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Segway Personal Transporter i2 User Manual

Segway Personal Transporter i2
126 pages
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Segway
®
Personal Transporter
i2, x2, x2 Turf
Parts Replacement Guide
October 2008
21657-00000 Rev.aa

Table of Contents

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Segway Personal Transporter i2 Specifications

General IconGeneral
Max Speed12.5 mph (20 km/h)
BatteryLithium-ion
Charging Time8-10 hours
Weight47.6 kg (105 lbs)
Max Load260 lbs (118 kg)
Tire TypePneumatic
RangeUp to 24 mi (38 km)

Summary

About This Guide

Purpose

Explains the purpose of the manual.

Audience

Identifies the intended readers of the manual.

Certification

Details the Segway technician certification process.

Organization

Describes how the manual is organized into categories.

Safety Messages

Explains safety standards, alert symbols, and signal words.

Terminology

Defines key terms used in the manual.

Customer Replaceable Kits and Technician Replaceable Parts

Differentiates between customer and technician replaceable parts.

Related User Materials

Lists additional reference materials for parts replacement.

i2/x2 Replacement Parts Diagram

Provides an exploded diagram of replacement parts.

1. LeanSteer™ Frame

When to Replace

Conditions for replacing the LeanSteer frame.

Handlebar Removal and Installation

Steps to remove and install the handlebar.

LeanSteer Frame Removal

Steps to remove the LeanSteer frame from the pivot assembly.

LeanSteer Frame Installation

Steps to install the LeanSteer frame onto the pivot assembly.

Wireless InfoKey™ Controller Removal and Installation

Steps for removing and installing the wireless InfoKey controller.

Wireless InfoKey Controller Dock Removal and Installation

Steps for removing and installing the InfoKey controller dock.

Wireless InfoKey Controller Battery Removal and Installation

Steps to remove and install the InfoKey controller battery.

2. Mats

When to Replace

Conditions for replacing the mats.

Mat Removal and Installation

Steps to remove and install the mats.

3. Battery Packs

When to Replace

Conditions for replacing the battery packs.

Battery Removal and Installation

Steps to remove and install the battery packs.

4. Tire/Wheel Assembly

When to Replace

Conditions for replacing the tire/wheel assembly.

Tire/Wheel Assembly Removal and Installation, i2 Only

Steps for i2 tire/wheel assembly removal and installation.

Tire/Wheel Assembly Removal and Installation, x2 only

Steps for x2 tire/wheel assembly removal and installation.

Tire/Wheel Assembly Removal and Installation, x2 Turf only

Steps for x2 Turf tire/wheel assembly removal and installation.

Hub Adapter Removal and Installation, x2/x2 Turf

Steps for hub adapter removal and installation.

Tire Tube Removal and Installation, i2

Steps for i2 tire tube removal and installation.

5. Fenders

When to Replace

Conditions for replacing the fender.

Fender Removal and Installation, i2

Steps for i2 fender removal and installation.

Fender Removal and Installation, x2

Steps for x2 fender removal and installation.

Fender Frame Removal and Installation, x2

Steps for x2 fender frame removal and installation.

6. Power Base Trim

When to Replace

Conditions for power base trim replacement.

Before Removing Fascias

Pre-removal steps for fascias.

Fascia Removal and Installation

Steps for fascia removal and installation.

Gearbox Trim Cover Removal and Installation

Steps for gearbox trim cover removal and installation.

Console Trim Removal or Installation

Steps for console trim removal or installation.

7. Serviceable Power Base

Establishing a Serviceable Power Base

Steps to prepare the power base for service.

8. Gearbox

When to Replace

Conditions for gearbox replacement.

How to tell the difference

Distinguishing between sealant and gasket types for gearbox.

Gearbox Removal

Steps to remove the gearbox assembly.

Gearbox Installation

Steps to install the gearbox assembly.

9. Console

When to Replace

Conditions for console replacement.

Before Servicing the Console

Pre-service steps for the console.

Console Cover Removal and Installation

Steps for console cover removal and installation.

EMI Shield Removal and Installation

Steps for EMI shield removal and installation.

Radio Board Removal and Installation

Steps for radio board removal and installation.

User Interface Console (UIC) Removal and Installation

Steps for UIC removal and installation.

Hi-Pot and Ground Bond Test Operation

Procedures for Hi-Pot and Ground Bond testing.

EMI Filter Removal and Installation

Steps for EMI filter removal and installation.

Pivot Base Assembly Removal and Installation

Steps for pivot base assembly removal and installation.

Console Housing Removal and Installation

Steps for console housing removal and installation.

10. Chassis Cover

When to Replace

Conditions for chassis cover replacement.

Chassis Cover Removal and Installation

Steps to remove and install the chassis cover.

11. CU Board

CU Board Removal

Steps to remove the Control Unit (CU) board.

CU Board Installation

Steps to install the Control Unit (CU) board.

12. Balance Sensor Assembly

BSA Removal and Installation

Steps to remove and install the Balance Sensor Assembly.

13. Motor

When to Replace

Conditions for replacing the motor.

Motor Removal

Steps to remove the motor assembly.

Motor Installation

Steps to install the motor assembly.

Elastomer Bushing Inspection, Removal, and Installation

Steps to inspect, remove, and install the elastomer bushing.

14. Power Base Chassis

When to Replace

Conditions for replacing the power base chassis.

Disassembling and Reassembling Chassis Components

Steps for disassembling and reassembling chassis components.

A. Post-Service Tests

Start-up Test

Procedure for performing a start-up test.

Standard Check

Steps for performing a standard check.

Operational Test

Steps for performing an operational test.

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