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Old 03-19-2022, 06:03 PM   #1
etak
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Question i167 - Battery charger unit failure

I have an original i167, purchased in 2004. It's been sitting in the shed for a few years. A couple of months ago, I brushed it off and took it up to Segway Australia in Burleigh Heads Queensland for them to have a look. For testing, they swapped the NiMH batteries out (they were dead) for a new pair of Lithium-Ion ones. Then, they put in the charging cable.

The result was that, on the Control Shaft Base (CSB), the front battery LED (labeled 'F') had a red light on it. This apparently indicates a failure. The rear battery LED (labeled 'R') lit up green, indicating no issues there.

From the 'Segway Service Manual' for the i167, you can see the root cause and recommended action of the CSB LEDs:

Charging Indicators: Red
Condition: Not charging
Recommended Action:
Power up machine and look for battery fault. If present, reseat battery pack(s) (p.3-3). If red light or unlit condition persists, switch front and rear battery packs to check if error indication follows problem battery pack. If defective battery confirmed, replace that battery pack (p.3-3). If not, replace platform/CSB (p. 7-5)

My questions:
Is it possible to fix the CSB or is it best to replace it (if it's even possible to find one these days)?
Or could it be a problem with the Lithium-Ion battery combination?

The original batteries are NiMH and I have heard you need a software upgrade for the new type.

Last edited by etak; 03-19-2022 at 08:46 PM..
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Old 03-20-2022, 03:54 AM   #2
dgbint
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Here is what I remember.

Yes the original Segway would have needed a software upgrade to accommodate Li-ion batteries.
I did a road trip to most parts of Australia, and did it all, years ago.
When I completed the upgrade, I affixed a flyguy round logo to the rear of the chassis.
So it would be obvious to me, if it ever came back for service.
Does yours have a sticker ?

I guess if you got one green light, then yes your machine has been upgraded.

If you have one green LED and one red LED when charging, there are 2 possibilities.
1
Yes the CSB ( which contains the charger ) may be faulty.

2
One of the batteries or battery connectors is at fault.
Swap batteries, and see if fault stays same or changes sides.

It may be possible ( but expensive ) to have an expert in switch mode supplies fix the CSB without any drawings.

Cheers
Michael
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