Segway Human Transporter e Series Instructor Manual And Participant Workbook Download | Manualshive

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Basic Rider Optimization Training for the Segway



HT

Instructor Guide and Participant Workbook

Rev 3.5i - January 2004

© Segway LLC 2002

P/N 1707100001aa

Required Tools

You will need the following tools:

>

Hex wrenches, sizes 2.5, 3, 4 and 5MM

>

Torque wrench with parameters where 50 Newton Meters (N-m) falls near the middle of the range

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16MM deep socket

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T-15 or T-20 six lobed wrench (depending on Segway HT vintage)

>

Flathead screwdriver

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Air pressure gauge

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Tire pump

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Plastic or rubber mallet

>

Alcohol wipes

>

Tweezers

HT Fastener Guidelines

1. Use only Segway-provided fasteners.
2. Do not reuse any fastener except for the screws used to attach the Battery Packs, Control Shaft

clamp bolt, and wheel nuts. Instead, when any other fastener is removed, replace the fastener
with a new Segway-provided fastener.

3.  Before using a fastener, make certain the fastener is the correct size and type.
4.  Do not attempt to repair any stripped or damaged screw hole. Instead, replace the part.
5.  Insert fasteners slowly and carefully. Do not cross-thread or over-tighten fasteners. Tighten only

to the prescribed torque. If a fastener is cross-threaded, call Segway Customer Operations at 1-
866-4SEGWAY.

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Summary of Contents for Human Transporter e Series

Page 1: ...articipant Workbook Rev 3 5i January 2004 Segway LLC 2002 P N 1707100001aa Basic Rider Optimization Training for the Segway Human Transporter HT i Series e Series and p Series models Instructor Guide and Participant Workbook ...

Page 2: ...e Do not let anyone power on your Segway HT e Series Segway HT or try to engage or disengage E Stand unless that person has completed training provided by a Segway authorized trainer Don t let anyone step on or ride your e Series Segway HT unless that person has completed training provided by a Segway authorized trainer Install the Side Bags onto the Lower Cargo Structure prior to operation Place ...

Page 3: ...this risk of injury always exists should cause you to be a more careful safer rider The Segway HT s unique balancing ability and ease of use can lead you to become overconfident If you exceed the ability of the Segway HT to balance such as by riding over obstacles uneven terrain slippery surfaces loose materials or steep slopes you can very quickly lose control leading to collisions falls and inju...

Page 4: ...ay HT Model Comparison 29 Demonstration and Guided Ride 29 Riding Form 32 Parking Stand Deployment and Retraction i Series only 33 Using the Keys 33 Stepping On i and p Series 33 Stepping On e Series 34 Turning 36 Loading and Unloading Cargo e Series only 36 Drills 37 Display Messages 42 Display Colors 42 Normal Operation 43 Error Conditions During Startup 43 Reduced Performance Levels 44 Critical...

Page 5: ...ront Trim 77 Replacing the Fender 78 Replacing a Parking Stand i Series only 79 Replacing the Handlebar Control Shaft Assembly 80 Replacing the Fixed Grip 81 Replacing the Steering Grip 82 Replacing the Charge Port Cover 83 Replacing the Control Shaft Clamp 84 Installing an Upper Frame and Bag Cargo Structure 85 Post repair Checklist 86 Lifting and Loading Your Segway HT 86 Packing Your Segway HT ...

Page 6: ...g 50 Newton Meters N m Course Expectations document emailed in advance including expectation that riders will bring their own helmets Appropriate clothing recommendations for this training comfortable clothing flat shoes Communicate information regarding medical conditions that may affect balance Just as with any other transportation Segway HT you must be mentally alert and free from physical impa...

Page 7: ...ased business founded by renowned inventor and entrepreneur Dean Kamen to provide a solution to short distance travel The company has created the Segway Human Transporter HT the first self balancing electric powered transporter designed to enhance the productivity of people by increasing the distance they can travel and the amount they can carry Kamen s first big breakthroughs were in the medical ...

Page 8: ...k shake Wide turns versus turning in place Maintaining lateral stability 5 30 min i and p Series only 15 min instruction 15 min break e Series only or combination of models for all riders 30 min More time required for stepping on stepping off and weight distribution with e Series All step off shut down Split i and p Series riders in one group and e Series riders in another 2 instructors Use of Key...

Page 9: ... What experience have you had to date with the Segway HT What specific information do you want to take away with you from this course Optional Exercise Explain phases of learning Unconscious Incompetence Conscious Incompetence Conscious Competence Unconscious Competence You don t know what you don t know You DO know what you don t know You DO know what you DO know You don t know what you do know 1...

Page 10: ...ry of Operation Summary and Q A 5 min Total Time 15 min Note Arrange all components on table for participants to see If you have a chassis lay in the Controller Board and BSA Introduction In this session you will learn the specifications for each Segway model You will be shown the main components of the Segway HT and then we will discuss how the Segway HT balances Objectives Upon completion of thi...

Page 11: ...les 10 km Weight Limits for Riders and Cargo 2 Make sure to review the weight limit information described in the Table Footnotes at the end of this table Maximum payload rider plus all cargo 260 lbs 118 kg 210 lbs 96 kg Minimum rider weight 100 lbs 45 kg 100 lbs 45 kg Maximum weight of Handlebar cargo and attachments 10 lbs 4 5 kg 10 lbs 4 5 kg Maximum weight of Segway approved side cargo bag each...

Page 12: ...e is affected by many variables including Temperature storing charging and riding within the recommended temperature parameters will improve range Rider Weight and Cargo lighter riders with less cargo will typically get better range than heaver riders with more cargo Tire Pressure riding with tire pressure below the specified limit reduces range Terrain smooth and flat terrain optimizes range ridi...

Page 13: ...riding on uneven terrain could damage the Segway HT Handlebar Cargo The total weight of any Handlebar payload plus any other attachments hanging from the Handlebar should not exceed 10 lbs 4 5 kg Exceeding this limit interferes with the Segway HT s balancing ability and could cause the Segway HT to accelerate on its own risking injury and damage Side bag Cargo The total weight of each Segway appro...

Page 14: ...ndlebar 06 Fixed Grip 07 Handlebar Trim 08 Display 09 Key 10 Mode Button 11 Height Adjustment Collar 12 Control Shaft 13 Mat 14 Control Shaft Cord 15 Front Trim 16 Control Shaft Clamp Wedge 1 of 2 17 Cover 18 Controller Boards 19 Balance Sensor Assembly 20 Parking Stand 21 Battery Packs 22 Motor 23 Gearbox 24 Fender 25 Tire Wheel Assembly 26 Wheel Nut 27 Charging Indicators 28 Charge Port Charge P...

Page 15: ...the Segway HT moves forward and backward when you twist the Steering Gripdoes not change with the different Keys Imagine a marching band in a row As the row begins to turn the outside marcher increases his pace while the innermost marcher reduces her pace They all accomplish the same turning radius Notes The Mode Button is used to transition between Power Assist Mode and Balance Mode tap and to tu...

Page 16: ... 18 000 000 000 000 000 000 not a typo unique combinations Notes Adjust the height with the Height Adjustment Collar DO NOT over tighten the Height Adjustment Collar Just make it snug The Height Adjustment Collar does not fix a Handlebar Control Shaft Assembly that twists If the Handlebar Control Shaft Assembly is twisting right and left loosen the Control Shaft Clamp bolt lay the Handlebar agains...

Page 17: ...e Mode with full functionality If you depress only one or two sensors the Segway HT will perform in reduced functionality by limiting forward speed Notes Each wheel is independently driven by redundant high speed electric Motors that produce no emissions Our brushless DC motors are maintenance free and employ computer technology to precisely regulate motion The motors have been tested to power lev...

Page 18: ... Segway HTs ship with NiMH Nickel Metal Hydride Battery Packs Range for an i or e Series Model is between 8 and 12 miles 13 and 19 km and for a p Series Model between 6 and 10 miles 10 and 16 km Recharge time 6 hours from empty Costs less than 10 cents per charge 300 to 500 full charge discharge cycles There are two Charging Indicators left for the front Battery Pack and right for the rear Battery...

Page 19: ...a Controller Board failure the Segway HT will continue operation for approximately 10 seconds while it performs a Safety Shutdown Notes The Balance Sensor Assembly BSA is composed of gyroscopes and tilt sensors The BSA determines the orientation of the Segway HT relative to the direction of gravity The BSA communicates with the Controller Boards to keep you balanced The tilt sensors check each oth...

Page 20: ...s This provides greater clearance When changing wheels or lifting the Segway HT keep your hands clear of the space between wheels and fenders Notes There is no Parking Stand on the e or p Series Segway HTs only on the i Series model Remember Using the Parking Stand should be the FIRST and LAST activity in the operational model The Parking Stand is not designed to bear a rider s weight Standing on ...

Page 21: ...ions 9 List conditions which affect charge range 10 How can you tell your Battery Packs are charging 11 Can you put the front Battery Pack in the rear and vice versa 12 How many Controller Boards are there 13 If one Controller Board has a malfunction what happens 14 How do the Controller Boards balance sensor assembly and motors interact 15 How many gyros How many tilt sensors Why so many What hap...

Page 22: ...h their center of gravity Ask everyone to take a step forward and notice their feet dynamically change position to keep them balanced Compare the Segway HT s wheel movement to a person s feet when you change the center of gravity Ask the participants to stand on one foot only and balance Ask if they can feel their grounded foot correcting to keep them balanced Explain that it is this type of input...

Page 23: ...nd drives the wheels as needed to keep you upright while moving forward Stand up straight center of gravity over the contact patch and the Segway HT slows to a stop Once stopped leaning back also allows you to move backwards The Segway HT can balance in place allowing you to stand motionless by detecting minute changes in balance and instantly responding There is no need to step off the Segway HT ...

Page 24: ...d the contact patch if it was forward or vice versa When moving forward I reorient my center of gravity aft of the contact patch to decelerate When moving backward I reorient my center of gravity forward of the contact patch to decelerate In both cases if I do NOT transition my center of gravity directly over the contact patch at the point when I am almost stopped I will simply begin to accelerate...

Page 25: ...d The rider must maintain dynamic lateral stability side to side This rider is demonstrating correct body position Note how the rider bends one knee more than the other to lean into the turn This rider is demonstrating incorrect body position The rider is not leaning into the turn Correct body position Incorrect body position Avoid any surface that can result in lateral instability When riding ove...

Page 26: ... HT safety alerts Demonstrate Segway Etiquette Respect pedestrians by yielding the right of way to them in all cases Avoid surprising pedestrians When approaching from behind announce yourself and slow down when passing When approaching a pedestrian from the front slow down In heavy pedestrian traffic slow down and proceed at the pace of sidewalk traffic Pass only if there is ample space to do so ...

Page 27: ...the white board or a Segway HT to show participants what to expect on their first ride You will find the Segway HTs plugged in i Series only Parking Stand may be deployed Unplug the Segway HT and retract the Parking Stand i Series only Instructor will start each Segway HT with a Beginner key and instruct the participant to put the Segway HT into Balance Mode by tapping the Mode Button Instructor w...

Page 28: ...g Stand properly i Series only Turn Segway HT on and off Step on and step off from the Segway HT without guidance Change from Balance to Power Assist without guidance Walk with Segway HT in Power Assist Mode Stop on command Ride on flat ground without guidance Turn smoothly on command and without hesitation as well as in response to terrain features Lean while turning Ride on flat ground Interpret...

Page 29: ...tely three feet stick shake and transition to Power Assist Mode DON T DO THIS The Segway HT will not stay stationary unless blocked e Series The Segway HT will transition to E Stand and stay in place E Stand as long as it is released correctly The Segway HT must be powered on to engage either Balance Mode or Power Assist Mode To transition to Balance Mode i and p Series Make sure the Platform is l...

Page 30: ... or Activate the Rider Detect Sensors by gently placing one foot flat on the Platform wait one second until Platform levels then step on with other foot Be careful to step in the center of the Platform Do NOT step on the back or front of the Platform because the Segway HT will respond by moving its wheels beneath the center of gravity 9 Demonstrate moving forward backward turning and staying stati...

Page 31: ...t trust that the Segway HT will balance The rider s confidence and stability may improve f Encourage the rider to trust the Segway HT and relax her hands shoulders arms and knees 8 Check position of feet and ensure that feet are placed in such a way that the rider can remain stationary Ideal foot position depends on the rider s body type not necessarily on foot position In some cases the rider s f...

Page 32: ...atform as if stepping off a stair or steep ladder Repeat all of above for next rider Maintain a position of control at all times by walking beside the Segway HT within a bent arm s length of the Handlebar Control Shaft Reinforce proper stance foot position and light hands Riding Form Your posture and stance have a significant effect on your ability to handle various terrain features and surface co...

Page 33: ...e Keys Make contact between the metal pad on the key and the center contact and one outside contact Do NOT push down to make contact as this can result in damage to both the Key and the Key Port Instead rest the Key in a Key Port until you hear the tone indicating that contact has been made Remove the Key when you hear the tone or see the Display light up Stepping On i and p Series Ready Segway HT...

Page 34: ...lled the E Stand or electronic Parking Stand Ready Segway HT is turned on The Mode Button has been pressed to enter Balance Mode Step on Make sure Display is green and smiling 1 Gently pull Segway HT back until Platform is level 2 Put one foot on the Platform 3 Listen for the tone 4 Put other foot onto Platform OR 1 Place hands on hand grips but don t push or pull 2 Gently place one foot onto Plat...

Page 35: ... HT into E Stand from that hold The rider must hold onto the Segway HT until it is in E Stand park Instructor Holding the Control Shaft while the rider steps off an e Series Segway HT can mitigate undesirable movement accidentally delivered by the rider Failure to hold onto the Segway HT will result in the Segway HT moving unexpectedly It is possible to use the E Stand on uneven surfaces On a hill...

Page 36: ...0 lbs 4 5 kg maximum Side Bags 30 lbs 13 6 kg maximum per bag Just like a person a balancing Segway HT may move slightly when cargo is removed or added The front bag should only be used for lightweight items An overloaded front bag can negatively impact the balancing system and make it difficult to use E Stand Place heavier items in the side bags Add and remove large items slowly Always load the f...

Page 37: ... in place with the new Key Start slowly then ask them to try turning with full input to the Steering Grip so they are aware of the full turning potential Then ask them to jerk the Steering Grip as though they had done it accidentally This shows the rider the resultant motion when erratically twisting the Steering Grip Emphasize that steering should be handled smoothly and gently The rider should n...

Page 38: ...pping on and stepping off 4 Check Display to ensure green smiling icon is showing and battery charge level is full enough for operation 5 Step on the Segway HT using following procedures a Stand at each Segway HT as the rider steps on for the first time b Instruct the rider to twist the Steering Grip while remaining in place to expose her to the advanced steering sensitivity on the new Key i and p...

Page 39: ... you you should be standing about 10 feet from their starting point It helps to have a line across the floor or a few cones for this exercise so that riders can try to learn to stop in a specific place c Tell riders to concentrate on feeling how they need to shift their weight to stop Note If some riders have trouble stopping work with them individually and try to use different ways of explaining ...

Page 40: ...w them to protect the fenders by always using Power Assist Mode by walking around to the front of the Handlebar This gives greater clearance to the fenders i Explain to them that initially it might not be intuitive as to how to power the Segway HT forwards moving in front of you and backwards moving in to you j Have riders practice twisting the Steering Grip GENTLY and carefully so they don t powe...

Page 41: ...lding knowledge not exceeding limits 3 Practice control and commitment If rider continues to roll forward after s he intends to stop then commitment was lacking Work on moving weight back until Segway HT actually reverses direction then immediately stand up If you hear squeaks see spinning tell the rider that s he has exceeded limits and needs to reduce either their riding speed or stopping speed ...

Page 42: ...s or hitting cones Drill 6 Straight Funnel 1 Approach cones that are just slightly wider than Segway HT footprint 2 Do not touch any cones 3 Ride slowly and concentrate on technique not speed This drill is important in exposing riders to the width of the Segway HT s wheelbase so they can use good judgment in narrow places doorways sidewalks between cars in manufacturing plants Display Messages The...

Page 43: ...r on until orange backlight disappears In cold weather it may take several seconds for this icon to disappear Error Conditions During Startup If you attempt to power on your Segway HT but the Segway HT detects a condition that precludes power on one of the following icons will appear in the Display The system fault icons described on pages 45 may also appear All of these icons are red You may clea...

Page 44: ... and inspect beneath it Reduced Performance Levels The following Display icon note that the face is not smiling will appear if the Segway HT is operating at reduced performance levels due to a temporary condition These conditions include riding up a steep hill riding on bumpy terrain low Battery Pack charge riding down a hill with fully charged Battery Packs the first few seconds after power on in...

Page 45: ...t After an Empty Battery Condition Notification The Segway HT will notify the rider of an empty Battery Pack condition A red unhappy face icon will appear in the Display the Segway HT s speed will be limited to 5 mph 8km h and the Handlebar will beep When you receive notification of an empty Battery Pack condition you should stop step off shut down and charge your Segway HT If you fail to stop and...

Page 46: ...Packs the icon changes to indicate that the fault is now in the other Battery Pack location then contact Segway at customeroperations segway com or call 1 866 4SEGWAY 1 866 473 4929 to order a new Battery Pack 6 Because the Segway HT performs at the level of the lesser Battery Pack whenever you replace a Battery Pack consider replacing both Battery Packs depending upon the age of the non fault Bat...

Page 47: ...f there are more than 6 participants Ask the participants to go around the room counting off A B A B A B etc Say Group A come with me for the first ride Group B stay here and complete this exercise Say to Group B You can work in groups of 2 3 When you have finished you can take a break Be sure to meet back here at XXX time Display ID A B C D 1 2 3 4 6 15 1 8 or 10 2 14 4 9 13 11 7 3 5 16 12 8 or 1...

Page 48: ...start using correct key If condition continues contact Segway LLC 9 Do not step on The Battery Packs are too low to allow safe operation of the Segway HT Charge your Battery Packs for several hours 10 The Platform is not level when you try to change from Power Assist to Balance mode i and p Series or the Control Shaft is not vertical e Series Orient correctly Tap Mode Button to set Balance mode 11...

Page 49: ... 2 How do you start the Segway HT Start the Segway HT with the key not with the Mode Button 3 How do you turn off the Segway HT Turn off the Segway HT with the Mode Button Hold it down for 2 seconds Rider must be off the Platform before the 2 seconds begin 4 How do you change from Power Assist Mode to Balance Mode Change modes with the Mode Button Tap the Mode Button once to change from Power Assi...

Page 50: ...Speed Limiter activates Describe appropriate actions to take when the Stick Shake Warning triggers Describe appropriate actions to take when Segway HT perform a Safety Shutdown Topics The following topics will be covered in this session Overview of Product Design Features Speed Limiter Rider Detection Safety Shutdown Torque and Traction Effect of Tire Pressure Safe lifting techniques Summary Overv...

Page 51: ...he five rate sensors fails a Safety Shutdown will occur Additionally the two tilt sensors are checking each other in a similar manner Systems in the Handlebar There are redundant communication systems in the Handlebar each backing up the Steering Grip and the Mode Button If there is a malfunction in either the Steering Grip or the Mode Button the Segway HT will perform a Safety Shutdown Each syste...

Page 52: ... Draw an arrow from Reduced Performance to Safety Shutdown Say If the transient condition progresses into a critical malfunction the Segway HT will perform a Safety Shutdown Draw an arrow from Normal Operations to Safety Shutdown Say In case of a critical component malfunction the Segway HT will perform a Safety Shutdown Speed Limiter Like your body the Segway HT has a top speed The Segway HT s to...

Page 53: ...d stumble on a root your feet need to speed up to get back underneath you The Segway HT wheels do the same thing When your Battery Packs are low just like when your muscles are tired you need to be more careful and you have a higher risk of falling The Speed Limiter reduces speed safeguarding the reserve capacity in the Segway HT The reserve capacity ensures that the Segway HT can respond by movin...

Page 54: ...e operator if they approach this operating point The HT endeavors to keep the operator away from this limit by limiting speed The term reserve is used to describe the torque and speed buffer between the current operating point and the capabilities of the drive system This works when the Segway HT is moving as opposed to stationary The Display indicates that the Segway HT is reducing performance de...

Page 55: ... a steep slope on rough terrain against an obstacle or by accelerating or decelerating abruptly Stick Shake Warning is more likely to occur when your Battery Packs are low cold heavily used or poorly maintained Stick Shake Warning can happen both when you are on and off the Segway HT as described in the following table Action User Response Riding aggressively accelerating or stopping abruptly Ease...

Page 56: ...afely step off Rider Detection The Segway HT Platform contains four Rider Detect sensors beneath the Mat which detect the presence or absence of a rider while the Segway HT is powered on When a rider weighing 100 lbs 45 kg or more is aboard with feet properly positioned on the Platform these Rider Detect sensors are depressed and allow the Segway HT to operate normally in Balance Mode If fewer tha...

Page 57: ...t the ability of the Segway HT to detect the presence or absence of a rider is a safety feature designed to stop the Segway HT from forward motion with no rider on the Platform Direct each participant to experience this behavior by moving the Segway HT forward she feels the Stick Shake Warning and sees the Segway HT transition to Power Assist Mode Instruct the each participant to put the Segway HT...

Page 58: ...fy you of a pending empty battery condition prior to initiating Safety Shutdown A red unhappy face icon will appear in the Display the Segway HT s speed will be limited and the Segway HT will beep You should come to a controlled stop and safely step off of the Segway HT prior to commencement of the Safety Shutdown The red unhappy face icon will be shown in the Display Never restart and ride your S...

Page 59: ...a condition in which it can no longer perform in an acceptable manner it will disable power This is the case if pitch or roll parameters are exceeded or if the wheels spin because of traction loss Demonstrate roll or pitch parameters being exceeded depending on the Segway HT model you have i or p Series Stand to the side and lean the Segway HT sideways without allowing the Platform to tilt forward...

Page 60: ...e speed Effect of Tire Pressure The tires on the Segway HT serve two primary functions Suspension Traction Dropping the tire pressure will soften the ride and increase traction while reducing range The appropriate pressure is a determined by the payload weight and the operating environment Optimum tire pressure is 15 psi 103 kPa for i and e Series models and for the p Series model it is 22 psi 152...

Page 61: ...form It attempts to stop the Segway HT from moving with no rider on On an i or p Series this takes much longer if released at speed than from a stationary position On an e Series this function is overridden by the E Stand function 8 When will the Segway HT perform a Safety Shutdown When there is a critical component or system malfunction in the Controller Board Motor Battery Pack Balance Sensor As...

Page 62: ...n this session Before You Ride Agility track Summary Before You Ride Exercise Segway Etiquette The Segway HT has been designed to be compatible with pedestrian environments You will have the ability to move seamlessly in these environments possibly with more cargo and speed than those around you Your judgment and courteous behavior will help you earn your place in these environments You have a res...

Page 63: ... an i and p Series model you can drive to the curb leave the Segway HT in Balance Mode and pull it over the curb from the front of the Segway HT but be aware that if you exceed speed or distance the Segway HT will give the Stick Shake Warning and or transition to Power Assist Mode For an e Series model you should use Power Assist Mode Do not leave an e Series Segway HT in Balance Mode and move it ...

Page 64: ...e instances Keep wheels clear of the sides of the doorway If your wheel catches on either side step off change to Power Assist Mode and maneuver the Segway HT away from doorway before stepping back on Stairs Use Power Assist Mode to go up and down stairs Stand to the side the first few times you use Power Assist Mode to get the feel of the Steering Grip Always have the Segway HT s weight below you...

Page 65: ...up or down a steep slope because he needs more traction In the same way if you ride your Segway HT up or down a steep slope you are more likely to lose traction and fall To be safe you should avoid riding up or down steep slopes Lean into turns and lean uphill When riding a Segway HT you must lean in the same way You are responsible for maintaining side to side balance by leaning uphill when ridin...

Page 66: ...HT can trip in the same way If a Segway HT wheel runs into an obstacle wall hole or off a curb or step the Segway HT might not be able to move as necessary to stay upright and the Segway HT and rider could fall To be safe you must avoid riding into holes walls other obstacles or into or off curbs or steps If you cannot avoid single wheel terrain features use the following guidelines Step off and u...

Page 67: ... examine a listing of user serviceable parts along with the procedures for replacing them Objectives Upon completion of this session the rider should be able to Perform routine user adjustments and maintenance Safely handle and charge the Battery Packs Replace common wear items Securely package Segway HT for shipment back to the factory Topics The following topics will be covered in this session S...

Page 68: ... pressing the Mode Button does not cause the Segway HT to power down or change into Power Assist Mode your Segway HT Mat may be sticking to the riding Platform If this happens lift the Mat to release it while being careful to hold onto your Segway HT and not to move it forward or backward If the problem persists call Segway Customer Operations at 1 866 4SEGWAY Tire Pressure Recommended tire air pr...

Page 69: ...ttery Packs out of reach of children and pets Ingesting toxic substances and exposure to battery voltage could result in death or serious injury Charging Heat is produced when charging NiMH Battery Packs It is very important to the life and performance of the Battery Packs that they remain in the appropriate temperature range during charging If you attempt to charge the Battery Packs and the Batte...

Page 70: ...y Pack They are marked with an F and R respectively The charging indicators provide independent information regarding whether each Battery Pack is charging Any time the LED green light is on the respective Battery Pack is receiving a pulse of current Slow pulse rates are slow charging rates faster rates denote faster charging and solid green is the maximum charge rate Charging Process There are fo...

Page 71: ...1 866 4SEGWAY 1 866 473 4929 Before Each Ride Remember to Close the Charge Port Cover Close the Charge Port Cover except when you are charging the Segway HT Closing the Charge Port Cover will prevent water dirt dust and other contaminates from entering through the Charge Port and causing damage to your Segway HT Battery Charge Level Display The dashed ring around the perimeter of the Display indic...

Page 72: ...Packs will generally be significantly warmer than the air temperature due to heating that occurs as electricity is delivered from them If the Battery Packs on your Segway HT become too hot or too cold while riding the Segway HT may reduce performance Display icon with straight mouth Speed Limiter and possibly Stick Shake Warning or perform Safety Shutdown Ease up If performance does not return to ...

Page 73: ...ts replacement instructions are provided as is without any representation or warranty express or implied of any kind including but not limited to warranties of merchantability noninfringement or fitness for any particular purpose The only warranties applicable to Segway replacement parts are stated on the Segway Human Transporter Replacement Parts Limited Warranty delivered with the replacement pa...

Page 74: ... mallet Alcohol wipes Tweezers HT Fastener Guidelines 1 Use only Segway provided fasteners 2 Do not reuse any fastener except for the screws used to attach the Battery Packs Control Shaft clamp bolt and wheel nuts Instead when any other fastener is removed replace the fastener with a new Segway provided fastener 3 Before using a fastener make certain the fastener is the correct size and type 4 Do ...

Page 75: ...ug the power cord before performing any maintenance or installing any part or accessory Read and follow the warning label on the Battery Pack Follow these instructions carefully Failure to follow these instructions carefully could damage your Segway HT and render it unsafe to use Do not mix Battery Pack types The Segway HT uses 2 NiCd or 2 NiMH Battery Packs The Segway HT operates at the performan...

Page 76: ... performance and break wheels Over inflated tires reduce suspension performance and tire traction Check tightness of wheel nuts for safe operation Torque wheel nuts to 50 0 N m Directions Removal Instructions 1 Remove the wheel nut with a 16mm deep socket wrench Hold the wheel from rotating and turn the wrench counter clockwise This may require considerable force 2 Strike down on the outside edge ...

Page 77: ... of Platform and bottom of Mat are clean dry and free of debris 3 Place new Mat on Platform and press down 4 For i and e Series models only press ears back into the fender channels Securing or Replacing the Front Trim Tools Required none Before you begin Make sure Segway HT is shut down and not plugged into an AC outlet Directions 1 To remove the trim pull from the bottom and lift up 2 If you are ...

Page 78: ...nder screws using the appropriately sized T 15 or T 20 six lobed wrench 4 Pull up on the front side of the fender and flex the fender away from the gearbox 5 Remove the fender from the gearbox The fender is positioned around the gearbox and requires some twisting for removal Installations Instructions Note Replace any fasteners you remove when performing this installation with the new fasteners in...

Page 79: ...r on page 78 Parking Stand Removal Instructions 3 Remove the two Parking Stand screws using a 4mm hex wrench 4 Disengage the Parking Stand lever from the Mat 5 Remove the Parking Stand Replace any fasteners you remove when performing this installation with the new fasteners included in the replacement kit Parking Stand Installation Instructions 6 Set the new Parking Stand on the side of the Chassi...

Page 80: ...he yellow cord from the Handlebar Control Shaft to the yellow cord in the Control Shaft Base Connect the black cord from the Handlebar Control Shaft to the black cord in the Control Shaft Base Make sure the locking tabs engage When you make these connections you should hear and feel a click 8 Loosen the Height Adjustment Collar and carefully extend the Control Shaft to approximately one half its f...

Page 81: ...ned to withstand the forces that may be generated Instead support the Platform with an object so that you have easy access to the Handlebar Directions Removal Instructions 1 Remove the fastener at the end of the Handlebar on the Fixed Grip side using a 5mm hex wrench 2 Slide the Fixed Grip off of the Handlebar Installation Instructions Replace all old components including fasteners with the materi...

Page 82: ...ess to the Handlebar Directions Removal Instructions 1 Remove the fastener at the end of the Handlebar on the Steering Grip side using a 5mm hex wrench 2 Slide the Fixed Steering Grip and Steering Control Grip off of the Handlebar Installation Instructions Replace all old components including fasteners with the materials included in this kit 3 Orient the new Steering Control Grip so that the raise...

Page 83: ...lvent and wipe away adhesive residue from the Control Shaft Base Installation Instructions 3 Use tweezers to peel the adhesive release sheet from the pink rubber seal on the back of the new Charge Port Cover 4 Orient the new Charge Port Cover so that the opening lines up with the AC power receptacle The rubber flap hinge from the bottom The tabs of the cover flap must be within the groove on the b...

Page 84: ...nician Control Shaft clamp parts must always be replaced as a kit Before you begin Make sure the Segway HT is shut down and not plugged into an AC outlet Remove any accessories from the Control Shaft Make sure the Segway HT is stabilized while you work on it Directions 1 Remove the Handlebar Control Shaft Assembly from the CSB see Replacing the Handlebar Control Shaft Assembly on page 80 2 Push th...

Page 85: ... frame with the screw locations in the bottom of the handlebar so that the frame is on the front side of the control shaft 3 Install the two button head screws through the holes in the wire frame and into the bottom of the handlebar using a 4mm hex wrench and torque to 7 5 N m 4 Install the clamp on the control shaft just above the height adjustment collar with the hook facing forward and up 5 Not...

Page 86: ...k for the green smiling face in the display Ride the Segway HT Move forward and backward Check Power Assist Mode both forward and backward Check E Stand functionality e Series only Safety Check Check that the fasteners are in place secure and tightened correctly Check the wheels for wear tightness and correct tire air pressure Check that the Mat is intact secure and free of debris Check the Grips ...

Page 87: ...level Check the Control Shaft for tightness rotation and tighten Control Shaft Clamp bolt if necessary Check the tire air pressure Perform brief external inspection of Segway HT including o Tires o Wheels o Battery Packs o Fenders o Mat o Handlebar orientation Remove and replace Control Shaft Remove and replace Battery Packs Ride the Segway HT Turn off the Segway HT Plug your Segway HT into AC pow...

Page 88: ...Select an environment free of hazards Explain the steering control of the Segway HT Help a new rider step on and off the Segway HT Stabilize a rider who is uncomfortable or oscillating Stop a rider who is not able to maintain control or is aggressive Stop a rider who is overconfident and under skilled Anticipate the rider s style and customize your approach Provide a new rider with a safe and enjo...

Page 89: ...ring Grip Mode Button Display and Rider Detect Sensors Explain the Steering Grip and Display Answer any other questions but don t offer information Rider steps on moves forward backward stops and turns Rider may negotiate cones or try another terrain Rider then steps off 3 10 minute guided ride Rider steps moves forward backward stops and turns rides once around an oval then steps off 1 3 minute g...

Page 90: ...forward and backward in a rapid movement The danger is loss of balance or traction resulting in injury or loss of confidence How to avoid it Always hold the Control Shaft or Handlebar firmly as a rider steps on the Segway HT Brace your feet in a way that you can stabilize the Segway HT It is VERY important that the rider has a solid hold on the Handlebar not a white knuckled clutch but enough to m...

Page 91: ...uickly grasp the Segway HT and stop it Determine if the rider was disregarding the instructions or was accidentally heading for the obstacle If the rider was purposely disregarding the instructions repeat Your safety during this demonstration is my responsibility Demonstration and Guided Ride Workshop This workshop is divided into two exercises Demonstrate how to operate and ride based on Type 1 e...

Page 92: ...st with one foot Feel the Segway HT balance with one foot before stepping on with the other c Choose a point in the distance to maintain a sense of perspective d Have rider step onto Platform with other foot Maintain firm hold of the Segway HT 6 While the Guide maintains a hold instruct the rider to gently roll slowly forward and backward 3 5 feet both directions until s he find neutral on the Seg...

Page 93: ...ouch the ground contact patch Explain that pitch oscillation is common because the brain is not used to having something else balance for them Encourage the rider to trust the Segway HT and relax his her hands shoulders arms and knees Check foot position and ensure that feet are placed in such a way that s he can stand still Ideal foot position depends on the rider s body type not necessarily on c...

Page 94: ...nsitioning terrain from flat to bumpy or bumpy to flat Expose rider to the types of terrain and obstacles to look for so that they can use their best judgment in negotiating the outside world Below are some examples of challenging surfaces and possible hazards to point out Grass with hidden rocks holes or curbs Gravel or sand especially on a slope Puddles Runoff or washout trough Wet grass soft gr...

Page 95: ... for which the Segway HT has been designed Respond to warnings and alerts from the Segway HT Perform maintenance and service procedures Discuss Riding Assessment and Safety Review Booklet You are now at the Conscious Competent stage You know what you know From here it takes practice and time to transition into the Unconscious Competent stage Evaluations Please complete the evaluation forms and han...

Page 96: ...omplete the tasks after the class Timing Introduction and Objectives 5 min Written Assessment 30 min Riding Assessment 30 min Summary Review the Written Assessment Q A 10 min Total Time 1 hour 15 min Overview This session covers the Written and Riding Assessments The instructor may ask you to complete this before during or after the training Turn the page to begin the Written Assessment Written As...

Page 97: ...bled Use Steering Grip to turn right and left OK to step on and ride 3 Which of the following displays indicates Balance Mode a a b c d 4 Which of the following best describes Balance Mode d a Whistle and the Segway HT will follow you around like a puppy b Power is on but balancing mechanism is not enabled Use Steering Grip to power the wheels forward and backward c Power is off Use Steering Grip ...

Page 98: ...tep off b Start the Segway HT change to Balance Mode step onto the Platform ride step off c Start the Segway HT change to Power Assist Mode step onto the Platform ride step off d Step onto the Platform ride step off shut down 10 Which of the following actions causes the Display to flash a red frown then become orange with no face a a Platform Control Shaft was not at the correct angle when enterin...

Page 99: ...ean in the opposite direction of the turn c Stand as upright as possible d Increase speed through the turn 19 When riding over uneven terrain it is important to maintain d a High speed over bumps b A stiff body to maintain your center of gravity c Tight grip on the Handlebar for control d Bent knees in order to absorb shock 20 When riding along and approaching a large obstacle which might only aff...

Page 100: ...gway to the bottom floor you should a a Ride your Segway on an elevator when there is room and you are not negatively impacting others b Disassemble your Segway prior to taking it with you on an elevator c Always take the stairs with your Segway HT in Power Assist Mode d Never take your Segway HT on an elevator 25 The Segway HT has an onboard universal input charger To charge the Segway HT in coun...

Page 101: ...nto your torso while you are riding this is because the Segway HT is alerting you to a a Slow down b Change to Power Assist Mode c Avoid a metal grate d All of the above 33 The best way to take a Segway HT up a set of stairs is b a Put Segway HT in Power Assist Mode stand below push up the stairs b Put Segway HT in Power Assist Mode stand above pull up the stairs c Keep Segway HT in Balance Mode s...

Page 102: ...or b d None of the above 39 An indication that the Segway HT has reduced performance when you are riding at 8mph is d a The Segway HT will limit your speed b The Platform tilts aft c The turning control is slowed d Both a and b 40 If you experience a Safety Shutdown while moving forward at 10 mph 16 km h you should know this because d a The Platform pitches aft to slow your speed b The Segway HT v...

Page 103: ...wobbles check the Wheel Nut ________ 6 46 Insert the Control Shaft into the Control Shaft Base ________ 4 after you have checked your Control Shaft cords 47 Twist the Steering Grip________ 2 left and right to turn when you are in Balance Mode or to power the wheels forward and backward when you are in Power Assist Mode 48 When you are stepping on hold onto the Fixed Grip ________ 9 and the non twi...

Page 104: ...ok Rev 3 5i January 2004 Segway LLC 2002 P N 1707100001aa Answer Key 1 d 26 a 2 b 27 b 3 a 28 c 4 d 29 b 5 c 30 a 6 a 31 d 7 c 32 a 8 d 33 b 9 b 34 d 10 a 35 c 11 a 36 c 12 d 37 d 13 a 38 c 14 d 39 d 15 b 40 d 16 c 41 c 17 a 42 7 18 a 43 1 19 d 44 8 20 d 45 6 21 c 46 4 22 b 47 2 23 b 48 9 24 a 49 3 25 b 50 5 ...

Page 105: ...omplete each task while Maintaining control of the Segway HT Demonstrating sound decision making ability regarding his her own capabilities Utilizing Segway HT capabilities Performing a clean ride without hitting cones Basic Rider Tasks Redo Acceptable Excellent Retract Parking Stand prior to startup i Series only Use Key effectively don t push down or damage contacts Change from Power Assist Mode...

Page 106: ...Page 106 of 106 Basic Rider Optimization Training for the Segway HT Instructor Guide and Participant Workbook Rev 3 5i January 2004 Segway LLC 2002 P N 1707100001aa Notes ...

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