Segway SE-3 Patroller Service Manual
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Segway SE-3 Patroller Service Manual

Segway se-3 patroller
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Summary of Contents for Segway SE-3 Patroller

  • Page 1 Service Manual SE-3 Patroller...
  • Page 2 Windshield (page 32) Headlight (page 34) Front Cowl (page 17) Fender (page 22) Light Cluster (page 36) Rear Tire/Wheel (page 30) Side Panel (page 20) Front Tire/Wheel (page 28) Front Fender (page 24) SE-3 Patroller...
  • Page 3 Front Brake Rear Brake Master Cylinder (page 59) Master Cylinder (page 59) Control Cluster (page 72) Throttle (page 74) Handlebar Grip (page 76) UI Module (page 70) Accessory Power Outlet (page 50) KeyLock (page 49) Bib Panel (page 14) Front Cowl (page 17) Glove Box Door (page 48) Light Cluster (page 36) Storage Tray (page 13)

  • Page 4: Copyright, Trademarks, Patent, And Contact Information

    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 5: Table Of Contents

    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..........................
  • Page 6 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 SE-3 Patroller...
  • Page 7 Contents 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 ..............................
  • Page 8 Contents 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 viii SE-3 Patroller...

  • Page 9: General Safety Precautions

    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.
  • Page 10 • 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).
  • Page 11 General Safety Precautions 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. Service Manual...
  • Page 12 General Safety Precautions SE-3 Patroller...

  • Page 13: Introduction

    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.

  • Page 14: General Service Procedure

    Replace — replace the malfunctioning component(s). 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.

  • Page 15: Battery Module

    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.

  • Page 16: Battery Module

    Grasp both the front handle and the top handle of the Battery Module (Figure 2). Slide the Battery Module completely out. Figure 1: Flip Out and Twist the Battery Module Latches Figure 2: Slide the Battery Module out of the SE-3 Patroller SE-3 Patroller...
  • Page 17 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 Twist latches outward Close latches to lock Figure 4: Twist and Close the Battery Module Latches...
  • Page 18 Battery Module SE-3 Patroller...

  • Page 19: Body Panels

    Body Panels Overview Contents Body Panels attach to the frame to create the shape and style of the SE-3 Patroller. • Exploded View Body panels serve a number of functions. Among other things, they provide a • Storage Tray mounting location for lights, they protect the internal components from the •...

  • Page 20: Exploded View

    Body Panels 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 Front Cowl (23758-00001) (23750-00001) Bib Panel (24117-00001) Right Fender (23757-00001) Right Side Panel (24130-00001) Left Fender...

  • Page 21: Storage Tray

    Tools Required: 4 mm hex wrench 24270-00006 Torque wrench 1.0 N-m (0.74 ft-lbf) Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Storage Tray Using a 4 mm hex wrench, remove the fastener at the Left 23758-00001 bottom of the Storage Tray.

  • Page 22: Bib Panel

    Torque wrench Wire cutters 24270-00006 4.0 N-m (3.0 ft-lbf) Removal Bib Panel Make sure the SE-3 Patroller is powered off, (24117-00001) unplugged, and the parking brake is engaged. Remove the following components: 24270-00006 Battery Module (page 8) 5.5 N-m (4.0 ft-lbf)
  • Page 23 Body Panels Installation 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-lbf).

  • Page 24: Glove Box

    4 mm hex wrench Torque wrench 20553-00001 1.6 N-m (1.2 ft-lbf) Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Storage Trays (page 13) Bib Panel (page 14) Using a 4 mm hex wrench, remove the three fasteners and Lock Plate as shown in Figure 13.

  • Page 25: Front Cowl

    The Front Cowl fastens to the left and right Side Panels. Tools Required: 4 mm hex wrench Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Front Cowl Remove the following components:...

  • Page 26: Light Cluster

    Tools Required: 4 mm hex wrench 24270-00006 Torque wrench 4.0 N-m (3.0 ft-lbf) Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Storage Trays (page 13)
  • Page 27 Body Panels Installation Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. 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 20, p.

  • Page 28: Side Panel

    The Side Panels attach to a floating bracket at the front of the steering column. Tools Required: 4 mm hex wrench Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Side Panel Battery Module (page 8)
  • Page 29 Installation 24270-00004 5.5 N-m (4.0 ft-lbf) 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 23.

  • Page 30: Fender

    Tools Required: 4 mm hex wrench 10 mm socket wrench Wire cutters Fender Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Push to Remove...
  • Page 31 Body Panels Installation (cont.) Install the following components: Bib Panel (page 14) Storage Trays (page 13) Battery Module (page 8) 10. Perform post-service tests (page 127). Inside Fasteners 2x (24270-00004) 1x (24270-00006) Fender Bracket Left 24297-00001 Right 24298-00001 P-Clip (24509-00001) P-Clip (24509-00001) 23202-00004...

  • Page 32: Front Fender (Boot)

    Torque wrench Removal 24270-00006 5.5 N-m (4.0 ft-lbf) Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Using a 6 mm hex wrench, remove the two large fasteners (one per side). See Figure 27.

  • Page 33: Front Splash Guard

    Tools Required: 4 mm hex wrench Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the Front Fender (page 24). Using a 4 mm hex wrench, remove the eight fasteners as shown in Figure 28.

  • Page 34: Main Splash Guard

    Front Panels together. Tools Required: 4 mm hex wrench Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Front Fender (page 24) 24270-00004 Front Splash Guard (page 25) 5.5 N-m (4.0 ft-lbf)

  • Page 35: Tire/Wheel Assemblies

    Safety 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.

  • Page 36: Front Tire/Wheel

    Raise the SE-3 Patroller until the front wheel is off the ground (Figure 30). 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.
  • Page 37 Tire/Wheel Assemblies Installation Prepare the SE-3 Patroller by following the Setup instructions (page 28). Slide the wheel onto the spindle. Orient the wheel so the valve stem is away from the rotor. See Figure 34. Using the wheel nut key, install the four fasteners attaching the wheel to the spindle.

  • Page 38: Rear Tire/Wheel

    Wheel Nuts. Place the vehicle jack under the back of the SE-3 Patroller skid plate, close to the wheel being changed (Figure 35). Raise the SE-3 Patroller until the wheel is just off the ground. WARNING! Do not lift both rear wheels off the ground. Two...

  • Page 39: Windshield

    Windshield Overview Contents The Windshield protects the UI Module. • Windshield When to Replace Replace the Windshield when it is cracked or otherwise broken.

  • Page 40: Windshield

    These grommets protect the Windshield from Figure 37: Windshield vibration. Orient the Windshield on the SE-3 Patroller so that the holes in the Windshield align with the holes in the handlebar frame. Insert fasteners from above. Hand tighten hex nuts from underneath.

  • Page 41: Lights

    Lights Overview Contents The SE-3 Patroller has a headlight, brake lights, directional lights, and strobe lights. • Headlight There are two colors of strobe lights: red/blue for police, and amber for security. • Headlight Alignment • Accessing the Light Cluster •...

  • Page 42: Headlight

    Windshield. Tools Required: 3 mm hex wrench Wire cutters Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Storage Trays (page 13) Bib Panel (page 14) 24315-00006 1.6 N-m (1.2 ft-lbf)

  • Page 43: Headlight Alignment

    10 mm socket wrench Digital level Torque wrench Procedure Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Using a 4 mm hex wrench and a 10 mm socket wrench, loosen the Headlight Bracket fasteners as shown in Figure 40.

  • Page 44: Accessing The Light Cluster

    To acess the Light Cluster, remove the body panels listed below. Remove Body Panels Side Strobe Light Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Front Strobe Light Remove the following components: Battery Module (page 8)

  • Page 45: Front Strobe Light

    Police 24252-00001 23202-00001 Security 24252-00002 1.6 N-m (1.2 ft-lbf) 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 36. Disconnect the wire harness.

  • Page 46: Side Strobe Light

    Torque wrench Removal Side Strobe Light Police 24253-00002 Make sure the SE-3 Patroller is powered off, Security 24253-00003 unplugged, and the parking brake is engaged. Access the Light Cluster by following the instructions to Remove Body Panels on page 36.

  • Page 47: Front Directional Light

    Tools Required: 3 mm hex wrench 7 mm socket wrench Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Access the Light Cluster by following the instructions 23202-00001 to Remove Body Panels on page 36.

  • Page 48: Brake Light

    Tools Required: 3 mm hex wrench 7 mm socket wrench Torque wrench Removal Make sure the SE-3 Patroller is powered off, Brake Light unplugged, and the parking brake is engaged. (24254-00001) Reach into the wheel well and disconnect the Brake Light harness.

  • Page 49: Rear Directional Light

    Tools Required: 3 mm hex wrench 7 mm socket wrench Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Reach into the wheel well and disconnect the Rear Directional Light harness. See Figure 54.

  • Page 50: Rear Strobe Light

    Rear Strobe Light Tools Required: 3 mm hex wrench Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Rider Detect Mat (page 82) Motor Cavity Lid (page 89) Disconnect the Rear Strobe Light harness.

  • Page 51: Battery Compartment

    Battery Compartment Overview Contents Inside the Battery Compartment are the Battery Slides and Battery Bumpers, which • Battery Slides together position the Battery Module correctly against the PI Board. • Battery Bumpers When to Replace Replace the Battery Slides or Battery Bumpers when they are cracked, excessively worn, or otherwise broken.

  • Page 52: Battery Slides

    20709-00001 Torque wrench 1.0 N-m (0.74 ft-lbf) Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the Battery Module (page 8). Using a 2.5 mm hex wrench, remove the fasteners from the Battery Slides. See Figure 58.

  • Page 53: Battery Bumpers

    8 mm socket wrench Torque wrench 23202-00003 1.4 N-m (1.0 ft-lbf) Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Front Fender (page 24) Figure 59: Brake Line P-Clips...
  • Page 54 Battery Compartment Installation 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 24409-00008 fastener. See Figure 61. 2.0 N-m (1.5 ft-lbf)

  • Page 55: Bib Panel Components

    Bib Panel Components Overview Bib Panel Components These are replaceable components that attach to the Bib Panel. • Glove Box Door • KeyLock • Accessory Power Outlet When to Replace Replace the Glove Box Door when it is cracked, excessively worn, or otherwise broken.

  • Page 56: Glove Box Door

    Remove the Glove Box Door. Glove Box Door (24120-00001) NOTICE Do not operate the SE-3 Patroller without the Glove Box Door O-ring installed. The warning label on the Glove Box Door must be (24423-00001) visible.

  • Page 57: Keylock

    Bib Panel Components KeyLock Tools Required: None Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) KeyLock Storage Trays (page 13) (23969-00001) Bib Panel (page 14) Press the tab on the side of the connector block and pull it off the back side of the KeyLock.

  • Page 58: Accessory Power Outlet

    Bib Panel Components Accessory Power Outlet Tools Required: None Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Accessory Power Outlet Remove the following components: (23979-00001) Battery Module (page 8) Storage Trays (page 13)

  • Page 59: Brakes

    Brakes Overview Contents There are two brake systems: front and rear. Each brake system includes a master • Brake Fluid cylinder (with brake lever), brake line, caliper(s), and rotor(s). • Draining Brake Lines • Bleeding Brake Lines When to Replace •...

  • Page 60: Brake Fluid

    1.5 N-m (1.1 ft-lbf) Checking the 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. Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged.

  • Page 61: Draining Brake Lines

    Dispose of used brake fluid in accordance with your local environmental regulations. Figure 68: Draining the Rear Brake Line 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...

  • Page 62: Bleeding Brake Lines

    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. Fit one end of the tubing over the bleeder valve on the Caliper. Place the other end in an empty container.
  • Page 63 Brakes Squeeze the brake lever. While the brake lever is being squeezed, open the bleeder valve. See Figure 70. As brake fluid drains out of the bleeder valve, the brake lever will move toward the handlebar. 10. Before the brake lever touches the handlebar, close the bleeder valve.

  • Page 64: Front Caliper

    Raise the SE-3 Patroller until the front wheel is off the ground (Figure 72). WARNING! Make sure the SE-3 Patroller is stable or use a jack Place jack here stand to stabilize it while the wheel is off the ground.
  • Page 65 Brakes Installation 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 (on the end of the brake line) to the Caliper. Torque to 28.5 N-m (21.0 ft-lbf).

  • Page 66: Front Rotor

    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 72). Remove the following components:...

  • Page 67: Master Cylinder

    14 mm socket wrench Digital level Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Drain the brake fluid out of the brake line. See page 53. Using a 14 mm socket wrench, remove the Banjo Bolt Banjo Bolt on the Master Cylinder.

  • Page 68: Brake Lever

    Phillips head screwdriver Torque wrench UltraLube marine & trailer bearing grease Removal Make sure the SE-3 Patroller is powered off, unplugged, and the wheels are chocked. CAUTION! You can’t remove the right-hand brake lever with the parking brake on. Chock the wheels and ensure the Parking SE-3 Patroller doesn’t move.
  • Page 69 (P/N 24431-00001). Spring Orient the brake lever with the end ball facing toward the front of the SE-3 Patroller (see Figure 85). Slide the brake lever in place, making sure the spring Figure 84: Spring Location 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.

  • Page 70: Rear Caliper & Rotor

    Tools Required: 6 mm hex wrench 14 mm socket wrench Torque wrench 23868-00001 Removal 28.5 N-m (21.0 ft-lbf) Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Rear Caliper Right 23812-00001...
  • Page 71 Brakes Installation Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. 23868-00001 28.5 N-m (21.0 ft-lbf) Ensure the Rotor, Spacer, and all mounting surfaces are clean and free of debris. Caliper Bracket 23861-00001 Install the Rotor and Spacer. See Figure 89.

  • Page 72: Front Brake Line

    Tools Required: 2.5 mm hex wrench 14 mm socket wrench Wire cutters Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Cable tie...
  • Page 73 Brakes Installation 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 78. Torque to 28.5 N-m (21.0 ft-lbf).

  • Page 74: Rear Brake Line

    8 mm socket wrench 14 mm socket wrench Wire cutters Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Storage Trays (page 13)
  • Page 75 Brakes Installation Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Using a 14 mm socket wrench, connect the upper Banjo Bolt to the Master Cylinder. See Figure 98. Torque to 28.5 N-m (21.0 ft-lbf).
  • Page 76 Brakes SE-3 Patroller...

  • Page 77: Controls

    Controls Overview Contents This chapter covers the UI, Control Cluster, Throttle, and Handlebar Grip. • UI Module • UI Housing • Control Cluster When to Replace • Throttle Replace the Control Cluster or Throttle when troubleshooting determines that it is malfunctioning.

  • Page 78: Ui Module

    Controls UI Module The UI Module is how the user interacts with the SE-3 Patroller. NOTICE The fault history is stored in the UI Module. Replacing the UI Module will essentially “reset” the fault history. UI Module (24088-00001) Tools Required: 4 mm hex wrench...

  • Page 79: Ui Housing

    Controls UI Housing Tools Required: 4 mm hex wrench Torque wrench Removal UI Housing Make sure the SE-3 Patroller is powered off, (23811-00001) unplugged, and the parking brake is engaged. Remove the following components: 24270-00001 2.8 N-m (2.1 ft-lbf) Battery Module (page 8)

  • Page 80: Control Cluster

    Tools Required: T15 Torx wrench Wire cutters Torque wrench Digital level Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Storage Trays (page 13) Bib Panel (page 14)
  • Page 81 Controls Installation Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Slide the Control Cluster onto the handlebar. Leave a small gap (5 mm) between the Control Cluster and the Handlebar Grip. Orient the Control Cluster so the bottom is parallel to the ground (0°).

  • Page 82: Throttle

    Wire cutters Torque wrench LPS heavy duty silicone lubricant Digital level Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. 4.0 N-m (3.0 ft-lbf) Figure 105: Throttle Remove the following components: Battery Module (page 8)
  • Page 83 Controls Installation 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.

  • Page 84: Handlebar Grip

    Tools Required: Cutting tool (box cutter or utility knife) Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Score the Handlebar Grip with a cutting tool.

  • Page 85: Siren

    Siren Siren Contents The Siren produces both the horn and siren sounds. • Siren When to Replace Replace when troubleshooting determines that the Siren is malfunctioning.

  • Page 86: Siren

    Tools Required: 4 mm hex wrench 10 mm socket wrench Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Storage Trays (page 13)
  • Page 87 Siren Installation 24270-00001 Make sure the SE-3 Patroller is powered off, 7.5 N-m (5.5 ft-lbf) unplugged, and the parking brake is engaged. Orient the bracket on the frame. Using a 4 mm hex wrench, install the two bracket fasteners. See Figure 110.
  • Page 88 Siren SE-3 Patroller...

  • Page 89: Rider Detect Mat

    The Rider Detect Mat acts as an operator presence control device by only allowing • Rider Detect Mat 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...

  • Page 90: Rider Detect Mat

    Rider Detect Mat. The cable can become damaged, rendering the Rider Detect Mat unusable. Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8).
  • Page 91 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.
  • Page 92 Rider Detect Mat SE-3 Patroller...

  • Page 93: Drive Train

    Drive Train Overview Contents The Drive Train consists of the Gearbox, Motor, Motor Controller, and the couplings • Gearbox that join them together. • Elastomer Bushing & Drive Hub • Accessing the Motor Cavity When to Replace • Motor Replace when troubleshooting determines that a component is malfuctioning. •...

  • Page 94: Gearbox

    Leave the SE-3 Patroller jacked up and chock the wheels. 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.
  • Page 95 Install the O-ring on the input side of the Gearbox. See Figure 116. 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 23868-00001 coupling fits over the Elastomer Bushing.

  • Page 96: Elastomer Bushing & Drive Hub

    Tools Required: Cotton swab Molykote G-n paste Removal Elastomer Bushing (21091-00001) Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Storage Trays (page 13) Bib Panel (page 14)

  • Page 97: Accessing The Motor Cavity

    Accessing the Motor Cavity Tools Required: 3 mm hex wrench Torque wrench Accessing Rider Detect Spacer Make sure the SE-3 Patroller is powered off, (23944-00001) unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8)

  • Page 98: Motor

    Torque wrench Cotton swab Molykote G-n paste Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Access the motor cavity (page 89). This involves disassembling the SE-3 Patroller until the motor cavity is exposed.
  • Page 99 Place an O-ring on the motor mount plate. 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 122). Using a 5 mm hex wrench, install the four fasteners as shown in Figure 122.

  • Page 100: Motor Controller

    7.5 N-m (5.5 ft-lbf) Flathead screwdriver Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Access the motor cavity (page 89). This involves disassembling the SE-3 Patroller until the motor cavity is exposed.

  • Page 101: Steering Column

    Steering Column Overview Contents The Steering Column is made up of two components: the Handlebar and the • Handlebar Front Fork. The Handlebar is the upper portion of the Steering Column, with the • Front Fork Windshield, Throttle, and other controls. The Front Fork is the lower portion of the •...

  • Page 102: Handlebar

    (23798-00001) Digital level Cutting tool (box cutter or utility knife) Heat gun Removal Heat-Shrink Tubing Make sure the SE-3 Patroller is powered off, (24502-00001) 23784-00001 unplugged, and the parking brake is engaged. 34 N-m (25 ft-lbf) 23868-00010 Remove the following components:...
  • Page 103 Steering Column Installation 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.

  • Page 104: Front Fork

    (23790-00001) Handlebar (page 94) Jack up the front of the SE-3 Patroller (Figure 130). WARNING! Make sure the SE-3 Patroller is stable or use a jack stand to stabilize it while the wheel is off the ground. Front Fork (23777-00001) Failure to stabilize the SE-3 Patroller could result in death or serious injury from the vehicle falling over.
  • Page 105 Jack up the front of the SE-3 Patroller (Figure 130). 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.

  • Page 106: Front Fender Bracket

    It also provides a mounting point for routing the brake line. Tools Required: 3 mm hex wrench 4 mm hex wrench Torque wrench Removal Make sure the SE-3 Patroller is powered off, Front Fender Bracket unplugged, and the parking brake is engaged. (24155-00001) Remove the following components:...

  • Page 107: Power Interface

    • Charger aluminum block for thermal dissipation. • PI Board All of the electronic components of the SE-3 Patroller connect to the PI Board via • Fuses cable harnesses. The Battery Module connects directly to the PI Board. • Maximum Speed...

  • Page 108: Electronics Shield

    Tools Required: 3 mm hex wrench Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Storage Trays (page 13)

  • Page 109: Charger

    Tools Required: 3 mm hex wrench Torque wrench 24491-00003 Removal 2.5 N-m (1.8 ft-lbf) Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Storage Trays (page 13)

  • Page 110: Pi Board

    Power Interface 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...
  • Page 111 Power Interface Installation Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Orient the PI Board and aluminum plate on the frame. See Figure 139. Using an 8 mm socket wrench, install the four nylock nuts as shown in Figure 138.

  • Page 112: Fuses

    Power Interface Fuses Tools Required: None Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the Battery Module (page 8). WARNING! 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.

  • Page 113: Maximum Speed

    Power Interface 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 Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged.
  • Page 114 Power Interface SE-3 Patroller...

  • Page 115: Harnesses

    Harnesses Overview Contents Harnesses connect the various electrical components together. • Left/Right Motor Power Harness • Left/Right Drive Harness • Handlebar Controls Harness When to Replace • User Interface Harness Replace a Harness when it is severed, frayed, or when diagnostic testing determines that it is malfunctioning.

  • Page 116: Left/Right Motor Power Harness

    Tools Required: Wire cutters 10 mm socket wrench Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Storage Trays (page 13)
  • Page 117 Harnesses Installation 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– Black Arrange the hardware stack as shown in Figure 147.

  • Page 118: Left/Right Drive Harness

    Tools Required: Flathead screwdriver Torque wrench Removal Make sure the SE-3 Patroller is powered off, Right Drive Logic unplugged, and the parking brake is engaged. Left Drive Logic Remove the following components:...
  • Page 119 Harnesses Installation Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Connect the Drive Harness to the Motor Controller. Brace Connect the Drive Harness to the Motor. Feed the harness through the hole in the front of the motor cavity.

  • Page 120: Handlebar Controls Harness

    Headlight, Throttle, and both Brake Levers. Tools Required: Wire cutters Removal Handle Bar Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Storage Trays (page 13)
  • Page 121 Harnesses Installation 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...

  • Page 122: User Interface Harness

    User Interface Harness This harness connects the PI Board and the UI Module. Tools Required: Wire cutters Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8)
  • Page 123 Harnesses Installation Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Insert the harness into the UI Housing and carefully press the grommet into place. See Figure 156. NOTICE Do not use any sharp or pointed tools. You could puncture the grommet, thereby allowing water to enter the UI Housing.

  • Page 124: Light Cluster Harness

    This harness connects the PI Board to the directional lights and the strobe lights in the Light Cluster. Tools Required: Wire cutters Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Front Lights Remove the following components:...
  • Page 125 Harnesses Installation Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Connect the wire harness to the lights. See Figure 159 & Figure 160. Route harness around the left side of the frame. Connect the wire harness to the PI Board.

  • Page 126: Tail Light Harness

    4 mm hex wrench Left Right 10 mm socket wrench Torque wrench Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Storage Trays (page 13)
  • Page 127 Harnesses Installation Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. P-Clip Connect the Tail Light Harness to the tail lights. (24509-00001) See Figure 164. 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 164.

  • Page 128: Rear Strobe Light Harness

    Rear Strobe Light Harness This harness connects the PI Board to the rear strobe lights. Tools Required: Wire cutters Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Rear Strobe Lights Remove the following components:...
  • Page 129 Harnesses Installation 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 Brace plate. See Figure 168. Connect the harness to the Rear Strobe Lights.

  • Page 130: 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 Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8)

  • Page 131: Keylock Harness

    This harness connects the PI Board to the KeyLock on the Bib Panel. Tools Required: Wire cutters Removal Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8)

  • Page 132: Siren Harness

    Siren Harness This harness connects the PI Board to the Siren. Tools Required: Wire cutters Removal Make sure the SE-3 Patroller is powered off, Siren unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8)

  • Page 133: Service Interface Harness

    SE-3 Patroller. Tools Required: Wire cutters Removal Service Port Make sure the SE-3 Patroller is powered off, unplugged, and the parking brake is engaged. Remove the following components: Battery Module (page 8) Storage Trays (page 13) Bib Panel (page 14)
  • Page 134 Harnesses SE-3 Patroller...

  • Page 135: Post-Service Tests

    Post-Service Tests This chapter describes standard tests to perform after servicing a Segway SE-3 Patroller. If 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 Use the key to turn on the SE-3 Patroller.

  • Page 136: Ride Test

    Post-Service Tests 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. Drive forward. Drive backward. Turn the handlebar full left and drive in a circle.

  • Page 137: Fasteners

    • 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.
  • Page 138 M5 Lock Nut PI Board 8 mm 6.0 N-m (4.4 ft-lbf) 23202-00003 Fender P-Clip 10 mm 5.5 N-m (4.0 ft-lbf) M6 Lock Nut Headlight Bracket 10 mm 6.0 N-m (4.4 ft-lbf) Windshield 10 mm 1.5 N-m (1.1 ft-lbf) 23202-00004 SE-3 Patroller...
  • Page 139 Fasteners Part Number Fastener Type Application Qty/PT Drive Torque Collar Nut Front Fork Spanner 45 N-m (33 ft-lbf) 23782-00001 M8 x 14 SHCS Front Caliper (to Front Fork) 6 mm 28.5 N-m (21.0 ft-lbf) 23783-00001 M8 Lock Nut Handlebar (to Front Fork) 13 mm 34 N-m (25 ft-lbf) 23784-00001...
  • Page 140 5.5 N-m (4.0 ft-lbf) Light Cluster 4 mm 4.0 N-m (3.0 ft-lbf) 24270-00006 Storage Tray 4 mm 1.0 N-m (0.74 ft-lbf) Windshield 1.5 N-m (1.1 ft-lbf) M4 x 10 SHCS Service Port 3 mm 1.6 N-m (1.2 ft-lbf) 24315-00001 SE-3 Patroller...
  • Page 141 Fasteners Part Number Fastener Type Application Qty/PT Drive Torque M4 x 12 SHCS Front Directional Light 3 mm 1.6 N-m (1.2 ft-lbf) 24315-00002 M4 x 16 SHCS Rear Directional Light 3 mm 1.0 N-m (0.74 ft-lbf) 24315-00004 Front Strobe Light 3 mm 1.6 N-m (1.2 ft-lbf) M4 x 20 SHCS...
  • Page 142 5.5 N-m (4.0 ft-lbf) 24437-00003 M4 x 8 SHCS Electronics Shield 3 mm 2.5 N-m (1.8 ft-lbf) 24491-00002 M4 x 10 SHCS Charger 3 mm 2.5 N-m (1.8 ft-lbf) 24491-00003 1/2 in. P-Clip Fender (Tail Light Harness) 24509-00001 SE-3 Patroller...

  • Page 143: Tools And Equipment

    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...
  • Page 144 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) Wire cutters Vehicle jack 1.5 Ton (or greater) floor jack SE-3 Patroller...

  • Page 145: Glossary

    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 A set of slides or rockers installed onto a printed ciruit board. These are commonly used to customize the behavior of a device.
  • Page 146 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. SE-3 Patroller...
  • Page 148 24538-00001 ad...

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