battery Compartment Battery Bumpers The Battery Bumpers position the Battery Module at the correct distance from the frame so that there is a good connection between the Battery Module and the PI Board Tools Required 4mm hex wrench 8 mm socket wrench Torque wrench lt 23202 00003 _ j 1 4 N m 1 0 ft Ibf Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the following components Battery Module page 8 Front Fender page 26 Front Splash Guard page 27 Front Fender Bracket page 100 e Main Splash Guard page 28 Figure 65 Br
26. tests page 129 Service Manual Figure 179 KeyLock Harness to Pl Board Figure 180 KeyLock Harness Routing Harnesses 125 Harnesses SEGWAY Siren Harness This harness connects the Pl Board to the Siren Tools Required Wire cutters Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the following components Battery Module page 8 Oo 2 Storage Trays page 15 Bib Panel page 16 Glove Box page 18 Front Cowl page 19 Light Cluster page 20 g Right Side Panel page 22 h Electronics Shield page 102 3 Disconnect the wire harness from the PI Board See Figure 181 4 Using a pair of wire cutters remove the two cable ties on the side of the frame gt pop Figure 181 Siren Harness to Pl Board 5 Disconnect the Siren Harness from the siren lead Remove the Siren Harness Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Connect the Siren Harness to the siren lead 3 Route the harness under the horizontal brace on the frame See Figure 182 4 Connect the wire harness to the Pl Board See Figure 181 5 Install two cable ties around the harnesses on the side of the frame 6 Install the following components Electronics Shield page 102 Side Panel page 22 L
27. the PI Board and other electronics 101 Power Interface SEGWAY Electronics Shield The Electronics Shield protects the PI Board and harnesses ZA WARNING Wait two minutes after removing the Battery Module before removing the Electronics Shield This is how long it takes for the capacitors on the Pl Board to self discharge Touching the E PI Board before the capacitors have fully discharged could 24491 00002 A result in electric shock 2 5 N m 1 8 eon 0 Tools Required 3 mm hex wrench Torque wrench Removal A 1 Make sure the SE 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 15 c Bib Panel page 16 d Glove Box page 18 3 Using a 3 mm hex wrench remove the four fasteners as shown in Figure 142 and Figure 143 4 Remove the Electronics Shield Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Orient the Electronics Shield with the opening toward the top 3 Using a 3 mm hex wrench install the four fasteners as shown in Figure 142 and Figure 143 Torque to 2 5 N m 1 8 ft Ibf 4 Install the following components a Glove Box page 18 b Bib Panel page 16 c Storage Trays page 15 d Battery Module page 8 5 Perform post service tests page 129 Figure 143 Right Side Fasteners 102 SE 3 Patroller SEGWAY Ch
28. the SE 3 Patroller fails any of these tests resolve the issue before returning the SE 3 Patroller to the owner or user Drive Disable and Rider Detect Mat 1 Use the key to turn on the SE 3 Patroller Front Brake Fluid Reservoir 2 Set the Drive Standby switch to Standby From Brake Lights Verify that the screen displays NO RIDER and DRIVE DISABLED 3 Step onto the SE 3 Patroller Verify that the screen displays RIDER PRESENT and DRIVE DISABLED 4 Set the Drive Standby switch to Drive Verify that the screen displays RIDER PRESENT and O MPH Lights Horn and Siren Horn Siren Reverse Perform the following tests and verify that the desired result occurs If the SE 3 Figure 184 Left Handlebar Controls Patroller fails any of these tests resolve the issue before returning the SE 3 Patroller to the owner or user Table 5 Lights Horn and Siren Tests Test Desired Result Rear brake left brake lever Both brake lights illuminate Front brake right brake lever Both brake lights illuminate Headlight Headlight and rear running lights illuminate 6 Strobe ights rontandrearstobeighsituinate 8 torre press anota Svensons Brake Check 1 Look at the brake fluid reservoir sight glass for both front and rear brakes Verify that the fluid level is at or above the fill line See Checking the Fluid Level p 54 2 Squeeze the brake levers one at a time Verify the brak
29. the Segway SE 3 Patroller a Certified Service Technician should always stand on a static mat wear a grounding heel or wear a grounding wrist strap while working on electrical elements of the SE 3 Patroller Enable Time The total 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 Fuse This type of fuse has a cylindrical glass body with metal caps on each end Harness A group of cables bound together to form one assembly typically with connectors that plug or snap into place Kit Acomponent and all the required fasteners for installing it Lithium ion Li ion Battery A type of rechargeable battery in which lithium ions move between electrodes when charging and discharging Odometer This keeps track of how far the vehicle has traveled Operational Time The total elapsed time during which the vehicle has been powered on Pan Head Cap Screw PHCS A type of screw with a wide flat head and an indentation hex or 6 lobe used for tightening PI Board Power Interface Board This is a printed circuit board that connects to the battery and harnesses Pigtail Ashort harness connected to a component at one end Rotor Also known as a Brake Disk A metal component that rotates with the wheel and is squeezed by the caliper when brakes are applied SEMS Ascrew and washer assembly 141
30. the brake lights There are two separate harnesses one for each fender Tools Required Wire cutters 4 mm hex wrench Left Right Pe 10 mm socket wrench eer ae YEN E Torque wrench z A ae o ol a tr Nee Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the following components Battery Module page 8 o 8 Storage Trays page 15 Bib Panel page 16 Glove Box page 18 Figure 170 Tail Light Harness to Pl Board Front Cowl page 19 Light Cluster page 20 g Side Panel page 22 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 gt pop h Electronics Shield page 102 3 Disconnect the wire harness from the Pl Board See Figure 170 4 Using a pair of wire cutters remove the two cable ties on the side of the frame P Clip 24509 00001 5 Using a 4 mm hex wrench remove the fastener and P clip shown in Figure 171 N 6 Using a 10 mm socket wrench remove the lock nut Ne 24270 00004 and P clip shown in Figure 172 5 5 N m 4 0 ft lbf 7 Disconnect the wire harness from the tail lights See Figure 172 8 Remove the Tail Light Harness Figure 171 Tail Light Harness P Clip 120 SE 3 Patroller SEGWAY Harnesses Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is eng
31. the grommet into place See Figure 164 NOTICE Do not use any sharp or pointed tools You could puncture the grommet thereby allowing water to enter the Ul Housing Route the harness down the steering column and around the left side of the frame See Figure 165 Connect the harness to the Pl Board See Figure 162 Install four cable ties a Two around the harnesses on the steering column b One connecting this harness to the Handlebar Controls Harness near the steering column c One connecting this harness to the frame Install the following components UI Module page 72 Electronics Shield page 102 Front Cowl page 19 Oo 2 Glove Box page 18 Bib Panel page 16 Storage Trays page 15 gt pop g Battery Module page 8 Perform post service tests page 129 Service Manual Figure 165 Ul Harness Routing Harnesses 117 Harnesses SEGWAY Light Cluster Harness This harness connects the Pl Board to the directional lights and the strobe lights in the Light Cluster Tools Required Wire cutters Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the following components a Battery Module page 8 Storage Trays page 15 Bib Panel page 16 Glove Box page 18 Front Cowl page 19 Electronics Shield page 102 3 Disconnect the wire harness from the PI Board See Figure 166 4 Using a pair
32. the three inside fasteners Figure 31 6 Reach inside the wheel well and disconnect the Tail Light Harness from the Brake Light and Rear Directional Light 7 Liftthe Fender off the frame Reach between the Fender and the Bracket push the center of the Fender away from the Bracket Installation A 1 Make sure the 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 hex wrench install the three inside fasteners Figure 31 Place the longer fastener through the upper hole Torque to 5 5 N m 4 0 ft Ibf 5 Install a P clip around the Tail Light Harness and slide it onto the back of the long fastener just installed 6 Using a 10 mm socket wrench install a lock nut to hold the P clip in place Torque to 5 5 N m 4 0 ft Ibf 7 Install a P clip around the Tail Light Harness and orient it as shown in Figure 30 8 Using a 4 mm hex wrench install the six outside fasteners and the P clip see Figure 30 Torque to 5 5 N m 4 0 ft Ibf SEGWAY Push to Remove Z 24509 00001 Some components not shown Figure 30 Outside Fasteners Fender Left 23756 00001 Right 23757 00001 23202 00004 5 5 N m 4 0 ft Ibf P Clip 24509 00001 24270 00006 5 5 N m 4 0 ft Ibf 24270 00004 5 5 N m 4 0 ft Ibf KAM Fig
33. the warning label found on the Battery Module General Safety Precautions SEGWAY Use only charging devices approved by Segway and never attempt to bypass or override their charging protection circuits Do not wash the SE 3 Patroller with a power washer or high pressure hose Avoid getting water into the Charge Port Avoid exposure to heavy downpours or extended periods of heavy rain including during riding storage or while being transported Clean with soap and water and a soft cloth Make sure that the Charge Port is dry before you plug in the Power Cord Failure to follow these instructions could expose you to electric shock injury burns or cause a fire Do not submerge the SE 3 Patroller or Battery Module in water If you suspect the Battery Module has 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 SE 3 Patroller outdoors and away from flammable objects Failure to do so could expose you to electric shock injury burns or cause a fire As with all rechargeable batteries do not charge near flammable materials When charging the batteries heat up and could ignite a fire e Failure to adhere to these warnings could lead to serious injury death fire or damage to property NOTICE e Failure to charge the Battery Module could result in permanent damage to the Battery Module Left unplugged the Battery Module cou
34. to front screw Brake Bracket 1 5 N m 1 1 ft Ibf Figure 95 Parking Brake Spring 63 Brakes 64 Rear Caliper amp Rotor Tools Required 6 mm hex wrench 14 mm socket wrench Torque wrench Removal Al Make sure the SE 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 15 c Bib Panel page 16 d Fender page 24 e Rear Tire Wheel page 32 NOTICE Leave the SE 3 jacked up 3 Chock the wheels Release the rear brake 5 Using a 6 mm hex wrench remove the two caliper fasteners See Figure 96 6 Remove the Caliper and secure it so it doesn t strain the brake line 7 Remove the Rotor and Spacer See Figure 97 Place the rotor on a clean surface NOTICE Scratching the Rotor or introducing debris could shorten the life of the Rotor 8 To remove the Caliper a Drain the brake line page 55 b Using a 14 mm socket wrench disconnect the Banjo Bolt SEGWAY 23868 00001 28 5 N m 21 0 ft Ibf Rear Caliper Right 23812 00001 Left 23810 00001 Figure 96 Rear Caliper Rear Rotor 23732 00001 Spacer 24318 00001 Figure 97 Rear Rotor SE 3 Patroller SEGWAY Installation A L Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Ensure the Rotor Spacer and all mounting surfaces are clean and free of debris Install the Rotor and S
35. 003 1 4 N m 1 0 ft Ibf Figure 105 Brake Line P Clips Hollow Screw le 28 5 N m 21 0 ft Ibf Crush Washer O 23958 00001 Qu Crush Washer 23958 00001 Figure 106 Brake Line Fasteners 69 Brakes SEGWAY 70 SE 3 Patroller Controls Overview This chapter covers the UI Control Cluster Throttle and Handlebar Grip When to Replace Replace 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 the Brakes chapter page 53 Contents e Ul Module e Ul Housing e Control Cluster e Throttle e Handlebar Grip 71 Controls 72 Ul Module The Ul Module is how the user interacts with the SE 3 Patroller NOTICE The fault history is stored in the Ul Module Replacing the UI Module will essentially reset the fault history Tools Required 4mm hex wrench Torque wrench Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the Battery Module page 8 3 Using a 4 mm hex wrench remove the four fasteners as shown in Figure 107 4 Disconnect the harness as shown in Figure 108 5 Remove the Ul Module Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Connect the harness as shown in Figure 108 3 Using a 4
36. 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Feed the Brake Light harness through the hole in the Fender 3 Reach into the wheel well and connect the harness Slide the plastic sleeves onto the fasteners then install the fasteners and Figure 57 5 Using a 3 mm hex wrench tighten the fasteners Torque to 1 0 N m 0 74 ft Ibf A CAUTION Do not overtighten Overtightening may damage the rubber seal around the light 6 Install a P clip around the pigtails from both the Brake Light and Directional Light see Figure 58 Slide the P clip onto the upper Brake Light fastener 7 Using a 7 mm socket wrench install a lock nut to hold the P clip in place Torque to 1 6 N m 1 2 ft Ibf 8 Perform post service tests page 129 SEGWAY Brake Light 24254 00001 _ os een 1 0 N m 0 74 ft Ibf Figure 57 Brake Light 23202 00001 1 6 N m 1 2 ft Ibf E ip 24346 00001 Figure 58 Tail Light Harnesses SE 3 Patroller SEGWAY Rear Directional Light Tools Required 3 mm hex wrench 7 mm socket wrench Torque wrench Removal A L Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Reach into the wheel well and disconnect the Rear Directional Light harness See Figure 60 3 Usea7mm socket wrench remove the lock nut and P clip on the back of the Brake Light See Figure 58 4 Using a3 mm
37. 23 4 Pull the Gearbox off of the chassis 5 Make note of the O ring and keep track of it See Figure 124 6 If replacing the gearbox remove the following components as well a Using a 6 mm hex wrench remove the two fasteners on the Caliper Bracket Set the Caliper Bracket aside See Figure 125 b Using a 4 mm hex wrench remove the three fasteners on the Fender Bracket Set the Fender Bracket aside See Figure 126 SEGWAY 20991 00002 67 N m 49 ft Ibf Via Flat Washer 24434 00005 30 Figure 123 Gearbox O Ring 23851 00001 Figure 124 Gearbox O Ring SE 3 Patroller SEGWAY Drive Train Installation Al Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Install the O ring on the input side of the Gearbox See Figure 124 Orient the Gearbox on the Frame so that the Gearbox is tipped toward the rear of the SE 3 Patroller Slide the Gearbox into place making sure the plastic coupling fits over the Elastomer Bushing 23868 00001 28 5 N m 21 0 ft Ibf Using an 8 mm hex wrench install the three Gearbox fasteners See Figure 123 Torque to 67 N m 49 ft lbf Using a 6 mm hex wrench install the Caliper Bracket See Figure 125 Torque to 28 5 N m 21 0 ft Ibf Using a 4 mm hex wrench install the Fender Bracket Caliper Bracket 7 See Figure 126 Torque to 4 0 N m 3 0 ft lbf 23861 00001 Figure 125 Caliper Bracket NOTICE Orient the
38. A a aa ea aeai aa fue danentaattanalyealtuete innen 78 vi SE 3 Patroller SEGWAY Contents SIEN ae ad 79 SIIEN ee e eee rer 80 Rider Detect Mat need 83 Rider Detect Mi nu ea eier ancsebe aban led tueduttdesexsberctaeSe tts 84 Drive AAA i CHR EB BERRECAMHERHBANES PEANAEFEIR ICHRRERATEBASERESARAURERT TEN 87 A ee ee ee eee eee 88 Elastomer Bushing amp Drive Hub an aa ne aaa 90 Accessing the MOON AS A AA ah Gavin 91 A A e E ee a eee el 92 Motor Cotler O tah 94 Steering CoM r an a aa e ete earch atana a adaa 95 E aa en ee 96 FRORLFOTK 2 le hha Te A Pa ee Ba E A N 98 Front Fender Bracket nn asien ei nen 100 Power Int rfaCe andinas d tiles 101 Electronics MAA aa 102 Gia devo OC a nal ee OA 103 A cis cerca Eur eed Grats sar pete 104 A A ye adda AA 106 Eat A O atener Savane tc Orta Onsen teeter eer reat 107 A A a aaa ai idaan 109 Left Right Motor Power Harness ii a 110 Left Right DING Harness einen Saale A 112 Handlebar Controlsamess er ee ee 114 User Interface Hannes ee 116 KIENEGlister HamMESS ara ASA DARA 118 AAA nes ses 120 Real Strobe Light Harness anne ea ea ea a 122 Accessory Power Harness anne een 124 GEOG arnes ds 125 SIN Harness aueh 126 Service Interface Hess it as 127 Service Manual vil Contents SEGWAY POSE Service sd 129 Drive Disable and Rider Detect Mat 52 2 eu A AN ad 129 A AAA o O Rein 129 Brake Cira dl aci E ARA 129 Rides das 130 A A A A eet anisi aitan 130 FAST ES LA 131 Tools and E
39. Directional Light Ax 1 Make sure the SE 3 Patroller is powered off i 24251 00001 unplugged and the parking brake is engaged dr 2 Feed the wire harness through the hole in the Light g Cluster and connect it to the Front Light Harness Figure 55 Front Directional Lights 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 sleeves onto the fasteners then install the fasteners and lock nuts Figure 55 4 Using a 3 mm hex wrench and a 7 mm socket wrench tighten the fasteners Torque to 1 6 N m 1 2 ft Ibf A CAUTION Do not overtighten Overtightening may damage the rubber seal around the light 5 Reassemble the SE 3 Patroller by following the instructions to Install Body Panels on page 38 6 Perform post service tests page 129 Figure 56 Directional Light Connectors Service Manual 41 Lights 42 Brake Light Tools Required 3 mm hex wrench 7 mm socket wrench Torque wrench Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Reach into the wheel well and disconnect the Brake Light harness See Figure 60 3 Use a 7 mm socket wrench remove the lock nut and P clip on the back of the Brake Light See Figure 58 4 Using a 3 mm hex wrench remove the two Brake Light fasteners See Figure 57 5 Remove the Brake Light Installation A
40. E 3 Patroller is powered off gt A HR o aep unplugged and the parking brake is engaged pa Re Strobelg 2 Remove the following components a mak lightst a Battery Module page 8 hi A b Storage Trays page 15 c Bib Panel page 16 d Glove Box page 18 e Front Cowl page 19 f Light Cluster page 20 g Right Side Panel page 22 h Electronics Shield page 102 i Rider Detect Mat page 84 j Motor Cavity Lid page 91 3 Disconnect the wire harness from the Pl Board See Figure 174 4 Remove the two cable ties on the side of the frame 5 Using a pair of wire cutters remove the two cable ties at the rear of the Motor Cavity 6 Remove the Rear Strobe Light Harness Figure 175 Rear Strobe Light Harness to Lights 122 SE 3 Patroller SEGWAY Installation Al 9 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Route the harness down the right side of the skid plate See Figure 176 Connect the harness to the Rear Strobe Lights See Figure 175 Install two cable ties connecting the harness to the rear of the Motor Cavity Route the harness up the right side of the frame and under the horizontal brace on the frame Connect the wire harness to the PI Board See Figure 174 Install two cable ties around the harnesses on the side of the frame Install the following components a Motor Cavity Lid page 91 b Rider Detect Mat page 84
41. Fender Bracket with the indent away toward the rider platform Install the following components Rear Caliper amp Rotor page 64 Rear Tire Wheel page 32 Fender page 24 Bib Panel page 16 os Storage Trays page 15 Oo 2 Fender Bracket Left 24297 00001 Right 24298 00001 po ap Battery Module page 8 24270 00006 Perform post service tests page 129 4 0 N m 3 0 ft Ibf Figure 126 Fender Bracket Service Manual 89 Drive Train SEGWAY Elastomer Bushing amp Drive Hub Check to see if the Elastomer Bushing is worn or damaged Presence of excessive particles of elastomer material indicates that replacement is necessary Tools Required Cotton swab Molykote G n paste Removal Elastomer Bushing 21091 00001 A 1 Make sure the SE 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 15 c Bib Panel page 16 d Fender page 24 e Rear Tire Wheel page 32 Drive Hub f Rear Caliper amp Rotor page 64 24093 00001 g Gearbox page 88 3 Pull the Drive Hub off the Motor Figure 127 Elastomer Bushing 4 Pull the Elastomer Bushing off of the Drive Hub Figure 127 Installation A 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 Drive Hub 3 Slide the Elastomer Bushing onto
42. Fluid Level WARNING Do not operate the SE 3 Patroller if the brake fluid level is low The brakes may not activate properly and the vehicle may not stop as intended Al Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Make sure the brake fluid reservoir is level 3 Inspect the sight glass and determine if fluid is below the low mark Figure 74 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 top of the brake fluid reservoir 2 Remove the reservoir cap and gasket 3 Add DOT 4 brake fluid do not overfill the reservoir NOTICE Use only fresh DOT 4 brake fluid from a new container Avoid getting any brake fluid on hands clothing or painted parts Immediately wipe up any spilled fluid 4 Replace the gasket and the reservoir cap 5 Use a Phillips screwdriver to install the two screws on top of the brake fluid reservoir Torque to 1 5 N m 1 1 ft Ibf SEGWAY Screws 1 5 N m 1 1 ft Ibf Low mark Figure 74 Checking the Brake Fluid Level SE 3 Patroller SEGWAY Draining Brake Lines Drain the brake line before replacing a master cylinder brake line or caliper Tools Required Gloves Shop Towels Ya in tubing Empty container Phillips screwdriver Ya in wrench Procedure A 1 Make sure t
43. Harness e Handlebar Controls Harness e User Interface Harness Light Cluster Harness Tail Light Harness Rear Strobe Light Harness e Accessory Power Harness KeyLock Harness Sirenn Harness Service Interface Harness 109 Harnesses SEGWAY Left Right Motor Power Harness This harness provides power to the motor There are separate harnesses for the left motor and the right motor Tools Required Wire cutters 10 mm socket wrench Torque wrench Removal A 1 Make sure the SE 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 15 c Bib Panel page 16 d Glove Box page 18 Figure 152 Motor Power Harnesses to Pl Board e Front Cowl page 19 f Light Cluster page 20 Brate g Side Panel page 22 NOTICE Remove the left Side Panel to access the Left Motor Power Harness Remove the right Side Panel to access the Right Motor Power Harness h Rider Detect Mat page 84 i Motor Cavity Lid page 91 3 Disconnect the wire harness from the Pl Board See Figure 152 NOTICE You do not need to remove the Electronics Shield to access the Motor Power Harnesses Figure 153 Motor Power Harnesses Routing 4 Using a pair of wire cutters remove the two cable ties on the side of the frame 5 Using a pair of wire cutters remove the two cable ties inside the motor cavity 6 Using a 10 mm socket wrench disc
44. MIOx40SHCS Gearbox 6 mm 67 Nm 49 tbh 20991 00002 M Front Strobe Light 1 6 N m 1 2 ft lbf Glove Box Door 1 6 N m 1 2 ft lbf Side Strobe Light 1 6 N m 1 2 ft Ibf Brake Light P Clip 1 6 N M 1 2 ft lbf Front Directional Light 1 6 N m 1 2 ft Ibf 23202 00001 4 Lock Nut Rear Brake Line P Clips 1 4 N m LO ft lbf en PI Board 6 0 N m 4 4 ft lbf oar mm f M 4 4 T 23202 00003 E Fender P Clip 5 5 N m 4 0 ft Ibf M6 Lock Nut Headlight Bracket 6 0 N m 4 4 ft Ibf Windshield 1 5 N m 1 1 ft Ibf M N 23202 00004 132 SE 3 Patroller SEGWAY Fasteners Part Number Fastener Type Application Quantity Drive Torque Collar Nut Front Fork 45 N m 33 ft Ibf o OL M8 x 14 SHCS Front Caliper to Front Fork 28 5 N m 21 0 ft Ibf 23783 00001 M8 Lock Nut Handlebar to Front Fork 34 N m 25 ft Ibf 23784 00001 M6 x 10 BHCS Front Rotor 7 0 N m 5 0 ft Ibf 23786 00001 mm Lug Nut Tire Wheel Assembly 67 N m 49 ft Ibf 23789 00001 O E Rear Caliper to Bracket 28 5 N m 21 0 ft lbf M8 x 20 SHCS 23868 00001 Rear Caliper Bracket to Gearbox 28 5 N m 21 0 ft Ibf M8 x 55 SHCS Handlebar to Front Fork 34 N m 25 ftlbf 23868 000010 Service Manual 133 Fasteners SEGWAY Part Number Fastener Type Application Quantity Drive Torque Motor to Gearbox Plate onFrame 8 5mm 12N m 89ftlbf M6 x 25 SHCS Motor to
45. Motor Mount Plate f8 5mm 12N m 8 9ftlbf 23869 00001 6x16 SHCS Motor Controller to Frame 8 5mm 75N m 55ftibf 23869 00003 A BEE M6 x 10 BHCS F Siren Bracket to Frame 7 5 N m 5 5 ft Ibf Ul Housing 2 8 N m 2 1 ft Ibf 24270 00001 Fender to Bracket 5 5 N m 4 0 ft Ibf Fender to Frame 5 5 N m 4 0 ft Ibf Front Cowl 6 4mm 40N m 3 0felf 24270 00004 FrontSpeshGuard fa emm 55m Nex I6BHCSFL Main Spiash Guard je amm 55m Side Panel Bracket to Side Pare 8 emm aonmGonan Side Panel tto frame 6 amm ssnmeronem Bib Panel into Frame 6 4mm 5 5 Nm 0 ftlbf Fender Bracket to Gearbox 6 4mm 40Nm SOfeb M6 x 20 BHCS FL 24270 00006 134 SE 3 Patroller SEGWAY Fasteners Part Number Fastener Type Application Quantity Drive Torque M x 10 SHCS L6N m 12 ftbi 24315 00001 N M4 x 12 SHCS Front Directional Light 1 6 N m 1 2 ft Ibf 24315 00002 DE M4 x 16 SHCS Rear Directional Light 1 0 N m 0 74 ft lbf 24315 00004 a Front Strobe Light 1 6 N m 1 2 ft lbf M4 x 20 SHCS Headlight 1 6 N m 1 2 ft lbf 24315 00006 Rear Strobe Light 1 6 N m 1 2 ft lbf M4 x 25 SHCS Side Strobe Light 1 6 N m 1 2 ft Ibf 24315 00007 n M4 x 30 SHCS Brake Light 1 0 N m 0 74 ft Ibf 24315 00008 1 4 in P Clip Plastic 24346 00001 O O Rider Detect Mat 4 0 N m 3 0 ft Ibf M5 x 10 BHCS 7 Rider Detect Spacer 8 3mm 40N m 3 0felf OA SHE KENAZ
46. Patroller Twist latches outward Close latches to lock LY T D Figure 4 Twist and Close the Battery Module Latches Battery Module SEGWAY 10 SE 3 Patroller Body Panels Overview Body Panels attach to the frame to create the shape and style of the SE 3 Patroller Body panels serve a number of functions Among other things they provide a mounting location for lights they protect the internal components from the elements and they protect the rider from touching the wheels When to Replace Replace a Body Panel when it is cracked bent or otherwise broken Safety ZA WARNING Do not operate the SE 3 Patroller without all body panels installed A CAUTION When removing body panels place them on a soft clean surface to prevent scratching or marring of the body panel Contents Exploded View e Threaded Inserts e Storage Tray e Bib Panel e Glove Box e Front Cowl e Light Cluster Side Panel e Fender Front Fender Boot e Front Splash Guard e Main Splash Guard ll Body Panels SEGWAY Exploded View The exploded view below identifies all of the body panels on the SE 3 Patroller Right Storage Tray 23759 00001 Left Storage Tray 23758 00001 Bib Panel 24117 00001 Right Fender Right Side Panel 23757 00001 24130 00001 Left Fender 23756 00001 Light Cluster 23776 0000 Front Fender 23761 00001 Sket Side Panel 24129 00001
47. QUIP een 139 A ya A a a a nr MNANSEE at 141 viii SE 3 Patroller General Safety Precautions Safety Conventions The following safety messaging conventions are used throughout this document ZA WARNING Warns you about actions that could result in death or serious injury A 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 SE 3 Patroller or other property or usage tips Important Safety Notices Read and follow all safety notices General ZA WARNING e Failure to follow these safety precautions could lead to electrical shock serious injury death or damage to property To replace parts on the SE 3 Patroller you must read and follow all instructions and warnings in this manual Always power off the SE 3 Patroller 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 Remove the Battery Module before performing any service on the SE 3 Patroller Wait two minutes after removing the Battery Module before removing the Electronics Shield or touching any electrical components This is how long it takes for the capacitors on the PI Board to self discharge Touching the PI Board before the capacitors have fully discharged could result in electric sh
48. See Figure 87 5 Pull the Master Cylinder off of the handlebar Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking 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 Cylinder so that it is 11 5 off of horizontal with the handlebar tipped downward See Figure 88 Torque to 10 N m 7 4 ft Ibf 5 Using a 14 mm socket wrench install the Banjo Bolt onto the Master Cylinder See Figure 83 Torque to 28 5 N m 21 0 ft Ibf CAUTION Always use new crush washers when attaching a Banjo Bolt to any component Used crush washers may leak causing a reduction in braking force 6 Install brake fluid and bleed the brake line see page 56 7 Peform post service tests page 129 Service Manual Brakes Banjo Bolt 28 5 N m 21 0 ft Ibf Figure 86 Master Cylinder Fasteners 10 N m 7 4 ft Ibf Figure 88 Aligning the Master Cylinder 61 Brakes 62 Brake Lever Tools Required Flathead screwdriver 10 mm socket wrench Phillips head screwdriver Torque wrench UltraLube marine amp trailer bearing grease Removal Al Make sure the SE 3 Patroller is powered off unplugged and the wheels are chocked A CAUTION You can t remove the right hand brake lever with the parking brake on Chock
49. Service Manual SEGWAY SE 3 Patroller SEGWAY Windshield page 34 Headlight page 36 Front Cowl page 19 Fender page 24 Light Cluster page 38 Side Panel page 22 Front Tire Wheel page 30 Front Fender page 26 ii SE 3 Patroller SEGWAY Front Brake Rear Brake Master Cylinder page 61 Master Cylinder page 61 Control Cluster page 74 ae SN we page 76 Handlebar Grip Sa 8 aan y__ page 78 E N EN ue ee S A UI Module page 72 Accessory Power Outlet page 52 KeyLock page 51 lt gt A Cowl 19 Bib Panel page 16 ront Cowl page Glove Box Door page 50 i Storage Tray page 15 Fender page 24 Light Cluster page 38 Rear Strobe Light page 44 Rider Detect Mat page 84 Rear Tire Wheel page 32 Brake Light page 42 Rear Directional Light page 43 Service Manual iil SEGWAY Copyright Trademarks Patent and Contact Information Document number amp revision 24538 00001 ae Copyright 2015 Segway Inc All rights reserved 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
50. WAY SE 3 Patroller SEGWAY Installation A L Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Spray some LPS Heavy Duty Silicone Lubricant P N 24430 00001 on the first 100 mm of the handlebar This will help the Throttle to rotate smoothly and evenly NOTICE Do not apply lubricant where the Throttle clamps to the Handlebar This could reduce the holding power of the Throttle clamp allowing it to rotate Slide the Throttle onto the handlebar Slide it until it bottoms out then pull it back 3 5 mm Using a digital level align the Throttle so that the rear face rider side is at 82 Using a Phillips screwdriver tighten the two fasteners on the underside of the Throttle Torque to 4 0 N m 3 0 ft Ibf NOTICE Tighten the fasteners carefully to make sure there is an even and consistent gap between the two halves Connect the wire harness See Figure 114 grey amp red black black amp orange black Install two cable ties around the harnesses on the steering column Install the following components a Front Cowl page 19 b Glove Box page 18 c Bib Panel page 16 d Storage Trays page 15 e Battery Module page 8 Perform post service tests page 129 Service Manual Figure 114 Throttle Harness Controls 71 Controls 78 Handlebar Grip The Handlebar Grip does not slide off easily To remove it you will have to cut it off the han
51. acity minimum 1 per service technician The following or similar is service area compressed air recommended Powermate 2 Gallon Side Stack Mini Air Compressor VSP0000201 system not installed Bar Clamp Brake fluid Brake bleeding kit Cable Ties Cleaning supplies Digital level Dril Drill Bits Epoxy Field electrostatic discharge ESD kit including anti static mat wrist strap line with gator clip and ground lead Correct grounding of mat and wrist strap is essential Mini blade fuses 1A 2 A 3 A Ceramic cartridge fuses 5 A See Table 3 p 106 for part numbers Heat gun Hex adapter Hex bits Hex wrenches KeyLock nut tool P N 24630 00001 Utility knife with replaceable blades Locking Pliers Low pressure inflation gauge For checking tire pressure LPS Heavy duty silicone lubricant P N 24430 00001 Molykote G n anti corrosion paste P N 24505 00001 Lubricants Permatex anti seize lubricant P N 24433 00001 UltraLube industrial strength corrosion inhibitor P N 24429 00001 UltraLube marine and trailer grade bearing grease P N 24431 00001 Mallet Plastic or rubber 24 oz Capable of measuring both voltage and resistance as called out in the Segway Gen2 PT Multi meter General Information and Diagnostics Guide Flashlight AA ESD equipment Fuses 139 Tools and Equipment SEGWAY Tool Description 1 4 inch drive Ratchet 3 8 inch drive 1 2 inch drive ETE Socket extension 3 inch long 3 8 inc
52. ack 111 Harnesses 112 Left Right Drive Harness This delivers control commands to the motor controllers and provides feedback information to the PI Board There are separate harnesses for the left motor controller and the right motor controller Tools Required Flathead screwdriver Torque wrench Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the following components Battery Module page 8 Oo 2 Storage Trays page 15 Bib Panel page 16 Glove Box page 18 Front Cowl page 19 Light Cluster page 20 g Side Panel page 22 NOTICE Remove the left Side Panel to access the left Drive Harness Remove the right Side Panel to access the right Drive Harness gt pop h Electronics Shield page 102 i Rider Detect Mat page 84 j Motor Cavity Lid page 91 3 Disconnect the wire harness from the PI Board See Figure 156 4 Using a pair of wire cutters remove the two cable ties on the side of the frame 5 Using a pair of wire cutters remove the two cable ties inside the motor cavity 6 Using a flathead screwdriver lift the tab on the Drive Harness while pulling the connector off See Figure 157 7 Disconnect the Drive Harness from the Motor 8 Remove the Drive Harness SE Figure 156 Drive Harness to PI Board Figure 157 Drive Harness to Motor Controller GWAY SE 3 Patroller SEGWAY Harnesses Insta
53. ack Removal Al Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Place a vehicle jack under the center front of the skid plate Raise the SE 3 Patroller until the front wheel is off the ground Figure 80 WARNING Make sure the SE 3 Patroller is stable or use a jack 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 Remove the Front Fender page 26 Using a bar clamp and socket compress the caliper as shown in Figure 81 then remove the bar clamp NOTICE If you don t have a bar clamp you will need to remove the rotor fasteners See page 60 Using a 6 mm hex wrench remove the two fasteners holding the caliper in place See Figure 82 Slide the caliper off the rotor NOTICE Secure the caliper so that it doesn t fall or otherwise stress the brake line Disconnect the brake line a Drain the brake line page 55 b Using a 14 mm socket wrench remove the Banjo Bolt Socket Place jack here Figure 80 Front Lifting Point Figure 81 Compress the Caliper Figure 82 Front Caliper Bolts SEGWAY Bar Clamp 23783 00001 28 5 N m 21 0 ft Ibf SE 3 Patroller SEGWAY Installation A L Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Using a 14 mm socket wrench attach the Banjo Bolt
54. aged 2 Connect the Tail Light Harness to the tail lights See Figure 172 3 Install a P clip around the Tail Light Harness and slide it onto the back of the upper Fender Bracket fastener as shown in Figure 172 4 Using a 10 mm socket wrench install a lock nut to hold the P clip in place Torque to 5 5 N m 4 0 ft Ibf 5 Install a P clip around the Tail Light Harness and orient it as shown in Figure 171 6 Using a 4 mm hex wrench install a fastener to hold the P clip in place Torque to 5 5 N m 4 0 ft Ibf 7 Route the harnessunder the horizontal brace on the frame See Figure 173 8 Connect the wire harness to the Pl Board See Figure 170 9 Install two cable ties connecting the harness to the frame 10 Install the following components a Side Panel page 22 NOTICE Ensure the harness goes over the wheel well and under the storage tray Light Cluster page 20 Front Cowl page 19 Electronics Shield page 102 Glove Box page 18 Bib Panel page 16 g Storage Trays page 15 h Battery Module page 8 ll Perform post service tests page 129 pap Service Manual P Clip 24509 00001 23202 00004 5 5 N m 4 0 ft Ibf Figure 172 Tail Light Harness to Lights Brace Figure 173 Tail Light Harness Routing 121 Harnesses SEGWAY Rear Strobe Light Harness This harness connects the PI Board to the rear strobe lights Tools Required Wire cutters Removal A 1 Make sure the S
55. ake Line P Clips a9 ow 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 65 4 Slide the P Clips off the threaded studs 5 Using a 4 mm hex wrench remove the Battery x Y Battery Bumpers Bumpers See Figure 66 23948 00001 NOTICE Keep track of how many washers go with each bumper Bumper alignment is critical for maintaining a solid battery connection Because of variations in the frame different SE 3 Patrollers may have different quantities of washers installed with the bumpers Figure 66 Battery Bumpers Service Manual 47 Battery Compartment 48 Installation Al Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Assemble the Battery Bumper Slide the fastener through the bumper then slide washers onto the fastener See Figure 67 NOTICE Use the same number of washers as were removed when the Battery Bumper was disassembled Using a4 mm hex wrench attach the Battery Bumpers to the frame Torque to 2 0 N m 1 5 ft Ibf Slide the three brake line P Clips onto the threaded studs on the front of the frame See Figure 65 Using an 8 mm socket wrench install the lock nuts on the threaded studs Torque to 1 4 N m 1 0 ft Ibf Install the following components a Main Splash Guard page 28 b Front Fender Bracket page 100 c Front Splash Guard page 27 d Front Fender
56. arger The Charger is mounted onto the same aluminum plate as the PI Board It can be serviced in place or the Pl Board assembly can be removed and the Charger can be serviced on a bench Tools Required 3 mm hex wrench Torque wrench Removal Al Make sure the SE 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 15 c Bib Panel page 16 d Glove Box page 18 e Electronics Shield page 102 3 Disconnect the harnesses connecting the Charger to the PI Board 4 Using a3 mm hex wrench remove the four fasteners as shown in Figure 144 and Figure 145 5 Remove the Charger Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Orient the Charger as shown in Figure 146 3 Using a 3 mm hex wrench install the four fasteners as shown in Figure 144 and Figure 145 Torque to 2 5 N m 1 8 ft Ibf 4 Connect the charger harness to the Pl Board 5 Install the following components a Electronics Shield page 102 b Glove Box page 18 c Bib Panel page 16 d Storage Trays page 15 e Battery Module page 8 6 Perform post service tests page 129 Service Manual Power Interface 24491 00003 2 5 N m 1 8 ft Ibf Bunpno ONS Bu P dond prsu P yeu 20004 ol SOON IP emt ou OH A ade Figure 144 Charger Left Side WAS o 8nig No umnog o
57. asteners holding the rotor in place See Figure 85 7 Remove the Rotor Installation 8 Align the Rotor with the flange on the spindle 9 Using a5 mm hex wrench install the five fasteners holding the Rotor in place See Figure 85 Torque to 7 N m 5 ft Ibf 10 Slide the wheel assembly onto the front fork Orient the wheel assembly so the rotor flange is toward the left side of the SE 3 11 Slide the axle through the forks and wheel assembly See Figure 84 12 Using a pair of 30 mm socket wrenches fasten the nut onto the axle Torque to 85 N m 63 ft Ibf 13 Install the following components a Front Caliper page 58 b Front Fender page 26 14 Perform post service tests page 129 SEGWAY Axle 23773 00001 24404 00001 gt 85 N m 63 ft Ibf Re Front Rotor 23762 00001 23786 00001 7 0 N m 5 0 ft Ibf Figure 85 Front Rotor Explode SE 3 Patroller SEGWAY Master Cylinder These instructions apply to both the Front left and Rear right Master Cylinders Tools Required 5 mm hex wrench 14 mm socket wrench Digital level Torque wrench Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Drain the brake fluid out of the brake line See page 55 3 Using a 14 mm socket wrench remove the Banjo Bolt on the Master Cylinder See Figure 86 4 Using a 5 mm hex wrench remove the two fasteners on the Master Cylinder
58. biota Raet 20 A A 22 A A A 24 Front Fender Boot AAA A A sad iqnanebialinnineans 26 de F IAK ETOT IA AA A A AE 27 Mat Splash GU o a a a 28 Tire Wheel Assembli8S cccccncconncnococnocncacnccnanncannanncnnncnnncnncan cnn ran cancer cananea crac 29 Front Tire Wheel 2 ee nern ae 30 Rear Tire WV UU ett aa sete ck a de td o ee ut 32 Windshield A cau vacua A a A Be ee 33 Windshield occ 34 Contents SEGWAY A A O O 35 Headlieh sans ee einzu 36 Headlight Alignment au ea suse Ranta ss 37 Accessing the Light Cluster een fees auraxadeesidtscvobebehy niesammachiesdedcasanasalniuien 38 PRONE Strobe big hT anne een te 39 Side Strobe A nee rennen 40 Front DirectionalLieht anda een 41 AAT EE A EEA a nt ae ea 42 Rear Directional Liria 43 REAESTIODE AA A A O A A O 44 Battery COMPANIES a 45 Battery S e Sica cua a eter teal ae N 46 Battery BUM Sisi AAA A eis pea 47 Bib Panel o ii 49 VOWS BOX DO 0a sense see E 50 Rey LOCK aaa near erinnere 51 Accessory FOWer DU sra A A e 52 Brakes a 53 A a een eek 54 Braining Brake LINES a a cion 55 Bleeding Brake Lines 2 ne 56 do A ines 58 PROT AUER TO ee as 60 E AAA A A A 61 Brake AO A a 62 Rear Caliber ROL Ras e de el di dl 64 AA A Rankine winnie eens 66 Pirae eE E E E O EE E 68 CAE OS ios Fea ace ccna ate a ee ai aaa aai aiaa daa aN aidaa aada Eee aeg 71 UlMod le ans o cates 72 UNAS A A RA 73 CARLO NG A A 74 nn Sahat E ded th Intel ead races ee attach an tad tated einen 76 PIMC AN AMM AAA
59. c Side Panel page 22 d Light Cluster page 20 e Front Cowl page 19 f Electronics Shield page 102 g Glove Box page 18 h Bib Panel page 16 i Storage Trays page 15 j Battery Module page 8 Perform post service tests page 129 Service Manual Figure 176 Rear Strobe Light Harness Routing Harnesses 123 Harnesses SEGWAY Accessory Power Harness This harness connects to the Accessory Power Outlet on the Bib Panel It provides 12 V power Tools Required Wire cutters Removal A 1 Make sure the SE 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 15 c Bib Panel page 16 d Glove Box page 18 3 Disconnect the wire harness from the PI Board See Figure 177 NOTICE You do not need to remove the Electronics Shield to access the Accessory Power Harnesses 4 Using a pair of wire cutters remove the two 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 Patroller is powered off unplugged and the parking brake is engaged 2 Connect the wire harness to the Pl Board See Figure 177 3 Route the harness around the right side of the frame and up to the top left of the frame See Figure 178 4 Install three cab
60. ck of the SE 3 Patroller skid plate close to the wheel being changed Figure 41 Raise the SE 3 Patroller until the wheel is just off the ground AA WARNING Do not lift both rear wheels off the ground Two wheels must always remain in contact with the ground to reduce the possibility of the SE 3 Patroller tipping over while it is on the jack 4 Using the wheel nut key remove all four Wheel nuts 5 Pull the wheel off the studs Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Jack up the SE 3 Patroller Figure 41 3 Make sure all mounting surfaces are clean and free of debris 4 Slide the wheel onto the studs 5 Using the wheel nut key install the four Wheel Nuts Ensure the wheel nuts are fully seated and are a little more than hand tight 6 Lower the SE 3 Patroller and remove the jack 7 Using the wheel nut key torque the four Wheel Nuts to 67 N m 49 ft Ibf Torque nuts in a cross pattern top bottom left right Figure 42 8 Perform post service tests page 129 SEGWAY Sy Figure 41 Rear Lifting Points lace jack here Torque the four Wheel Nuts in a cross pattern Figure 42 Installing a Rear Wheel SE 3 Patroller Windshield Overview The Windshield protects the UI Module When to Replace Replace the Windshield when it is cracked or otherwise broken Contents e Windshield 33 Windshield Wi
61. d thread lock in place 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 Failure to adhere to these warnings could lead to serious injury or death or damage to property Reusing Fasteners Before reusing any fastener check if it has any threadlock residue on it If so you must remove the old threadlock and apply new threadlock before reusing the fastener Tools Required 1 4 inch tube brush Wire brush Loctite 242 1 Use a tube brush in a drill or by hand to clean any existing threadlock off the threads of the nut or threaded insert 2 Useawire brush to clean any existing threadlock off the threads of the fastener 3 Before reinstalling the fastener place a drop of Loctite 242 on the threads 131 Fasteners SEGWAY Table 6 Fasteners Part Number Fastener Type Application Quantity Drive Torque Front Brake Line 2 5 N m 1 8 ft lbf M4 x 8 BHOS 20307 00002 Rear El 2 5 N m 1 8 ft lbf Glove Box Door 1 6 N m 1 2 ft lbf es Charger to Bib Panel 2 2 5mm 1 6N m 1 2 ft Ibf arger to DID Fane mm M 2 2 TC 20307 00005 M4 Flat Washer Glove Box Door 20450 00001 moon M6 x 25 BHCS L6 N m 1 2 fbf 20553 00001 m M4 x 10 FHCS Battery Slides 1 0 N m 0 74 ft lbf 20709 00001
62. dlebar Tools Required Cutting tool box cutter or utility knife Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Score the Handlebar Grip with a cutting tool A CAUTION Be careful not to cut yourself with the sharp 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 A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Slide the end of the Handlebar Grip onto the left handlebar See Figure 115 3 Press the palm of your hand onto the end of the Handlebar Grip Push the Handlebar Grip onto the handlebar until it is fully seated NOTICE Do not twist the Handlebar Grip when installing it SEGWAY Handlebar Grip 23807 00001 Figure 115 Handlebar Grip SE 3 Patroller Siren Siren The Siren produces both the horn and siren sounds When to Replace Replace when troubleshooting determines that the Siren is malfunctioning Contents e Siren 79 Siren SEGWAY Siren Tools Required 4mm hex wrench 10 mm socket wrench Torque wrench Removal A 1 Make sure the SE 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 15 c Bib Panel page 16 d Glove Box page 18 e Main Splas
63. 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 Segway Patent Information The SE 3 Patroller is covered by U S and foreign patents For a patent listing see http www segway com downloads pdfs patents pdf 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 Segway Customer Care 866 4SEGWAY 866 473 4929 Fax 603 222 6001 E mail technicalsupport segway com Website http www segway com SE 3 Patroller Contents Copyright Trademarks Patent and Contact Information nuuenneennenennnnnnnnnene iv General Safety Prec utionsi u un ae 1 Salely CON EIN an nu RIESTER AR 1 limportant Safety NOU COS et ana a a aeaa E E e aeaa Ea a a rE EREE 1 A A nnnnnnnnnn nannan nanan 5 PUFDOSE a 5 A A II A O YONA 5 CA a e e o ete al eo ee 5 General Service Procedure ana en A A AS 6 Reusing A A A aus ebeteas tale tietlaluueesule 6 Related User e dl 6 An ec cscin cede mt edlen 7 Battery Mod o ee 8 A 11 EXPIDA Wat EE A AAA a 12 Threaded Insert e ds o dal e al o 13 A A A A A IE 15 BP 23222 42 2 an A ae Be 16 cnn A AA Gan 18 A A ep alole tens 19 Fe CY senate A A aaa a
64. e 18 Bib Panel page 16 Storage Trays page 15 peop g Battery Module page 8 Perform post service tests page 129 Service Manual Figure 121 Rider Detect Harness Figure 122 Rider Detect Mat Harness Rider Detect Mat 85 Rider Detect Mat SEGWAY 86 SE 3 Patroller Drive Train Overview The Drive Train consists of the Gearbox Motor 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 amp Drive Hub e Accessing the Motor Cavity e Motor Motor Controller 87 Drive Train 88 Gearbox Tools Required 8 mm hex wrench 6 mm hex wrench 4mm hex wrench Torque wrench Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the following components Battery Module page 8 ao 2 Storage Trays page 15 Bib Panel page 16 Fender page 24 Rear Tire Wheel page 32 Rear Caliper amp Rotor page 64 peop NOTICE Leave the SE 3 Patroller jacked up and chock the wheels ZA WARNING Make sure the SE 3 Patroller is stable or use a jack 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 3 Using a 8 mm hex wrench remove the three fasteners as shown in Figure 1
65. e SE 3 Patroller until the front wheel is off the ground Figure 36 AA WARNING Make sure the SE 3 Patroller is stable or use a jack 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 Patroller by following the Setup instructions above Remove the Front Fender page 26 Using a bar clamp and socket compress the caliper as shown in Figure 37 then remove the bar clamp NOTICE If you don t have a bar clamp you will need to remove the rotor fasteners See page 60 Using a 6 mm hex wrench remove the two fasteners holding the caliper in place See Figure 38 Slide the caliper off the rotor NOTICE Secure the caliper so that it doesn t fall or otherwise stress the brake line Using a 30 mm socket wrench remove the axle and slide it out See Figure 39 Slide the wheel assembly out of the front fork Using the wheel nut key remove the four fasteners holding the wheel onto the Spindle See Figure 40 Slide the wheel off the Spindle Socket Place jack here Figure 36 Front Lifting Point Figure 37 Compress the Caliper Figure 38 Front Caliper Bolts SEGWAY Bar Clamp 23868 00001 28 5 N m 21 0 ft Ibf SE 3 Patroller SEGWAY Installation 1 Prepare the SE 3 Patroller by following the Setup instructions page 30 2 Slide the wheel onto t
66. e Service Port to the back of the Glove Box Figure 20 6 Remove the Splash Shield Figure 21 Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Install the Splash Shield Figure 21 pye 3 Using a 3 mm hex wrench attach the Service Port 24400 00001 7 5 harness to the back of the Glove Box Figure 20 1 6 N m 1 2 ft Ibf Orient the connector with the narrow side down Torque to 1 6 N m 1 2 ft Ibf 4 Align the Glove Box on the frame The back of the Glove Box has holes which slide over studs in the frame The Glove Box opening has holes that line up with the holes in the frame Splash Shield 24419 00001 Figure 20 Service Port 5 Using a 4 mm hex wrench install the three fasteners and Lock Plate as shown in Figure 19 Torque to 1 6 N m 1 2 ft Ibf 6 Install the following components a Bib Panel page 16 b Storage Trays page 15 c Battery Module page 8 7 Perform post service tests page 129 Figure 21 Splash Shield SEGWAY 24315 00001 1 6 N m 1 2 ft Ibf SE 3 Patroller SEGWAY Front Cowl The Front Cowl fastens to the left and right Side Panels Tools Required 4mm hex wrench Torque wrench Removal Ax 1 Make sure the SE 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 15 c Bib Pane
67. e lever does not touch the handlebar when fully engaged Otherwise add more brake fluid See Adding Brake Fluid p 54 3 Check for brake fluid leakage around the master cylinders Wipe up any fluid and verify component torques 129 Post Service Tests 130 Ride Test Verify that the SE 3 Patroller drives as expected Make sure that driving and turning are smooth and easy and there is no binding of the handlebar cabling or wiring 1 2 3 4 Drive forward Drive backward Turn the handlebar full left and drive in a circle Turn the handlebar full right and drive in a circle Charge Test 1 2 Use an IEC cable to connect the SE 3 Patroller to a powered outlet Verify that the screen displays the charging icon SEGWAY SE 3 Patroller Fasteners Overview Fasteners are listed by part number For each fastener a variety of information is provided including Type of fastener e Location used e Quantity used per part Drive used when installing removing e Torque required at this location e Image actual size Safety ZA WARNING Use only Segway approved fasteners Other fasteners may not perform as expected and may come loose Do not tighten or reuse any lock nut 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 necessary washer an
68. e the two fasteners See Figure 62 5 Remove the Rear Strobe Light Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Feed the Rear Strobe Light harness through the hole in the Skid Plate 3 Connect the Rear Strobe Light harness See Figure 61 4 Orient the light Police Red toward center Blue toward outside Security Locate the heat vent Figure 63 Right light heat vent down Left light heat vent up 5 Using a 3 mm hex wrench install the two fasteners See Figure 62 Torque to 1 6 N m 1 2 ft Ibf 6 Secure the Motor Cavity page 91 7 Perform post service tests page 129 Security 24252 00002 SEGWAY Figure 61 Rear Strobe Light Harnesses Rear Strobe Light Police 24252 00001 24315 00006 gt I 1 6 N m 1 2 ft Ibf Figure 62 Rear Strobe Lights Heat Vent Figure 63 Heat Vent Location SE 3 Patroller Battery Compartment Overview Inside the Battery Compartment are the Battery Slides and Battery Bumpers which together position the Battery Module correctly against the Pl Board When to Replace Replace the Battery Slides or Battery Bumpers when they are cracked excessively worn or otherwise broken Contents Battery Slides Battery Bumpers 45 Battery Compartment SEGWAY Battery Slides The Battery Slides orient the Battery Module in the frame They also allow the Battery Module to slide
69. er wrench install the two collar nuts Torque to 45 N m 33 ft Ibf Install the following components Handlebar page 96 Front Caliper page 58 Front Fender Bracket page 100 Front Splash Guard page 27 Oo w a p D Front Fender page 26 Light Cluster page 20 Front Cowl page 19 se Glove Box page 18 i Bib Panel page 16 j Storage Trays page 15 k Battery Module page 8 Perform post service tests page 129 Service Manual 23777 00001 Front Fork AS Figure 140 Front Fork Removal Installation Steering Column 99 Steering Column Front Fender Bracket This bracket holds the Front Fender and the Front Splashguard It also provides a mounting point for routing the brake line Tools Required 3 mm hex wrench 4 mm hex wrench Torque wrench Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the following components a Front Fender page 26 b Front Splash Guard page 27 3 Using a 3 mm hex wrench remove the P clip that holds the brake line to the Bracket 4 Using a 4 mm hex wrench remove the four fasteners as shown in Figure 141 5 Remove the Bracket Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Slide the Bracket onto the Front Fork 3 Using a 4 mm hex wrench install the four fasteners as shown in Fi
70. form post service tests page 129 Service Manual Drive Train Rider Detect Spacer 23944 00001 24367 00002 4 0 N m 3 0 ft Ibf Figure 128 Motor Cavity Lid 91 Drive Train Motor Tools Required 5 mm hex wrench 92 10 mm socket wrench Torque wrench Cotton swab Molykote G n paste Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Access the motor cavity page 91 3 Disconnect the Hall Sensor Feedback harness 4 Using a 10 mm socket wrench disconnect the motor phase leads See Figure 129 5 Using a 5 mm hex wrench remove the four fasteners as shown in Figure 130 Liftthe Motor Assembly out of the motor cavity 6 Make note of the O ring and keep track of it 7 Using a5 mm hex wrench remove the four fasteners as shown in Figure 131 8 Remove the motor mount plate and keep track of the O ring 9 Remove the Drive Hub SEGWAY Motor Phase y Leads Figure 129 Motor Harnesses O Ring 23863 00001 Motor Mount Plate 23860 00001 23869 00001 12 N m 8 9 ft Ibf Figure 130 Motor Assembly SE 3 Patroller SEGWAY Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Useacotton swab to spread some Molykote G n paste P N 24505 00001 on the splines inside the Drive Hub This paste helps reduce wear between the Drive Hub and the Motor 3 Slide t
71. ft Ibf 4 Using a 4 mm hex wrench install the four small fasteners two per side Torque to 5 5 N m 4 0 ft Ibf SEGWAY 24270 00006 5 5 N m 4 0 ft Ibf Sa AS 24437 00003 5 5 N m 4 0 ft Ibf Figure 33 Front Fender Fasteners SE 3 Patroller SEGWAY Body Panels Front Splash Guard The Front Splash Guard is flexible and bends around the bracket on the Front Fork Tools Required 4mm hex wrench 24270 00004 5 5 N m 4 0 ft Ibf 2 Torque wrench 7 Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged a 2 Remove the Front Fender page 26 A 3 Using a 4 mm hex wrench remove the eight fasteners as shown in Figure 34 4 Remove the Front Splash Guard Installation A 1 Make sure the SE 3 Patroller is powered off Front Splash Guard unplugged and the parking brake is engaged ee 2 Align the Front Splash Guard against the bracket on Orient the part number toward the wheel 3 Using a 4 mm hex wrench install the eight fasteners as shown in Figure 34 Torque to 5 5 N m 4 0 ft Ibf 4 Install the Front Fender page 26 Figure 34 Front Splash Guard Service Manual 27 Body Panels Main Splash Guard The Main Splash Guard is flexible and attaches to the frame and to the floating bracket that holds the Front Panels together Tools Required 4mm hex wrench Torque wrench Removal A 1 Make sure the SE 3 Patroller is powered
72. gure 141 Torque to 7 5 N m 5 5 ft Ibf 4 Using a 3 mm hex wrench install the P clip to affix the brake line to the Bracket 5 Install the following components a Front Splash Guard page 27 b Front Fender page 26 SEGWAY Front Fender Bracket 24155 00001 24270 00004 7 5 N m 5 5 ft Ibf Figure 141 Front Fender Bracket SE 3 Patroller Power Interface Overview Contents The Power Interface is composed of the Power Interface Board PI Board the e Electronics Shield Charger and the Electronics Shield These components are mounted on an Charger aluminum block for thermal dissipation id oar All of the electronic components of the SE 3 Patroller connect to the Pl Board via cable harnesses The Battery Module connects directly to the PI Board Fuses e Maximum Speed When to Replace Replace the Power Interface Board or Charger when troubleshooting indicates that it is malfunctioning Replace fuses when they blow NOTICE If any fuse blows other than FH9 12V Accessory Supply a deeper issue may exist Contact Segway Technical Support see page iv Safety A WARNING Wait two minutes after removing the Battery Module before removing the Electronics Shield This is how long it takes for the capacitors on the PI Board to self discharge Touching the PI Board before the capacitors have fully discharged could result in electric shock A CAUTION Use ESD best practices to avoid damaging
73. h Guard page 28 3 Locate the Siren on the front of the frame See Figure 116 4 Reach behind the Right Side Panel and disconnect Figure 116 Siren the siren harness See Figure 117 5 Using a 10 mm socket wrench loosen the nut on each side of the Siren See Figure 119 6 Pull the Siren off the bracket 7 Using a 4 mm hex wrench remove the two fasteners holding the bracket to the frame See Figure 118 8 Remove the bracket Figure 117 Siren Harness Connector 80 SE 3 Patroller SEGWAY Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Orient the bracket on the frame 3 Using a 4 mm hex wrench install the two bracket fasteners See Figure 118 Torque to 7 5 N m 5 5 ft Ibf 4 Verify that the bolts are loosely installed on the bracket 5 Slide 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 119 Torque to 2 5 N m 1 8 ft Ibf 7 Thread the siren lead behind the Right Side Panel and connect it to the Siren Harness See Figure 116 8 Install the following components a Main Splash Guard page 28 b Glove Box page 18 c Bib Panel page 16 d Storage Trays page 15 e Battery Module page 8 9 Perform post service tests page 129 Service Manual Siren 24270 00001 7 5 N m 5 5 ft Ibf T Figure 118 Si
74. h drive SKFHN 8 9 spanner wrench Loctite 242 Threadlocker P N 23212 00001 Loctite 425 Adhesive Threadlocker P N 24620 00001 Air pump with Schrader valve attachment 1 4 inch drive torque limiting screwdriver 1 6 N m range Thread Lock Torque wrenches 1 4 inch drive torque limiting ratchet 5 15 N m range 3 8 inch drive torque limiting ratchet 25 80 N m range Wheel nut key Spline drive to 3 4 in and 13 16 in hex P N 24361 00001 l 1 4 inch tube brush with abrasive nylon bristles P N 24744 00001 Wire brushes Wire brush with brass bristles MATES A Vehicle jack 1 5 Ton or greater floor jack 140 SE 3 Patroller Glossary Blade Type Fuse This type of fuse has a plastic body and metal prongs It is most commonly used in automobiles Body Panel An exterior component of the SE 3 primary purpose is to provide shape and style Button Head Cap Screw BHCS A type of screw with a rounded head and an indentation hex or 6 lobe used for tightening Cable Tie A single use plastic band that is wrapped around cables and components to hold them in place Chassis The chassis is the aluminum frame that all the other components of the SE 3 Patroller are mounted to DIP Switch Aset of slides or rockers installed onto a printed ciruit board These are commonly used to customize the behavior of a device Electrostatic Discharge ESD The rapid discharge of accumulated electrical charge To prevent damage to
75. he Drive Hub onto the Motor Place an O ring on the motor 5 Orient the Motor Mount Plate on the Motor so the notch on the mount plate is centered between the harnesses on the motor See Figure 131 6 Using a 5 mm hex wrench install the four fasteners as shown in Figure 131 Torque to 12 N m 8 9 ft Ibf 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 SE 3 Patroller Slide the Motor Assembly into place Figure 130 9 Using a 5 mm hex wrench install the four fasteners as shown in Figure 130 Torque to 12 N m 8 9 ft Ibf 10 Using a 10 mm socket wrench connect the motor phase leads W White V Red U Brown Arrange the hardware stack as shown in Figure 134 Torque to 7 5 N m 5 5 ft Ibf 11 Connect the Hall Sensor Feedback harness See Figure 129 12 Secure the motor cavity page 91 13 Perform post service tests page 129 Service Manual Drive Train O Ring 23864 00001 23869 00001 12 N m 8 9 ft Ibf A wv v Drive Hub 24008 00001 Figure 131 Motor Mount Plate 93 Drive Train 94 Motor Controller When replacing the left motor controller the throttle needs to be recalibrated For instructions on calibrating the throttle contact Segway Technical Support Tools Required 5 mm hex wrench 10 mm socket wrench Flathead screwdriver Torque wrench Removal A 1 Make su
76. he SE 3 Patroller is powered off unplugged and the wheels are chocked 2 Access the Caliper Front remove the Front Fender page 26 Rear remove a Rear Wheel page 32 3 Using a Phillips screwdriver remove the cover of the Master Cylinder 4 Fit one end of the tubing over the bleed valve on the Caliper Place the other end in an empty container See Figure 75 5 Using a in wrench open the bleed valve Brake fluid will flow out of the bleed valve See Figure 76 6 Pump the brake lever to drain the Master Cylinder 7 After all the fluid has drained use the Y in wrench to close the bleed valve NOTICE Some fluid will remain in the brake line and Master Cylinder When disconnecting components of the brake system use shop towels to absorb any brake fluid that leaks out 8 Dispose of used brake fluid in accordance with your local environmental regulations AA WARNING Do not operate the SE 3 Patroller with the brake line drained You may not be able to come to a stop Service Manual Figure 75 Draining the Front Brake Line Figure 76 Draining the Rear Brake Line Brakes 55 Brakes SEGWAY Bleeding Brake Lines Bleed the brake line after replacing a master cylinder brake line or caliper Also bleed the brake line if air is in the brake line or if there is insufficient pressure in the brake lever AA WARNING Use only DOT 4 brake fluid from a sealed container e Use a clean funnel when
77. he brake line down the steering column and around the right side of the front fork See Figure 103 4 Install a cable tie around both brake lines on the steering column NOTICE Make sure there is enough slack to turn the handlbar full left and right 5 Install three P Clips onto the brake line then slide the P Clips onto the threaded studs on the frame See Figure 105 6 Using an 8 mm socket wrench install a lock nut over the P Clip on each threaded stud Torque to 1 4 N m 1 0 ft Ibf 7 Route one end of the brake line along the right side of the frame Thread the brake line between the harnesses and the frame See Figure 104 8 Using a 14 mm socket wrench attach the Banjo Bolt to the Caliper See Figure 106 Torque to 28 5 N m 21 0 ft Ibf 9 Using a 2 5 mm hex wrench install a P Clip holding the brake line to the side of the frame NOTICE Make sure the brake line has plenty of slack around corners to avoid pinching or rubbing 10 Repeat steps 7 9 on the left side of the frame 11 Install brake fluid and bleed the brake line page 56 12 Install the following components Main Splash Guard page 28 Fenders page 24 Side Panels page 22 Light Cluster page 20 Front Cowl page 19 o w gt pop Glove Box page 18 Bib Panel page 16 Storage Trays page 15 m i Battery Module page 8 13 Perform post service tests page 129 Service Manual P Clip 24346 00001 Nut 23202 00
78. he spindle Orient the wheel so the valve stem is away from the rotor See Figure 40 3 Using the wheel nut key install the four fasteners attaching the wheel to the spindle Torque to 67 N m 49 ft Ibf 4 Slide the wheel assembly onto the front fork Orient the Wheel assembly so the rotor is toward the left side of the SE 3 5 Slide the axle through the forks and wheel assembly See Figure 39 6 Using a pair of 30 mm socket wrenches fasten the nut onto the axle Torque to 85 N m 63 ft Ibf 7 Using a bar clamp and socket compress the caliper as shown in Figure 37 then remove the bar clamp 8 Slide Caliper onto the Rotor so that the Rotor rests between the two brake pads 9 Using a 6 mm hex wrench install the two fasteners holding the Caliper in place See Figure 38 Torque to 28 5 N m 21 ft Ibf 10 Install the Front Fender page 26 11 Perform post service tests page 129 Service Manual Tire Wheel Assemblies Axle 23773 00001 24404 00001 85 N m 63 ftlbf ae Front Tire Wheel 23765 00001 Figure 40 Front Wheel on Spindle 31 Tire Wheel Assemblies Rear Tire Wheel Tools Required Vehicle jack 32 Wheel nut key 19 mm or 21 mm socket wrench torque wrench Removal Al Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Using the wheel nut key loosen but do not remove the four Wheel Nuts 3 Place the vehicle jack under the ba
79. hex wrench remove the two fasteners See Figure 59 5 Remove the Rear Directional Light Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 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 Figure 59 5 Using a 3 mm hex wrench tighten the fasteners Torque to 1 0 N m 0 74 ft Ibf A CAUTION Do not overtighten Overtightening may damage the rubber seal around the light 6 Install a P clip around the pigtails from both the Brake Light and Directional Light see Figure 58 Slide the P clip onto the upper Brake Light fastener 7 Using a 7 mm socket wrench install a lock nut to hold the P clip in place Torque to 1 6 N m 1 2 ft Ibf 8 Perform post service tests page 129 Service Manual Lights Rear Directional Light 24251 00001 24315 00004 1 0 N m 0 74 ft Ibf Pr e 7 Figure 59 Rear Directional Light Figure 60 Wire Harnesses 43 Lights 44 Rear Strobe Light Tools Required 3 mm hex wrench Torque wrench Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Access the Motor Cavity page 91 3 Disconnect the Rear Strobe Light harness See Figure 61 4 Using a 3 mm hex wrench remov
80. hole on the left hand side of the Bib Panel 3 Thread the plastic nut onto the back of the Accessory Power Outlet Tighten finger tight then turn an additional 1 8 turn 4 Install the following components a Bib Panel page 16 b Storage Trays page 15 c Battery Module page 8 5 Perform any post service tests page 129 SEGWAY Accessory Power Outlet 23979 00001 Figure 73 Accessory Power Outlet SE 3 Patroller Brakes Overview There are two brake systems front and rear Each brake system includes a master cylinder with brake lever brake line caliper s and rotor s When to Replace Replace rotors at or before they reach the wear limit 3 2 mm Replace caliper when less than 1 mm of brake pad material remains 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 fluid on plastic rubber or painted parts Protect these parts with a shop towel when servicing the brake system Contents Brake Fluid Draining Brake Lines e Bleeding Brake Lines e Front Caliper Front Rotor Master Cylinder Brake Lever Rear Caliper amp Rotor Front Brake Line Rear Brake Line 53 Brakes Brake Fluid Check the Brake Fluid level as part of your regular maintenance routine Be sure to check both the left and right master cylinders Checking the
81. ight Cluster page 20 Front Cowl page 19 ao 2 Glove Box page 18 Bib Panel page 16 g Storage Trays page 15 Figure 182 Siren Harness Routing gt pap h Battery Module page 8 7 Perform post service tests page 129 126 SE 3 Patroller SEGWAY Service Interface Harness This harness is used by service technicians when diagnosing problems with the SE 3 Patroller Tools Required Wire cutters Removal A 1 4 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Remove the following components a Battery Module page 8 b Storage Trays page 15 c Bib Panel page 16 d Glove Box page 18 e Electronics Shield page 102 Disconnect the wire harness from the PI Board See Figure 183 Remove the Service Interface Harness Installation Al Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Connect the wire harness to the PI Board See Figure 183 Install the following components a Electronics Shield page 102 b Glove Box page 18 c Bib Panel page 16 d Storage Trays page 15 e Battery Module page 8 Perform post service tests page 129 Service Manual Figure 183 Service Interface Harness to PI Board Harnesses 127 Harnesses SEGWAY 128 SE 3 Patroller Post Service Tests This chapter describes standard tests to perform after servicing a Segway SE 3 Patroller If
82. igure 94 and on the end of the piston Figure 92 Use UltraLube marine and trailer grade bearing grease P N 24431 00001 3 Orient the brake lever with the end ball facing toward the front of the SE 3 Patroller see Figure 93 4 Slide the brake lever in place making sure the spring is seated correctly One end of the spring fits into a hole in the brake housing and the other end fits into a hole in the brake lever 5 If installing the right hand brake lever position the parking brake bracket on top of the brake housing 6 Using a 10 mm socket wrench install the shoulder bolt Figure 91 Torque to 10 N m 7 4 ft Ibf 7 Using a 10 mm socket wrench install the nut underneath the brake lever Figure 90 Torque to 10 N m 7 4 ft Ibf 8 If installing the right hand brake lever install the parking brake as follows a Using a phillips head screwdriver install the spring and front screw as shown in Figure 95 b Using a phillips head screwdriver install the second screw c Torque both screws to 1 5 N m 1 1 ft Ibf d Place the parking brake cap over the spring and slide the pin through the holes e Install a retaining ring on the end of the pin 9 Perform post service tests page 129 to verify the brakes are functioning properly Service Manual Brakes Figure 92 Spring Location Front Figure 93 Brake Lever Lubricate Shoulder Only Figure 94 Shoulder Bolt Spring attaches
83. ing with a cutting tool then remove the heat shrink tubing A CAUTION Be careful not to cut yourself with the sharp blade 7 Using a 6 mm hex wrench and a 13 mm socket wrench remove the two fasteners as shown in Figure 135 8 Slide the Handlebar up and out SEGWAY Handlebar dias o Heat Shrink Tubing 24502 00001 23784 00001 34 N m 25 ft Ibf 23868 00010 di Figure 135 Handlebar SE 3 Patroller SEGWAY Installation A L 10 11 12 13 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Spray some UltraLube Industrial Grade Corrosion Inhibitor P N 24429 00001 on the bottom of the Handlebar where it slides into the Front Fork This will make it easier to remove the Handlebar in the future Slip a piece of heat shrink tubing onto the Handlebar Slide the Handlebar into the top of the Front Fork Using a 6 mm hex wrench and a 13 mm socket wrench install the fasteners as shown in Figure 135 Torque to 34 N m 25 ft Ibf Slide the heat shrink tubing over the fasteners Then use a heat gun to shrink the tubing around the fasteners NOTICE The purpose of the heat shrink tubing is to keep wire harnesses from catching on the fasteners when turning the Handlebar Using a 5 mm hex wrench install the Brake Levers See Figure 137 Do not fully tighten Rotate the Brake Lever so that it is 11 5 from horizontal Figure 136 Then
84. irst component to remove when removing body panels Both Storage Trays must be removed before removing the Bib Panel Tools Required 4mm hex wrench Torque wrench Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Usinga4mm hex wrench remove the fastener at the bottom of the Storage Tray 3 Remove the Storage Tray Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Insert the Storage Tray and line up the hole in the bottom of the Storage Tray with the threaded hole in the vehicle s frame 3 Using a 4 mm hex wrench install the fastener Torque to 1 0 N m 0 74 ft Ibf Do not over tighten Service Manual Body Panels 24270 00006 1 0 N m 0 74 feb ap I i 1 GA Storage Tray Left 23758 00001 Right 23759 00001 gt K 9 A Figure 12 Storage Tray 15 Body Panels Bib Panel The Bib Panel is also known as the Front Tower Panel 16 Tools Required 4mm hex wrench 2 5 mm hex wrench Torque wrench Wire cutters Removal A 1 Make sure the SE 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 15 3 Using a 4 mm hex wrench remove the eight fasteners as shown in Figure 13 4 Gently pull the Bib Panel off the frame to access the cable harnesses connected to it 5 Discon
85. ity Locate the heat vent Figure 52 Right light heat vent down Left light heat vent up 4 Slide the plastic sleeves onto the fasteners then install the fasteners and lock nuts Figure 50 5 Using a 3 mm hex wrench and a 7 mm socket wrench tighten the fasteners Torque to 1 6 N m 1 2 ft lbf A CAUTION Do not overtighten Overtightening may damage the rubber seal around the light 6 Reassemble the SE 3 Patroller by following the instructions to Install Body Panels on page 38 7 Perform post service tests page 129 Service Manual Lights Front Strobe Light Police 24252 00001 Security 24252 00002 23202 00001 1 6 N m 1 2 ft Ibf 0 one Figure 51 Light Harnesses Heat Vent Figure 52 Heat Vent Location 39 Lights Side Strobe Light Tools Required 3 mm hex wrench 40 7 mm socket wrench Torque wrench Removal Al 5 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Access the Light Cluster by following the instructions to Remove Body Panels on page 38 Disconnect the wire harness Using a 3 mm hex wrench and a 7 mm socket wrench remove the two fasteners securing the light See Figure 53 Remove the light Installation Al Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Feed the wire harness through the hole in the Light Cluster and connect it to the Front Light Harne
86. l page 16 d Glove Box page 18 3 Using a 4 mm hex wrench remove the six fasteners as shown in Figure 22 4 _ Lift the Front Cowl off of the frame Installation A 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 it rests on the Light Cluster and the Side Panels 3 Using a 4 mm hex wrench install the six fasteners as shown in Figure 22 Torque to 4 0 N m 3 0 ft Ibf 4 Install the following components a Glove Box page 18 b Bib Panel page 16 c Storage Trays page 15 d Battery Module page 8 5 Perform post service tests page 129 Service Manual Front Cowl 23750 00001 Figure 22 Fasten the Front Cowl Body Panels 19 Body Panels Light Cluster These instructions describe how to remove and install the Light Cluster body panel For instructions on replacing individual lights see page 35 Tools Required 4mm hex wrench Torque wrench Removal A 1 Make sure the SE 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 15 c Bib Panel page 16 d Glove Box page 18 e Front Cowl page 19 3 Using a 4 mm hex wrench remove the two fasteners as shown in Figure 23 4 Remove the two cable ties around the light cluster harnesses 5 Detach the wire harnesses Figure 24 Slide the
87. ld fully discharge over time causing permanent damage Comply with all local and federal or individual country laws when disposing of and transporting Battery Modules Fasteners ZA WARNING Use only Segway approved fasteners Other fasteners may not perform as expected and may come loose e Do not tighten or reuse any lock nut 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 necessary washer and thread lock in place 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 e Insert fasteners slowly and carefully Do not cross thread or over tighten fasteners Tighten only to the prescribed torque Failure to adhere to these warnings could lead to serious injury or death or damage to property Cable Ties A CAUTION When removing cable ties be careful not to cut or nick harnesses Damaged harnesses must be replaced You must replace all cable ties that you remove Loose wires can rub against sharp edges which can cause them to break over time Eye Protection ZA 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 A CAUTION When a repair involves a
88. le ties a One at the top of the frame b Two holding the harness to the frame 5 Install the following components a Glove Box page 18 b Bib Panel page 16 c Storage Trays page 15 d Battery Module page 8 6 Perform post service tests page 129 Figure 178 Accessory Power Harness Routing 124 SE 3 Patroller SEGWAY KeyLock Harness This harness connects the PI Board to the KeyLock on the Bib Panel Tools Required Wire cutters Removal A 1 Make sure the SE 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 15 c Bib Panel page 16 d Glove Box page 18 e Electronics Shield page 102 3 Disconnect the wire harness from the PI Board See Figure 179 4 Using a pair of wire cutters remove the cable tie holding the harness to the top of the frame 5 Remove the KeyLock Harness Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Connect the wire harness to the PI Board See Figure 179 3 Route the harness through the frame and up to the top right of the frame See Figure 180 4 Install a cable tie at the top of the frame 5 Install the following components a Electronics Shield page 102 b Glove Box page 18 c Bib Panel page 16 d Storage Trays page 15 e Battery Module page 8 6 Perform post service
89. llation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Connect the Drive Harness to the Motor Controller Brace 3 Connect the Drive Harness to the Motor Feed the harness through the hole in the front of the motor cavity Send the Left Drive Harness out the left side of the frame Send the Right Drive Harness out fe the right side of the frame 5 Feed the harness under the horizontal brace on the frame see Figure 158 and connect it to the PI Board 6 Install two cable ties around the harnesses in the motor cavity 7 Install two cable ties around the harnesses on the side of the frame 8 Install the following components a Motor Cavity Lid page 91 b Rider Detect Mat page 84 c Electronics Shield page 102 d Side Panel page 22 e Light Cluster page 20 f Front Cowl page 19 g Glove Box page 18 h Bib Panel page 16 i Storage Trays page 15 j Battery Module page 8 Figure 158 Drive Harness Routing 9 Perform post service tests page 129 Service Manual 113 Harnesses SEGWAY Handlebar Controls Harness This harness connects the Pl Board to the Control Cluster Headlight Throttle and both Brake Levers Tools Required Wire cutters Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the following components a Battery Module page 8 Storage Trays page 15 Bib
90. llowing components a Battery Module page 8 b Storage Trays page 15 c Bib Panel page 16 d Glove Box page 18 e Front Cowl page 19 f Light Cluster page 20 g Front Fender page 26 3 Drain the brake fluid out of the front brake line see page 55 4 Using a 14 mm socket wrench disconnect the Banjo Bolt from the Caliper See Figure 101 NOTICE Place the Banjo Bolt in a container to catch any brake fluid that drains out 5 Using a 2 5 mm hex wrench remove the three P Clips See Figure 100 6 Using wire cutters remove the cable tie on the steering column See Figure 100 7 Using a 14 mm socket wrench disconnect the Banjo Bolt from the Master Cylinder See Figure 86 8 Remove the brake line SEGWAY Cable tie Front Brake Line 23955 00001 Steel P Clips 2440 00001 2 5 N on Ibf WO R P Clip 24346 00001 2 5 N m 1 8 ft Ibf All P Clips use 20307 00002 fasteners Figure 100 Front Brake Line SE 3 Patroller SEGWAY Installation Al Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Using a 14 mm socket wrench connect a Banjo Bolt to the Master Cylinder See Figure 86 Torque to 28 5 N m 21 0 ft Ibf Thread the Brake Line between the Main Splash Guard and the frame Run the Brake Line down the steering column and through both cable clamps Install a cable tie around both brake lines on the steering column
91. mm hex wrench install the four fasteners as shown in Figure 107 Torque to 1 8 N m 1 3 ft Ibf 4 Install the Battery Module page 8 5 Perform post service tests page 129 SEGWAY Ul Module 24088 00001 i ba 24409 00003 1 8 N m 1 3 ft Ibf Figure 107 UI Module Figure 108 UI Harness SE 3 Patroller SEGWAY Ul Housing Tools Required 4mm hex wrench Torque wrench Removal A L 5 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Remove the following components a Battery Module page 8 b Ul Module page 72 Using a 4 mm hex wrench remove the four fasteners as shown in Figure 109 Carefully push the rubber grommet out of the hole in the back of the UI Housing See Figure 110 NOTICE Do not use any sharp or pointed tools You could puncture the grommet thereby allowing water to enter the Ul Housing Remove the UI Housing Installation Al Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Orient the UI Housing on the frame Insert the UI Harness into the UI Housing and carefully press the grommet into place See Figure 110 NOTICE Do not use any sharp or pointed tools You could puncture the grommet thereby allowing water to enter the UI Housing Using a 4 mm hex wrench install the four fasteners as shown in Figure 109 Torque to 2 8 N m 2 1 ft Ibf Install the following c
92. ndshield Tools Required 4mm hex wrench 10 mm socket wrench Torque wrench Removal 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Using both a 4 mm hex wrench and a 10 mm socket wrench remove the four hex nuts on the underside of the Windshield See Figure 43 3 Remove the fasteners and lift the Windshield off the handlebar frame Installation Ax 1 Make sure the SE 3 Patroller is powered off 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 Patroller so that the holes in the Windshield align with the holes in the handlebar frame 4 Insert fasteners from above Hand tighten hex nuts from underneath 5 Using both a 4 mm hex wrench and a 10 mm socket wrench tighten the fasteners Torque to 1 5 N m 1 1 ft Ibf NOTICE Do not over tighten Over tightening could damage the Windshield 34 SEGWAY Windshield Grommet 23805 00001 23202 00004 1 5 N m 1 1 ft Ibf Figure 43 Windshield SE 3 Patroller Lights Overview The SE 3 Patroller has a headlight brake lights directional lights and strobe lights There are two colors of strobe lights red blue for police and amber for security When to Replace Replace a light when diagnostic testing indicates that a light is malfunctioning
93. nect the two quick connect terminals from the back of the Accessory Power Outlet Figure 16 6 Using wire cutters remove the cable tie on the KeyLock See Figure 15 7 Slide the rubber protector off the KeyLock 8 Press the tab on the side of the Connector Block and pull it off the KeyLock Figure 17 9 Using a 2 5 mm hex wrench remove the two fasteners on the Charge Port IEC Socket See Figure 14 10 Pull the Bib Panel completely off the frame SEGWAY 24270 00006 4 0 N m 30ftIbf N A Re a Bib Panel 24117 00001 Figure 13 Bib Panel IEC Socket 20307 00005 O 1 6 N m 1 2 ft Ibf Figure 14 Charge Port Figure 15 Rubber Protector Covering the KeyLock SE 3 Patroller SEGWAY Installation A 1 10 11 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Using a 2 5 mm hex wrench and two fasteners install the Charge Port IEC Socket onto the Bib Panel Torque to 1 6 N m 1 2 ft Ibf NOTICE Make sure the IEC socket is aligned correctly Slide the connector block onto the back of the KeyLock Pull on it to verify that it is locked in place If necessary connect the two quick connect terminals to the KeyLock Figure 17 Pinl Black Pin2 Red Pin3 Empty Slide the rubber protector over the connector block and secure with a cable tie See Figure 15 Connect the two quick connect terminals to the Accessory Power Outlet Figure 16
94. ny electronic components or harnesses best practice electrostatic discharge ESD control procedures must be followed Failure to follow ESD procedures could result in personal injury or damage to property 2 SE 3 Patroller SEGWAY General Safety Precautions Questions ZA 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 Service Manual 3 General Safety Precautions SEGWAY 4 SE 3 Patroller Introduction Purpose The purpose of this manual is to provide instructions for servicing the Segway SE 3 Patroller Audience This manual is written for Segway Certified Service Technicians working under agreement with Segway Inc Certification Becoming a Segway Certified Service Technician SE 3 Patroller involves a two 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 SE 3 Patroller parts and assemblies according to the following scheme Table 1 Certification Levels Parts and Assemblies Instructions Body Panels Tire Wheel Assemblies Windshield Lights Battery Compartment Bib Components All Level 1 see above See above Brakes page 53 Controls page 71 Siren page 79 Rider Detect Mat page 83 Drive Train page 87 Steering Column
95. o 2 Storage Trays page 15 Bib Panel page 16 Glove Box page 18 Front Cowl page 19 Light Cluster page 20 g Side Panels page 22 h gt peop Fenders page 24 i Main Splash Guard page 28 3 Drain the brake fluid out of the rear brake line see page 55 4 Using a 14 mm socket wrench disconnect 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 mm hex wrench remove the P Clips on the sides of the frame one each side See Figure 104 7 Using an 8 mm socket wrench remove the lock nuts holding the three P Clips to the front of the frame Then slide the P Clips off the threaded studs See Figure 105 8 Using wire cutters remove the cable tie holding the brake lines to the steering column 9 Using a 14 mm socket wrench disconnect the Banjo Bolt from the Master Cylinder 10 Remove the Brake Line o i P Clip 24346 00001 Fastener 20307 00002 ha 2 5 N m 1 8 ft Ibf Figure 104 Rear Brake Line 68 SE 3 Patroller SEGWAY Brakes Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Using a 14 mm socket wrench connect the upper Banjo Bolt to the Master Cylinder See Figure 106 Torque to 28 5 N m 21 0 ft Ibf 3 Route t
96. ock A CAUTION Always wear gloves when handling chemicals such as lubricants corrosion inhibitors greases or oils to reduce the potential for skin damage or irritation Battery Module ZA WARNING Do not use the Battery Module if the casing is broken or if the Battery Module emits an unusual odor smoke or excessive heat or leaks any substance Avoid contact with any substance seeping from the Battery Module Batteries contain toxic and corrosive materials that could cause serious injury e Keep out of reach of children and pets Exposure to battery voltage could result in death or serious injury Unplug or disconnect the SE 3 Patroller from AC power before removing or attaching the Battery Module or performing any service Never work on any part of the SE 3 Patroller when it is plugged into AC power You risk serious bodily injury from electric shock as well as damage to the SE 3 Patroller The cells within the Battery Module contain toxic substances Do not attempt to open the Battery Module Do not insert any object into the Battery Module or use any device to pry at the Battery Module casing If you insert an object into any of the Battery Module ports or openings you could suffer electric shock injury burns or cause a fire Attempting to open the Battery Module casing will damage the casing and could release toxic and harmful substances and will render the Battery Module unusable e Observe and follow all safety information on
97. omponents a Ul Module page 72 b Battery Module page 8 Perform post service tests page 129 Service Manual Ul Housing 23811 00001 I 24270 00001 2 8 N m 2 1 ft Ibf Figure 110 Ul Harness Grommet Controls 73 Controls 74 Control Cluster Tools Required 115 Torx wrench Removal Wire cutters Torque wrench Digital level A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the following components a b C d e Battery Module page 8 Storage Trays page 15 Bib Panel page 16 Glove Box page 18 Front Cowl page 19 3 Disconnect the wire harness See Figure 111 Using a pair of wire cutters remove the two cable ties on the steering column 5 Using a T15 Torx wrench loosen the three fasteners on the under side of the Control Cluster See Figure 112 6 Pull the two halves apart and lift the Control Cluster off the Handlebar SEGWAY Figure 111 Control Cluster Harness SE 3 Patroller SEGWAY Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Slide the Control Cluster onto the handlebar 3 Leave a small gap 5 mm between the Control Cluster and the Handlebar Grip 4 Orient the Control 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 Ibf NOTICE Tigh
98. omponents a Windshield page 34 b Front Cowl page 19 c Glove Box page 18 d Bib Panel page 16 y e Storage Trays page 15 Y f Battery Module page 8 Figure 45 Headlight Harness 8 Perform post service tests page 129 36 SE 3 Patroller SEGWAY Headlight Alignment Always align the Headlight after performing any service that affects the Headlight Tools Required 4mm hex wrench 10 mm socket wrench Digital level Torque wrench Procedure A 1 Make sure the SE 3 Patroller is powered 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 46 Loosen just enough to adjust the headlight angle 3 Place a digital level on top of the bracket Adjust the bracket until it is at 12 4 Tighten the Headlight Bracket fasteners and torque to 6 0 N m 4 4 ft Ibf Service Manual Figure 46 Headlight Bracket 23202 00004 6 0 N m 4 4 ft Ibf 24270 00004 Lights 37 Lights Accessing the Light Cluster To acess the Light Cluster remove the body panels listed below Remove Body Panels A 1 Make sure the SE 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 15 c Bib Panel page 16 d Glove Box page 18 e Front Cowl page 19 NOTICE Some of the lights requi
99. onnect the power leads from the Motor Controller See Figure 154 7 Remove the Motor Power Harness 110 SE 3 Patroller SEGWAY Installation A L 2 8 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Using a 10 mm socket wrench connect the leads to the Motor Controller B Red B Black Arrange the hardware stack as shown in Figure 155 Torque to 7 5 N m 5 5 ft Ibf Feed the harness through the hole in the front of the motor cavity Send the left Motor Power Harness out the left side of the frame Send the right Motor Power Harness out the right side of the frame Feed the harness under the horizontal brace on the frame and connect it to the Pl Board See Figure 152 Install two cable ties around the harnesses in the motor cavity Install two cable ties around the harnesses on the side of the frame See Figure 153 Install the following components Motor Cavity Lid page 91 Rider Detect Mat page 84 Side Panel page 22 Light Cluster page 20 Front Cowl page 19 mo 29 5 BP Glove Box page 18 Bib Panel page 16 Storage Trays page 15 gt 08 i Battery Module page 8 Perform post service tests page 129 Service Manual Harnesses Figure 154 Motor Power Harness to Motor Controller 24436 00004 7 5 N m 5 5 ft Ibf Lock Washer 24435 00003 Flat Washer Ring Terminal 24434 00003 Figure 155 Hardware St
100. ot limited to e Persistent leak in tire after reinflation e Wheel is cracked or bent e Tire is flat cracked or excessively worn Excess wear is determined as follows Front tire tread 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 wear Ensure tires are properly inflated as follows e Front 22 psi 1 52 Bar 152 kPa e Rear 25 psi 1 72 Bar 172 kPa Safety ZA WARNING When jacking up the SE 3 Patroller make sure the SE 3 Patroller is stable or use a jack 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 29 Tire Wheel Assemblies Front Tire Wheel Replacing the Front Tire Wheel involves removing the Front Fender Boot removing the caliper and rotor and removing the Front Spindle off of the Front Fork Tools Required Vehicle jack 30 Setup 4 inch bar clamp 6mm hex wrench 30 mm socket wrench 2 Wheel nut key 19 mm or 21 mm socket wrench Torque wrench When removing or installing the front Tire Wheel prepare the SE 3 Patroller by following these steps Al Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Place a vehicle jack under the center front of the skid plate Raise th
101. p 16 Front Cowl Side Panel Non Flanged Figure 22 p 19 Light Cluster Side Panel Non Flanged Figure 23 p 20 Side Panel Floating Bracket Side Panel Non Flanged Figure 26 p 22 Side Panel Bracket Side Panel Non Flanged Figure 29 p 23 Flanged Insert Non Flanged Insert 24742 00001 24741 00001 a de Figure 8 Replacement Inserts Service Manual 13 14 Installation 1 Drill out the mounting hole in the panel using a 23 64 inch or 9 12 mm drill bit Figure 9 If using the Non flanged Inserts be careful not to drill through the panel wall Mix the epoxy according to the manufacturer s instructions Using a cotton swab or similar instrument apply the epoxy to the drilled hole and to the replacement insert Figure 10 NOTE Depending on the mounting location use one of two different replacement inserts Table 2 Using a 6 mm hex wrench install the epoxy coated insert into the mounting hole Figure 11 Flanged inserts should be screwed in until the flange is snugged securely against the top of the panel boss Non flanged inserts should be screwed in until they are flush with the top of the panel boss If the threaded insert protrudes through the panel apply additional epoxy to the outside threads of the insert Wait for the epoxy to cure before reinstalling the panels on the SE 3 Figure 10 Apply Epoxy SEGWAY SE 3 Patroller SEGWAY Storage Tray The Storage Tray is the f
102. pacer See Figure 97 Using a 14 mm socket wrench attach the Banjo Bolt on the end of the brake line to the Caliper See Figure 99 Torque to 28 5 N m 21 0 ft Ibf A CAUTION Always use new crush washers when attaching a Banjo Bolt to any component Used crush washers may leak causing a reduction in braking force Carefully slide the Caliper onto the Rotor so the Rotor is between the two brake pads Using a 6 mm hex wrench install the two caliper fasteners See Figure 96 Torque to 28 5 N m 21 0 ft Ibf Install the following components a Rear Tire Wheel page 32 b Fender page 24 c Bib Panel page 16 d Storage Trays page 15 e Battery Module page 8 Perform post service tests page 129 Service Manual Brakes 23868 00001 28 5 N m 21 0 ft Ibf Caliper Bracket 23861 00001 Figure 98 Rear Caliper Bracket Hollow Screw 28 5 N m 21 0 ft Ibf Crush Washer 23958 00001 Crush Washer 23958 00001 Figure 99 Brake Line Fasteners 65 Brakes 66 Front Brake Line Replacing the Front Brake Line can be a messy job Be careful not to let any brake fluid get on the harnesses electronics or rotor Immediately wipe up any spilled brake fluid with a shop towel Tools Required 2 5 mm hex wrench 14 mm socket wrench Wire cutters Torque wrench Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the fo
103. page 26 e Battery Module page 8 Perform post service tests page 129 SEGWAY 24409 00008 2 0 N m 15 ft Ibf Washers 7 Figure 67 Assembled Battery Bumper SE 3 Patroller Bib Panel Components Overview Bib Panel Components These are replaceable components that attach to the Bib Panel e Glove Box Door e KeyLock When to Replace e Accessory Power Outlet 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 49 Bib Panel Components Glove Box Door Tools Required 2 5 mm hex wrench 7 mm socket wrench Torque wrench Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Pop off the top hinge caps Figure 68 3 Open the Glove Box Door and locate the fasteners on the inside top of the Glove Box 4 Using a 2 5 mm hex wrench and a 7 mm socket wrench remove the four fasteners 5 Remove the Glove Box Door NOTICE Do not operate the SE 3 Patroller without the Glove Box Door installed The warning label on the Glove Box Door must be visible Installation A 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 fasteners from above through the hinges and into the holes in the Bib Panel 4
104. re plastic sleeves to be installed on the fasteners See Figure 49 Install Body Panels Ax 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Install the following components a Front Cowl page 19 b Glove Box page 18 c Bib Panel page 16 d Storage Trays page 15 e Battery Module page 8 38 SEGWAY N Side Strobe Light Directional Hehe Fi er l Figure 47 Light Cluster Components Right Stobe Lights Left Directional Light Order Not Important Directional Light Figure 48 Light Cluster Harness AAIEN IA Eha h 1 Figure 49 Fastener with Plastic Sleeve SE 3 Patroller SEGWAY Front Strobe Light Tools Required 3 mm hex wrench 7 mm socket wrench Torque wrench Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Access the Light Cluster by following the instructions to Remove Body Panels on page 38 3 Disconnect the wire harness Using a 3 mm hex wrench and a 7 mm socket wrench remove the two fasteners securing the light See Figure 50 5 Remove the light Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Feed the wire harness through the hole in the Light Cluster and connect it to the Front Light Harness See Figure 51 3 Orient the light Police Red toward center Blue toward outside Secur
105. re the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Access the motor cavity page 91 3 Using a 10 mm socket wrench disconnect the power and motor current harnesses 4 Using a flathead screwdriver lift the tab on the Drive Harness while pulling the connector off See Figure 133 5 Using a 5 mm hex wrench remove the four fasteners holding the motor plate onto the bottom of the motor cavity See Figure 132 NOTICE Do not remove the four star drive fasteners holding the Motor Controller cover 6 Remove the Motor Controller Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Place the Motor Controller in the Motor Cavity Orient it so the large connector is toward the rear 3 Using a 5 mm hex wrench install the four fasteners Torque to 7 5 N m 5 5 ft Ibf 4 Connect the Drive Harness Using a 10 mm socket wrench install the remaining harnesses Power B Red B Black Motor W White V Red U Brown Arrange the hardware stack as shown in Figure 134 Torque to 7 5 N m 5 5 ft Ibf 5 Secure the motor cavity page 91 Perform post service tests page 129 23869 00003 7 5 N m 5 5 ft Ibf SEGWAY Motor Controller a 23722 00001 Figure 132 Motor Controller Figure 133 Removing the Harness 24436 00004 7 5 N m 5 5 ft Ibf Lock Washer 24435 00003
106. ren Bracket Siren Bracket Figure 119 Siren Fasteners 81 Siren SEGWAY 82 SE 3 Patroller Rider Detect Mat Overview The Rider Detect Mat acts as an operator presence control device 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 determines that it is malfunctioning Contents e Rider Detect Mat 83 Rider Detect Mat Rider Detect Mat Tools Required 3 mm hex wrench Torque wrench A CAUTION Do not bend the Rider Detect Mat harness where it connects to the Rider Detect Mat The cable can become damaged rendering the Rider Detect Mat unusable Service Access To access the Motor Cavilty beneath the Rider Detect Mat you do not need to remove the Rider Detect Mat entirely Simply lean it out of the way as described below A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the Battery Module page 8 3 Using a3 mm hex wrench remove the four fasteners as shown in Figure 120 4 Lift the Rider Detect Mat until you can see the harness as shown in Figure 122 A CAUTION Be careful not to bend kink or otherwise damage the Rider Detect Mat harness If this harness becomes damaged the Rider Detect Mat will need to be replaced 5 Carefully pull the Rider Detect Mat back a couple inches and lean i
107. s 6 SE 3 Patroller Battery Module Overview Contents This component is not serviceable if there is a problem with the Battery Module it Battery Module must be replaced When to Replace Replace when troubleshooting determines that the Battery Module is malfunctioning Safety AA WARNING Always remove the Battery Module before servicing the SE 3 Patroller Failure to remove the Battery Module could result in serious injury or death due to electric shock Battery Module SEGWAY Battery Module Tools Required None Removal Ax 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Flip latches out Quo Twist latches inward 2 Flip out and twist the 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 completely out Figure 2 Slide the Battery Module out of the SE 3 Patroller 8 SE 3 Patroller SEGWAY Installation 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Make sure the latches are configured 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 Service Manual Battery Module Figure 3 Slide the Battery Module into the SE 3
108. ss 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 See Figure 54 Slide the plastic sleeves onto the fasteners then install the fasteners and lock nuts Figure 53 Using a 3 mm hex wrench and a 7 mm socket wrench tighten the fasteners Torque to 1 6 N m 1 2 ft Ibf A CAUTION Do not overtighten Overtightening may damage the rubber seal around the light Reassemble the SE 3 Patroller by following the instructions to Install Body Panels on page 38 Perform post service tests page 129 SEGWAY a Side Strobe Light Pe ae Police 24253 00002 Security 24253 00003 23202 00001 1 6 N m 1 2 ft Ibf 2 24315 00007 Figure 53 Side Strobe Lights Pigtail is offset toward the top il Figure 54 Harness Offset SE 3 Patroller SEGWAY Lights Front Directional Light Tools Required 3 mm hex wrench 7 mm socket wrench Torque wrench Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged ER oe 2 Access the Light Cluster by following the instructions ee nee to Remove Body Panels on page 38 a ge iE ee 12 ft lbf 3 Disconnect the wire harness 9 Using a 3 mm hex wrench and a 7 mm socket wrench remove the two fasteners securing the light See Figure 55 5 Remove the light 24315 00002 N Installation fr Front
109. t against the Bib Panel SEGWAY 24367 00002 4 0 N m 3 0 ft Ibf ga a Rider Detect Mat 23714 00001 Figure 120 Rider Detect Mat SE 3 Patroller SEGWAY Removal A L 2 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Remove the following components Battery Module page 8 Oo w Storage Trays page 15 Bib Panel page 16 Glove Box page 18 Front Cowl page 19 Light Cluster page 20 g Left Side Panel page 22 gt pap Using a 3 mm hex wrench remove the four fasteners as shown in Figure 120 Disconnect the harness from the Pl Board See Figure 121 Lift the Rider Detect Mat and slide it off of the SE 3 Patroller Installation Al 8 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged Orient the Rider Detect Mat on the SE 3 Patroller with the wire harness toward the front Feed the wire harness through the hole in the frame Connect the wire harness to the left side of the Pl Board See Figure 121 Slide the Rider Detect Mat in place The front should rest under the tab and the rear should line up with the threaded studs Using a 3 mm hex wrench install the four fasteners as shown in Figure 120 Torque to 4 0 N m 3 0 ft Ibf Install the following components Left Side Panel page 22 Light Cluster page 20 Front Cowl page 19 ao w Glove Box pag
110. ten the fasteners carefully to make sure the two halves align correctly with each other 6 Connect the wire harness See Figure 111 7 Install two cable ties around the harnesses on the steering column 8 Install the following components a Front Cowl page 19 b Glove Box page 18 c Bib Panel page 16 d Storage Trays page 15 e Battery Module page 8 9 Perform post service tests page 129 Service Manual o ve 2 8 N m 2 0 ft Ibf Figure 112 Control Cluster Fasteners Controls 75 Controls 76 Throttle The throttle needs to be calibrated for the particular SE 3 Patroller it is installed on For instructions on calibrating the throttle contact Segway Technical Support Tools Required Phillips screwdriver Removal Wire cutters Torque wrench LPS heavy duty silicone lubricant Digital level A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the following components a b C d e Battery Module page 8 Storage Trays page 15 Bib Panel page 16 Glove Box page 18 Front Cowl page 19 3 Disconnect the wire harness See Figure 114 4 Using a pair of wire cutters remove the two cable ties on the steering column 5 Using a Phillips screwdriver loosen the two fasteners on the underside of the Throttle See Figure 113 6 Slide the Throttle off the handlebar a ae 4 0 N m 3 0 ft Ibf Figure 113 Throttle SEG
111. the Drive Hub 4 Use a cotton swab to spread some Molykote G n paste P N 24505 00001 on the splines inside the Drive Hub This paste helps reduce wear between the Drive Hub and the Motor 5 Slide the Drive Hub onto the Motor Install the following components Gearbox page 88 Rear Caliper amp Rotor page 64 Rear Tire Wheel page 32 Fender page 24 Bib Panel page 16 Storage Trays page 15 mo 29 5 Bp g Battery Module page 8 7 Perform post service tests page 129 90 SE 3 Patroller SEGWAY Accessing the Motor Cavity Tools Required 3 mm hex wrench Torque wrench Accessing A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the Battery Module page 8 3 Lean the Rider Detect Mat against the Bib Panel Service Access page 84 4 Lean the Rider Detect Spacer against the Rider Detect Mat 5 Using a 3 mm hex wrench remove the eight fasteners as shown in Figure 128 6 Remove the Motor Cavity Lid Securing A 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 hex wrench install the eight fasteners as shown in Figure 128 Torque to 4 0 N m 3 0 ft Ibf 4 Place the Rider Detect Spacer on top of the Motor Cavity Lid 5 Install the following components a Rider Detect Mat page 84 b Battery Module page 8 6 Per
112. the wheels and ensure the SE 3 Patroller doesn t move If removing the left hand brake lever proceed to step 3 below If removing the right hand brake lever first remove the parking brake cap a Using a flathead screwdriver remove the retaining ring Figure 89 NOTICE Be careful not to lose the retaining ring Since it is under spring tension it can travel along distance through the air Use your hand to catch or deflect it so it doesn t get lost b Slide the pin out and remove the parking brake cap c Using a phillips head screwdriver remove the two screws Keep track of the spring and lock washers Using a 10 mm socket wrench remove the nut underneath the brake lever Figure 90 Using a 10 mm socket wrench unscrew and remove the shoulder bolt Figure 91 Remove the brake lever and the parking brake bracket if applicable SEGWAY Parking Retaining Ring Figure 89 Retaining Ring Nut 10 N m 7 4 ft Ibf Figure 90 Nut Location Parking Brake 7 a Bracket Shoulder Bolt 10 N m 7 4 ft Ibf Figure 91 Parking Brake Cap Removed SE 3 Patroller SEGWAY Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the wheels are chocked CAUTION You can t service the right hand brake lever with the parking brake on Chock the wheels and ensure the SE 3 Patroller doesn t move 2 Putathin film of lubrication on the shoulder of the shoulder bolt F
113. tighten the fasteners Torque to 10 N m 7 4 ft Ibf Install a cable tie in the upper bracket on the steering column Secure both brake lines NOTICE Make sure there is enough slack in the brake lines to turn the handlebar full left and right Connect the Handlebar Controls Harness to the handlebar components page 114 Install two cable ties around the handlebar harnesses Install the following components Light Cluster page 20 Front Cowl page 19 Oo w Glove Box page 18 Bib Panel page 16 Storage Trays page 15 Battery Module page 8 Oo 29 Perform post service tests page 129 Service Manual Figure 137 Master Cylinder Fasteners Steering Column 97 Steering Column Front Fork Some text goes here Tools Required SKF HN 8 9 spanner wrench Removal Torque wrench UltraLube marine amp trailer bearing grease Permatex anti seize lubricant Vehicle jack A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Remove the following components 2 o Oo gt 0 08 j k Battery Module page 8 Storage Trays page 15 Bib Panel page 16 Glove Box page 18 Front Cowl page 19 Light Cluster page 20 Front Fender page 26 Front Splash Guard page 27 Front Fender Bracket page 100 Front Caliper page 58 Handlebar page 96 3 Jack up the front of the SE 3 Patroller Figure 138 ZA WARNING Make sure the SE
114. ure 31 Inside Fasteners SE 3 Patroller SEGWAY Body Panels Installation cont 9 Install the following components a Bib Panel page 16 b Storage Trays page 15 c Battery Module page 8 10 Perform post service tests page 129 Inside Fasteners 2x 24270 00004 1x 24270 00006 a Bracket Left 24297 00001 Right 24298 00001 P Clip 24509 00001 P Clip o 24509 00001 23202 00004 5 5 N m 4 0 ft Ibf Outside Fasteners wee 24270 00004 Bracket Fasteners 24270 00006 4 0 N m 3 0 ft Ibf Gearbox Assembly Figure 32 Exploded View of Fender Service Manual 25 Body Panels Front Fender Boot The Front Fender must be removed any time Front Fork components need to be accessed Tools Required 4mm hex wrench 6mm hex wrench Torque wrench Removal A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Using a 6 mm hex wrench remove the two large fasteners one per side See Figure 33 3 Using a 4 mm hex wrench remove the four small fasteners two per side 4 Remove the Front Fender Installation A 1 Make sure the SE 3 Patroller is powered off unplugged and the parking brake is engaged 2 Place the Front Fender over the front wheel so that it rests on the bracket 3 Using a 6 mm hex wrench install the two large fasteners one per side See Figure 33 Torque to 5 5 N m 4 0

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