Segway Personal Transporter i2 Parts Replacement Manual Download Page 2

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RISK OF DEATH OR SERIOUS INJURY

To replace parts on the Segway Personal Transporter, you must read

and follow all instructions and warnings in the Segway Personal

Transporter Parts Replacement Guide. Failure to do so could result in

serious injury or death.

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instructions.

Summary of Contents for Personal Transporter i2

Page 1: ...Segway Personal Transporter i2 x2 x2 Turf Parts Replacement Guide October 2008 21657 00000 Rev aa...

Page 2: ...place parts on the Segway Personal Transporter you must read and follow all instructions and warnings in the Segway Personal Transporter Parts Replacement Guide Failure to do so could result in seriou...

Page 3: ...emarks 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 Segway products are not actively marketed or are no...

Page 4: ...iv This page intentionally left blank...

Page 5: ...rials xiv i2 x2 Replacement Parts Diagram xv 1 LeanSteer Frame When to Replace 1 3 Handlebar Removal and Installation 1 4 LeanSteer Frame Removal 1 5 LeanSteer Frame Installation 1 6 Wireless InfoKey...

Page 6: ...stallation i2 4 7 5 Fenders When to Replace 5 2 Fender Removal and Installation i2 5 3 Fender Removal and Installation x2 5 4 Fender Frame Removal and Installation x2 5 5 6 Power Base Trim When to Rep...

Page 7: ...MI Filter Removal and Installation 9 12 When to Replace 9 12 Pivot Base Assembly Removal and Installation 9 14 When to Replace 9 14 Console Housing Removal and Installation 9 16 When to Replace 9 16 1...

Page 8: ...Power Base Chassis When to Replace 14 3 Disassembling and Reassembling Chassis Components 14 4 A Post Service Tests A 1 Start up Test A 1 Standard Check A 2 Operational Test A 2 B Parts List B 1 C Fa...

Page 9: ...odor smoke or excessive heat or leaks any substance Avoid contact with any substance seeping from the battery pack Keep out of reach of children and pets Exposure to battery pack voltage could result...

Page 10: ...ception of the wheel nuts battery fasteners and LeanSteer clamp bolt Do not attempt to repair any stripped or damaged screw hole Instead replace the part If replacement part is not available do not re...

Page 11: ...chnician may be required to undergo training at each level Upon satisfactory completion of this training the service technician becomes certified to maintain the Segway PT parts and assemblies accordi...

Page 12: ...e wheel assembly Chapter 5 Describes removal and installation procedures for the fender Chapter 6 Describes removal and installation procedures for the power base trim fascia Chapter 7 Describes proce...

Page 13: ...O Safety Alert Symbol Signal Words Terminology Throughout this guide the term model x2 refers to both the x2 and x2 Turf models unless otherwise noted This is the safety alert symbol It is used to ale...

Page 14: ...r All parts included in a Replaceable Kit should be replaced When individual parts of a subassembly are available for replacement these parts are shipped without fasteners and are intended for install...

Page 15: ...58 00001 Aluminum 20659 00001 Comfort 20943 00001 21064 00001 Programmed 21065 00001 Unprogrammed 20944 00001 20948 00001 20946 00001 20947 00001 20878 00001 20950 00001 20956 00001 Black 20956 00002...

Page 16: ...This page intentionally left blank About This Guide xvi Segway Personal Transporter i2 x2 x2 Turf Parts Replacement...

Page 17: ...nSteer frame and or maintain the torque on the wedge clamp fastener could result in machine malfunction and could cause personal injury or damage to the Segway PT Using the Segway PT without properly...

Page 18: ...r removed replace the fastener with a new Segway approved fastener See Appendix C Fasteners for more information Do not attempt to repair any stripped or damaged screw hole Instead replace the part If...

Page 19: ...eer Frame F Handlebar Hub Trim G Height Adjustment Knob H M4 Threaded Rod I Washer J Height Adjustment Wedge K Wedge Counterbore Side L Fastener SHCS M6 x 1 0 x 45 Hex M Slide Top Spacer N Upper Handl...

Page 20: ...ar against LeanSteer frame with the bevel facing backward and Segway logo facing up See Figure 1 2 3 Position handlebar clamp against handlebar 4 Insert 3 fasteners 20306 00001 through handlebar clamp...

Page 21: ...all the way to the left and right until loose You might hear and feel a click when wedge clamp assembly releases from pivot assembly See Figure 1 4 4 Slide LeanSteer frame away from pivot assembly as...

Page 22: ...tered If it is not straight and centered adjust LeanSteer frame to straighten and center it Fastener must go through notch in pivot assembly 6 Tighten fastener 20631 00001 to 11 0 N m 8 1 ft lbf See F...

Page 23: ...2 Slide Wireless InfoKey Controller out of Wireless InfoKey controller dock adapter See 2 in Figure 1 10 Figure 1 10 Remove Wireless InfoKey Controller To install Wireless InfoKey controller 1 Make su...

Page 24: ...InfoKey controller dock Figure 1 11 Replace Wireless InfoKey Controller Dock To install Wireless InfoKey controller dock 1 Make sure Segway PT is powered off and unplugged 2 Place Wireless InfoKey con...

Page 25: ...oller and remove battery See Figure 1 13 Figure 1 13 Remove or Install Wireless InfoKey Controller Battery To install battery 1 Make sure Segway PT is powered off and unplugged 2 Verify that new batte...

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Page 27: ...us injury death or damage to property MATS Always ensure that the top of the powerbase and bottom of mat are clean dry and free of debris These mats protect the rider detect sensors located beneath th...

Page 28: ...are a functional component of the Rider Detect feature mats permit a wide range of foot positions to achieve rider detection These mats protect the rider detect sensors located beneath them and provi...

Page 29: ...is powered off and unplugged 2 Verify that top of power base and bottom of mat are clean dry and free of debris 3 Place mat on power base 4 Fit mat s rubber tabs into slots formed by gap between front...

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Page 31: ...only Segway approved fasteners Do not tighten or reuse any fastener except the screws used to attach the battery packs wheel nuts and LeanSteer frame Instead when any other fastener is loose or remov...

Page 32: ...the battery pack Do not insert any object into the battery pack or use any device to pry at the battery pack casing If you insert an object into any of the battery ports or openings you could suffer e...

Page 33: ...own so that bottom of chassis is exposed See Figure 3 1 3 Using 3mm hex wrench remove fasteners that hold battery in place 4 per battery 4 Pull battery straight off chassis 5 Repeat Steps 3 and 4 for...

Page 34: ...6 N m Do not use power tool Do not cross thread or over tighten fasteners Tighten only to the prescribed torque 7 Repeat Steps 3 through 5 for other battery 8 Perform post service tests page A 1 Be su...

Page 35: ...s in the software i2 and x2 x2 Turf wheels and tires are not interchangeable Use only i2 wheels and tires on i2 models x2 and x2 Turf wheels and tires on x2 and x2 Turf models Failure to adhere to the...

Page 36: ...steners 40mm i2 Tube Replacement Kit 21193 00001 5 Tubes i2 Tire Replacement Kit 21471 00001 5 Tires Required Tools Torque wrench 3 8 drive Hex socket wrench 13mm Hex wrench 8mm 3 in 3 8 drive socket...

Page 37: ...l cap Press on edge of wheel cap and lift off from opposite edge Model x2 Turf has spacer as shown on page xv See Figure 4 1 4 Using 13mm socket wrench remove 3 wheel nuts 20158 00001 Figure 4 1 Remov...

Page 38: ...de of wheel with plastic or rubber mallet 7 Lift off tire wheel assembly To install tire wheel assembly 1 Make sure Segway PT is powered off and unplugged 2 Inspect wheel mounting surfaces use alcohol...

Page 39: ...ift off tire wheel assembly including spacer See Figure 4 3 To install tire wheel assembly 1 Make sure Segway PT is powered off and unplugged 2 Inspect wheel mounting surfaces use alcohol wipes to cle...

Page 40: ...ch remove 3 fasteners attaching hub adapter to wheel 4 Lift off hub adapter To install hub adapter 1 Make sure Segway PT is powered off and unplugged 2 Inspect mounting surface use alcohol wipes to cl...

Page 41: ...The i2 tire is tightly fitted to wheel in a manner similar to a motorcycle tire mounted to a rim 4 Using a bar clamp break tire bead by positioning clamp jaws against inner and outer sidewall of tire...

Page 42: ...re iron under tire bead about 6 away from first tire iron and pry that portion of tire over rim Figure 4 9 Figure 4 9 Insert Second Tire Iron 9 Pull first tire iron out and reinsert under bead about 6...

Page 43: ...red off and unplugged 2 Reminder Wear safety glasses 3 Inflate tube with just enough air to give tube a circular shape Figure 4 13 Figure 4 13 Inflate Tube Until Circular in Shape 4 Align valve stem w...

Page 44: ...air pump with Schrader valve attachment or other source of forced air inflate tire enough to seat tire beads Figure 4 17 It may be necessary to over inflate tire to properly seat tire beads When prope...

Page 45: ...follow these instructions could lead to electrical shock serious injury death or damage to property Failure to follow these instructions could lead to electrical shock serious injury death or damage...

Page 46: ...ion Before using a fastener make certain the fastener is the correct size and type with any necessary washer and thread lock in place see Table C 1 on page C 1 Since the pre applied thread lock compou...

Page 47: ...ve 4 button head fasteners See Figure 5 1 Figure 5 1 Remove or Install Fender i2 4 Lift fender and remove from gearbox To install fender 1 Make sure Segway PT is powered off and unplugged 2 Orient and...

Page 48: ...tall fender 1 Make sure Segway PT is powered off and unplugged 2 Orient and place left fender on left fender frame and right fender on right fender frame 3 Ensure grommets are in place on fender If gr...

Page 49: ...der frame assembly can be removed as a unit not shown If so frame fasteners should be discarded and replaced with new ones To install fender frame 1 Make sure Segway PT is powered off and unplugged 2...

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Page 51: ...structions Power off the Segway PT Unplug the Segway PT Finger or hand hazard Applies to Models i2 x2 x2 Turf Qualifications Customer Replaceable Customer Replaceable Kits i2 x2 Power Base Front Trim...

Page 52: ...r See Appendix C Fasteners for more information Before using a fastener make certain the fastener is the correct size and type with any necessary washer and thread lock in place see Table C 1 on page...

Page 53: ...etermined by the part number of the console trim which is located on the forward part of the housing and is visible after the cover is removed The part numbers for each revision of the console trim ar...

Page 54: ...t fascia tabs with holes beneath pivot base hub and be sure they are free of debris and properly seated before threading fasteners See Figure 6 1 TABS ARE DELICATE AND CAN BREAK EASILY IF NOT PROPERLY...

Page 55: ...over See Figure 6 3 Figure 6 3 Remove Gearbox Trim Cover 4 Set aside fasteners and trim piece To install gearbox trim cover 1 Make sure Segway PT is powered off and unplugged 2 Align holes in gearbox...

Page 56: ...harge port See Figure 6 4 Figure 6 4 Remove or Install Console Trim Make sure IEC connector charge port remains clean and dry To install console trim 1 Make sure Segway PT is powered off and unplugged...

Page 57: ...r 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 Warranty will be void if c...

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Page 59: ...ower Base Failure to do so could result in serious injury or death Failure to follow these instructions could lead to electrical shock serious injury death or damage to property Failure to follow thes...

Page 60: ...ad lock compound is intended for single use only reuse of fasteners is not permitted with the exception of the wheel nuts battery fasteners and LeanSteer clamp bolt Do not attempt to repair any stripp...

Page 61: ...lowing components from the Segway PT LeanSteer frame qty 1 page 1 5 Mat qty 2 page 2 3 Battery packs qty 2 page 3 3 Tire wheel assembly qty 2 Model i2 page 4 3 Model x2 page 4 4 Model x2 Turf page 4 5...

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Page 63: ...njury death or damage to property Failure to follow these instructions could lead to electrical shock serious injury death or damage to property Failure to follow these instructions could cause person...

Page 64: ...exception of the wheel nuts battery fasteners and LeanSteer clamp bolt Do not attempt to repair any stripped or damaged screw hole Instead replace the part If replacement part is not available do not...

Page 65: ...anizing RTV silicone sealant to seal the gearbox to the Segway PT chassis More recently some parts were changed to allow use of a gasket in place of the RTV silicone sealant How to tell the difference...

Page 66: ...ound and require significant leverage to loosen for the duration of thread engagement Use of new gearbox fasteners with new thread lock compound is required for proper installation 10 Remove gearbox U...

Page 67: ...ly scrape away all RTV sealant residue from chassis mating surface Do not scratch machined surface Always work in downward direction to prevent contaminants from falling into motor cavity See Figure 8...

Page 68: ...in on right not pictured See Figure 8 6 Although motor is shown out of position in Figure 8 6 to make couplings and roll pins visible motor is still in place during this procedure Figure 8 6 Align Cou...

Page 69: ...00002 Thread in by hand and then torque to 40 N m using T 45 6 lobe wrench with 3 8 drive socket See Figure 8 8 Figure 8 8 Install Gearbox Fasteners 11 Reinstall fascia trim page 6 4 12 Reinstall gear...

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Page 71: ...age to property Failure to follow these instructions could lead to electrical shock serious injury death or damage to property Failure to follow these instructions could cause personal injury Read all...

Page 72: ...e Table C 1 on page C 1 Since the pre applied thread lock compound is intended for single use only reuse of fasteners is not permitted with the exception of the wheel nuts battery fasteners and LeanSt...

Page 73: ...002 Second Revision 20925 00002 First revision console housing cover parts are no longer manufactured or supported First revision components are not compatible with second revision components similarl...

Page 74: ...replacement with a new cover or gasket will be necessary To remove console cover 1 Make sure Segway PT is powered off and unplugged 2 Remove console cover trim page 6 6 3 Depending on revision use T...

Page 75: ...el in cover using a 20 gauge 0 32in 0 8mm tip Lay gasket into RTV bead and press lightly to seat Figure 9 4 Apply Bead of RTV Silicone Sealant 3 Install a 14 gauge 0 64in 1 6mm tip on RTV tube and lay...

Page 76: ...emove the four 4 M3 x 6 button head cap screws holding the electromagnetic interference EMI shield to the UIC See Figure 9 6 Figure 9 6 Remove or Install EMI Shield DISCARD FASTENERS AFTER REMOVAL DO...

Page 77: ...e the radio board for return to customer because it cannot be reused Place radio board in ESD bag or on clean ESD work surface Figure 9 8 Remove or Install Radio Board 7 Verify that the serial number...

Page 78: ...9 8 Segway Personal Transporter i2 x2 x2 Turf Parts Replacement 5 Install console cover page 9 4 6 Install battery packs page 3 3 7 Perform post service tests page A 1...

Page 79: ...Segway PT When to Replace Replace the UIC when directed to do so by a Segway Service Representative The console radio is electronically bound to the other electronics inside the power base and the Wi...

Page 80: ...g mechanism is intact If harness wires are pinched or exhibit insulation damage or the connector is damaged so as to prevent positive locking upon installation the harness must be replaced 3 Orient UI...

Page 81: ...ge 9 4 15 Perform post service tests page A 1 Hi Pot and Ground Bond Test Operation Only personnel who have been trained on Hi Pot and Ground Bond test equipment should perform these tests Use of Hi P...

Page 82: ...9 4 Disconnect 2 steering sensor harness connectors at top of EMI filter Keep retention putty for reuse during installation While pressing connector locking tabs gently remove connectors to disconnec...

Page 83: ...d EMI filter One large ferrite core 21271 00001 is placed on B side CU hardness 10 pin connector between chassis cover and UIC Ferrite cores can physically impede installation of new UIC Take special...

Page 84: ...er and set aside page 9 12 6 Use T 30 6 lobe wrench to remove 2 screws that anchor base plate to chassis see Figure 9 16 7 Carefully remove large ferrite core from CU harness and small ferrite cores f...

Page 85: ...gnment 6 Using T 30 6 lobe wrench drive each screw and torque to 11 0 N m 7 Install EMI filter page 9 13 8 Any PT without ferrite cores must be retrofitted with ferrites upon reassembly One small ferr...

Page 86: ...f the inserts or plastic are damaged the console housing must be replaced To install console housing 1 Make sure Segway PT is powered off and unplugged 2 Thread 6 SHCS M4 x 0 7 x 16 6 lobe screws 2020...

Page 87: ...instructions could lead to electrical shock serious injury death or damage to property ESD PROCEDURES Any time repair involves opening the console or chassis cover best practice electrostatic discharg...

Page 88: ...used to attach the battery packs wheel nuts and LeanSteer frame Instead when any other fastener is loose or removed replace the fastener with a new Segway approved fastener See Appendix C Fasteners fo...

Page 89: ...ure 10 1 Remove or Install Chassis Cover To install chassis cover Make sure motor and BSA harnesses are seated in notches in chassis and cable router so that they cannot be pinched when cover is insta...

Page 90: ...Viewing from the rear of the chassis the cable connections should be as follows Left side 10 pin connector and a smaller connector with purple wires Right side 12 pin connector and a smaller connecto...

Page 91: ...ions could lead to electrical shock serious injury death or damage to property Failure to follow these instructions could lead to electrical shock serious injury death or damage to property Failure to...

Page 92: ...y other fastener is loose or removed replace the fastener with a new Segway approved fastener See Appendix C Fasteners for more information Before using a fastener make certain the fastener is the cor...

Page 93: ...nnector and then carefully pull on connector to unseat See Figure 11 2 Figure 11 2 Pry Connector Tab 7 Disconnect balance sensor assembly harness and CU harness from CU board by squeezing plastic tab...

Page 94: ...sonal Transporter i2 x2 x2 Turf Parts Replacement 10 Using proper ESD practices place CU board in static bag for return shipment pursuant to terms and conditions of Segway PT warranty or other establi...

Page 95: ...6 Connect balance sensor assembly harness and CU harness to socket on CU board See Figure 11 6 CU harnesses are different lengths Short CU harness connects to the A side of CU board rear and long CU h...

Page 96: ...arts Replacement Make sure motor and BSA harnesses are seated in notches in chassis and cable router so that they cannot be pinched when cover is installed Figure 11 8 Place Wires in Abrasion Protecti...

Page 97: ...hock serious injury death or damage to property Failure to follow these instructions could lead to electrical shock serious injury death or damage to property Failure to do so could result in serious...

Page 98: ...and thread lock in place see Table C 1 on page C 1 Since the pre applied thread lock compound is intended for single use only reuse of fasteners is not permitted with the exception of the wheel nuts...

Page 99: ...balance sensor assembly from chassis Avoid touching circuit board located on bottom of balance sensor assembly 9 If you are reusing this balance sensor assembly place on appropriate anti static surfac...

Page 100: ...12 4 Segway Personal Transporter i2 x2 x2 Turf Parts Replacement 6 Perform post service tests page A 1 7 Start machine before finishing assembly...

Page 101: ...to property Failure to follow these instructions could lead to electrical shock serious injury death or damage to property Failure to do so could result in serious injury or death or damage to propert...

Page 102: ...he fastener is the correct size and type with any necessary washer and thread lock in place see Table C 1 on page C 1 Since the pre applied thread lock compound is intended for single use only reuse o...

Page 103: ...emove chassis cover page 10 3 6 Use small flathead screwdriver and gently lift tab on connector see Figure 13 1 from back of motor and then carefully pull on both connectors to unseat See Figure 13 2...

Page 104: ...SA 5 Thread 2 SHCS M5 x 0 8 x 12 6 lobe screws 20536 00001 through motor mounting tabs into chassis See Figure 13 4 Use of new motor fasteners with new thread lock compound is required for proper inst...

Page 105: ...unplugged 2 Pull elastomer bushing off motor coupling Completely clean residue from drive coupling and cavity using cotton swabs and household window cleaner Repeat process with isopropyl alcohol unti...

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Page 107: ...injury or death Failure to follow these instructions could lead to electrical shock serious injury death or damage to property Failure to follow these instructions could lead to electrical shock serio...

Page 108: ...ead lock compound is intended for single use only reuse of fasteners is not permitted with the exception of the wheel nuts battery fasteners and LeanSteer clamp bolt Do not attempt to repair any strip...

Page 109: ...etermines the assembly is defective 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 ser...

Page 110: ...ge 9 14 5 Remove chassis cover page 10 3 6 Remove CU board qty 2 page 11 3 7 Remove balance sensor assembly page 12 3 8 Remove motor qty 2 page 13 3 To reassemble chassis components Install components...

Page 111: ...Start up Test To perform a start up test do the following Make sure Wireless InfoKey controller properly powers on machine without an error message Failure to do so could result in serious injury or d...

Page 112: ...damaged or loose Operational Test To perform an operational test do the following 1 Check for obstruction under mats 2 Check LeanSteer frame for tightness and centered orientation 3 Turn on and power...

Page 113: ...it Includes dock and fastener battery and all bezels 20947 00001 i2 x2 Power Base Front Trim Fascia Kit Includes front trim fascia 1 fasteners 4 20948 00001 i2 x2 Power Base Rear Trim Fascia Kit Inclu...

Page 114: ...Includes Serviceable Power Base Kit x2 Table B 2 Parts List excluding LeanSteer frame Part Number Name Description 17124 00003 Power Base Chassis Includes power base chassis 1 18911 00001 i2 Tube Rep...

Page 115: ...s console cover 1 20934 00001 Console Trim v2 Black 20934 00002 Console Trim v2 White 20934 00003 Console Trim V2 Metallic Sage 21089 00001 Motor with Coupling Kit Includes motor with coupling 2 21091...

Page 116: ...eners 20mm 20954 00003 x2 Handlebar Clamp Kit Silver Clamp Fasteners 20mm 20955 00001 i2 x2 Handlebar with Grips Kit Handlebar with grips 20957 00001 i2 Upper LeanSteer Frame Kit Black Slide top space...

Page 117: ...F Handlebar hub trim 20358 00001 20358 00001 20358 00001 20358 00001 G Height adjustment knob 20750 00001 20750 00001 20750 00001 20750 00001 H M4 threaded rod 20752 00001 20752 00001 20752 00001 2075...

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Page 119: ...teners and LeanSteer clamp bolt Do not attempt to repair any stripped or damaged screw hole Instead replace the part If replacement part is not available do not reassemble Insert fasteners slowly and...

Page 120: ...bly Front and Rear 2 T 30 11 0 20539 00001 Pivot Base Assembly Center 1 T 30 11 0 20158 00001 Wheels i2 6 13mm 30 0 20203 00002 UIC top and cover 8 each T 20 1 8 20203 00002 Console Housing 6 T 20 2 6...

Page 121: ...6 4mm 6 0 20554 00001 Fascias 8 4mm 1 5 10mm for installation without parking stand 20554 00003 Fascias Parking Stand 8 4mm 1 5 14mm for installation with parking stand 20631 00001 LeanSteer Frame Cla...

Page 122: ...l Transporter i2 x2 x2 Turf Parts Replacement 20991 00001 x2 Wheel Hub Adapter 8 8mm 35 0 20991 00002 x2 Turf Wheel Hub Adapter 8 8mm 35 0 Table C 1 Fasteners Continued Part Number Application Qty Uni...

Page 123: ...permitted with the exception of the wheel nuts battery fasteners and LeanSteer clamp bolt Do not attempt to repair any stripped or damaged screw hole Instead replace the part If replacement part is no...

Page 124: ...t extension 3 in 3 8 drive Socket Hex 13mm 6 point is preferred Tire pump Air pump with Schrader valve attachment Tire iron qty 2 Approximately 14 long motorcycle type Trigger style bar clamp 12 bar c...

Page 125: ...tic discharge Electrostatic discharge 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 or wear...

Page 126: ...y be serviced by a trained authorized Segway technician torque wrench A wrench that measures the amount of turning and twisting force applied in tightening a nut or bolt user interface console UIC Com...

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