Page 1
Segway® Personal Transporter Service Manual i2 SE i2 SE Patroller x2 SE x2 SE Turf x2 SE Patroller March 2014 24019-00001 aa...
Page 2
WARNING! To replace parts on the Segway Personal Transporter, you must read and follow all instructions and warnings in this Service Manual. Failure to do so could result in serious injury or death. Segway Personal Transporter SE Service Manual...
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.
Page 4
Segway Personal Transporter SE Service Manual...
Mats ................................2–2 3 Batteries ........................3–1 Batteries ..............................3–2 4 Tire/Wheel Assembly ....................4–1 i2 SE Wheel Assembly ..........................4–2 x2 SE Wheel Assembly ..........................4–3 x2 SE Turf Wheel Assembly ........................4–4 x2 SE Turf Hub Adapter ..........................4–5 i2 SE Tire Tube ............................4–6...
Page 6
Contents 5 Fenders ......................... 5–1 i2 SE Fender ............................... 5–2 x2 SE Fender .............................. 5–3 x2 SE Fender Frame ..........................5–4 6 Powerbase Trim ......................6–1 Gearbox Cover ............................6–2 Console Cover ............................6–3 Front and Rear Fascia ..........................6–4 7 Gearbox .........................7–1 Gearbox ..............................
Page 7
Standard Check ............................A–1 Operational Test ............................A–1 B Parts List ........................B–1 Customer Replaceable Kits ........................B–1 Technician Replaceable Parts ........................B–2 C Fasteners ........................C–1 D Tools and Equipment ....................D–1 E Glossary ........................E–1 Segway Personal Transporter SE Service Manual...
Page 8
Contents viii Segway Personal Transporter SE Service Manual...
Failure to follow these safety precautions could lead to electrical shock, serious injury, death, or damage to property. • To replace parts on the Segway PT, you must read and follow all instructions and warnings in this Service Manual. •...
Page 10
Use of any other type of solvent is not allowed. Questions WARNING! • If you have any questions about the instructions in this guide, please contact a Segway Service Representative to avoid confusion leading to serious injury or death or damage to property. Segway Personal Transporter SE Service Manual...
SE Turf. Audience Chapters 1 – 8 of this manual are written for either customers or Segway Certified Service Technicians working under agreement with Segway Inc. Chapters 9 – 14 of this manual are written only for Segway Certified Service Technicians working under agreement with Segway Inc.
Parts Lists for the Segway PT. Appendix C Fastener descriptions and specifications. Appendix D Tools and diagnostic equipment necessary to properly service a Segway PT. Appendix E Definitions of product-specific words used in this manual. 0–2 Segway Personal Transporter SE Service Manual...
The following additional materials may be needed for reference during service: • User Manual: Segway Personal Transporter (PT) i2 SE, x2 SE, x2 SE Turf 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.
Console Trim LeanSteer Stem 20152-00001 23478-00001 23508-00001 (Standard) 23507-00001 (Patroller) Stem Cap 23519-00001 Front Console Trim 23399-00001 Front Fascia 23550-00001 i2 Fender 20190-00001 Rear Fascia 23550-00002 i2 Hubcap 20325-00001 i2 Wheel Battery 20162-00001 20967-00001 0–4 Segway Personal Transporter SE Service Manual...
Segway PT. Using the Segway PT without properly assembling the LeanSteer components and/or maintaining proper torque on the fasteners could lead to an unexpected change in steering and could result in serious injury and/or damage to the Segway PT from loss of control, collisions, and falls. •...
Page 16
20041-00001 Height Adjust Knob 20753-00001 Washer 20751-00001 Lower LeanSteer Tube Wedge 23509-00001 20042-00001 #6-19x19mm PHCS Bolt Trim 23558-00001 23516-00001 (Standard) End Cap Washer Plate 23541-00001 23545-00001 (Standard) Figure 1–1: Standard LeanSteer Frame Components 1–2 Segway Personal Transporter SE Service Manual...
Page 17
23511-00001 Height Adjust Knob 20753-00001 Washer 20751-00001 Lower LeanSteer Tube Wedge 23509-00001 20042-00001 #6-19x19mm PHCS Bolt Trim 23558-00001 23545-00002 (Patroller) End Cap Washer Plate 23541-00001 23545-00002 (Patroller) Figure 1–2: Patroller LeanSteer Frame Components Segway Personal Transporter SE Service Manual 1–3...
Removal Handlebar Tool Required: 3 mm hex wrench Make sure the Segway PT is powered off and unplugged. Using a 3 mm hex wrench, remove the three fasteners that secure the Handlebar Clamp to the LeanSteer Frame. See Figure 1–3.
Check the fasteners at least monthly to be sure they remain tight. If they are loose, tighten the fasteners to 11.0 N-m (8.1 ft-lbf). Perform post-service tests (page A–1). Figure 1–6: Check LeanSteer Frame Segway Personal Transporter SE Service Manual 1–5...
Verify that the LeanSteer Stem is still vertical. Place the LeanSteer Stem Cap over the front of the LeanSteer Stem and press until it snaps in place. Perform post-service tests (page A–1). Figure 1–8: LeanSteer Stem Comparison 1–6 Segway Personal Transporter SE Service Manual...
Using a 3 mm hex wrench, install the fastener through the hole in the InfoKey Dock and into the upper LeanSteer Frame. Torque to 2.0 N-m (18 in-lbf). Perform post-service tests (page A–1). Figure 1–10: InfoKey Dock Segway Personal Transporter SE Service Manual 1–7...
Coin or flathead screwdriver Make sure the PT is powered off and unplugged. Verify that the new battery is type CR2430, available as part of the Segway InfoKey Kit. Insert the InfoKey Controller Battery with the positive (+) side showing. See Figure 1–12.
This chapter describes removal, inspection, and installation of Mats on a Segway PT. i2 SE, x2 SE, x2 SE Turf Your Segway PT comes with two Mats installed to the right and left of the console. Mats are a functional component of the Rider Detect feature; Mats Qualifications permit a wide range of foot positions to achieve rider detection.
Page 24
Powerbase. See Figure 2–1. Visually confirm that the Mat is properly aligned and all rubber tabs are tucked in prior to riding. Perform post-service tests (page A–1). Figure 2–1: Mat Installation 2–2 Segway Personal Transporter SE Service Manual...
Applies to Models This chapter describes removal and installation procedures for the Li-ion batteries used on a Segway PT. For information on using the batteries, including i2 SE, x2 SE, x2 SE Turf charging, maintenance, safety, specification, and general care please refer...
Page 26
PT, because the PT is designed to operate only at the level allowed by the lower-energy Battery. Redundancy is a critical safety feature built into the Segway PT that also applies to the Batteries. Therefore, you should...
Page 27
Verify the battery is aligned and straight against the Powerbase edge trim and there are no uneven gaps. Figure 3–2: Torque the two center fasteners first. Repeat Steps 1–8 for the second Battery. 10. Perform post-service tests (page A–1). Segway Personal Transporter SE Service Manual 3–3...
Page 28
Batteries 3–4 Segway Personal Transporter SE Service Manual...
Applies to Models This chapter describes the removal and installation procedures for the Tire/ Wheel Assembly of a Segway PT. For general tire care information, refer to the i2 SE, x2 SE, x2 SE Turf Segway PT User Manual .
Tire/Wheel Assembly i2 SE Wheel Assembly NOTICE Support your Segway PT by means other than resting it on its wheels. Support of the unit from below the batteries is recommended. As an alternative, the Segway PT can be positioned on its side on the opposite wheel. Do not rest the Segway PT on an exposed gearbox.
Holding the wheel to prevent rotation, use a 13 mm Wheel Nuts socket wrench to install the three wheel nuts. Torque 20158-00001 to 30 N-m (22 ft-lbf). 30 N-m (22 ft-lbf) Perform post-service tests (page A–1). Figure 4–2: x2 SE Tire/Wheel Assembly Segway Personal Transporter SE Service Manual 4–3...
Insert four fasteners through the wheel trim, Wheel, and Spacer. Using an 8 mm hex wrench, thread the fasteners into the Hub Adapter. Torque to 35 N-m (26 ft-lbf). Perform post-service tests (page A–1). 4–4 Segway Personal Transporter SE Service Manual...
SE Turf Wheel Assembly with the lugs on the gearbox flange. See Figure 4–4. Using a 13 mm socket wrench, thread the wheel nuts onto the lugs. Torque to 30 N-m (22 ft-lbf). Perform post-service tests (page A–1). Segway Personal Transporter SE Service Manual 4–5...
See Figure 4–5. Figure 4–5: Deflate the Tire NOTICE The i2 SE tire is tightly fitted to the wheel in a manner similar to a motorcycle tire mounted to a rim. Using a bar clamp, break the tire bead by positioning the clamp jaws against the inner and outer sidewalls of the tire and tightening the clamp.
Page 35
Tire/Wheel Assembly i2 SE Tire Tube Removal (cont.) Place the wheel face down on a clean, smooth surface. With the inside of the wheel facing up, pry one end of the tire iron underneath the lip of the tire bead, pulling it up above the rim. See Figure 4–8.
Page 36
Tire/Wheel Assembly i2 SE Tire Tube (cont.) Installation NOTICE Use only Segway-approved tubes. The 90-degree bend in the valve stem is necessary for proper clearance. Tools Required: Tire iron Air pump To install a new tire, seat the outside bead on the wheel by hand before installing the tube.
There are two fenders per Segway PT. Qualifications The i2 SE has one type of fender. The x2 SE and x2 SE Turf has another type of Customer Replaceable fender that attaches to a fender frame.
Orient and place the Fender on the gearbox. See 1.5 N-m (13 in-lbf) Figure 5–1. Figure 5–1: i2 SE Fender Using a T-20 6-lobe wrench, install the four fasteners. Torque to 1.5 N-m (13 in-lbf). Install the Tire/Wheel Assembly (page 4–2).
Fender. Using a 4 mm hex wrench, install the four fasteners until seated. Tighten one-half to one full turn. See Figure 5–2. Install the Tire/Wheel Assembly (page 4–3). Perform post-service tests (page A–1). Segway Personal Transporter SE Service Manual 5–3...
Using a 4 mm hex wrench, install three new Fender Frame fasteners. Torque to 6.0 N-m (4.5 ft-lbf). Install the Fender (page 5–3). Install the Tire/Wheel Assembly (page 4–3). Perform post-service tests (page A–1). 5–4 Segway Personal Transporter SE Service Manual...
Powerbase Trim Applies to Models This chapter describes removal and installation procedures for the powerbase trim (fascia, gearbox cover, and console cover). Each Segway PT has front and i2 SE, x2 SE, x2 SE Turf rear fascia. Qualifications WARNING! •...
Make sure the PT is powered off and unplugged. 2a. x2 SE: remove the Fender and Fender Frame assembly (page 5–4). Remove the Gearbox Cover. 2b. i2 SE: using a 4 mm hex wrench, remove the three fasteners and discard them. See Figure 6–1. Remove the Gearbox Cover.
Slide the Front Console Cover over the legs of the Center Console Cover. Using a 4 mm hex wrench, install the two fasteners. Torque to 1.5 N-m (13 in-lbf). See Figure 6–2. Perform post-service tests (page A–1). Figure 6–3: Center Console Cover Segway Personal Transporter SE Service Manual 6–3...
− x2 SE (page 4–3) − x2 SE Turf (page 4–4) Remove both fenders. − i2 SE Fenders (page 5–2) − x2 SE Fender Frames (page 5–4) Remove the Console Cover (page 6–3). Using a 4 mm hex wrench, remove the two fasteners holding the Fascia.
Gearbox Applies to Models This chapter describes troubleshooting, removal, and installation procedures for the Gearbox assembly on a Segway PT. Each Segway PT has two Gearboxes. i2 SE, x2 SE, x2 SE Turf WARNING! Qualifications • Failure to follow these safety precautions could lead to electrical shock, serious injury, death, or damage to property.
Page 46
Remove the LeanSteer Stem (page 1–6). Remove the Mats (page 2–2). Remove the Batteries (page 3–2). Remove the Tire/Wheel Assemblies. − i2 SE (page 4–2) − x2 SE (page 4–3) − x2 SE Turf (page 4–4) Gearbox Spacer Remove the Fenders −...
Page 47
Ensure the gasket is present and oriented properly in the grooves of the gearbox spacer gasket. See Figure 7–4. Gasket Figure 7–4: Align the Gearbox Spacer Gasket Segway Personal Transporter SE Service Manual 7–3...
Page 48
10. Install the Front and Rear Fascia (page 6–4). 11. Install the Console Cover (page 6–3). 12. Install the Fenders − i2 SE (page 5–2) − x2 SE (page 5–3) 13. Install the Tire/Wheel Assemblies. − i2 SE (page 4–2) −...
Serviceable Powerbase Applies to Models This chapter describes the Serviceable Powerbase in a Segway PT. i2 SE, x2 SE, x2 SE Turf WARNING! • Failure to follow these safety precautions could lead to electrical shock, Qualifications serious injury, death, or damage to property.
Page 51
Serviceable Powerbase NOTICE The following sections in this Service Manual are intended for use by Segway Certified Service Technicians only. Segway does not recommend that non-certified individuals replace any of the components described in the following sections. The warranty will be void if components in any of the following sections are replaced by an individual other than a Segway Certified Service Technician.
Page 52
Serviceable Powerbase 8–4 Segway Personal Transporter SE Service Manual...
When to Replace Power Supply Harness (23593-00001) 1 Power Supply Harness Replace a console component when diagnostic testing determines that the component is defective. For diagnostic procedures, contact a Segway Service Interconnect Board (23411-00001) Representative. 1 Interconnect Board AC Input Filter (23405-00001)
Gasket Pivot Assembly 23393-00001 23502-00001 Gap Pad 23699-00001 Console Base Front Light Pipe 23390-00001 23402-00001 Insulator 23575-00001 AC Input Filter 23405-00001 Interconnect Board 23411-00001 Power Board 23371-00001 Insulator 23598-00001 Figure 9–1: Console Components 9–2 Segway Personal Transporter SE Service Manual...
Radio Board in place. Discard the Radio Board fasteners. Remove the Radio Board. Using ESD best practices, place the Radio Board in an ESD bag for return shipment to Segway. Installation Tools Required: T-10 6-lobe wrench T-20 6-lobe wrench Orient the Radio Board on the Console Base.
Torque to 11.0 N-m (8.1 ft-lbf). Install the Radio Board (page 9–3). Reassemble the PT from the Serviceable Powerbase (page 8–2). Perform post-service tests (page A–1). Figure 9–4: Console Harnesses 9–4 Segway Personal Transporter SE Service Manual...
Figure 9–5: Power Board Insulator the Console Base, leaving the Interconnect Board behind. Using ESD best practices, place the Power Board in 20567-00001 (self-tapping) an ESD bag for return shipment to Segway. 20973-00001 (non-tapping) 1.6 N-m (14 in-lbf) Installation Tools Required: T-10 6-lobe wrench Torque Wrench Install the Power Board.
Pivot Assembly Remove the Interconnect Board. Using ESD best practices, place the Interconnect Board in an ESD bag for return shipment to Segway. Figure 9–7: Interconnect Board Installation Orient the Interconnect Board so the notched side...
AC Input Filter in place. Discard the fasteners. Remove the AC Input Filter. 10. Using ESD best practices, place the AC Input Filter in an ESD bag for return shipment to Segway. 11. Remove the insulator. Segway Personal Transporter SE Service Manual 9–7...
Page 60
Connect the Power Supply Harness. See Figure 9–10. Install the Console onto the Powerbase (page 9–4). Install the Radio Board (page 9–3). 10. Reassemble the PT from the Serviceable Powerbase (page 8–2). 11. Perform post-service tests (page A–1). 9–8 Segway Personal Transporter SE Service Manual...
Install the Console onto the Powerbase (page 9–4). Gap Pad Install the Radio Board (page 9–3). 10. Reassemble the PT from the Serviceable Powerbase (page 8–2). 11. Perform post-service tests (page A–1). Figure 9–12: Gap Pad Segway Personal Transporter SE Service Manual 9–9...
Install the Power Board (page 9–5). Install the Console onto the Powerbase (page 9–4). Install the Radio Board (page 9–3). Reassemble the PT from the Serviceable Powerbase (page 8–2). 10. Perform post-service tests (page A–1). 9–10 Segway Personal Transporter SE Service Manual...
The edge gasket must be capable of maintaining a seal between the cover and the chassis. Damage to the edge gasket requires replacement of the cover. Operating a Segway PT without the proper seal between cover and chassis could result in malfunction leading to injury or property damage.
Page 64
Using a T-27 6-lobe wrench, remove the ten fasteners and discard. See Figure 10–1. Feed the harnesses down through the holes in the Chassis Cover. Remove the Chassis Cover. Rear BSA Cable Router Front Figure 10–1: Chassis Cover 10–2 Segway Personal Transporter SE Service Manual...
Page 65
Figure 10–3: Feed Harnesses Through Holes in Chassis Cover Install the Console (page 9–4). Install the Radio Board (page 9–3). Reassemble the PT from the Serviceable Powerbase (page 8–2). 10. Perform post-service tests (page A–1). Segway Personal Transporter SE Service Manual 10–3...
Page 66
Chassis Cover 10–4 Segway Personal Transporter SE Service Manual...
11 CU Board Applies to Models This chapter describes troubleshooting, removal, and installation procedures for the Control Unit (CU) Boards on a Segway PT. There are two CU Boards on each i2 SE, x2 SE, x2 SE Turf Segway PT.
Page 68
Chassis. Figure 11–1: Motor Harnesses Locations 10. Using ESD best practices, place the CU Board in an ESD bag for return shipment to Segway. CU Harness BSA Harness Figure 11–2: BSA Harness and CU Harness 11–2...
Page 69
Install the Chassis Cover (page 10–2). Install the Console (page 9–4). 10. Install the Radio Board (page 9–3). 11. Reassemble the PT from the Serviceable Powerbase (page 8–2). 12. Perform post-service tests (page A–1). Segway Personal Transporter SE Service Manual 11–3...
Page 70
CU Board 11–4 Segway Personal Transporter SE Service Manual...
Failure to follow ESD procedures could result in personal injury or damage to property. When to Replace Replace the BSA when diagnostic testing determines the component is defective. For diagnostic procedures, contact a Segway Service Representative. Segway Personal Transporter SE Service Manual 12–1...
Page 72
BSA. 1.6 N-m (14 in-lbf) 11. Using ESD best practices, place the BSA in an ESD bag for return shipment to Segway, pursuant to the terms and conditions of the Segway PT Warranty or other established procedures.
13 Motor Applies to Models This chapter describes the removal and installation of a Motor assembly on a Segway PT. There are two Motors on each Segway PT. i2 SE, x2 SE, x2 SE Turf WARNING! Qualifications • Failure to follow these safety precautions could lead to electrical shock, serious injury, death, or damage to property.
Page 74
See Figure 13–1. Using a T-25 6-lobe wrench, remove the two fasteners attaching the Motor to the Chassis. See Figure 13–1: CU Motor Harnesses Figure 13–2. Pull the Motor straight out of the Chassis. 13–2 Segway Personal Transporter SE Service Manual...
Page 75
Install the Chassis Cover (page 10–2). Install the Console (page 9–4). 10. Install the Radio Board (page 9–3). 11. Reassemble the PT from the Serviceable Powerbase (page 8–2). 12. Perform post-service tests (page A–1). Segway Personal Transporter SE Service Manual 13–3...
Do not remove the coupling from the Motor. If damaged, replace the entire Motor assembly. If the Motor assembly is modified, the PT could malfunction causing injury or damage to property. Perform post-service tests (page A–1). Figure 13–4: Elastomer Bushing Alignment 13–4 Segway Personal Transporter SE Service Manual...
For diagnostic procedures, contact a Segway Service Representative. The Segway PT Chassis is serialized and may only be replaced with permission from Segway. A new serial number may be issued, and the serialized replacement Chassis may be shipped to order from Segway Service Headquarters.
Page 78
Install the Chassis Cover (page 10–2). Install the Console (page 9–4). Install the Radio Board (page 9–3). Install both Gearboxes (page 7–2). Reassemble the PT from the Serviceable Powerbase (page 8–2). Perform post-service tests (page A–1). 14–2 Segway Personal Transporter SE Service Manual...
A Post-Service Tests This chapter describes standard tests to perform after servicing a Segway PT. WARNING! • Read all instructions. Failure to do so could lead to electrical shock, serious injury, death, or damage to property. CAUTION! • When a repair involves opening the console or chassis cover, best practice electrostatic discharge (ESD) control procedures must be followed.
Page 80
Post-Service Tests A–2 Segway Personal Transporter SE Service Manual...
Pivot Assembly 23502-00001 Front Light Pipe 23402-00001 Console Base 23990-00001 Chassis Cover 20316-00001 CU Board 23244-00001 Balance Sensor Assembly 19457-00003 Motor with Coupling 22252-00001 Drive Hub 21783-00004 Elastomer Bushing 21461-00001 Powerbase Chassis 17124-00003 B–2 Segway Personal Transporter SE Service Manual...
C Fasteners This appendix provides information about the fasteners used in the Segway PT. WARNING! • Use only Segway-approved fasteners. Other fasteners may not perform as expected and may come loose. • Do not tighten or reuse any fastener except the screws used to attach the batteries, wheel nuts, and LeanSteer frame.
Page 84
1.5 N-m (13 in-lbf) 20538-00001 SHCS, M6 x 1.0 x 30 LeanSteer Stem T-30 11 N-m (8.1 ft-lbf) 20539-00001 BHCS, M6 x 1.0 x 14 Chassis Cover T-27 6.0 N-m (4.5 ft-lbf) 20540-00001 C–2 Segway Personal Transporter SE Service Manual...
Page 85
Radio Board, Power Board, or AC Input Filter into a new Console. BHCS, M6 x 1.0 x 18 Fender (x2) 4 mm See note. 20871-00001 Tighten one-half to one full turn after fastener is seated. Segway Personal Transporter SE Service Manual C–3...
Page 86
BHCS, M4 x 0.7 x 12, SEMS AC Input Filter, Plug T-20 1.0 N-m (9 in-lbf) 23559-00001 SHCS, M5 x 0.8 x 8 AC Input Filter, Ground 4 mm 3.0 N-m (27 in-lbf) 23591-00001 C–4 Segway Personal Transporter SE Service Manual...
2.5 mm, 3 mm, 4 mm, 5 mm, 8 mm Low pressure inflation gauge 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 . Pen light...
Page 88
Tools and Equipment D–2 Segway Personal Transporter SE Service Manual...
Electrostatic Discharge (ESD) The rapid discharge of accumulated electrical charge. To prevent damage to the Segway PT, 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 PT.
Page 90
Glossary E–2 Segway Personal Transporter SE Service Manual...
Need help?
Do you have a question about the i2 SE and is the answer not in the manual?
Questions and answers