Segway SE-3 Patroller User manual

Service Manual
SE-3 Patroller

SE-3 Patrollerii
Front Tire/Wheel (page 28) Front Fender (page 24)
Side Panel (page 20)
Fender (page 22)
Rear Tire/Wheel
(page 30)
Light Cluster (page 36)
Front Cowl (page 17)
Headlight (page 34)
Windshield (page 32)

Service Manual iii
UI Module (page 70)
Throttle (page 74)
Rear Brake
Master Cylinder (page 59)
Front Brake
Master Cylinder (page 59)
Control Cluster (page 72)
Handlebar Grip
(page 76)
KeyLock (page 49)
Glove Box Door (page 48)
Bib Panel (page 14)
Accessory Power Outlet (page 50)
Front Cowl (page 17)
Light Cluster (page 36)
Side Panel (page 20)
Storage Tray (page 13)
Fender (page 22)
Rear Tire/Wheel (page 30)
Rear Strobe Light (page 42)
Rider Detect Mat (page 82)
Brake Light (page 40)
Rear Directional Light (page 41)
Battery Module (page 8)

SE-3 Patrolleriv
Copyright, Trademarks, Patent, and Contact Information
Document number & revision: 24538-00001 ad
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
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: [phone]
E-mail: [e-mail]
Website: http://www.segway.com

v
Contents
Copyright, Trademarks, Patent, and Contact Information ..........................................................................iv
General Safety Precautions..................................................................................................1
Safety Conventions........................................................................................................................................ 1
Important Safety Notices .............................................................................................................................. 1
Introduction.......................................................................................................................... 5
Purpose ..........................................................................................................................................................5
Audience.........................................................................................................................................................5
Certification ...................................................................................................................................................5
General Service Procedure............................................................................................................................6
Related User Materials...................................................................................................................................6
Battery Module......................................................................................................................7
Battery Module...............................................................................................................................................8
Body Panels.......................................................................................................................... 11
Exploded View ..............................................................................................................................................12
Storage Tray .................................................................................................................................................13
Bib Panel....................................................................................................................................................... 14
Glove Box......................................................................................................................................................16
Front Cowl..................................................................................................................................................... 17
Light Cluster.................................................................................................................................................18
Side Panel.................................................................................................................................................... 20
Fender.......................................................................................................................................................... 22
Front Fender (Boot) .................................................................................................................................... 24
Front Splash Guard ..................................................................................................................................... 25
Main Splash Guard...................................................................................................................................... 26
Tire/Wheel Assemblies...................................................................................................... 27
Front Tire/Wheel ......................................................................................................................................... 28
Rear Tire/Wheel.......................................................................................................................................... 30
Windshield ...........................................................................................................................31
Windshield................................................................................................................................................... 32

SE-3 Patrollervi
Lights................................................................................................................................... 33
Headlight ..................................................................................................................................................... 34
Headlight Alignment ................................................................................................................................... 35
Accessing the Light Cluster........................................................................................................................ 36
Front Strobe Light ........................................................................................................................................37
Side Strobe Light ........................................................................................................................................ 38
Front Directional Light ................................................................................................................................ 39
Brake Light .................................................................................................................................................. 40
Rear Directional Light ..................................................................................................................................41
Rear Strobe Light........................................................................................................................................ 42
Battery Compartment........................................................................................................43
Battery Slides.............................................................................................................................................. 44
Battery Bumpers......................................................................................................................................... 45
Bib Panel Components....................................................................................................... 47
Glove Box Door............................................................................................................................................ 48
KeyLock ....................................................................................................................................................... 49
Accessory Power Outlet.............................................................................................................................. 50
Brakes...................................................................................................................................51
Brake Fluid................................................................................................................................................... 52
Draining Brake Lines................................................................................................................................... 53
Bleeding Brake Lines .................................................................................................................................. 54
Front Caliper................................................................................................................................................ 56
Front Rotor .................................................................................................................................................. 58
Master Cylinder........................................................................................................................................... 59
Brake Lever.................................................................................................................................................. 60
Rear Caliper & Rotor ................................................................................................................................... 62
Front Brake Line .......................................................................................................................................... 64
Rear Brake Line ........................................................................................................................................... 66
Controls............................................................................................................................... 69
UI Module .................................................................................................................................................... 70
UI Housing.................................................................................................................................................... 71
Control Cluster.............................................................................................................................................72
Throttle.........................................................................................................................................................74
Handlebar Grip.............................................................................................................................................76
Contents

Service Manual vii
Siren .....................................................................................................................................77
Siren..............................................................................................................................................................78
Rider Detect Mat .................................................................................................................81
Rider Detect Mat......................................................................................................................................... 82
Drive Train ........................................................................................................................... 85
Gearbox ....................................................................................................................................................... 86
Elastomer Bushing & Drive Hub................................................................................................................. 88
Accessing the Motor Cavity........................................................................................................................ 89
Motor ........................................................................................................................................................... 90
Motor Controller.......................................................................................................................................... 92
Steering Column................................................................................................................. 93
Handlebar.................................................................................................................................................... 94
Front Fork .................................................................................................................................................... 96
Front Fender Bracket .................................................................................................................................. 98
Power Interface ..................................................................................................................99
Electronics Shield ..................................................................................................................................... 100
Charger....................................................................................................................................................... 101
PI Board......................................................................................................................................................102
Fuses...........................................................................................................................................................104
Maximum Speed ........................................................................................................................................105
Harnesses...........................................................................................................................107
Left/Right Motor Power Harness ..............................................................................................................108
Left/Right Drive Harness........................................................................................................................... 110
Handlebar Controls Harness ..................................................................................................................... 112
User Interface Harness .............................................................................................................................. 114
Light Cluster Harness ................................................................................................................................ 116
Tail Light Harness....................................................................................................................................... 118
Rear Strobe Light Harness ........................................................................................................................120
Accessory Power Harness .........................................................................................................................122
KeyLock Harness........................................................................................................................................123
Siren Harness.............................................................................................................................................124
Service Interface Harness .........................................................................................................................125
Contents

SE-3 Patrollerviii
Post-Service Tests.............................................................................................................127
Drive Disable and Rider Detect Mat .......................................................................................................... 127
Lights, Horn, and Siren .............................................................................................................................. 127
Brake Check ............................................................................................................................................... 127
Ride Test .....................................................................................................................................................128
Charge Test.................................................................................................................................................128
Fasteners........................................................................................................................... 129
Tools and Equipment........................................................................................................ 135
Glossary..............................................................................................................................137
Contents

1
General Safety Precautions
Safety Conventions
The following safety messaging conventions are used throughout this document:
WARNING! Warns you about actions that could result in death or serious injury.
CAUTION! Warns you about actions that could result in minor or moderate injury.
NOTICE
Indicates information considered important, but not related to personal injury. Examples
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
WARNING!
• 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 shock.
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
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.
• 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.
• Observe and follow all safety information on the warning label found on the Battery Module.

SE-3 Patroller2
• 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.
• Failure to adhere to these warnings could lead to serious injury, death, fire, or damage to property.
NOTICE
• Failure to charge the Battery Module could result in permanent damage to the Battery Module. Left unplugged, the
Battery Module could 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
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 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.
• 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
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
WARNING!
• When procedures require the use of safety glasses (such as those in which a mallet or solvent is used), failure to wear eye
protection could result in serious injury.
ESD Procedures
CAUTION!
• When a repair involves any 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.
General Safety Precautions

Service Manual 3
Questions
WARNING!
• If you have any questions about the instructions in this guide, please contact a Segway Service Representative to avoid
confusion leading to serious injury or death or damage to property.
General Safety Precautions

SE-3 Patroller4
General Safety Precautions

5
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:
Level Parts and Assemblies Instructions
1 • Body Panels
• Tire/Wheel Assemblies
• Windshield
• Lights
• Battery Compartment
• Bib Components
page 11
page 27
page 31
page 33
page 43
page 47
2 • All Level 1 (see above)
• Brakes
• Controls
• Siren
• Rider Detect Mat
• Drive Train
• Steering Column
• Power Interface
• Harnesses
See above
page 51
page 69
page 77
page 81
page 85
page 93
page 99
page 107
Table 1: Certication Levels

SE-3 Patroller6
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
publications.
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.
Introduction

7
Overview
This component is not serviceable; if there is a problem with the Battery Module it
must be replaced.
When to Replace
Replace when troubleshooting determines that the Battery Module is
malfunctioning.
Safety
WARNING!
Always remove the Battery Module before servicing the SE-3 Patroller. Failure to
remove the Battery Module could result in serious injury or death due to electric
shock.
Battery Module
Contents
• Battery Module

SE-3 Patroller8
Battery Module
Tools Required: None
Removal
1. Make sure the SE-3 Patroller is powered off,
unplugged, and the parking brake is engaged.
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
Figure 1: Flip Out and Twist the Battery Module Latches
Flip latches out Twist latches inward
Battery Module

Service Manual 9
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.
Figure 3: Slide the Battery Module into the SE-3 Patroller
Close latches to lock
Twist latches outward
Figure 4: Twist and Close the Battery Module Latches
Battery Module

SE-3 Patroller10
Battery Module

11
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
WARNING!
Do not operate the SE-3 Patroller without all body panels installed.
CAUTION!
When removing body panels, place them on a soft, clean surface to prevent
scratching or marring of the body panel.
Body Panels
Contents
• Exploded View
• Storage Tray
• Bib Panel
• Glove Box
• Front Cowl
• Light Cluster
• Side Panel
• Fender
• Front Fender (Boot)
• Front Splash Guard
• Main Splash Guard

SE-3 Patroller12
Exploded View
The exploded view (below) identifies all of the body panels on the SE-3 Patroller.
Left Side Panel
(24129-00001)
Right Side Panel
(24130-00001)
Light Cluster
(23776-00001)
Front Fender
(23761-00001)
Front Cowl
(23750-00001)
Left Fender
(23756-00001)
Right Fender
(23757-00001)
Bib Panel
(24117-00001)
Left Storage Tray
(23758-00001)
Right Storage Tray
(23759-00001)
Main Splash Guard
(24076-00001)
Front Splash Guard
(24077-00001)
Figure 5: Body Panels, Expoded View
Body Panels