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for i167 andp133 models

about this manualCongratulations on the purchase of your new Segway™ Human Transporter (HT)! You are about to experience human mobility like you never have before. This manual describes the technology and engineering incorporated into your Segway HT. It also provides information on battery charging, maintenance, and troubleshooting. Keep this manual and refer to it regularly. If you have any questions about your Segway HT, call Segway Customer Operations at 1-866-4SEGWAY (1-866-473-4929).

Cover more ground. Be more productive. Move more intelligently.

© 2003 Segway LLC

This Reference Manual applies to the Segway HT i167 and p133 models. The Segway HT e Series models have different features. Segway provides different user materials for use with Segway HT e Series models.

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If you don’t have the Riders’ Guide for your Segway HT model or the Safety Video, call Segway Customer Operations at 1-866-4SEGWAY (1-866-473-4929).

Check www.segway.com for updates to this manual.

Record your Segway HT Serial Number and Key CodeSerial number (on bar code strip on rear of Platform): __________________ Key code (with key pouch): _____________________ You need this information to order replacement keys.

RISK OF DEATH OR SERIOUS INJURY.Whenever you ride the Segway HT, you risk death or serious injury from loss of control, collisions, and falls. To ride safely, you must read and follow all instructions and warnings in the Riders’ Guide for your Segway HT model and you must watch the Safety Video.

WARNING!

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remindersTo assemble and charge your Segway HT for the first time, follow the separate assembly instructions included with your Segway HT.

To be safe, you must read and understand the Riders’ Guide for your Segway HT model and watch the Safety Video before you attempt to ride the Segway HT. This Reference Manual does not contain instructions on how to ride the Segway HT.

If you don’t have the Riders’ Guide, Safety Video, or assembly instructions for your Segway HT model, call Segway Customer Operations at 1-866-4SEGWAY (1-866-473-4929) or visit www.segway.com.

WARNING indicates a potentially hazardous situation that, if not avoided, could result in serious injury or death.

notesLook for this icon for important information.

troubleshootingLook for this icon for guidance in troubleshooting problems with your Segway HT.

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contentsyour Segway HT: 6specifications: 7chapter 1: how the Segway HT works: 11chapter 2: helpful hints: 18chapter 3: batteries: 21chapter 4: troubleshooting: 27chapter 5: service: 35chapter 6: frequently asked questions: 40chapter 7: glossary: 42chapter 8: contact numbers and legal: 43index: 46

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your

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your Segway HT

Steering Grip

Mode Button Key Port

Display

Height Adjustment Collar

Fixed Grip

Top View of Handlebar

Charge Port Indicator Charge Port

MatPlatform

Back View of Platform

Handlebar Trim

Handlebar

Height Adjustment Collar

Control Shaft

Control Shaft Clamp Bolt

Control Shaft Base

Tire/Wheel Assembly

Battery Packs

Fender

Parking Stand (i Series models only)

Front Trim

i167 p133

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specifications

Battery Pack Type NiMH NiMH

12 miles (19 km)

Rider and Cargo Weight Limits2

260 lbs. (118 kg)

Segway HT Model i167

10 miles (16 km)

p133

210 lbs. (96 kg)

Range on a Full Charge1

Maximum Payload (Rider plus all Cargo):

100 lbs. (45 kg) 100 lbs. (45 kg)Minimum Rider Weight:

10 lbs. (4.5 kg) 10 lbs. (4.5 kg)Maximum Weight of Handlebar Cargo and Attachments:

Optimum range:

Typical range (good conditions):

Typical range (varying terrain and speed):

10 miles (16 km) 8 miles (13 km)

8 miles (13 km) 6 miles (10 km)

8.3" (21 cm) 6.7" (17 cm)

Dimensions

Platform height:

Footprint:

Height: 37" to 50" (94 to 127 cm) 35.5" to 48.5" (90 to 123 cm)

19" x 25" (48 x 64 cm) 16" x 21.8" (41 x 55 cm)

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Weight

Segway HT Model i167 p133

83 lbs. (38 kg) 70 lbs. (32 kg)

Operating Conditions Temperature: 32°F to 122°F (0°C to 50°C)Humidity: 5% to 95% RHAltitude: Sea Level to 12,000 ft (3,658 m)

Temperature: 40°F to 122°F (4°C to 50°C)Humidity: 5% to 95% RHAltitude: Sea Level to 12,000 ft (3,658 m)

Storage and Transport Conditions (less than 1 month, only)

Temperature: -4°F to 122°F (-20°C to 50°C) Humidity: 5% to 95% RHSea Level to 40,000 ft (12,192 m)

Turning Radius Zero. The wheels can rotate in opposite directions, enabling the Segway HT to turn in place.

Operating, Charging and Storage Conditions

Temperature: -4°F to 122°F (-20°C to 50°C) Humidity: 5% to 95% RHSea Level to 40,000 ft (12,192 m)

If you use, charge or store your Segway HT outside these conditions, you may experience reduced range, ineffective battery charging, and damage to your Segway HT. See chapter 3: batteries, beginning on page 21.

Optimum Charging Conditions

Temperature: 41°F to 68°F (5°C to 20°C)Humidity: 5% to 95% RHAltitude: Sea Level to 12,000 ft (3,658 m)

Temperature: 41°F to 68°F (5°C to 20°C)Humidity: 5% to 95% RHAltitude: Sea Level to 12,000 ft (3,658 m)

Zero. The wheels can rotate in opposite directions, enabling the Segway HT to turn in place.

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Table footnotes 1 Range on a battery charge 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; riding on hilly terrain and unpaved surfaces decreases range.> Speed — consistent, moderate speed increases range; frequent acceleration and deceleration decreases range.> Battery Pack Condition — properly charged and maintained Battery Packs provide greater range; old, cold, heavily used, or poorly maintained Battery Packs provide

less range.> Wind — tailwind increases range; headwind reduces range.Only experienced riders riding in optimum conditions will reach the optimum range distances stated above.

2 Weight Limits for Riders and CargoSegway sets weight limits for two reasons: rider safety and to reduce risk of damage to the Segway HT.

Dynamic Weight LimitsTo keep the Segway HT and rider upright, the Segway HT must always have enough power to be able to turn its wheels forward and backward. Exceeding the weight limits, especially when combined with other variables that require more power (see list below), will increase your risk of falling or damaging the Segway HT.

Variables that require more power include:> Higher payloads (weight of rider and all cargo)> Steeper slopes> Bumpier surface conditions> Higher speeds> Abrupt maneuversSince the Segway HT can monitor the amount of power being used, the Segway HT will limit the speed (and potentially perform the Stick Shake Warning) in response to these variables. It is important that all riders learn to anticipate and recognize when the Segway HT is reaching the limits of performance.

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Minimum Weight LimitThe rider’s weight must not be less than 100 lbs. (45 kg). If the rider is below the minimum rider weight limit, she may not be able to ride safely because she cannot shift her weight far enough back (behind the centerline of the wheels) to safely slow down and stop, especially when riding downhill. Also, riders below the minimum weight limit might fail to properly activate the Segway HT’s balancing system.

Structural Weight LimitsIncreased risk of damage to the Segway HT is another consequence of exceeding the maximum weight limits. Heavier payloads place greater stresses on the Segway HT. Segway’s testing has shown that the stresses created by a payload within the total payload weight limit (with any cargo not exceeding the applicable cargo weight limits), ridden on a wide variety of terrain in accordance with the instructions in the Segway HT Riders’ Guide, the Segway HT Reference Manual, and the Segway HT Safety Video will not damage the Segway HT. Just like the dynamic weight limits, several factors affect the loads transmitted to the Segway HT:> Skill level of the rider> Payload (weight of the rider and all cargo)> Surface condition (obstacle height, etc.)The stresses created by exceeding the rider or cargo weight limits, especially when riding on uneven terrain, could damage the Segway HT.

Handlebar CargoThe 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.

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chapter 1: how the Segway HT works

The Segway HT works like the human body. If you lean forward, you take a step forward to keep your balance. If you lean back, you step back. Substitute wheels for feet, and you have an empowered pedestrian on a Segway HT.

The Segway HT uses technology called dynamic stabilization. When you lean forward, your center of gravity moves forward of the contact patch (the place where the tire contacts the ground) causing the Segway HT to tilt forward. The Segway HT’s systems sense this change (measuring 100 times per second), and power the wheels to keep them underneath you.

The Segway HT’s technology balances forward and backward but not side-to-side. That means that if the rider tilts the Segway HT onto one wheel, it will not dynamically bring itself underneath the rider. It could fall over. The rider is responsible for dynamically stabilizing laterally while riding the Segway HT. Leaning into turns and leaning uphill when riding across a slope are the rider’s responsibility (see the Riders’ Guide for details).

Redundant SubsystemsThe Segway HT has been designed with the utmost concern for the safety of the rider and those who may be nearby. Redundant subsystems are provided to maintain controlled operation of the Segway HT in the unlikely event of a component failure. If one of the redundant components fails, the other component continues to operate, bringing the rider to a safe stop.

Five of the subsystems in the Segway HT are designed with a redundant architecture: Controller Boards, Motors, Battery Packs, the Balance Sensor Assembly, and Handlebar Electronics.

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> Controller BoardsThe two Controller Boards receive input from the gyroscopes and other sensors, and from the Handlebar Electronics. They also monitor battery condition. The Controller Boards send commands to the Motors. The Controller Boards are interchangeable. They are connected to the Control Shaft Cords, the Balance Sensor Assembly, the Batteries, and the Motors, so that if there is a malfunction in any of these components or the connections between them, the Segway HT will perform a Safety Shutdown (see page 16).

> MotorsEach wheel is independently driven by redundant, high-speed electric Motors that produce no pollution emissions. The brushless design employs computer technology to precisely regulate motion. The Motors have been tested to power levels of two horsepower. Each Motor is wound as two separate electrical circuits, capable of independent operation, acting as one mechanical entity.

The Motor for each wheel (right/left) is connected to the front and rear drive systems.

This allows either the front or the rear drive system to produce torque on the Motor Shaft. The system uses independent controllers for the front and rear drive systems. If either Motor fails, the Segway HT will perform a Safety Shutdown.

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> Battery PacksThe two Battery Packs are sealed units that require no maintenance besides proper charging and storage. The Battery Packs are interchangeable. If either Battery Pack fails, the Segway HT will perform a Safety Shutdown. While riding, if the Battery Packs are too hot or too cold, the Segway HT will enter reduced performance mode (see page 32).

> Balance Sensor AssemblyThe Balance Sensor Assembly contains five angular rate sensors (solid state gyroscopes) and two tilt sensors. These sensors gather information about the orientation of the Platform in all three planes (pitch, roll, and yaw). This information is sent to the Controller Boards. All five of the rate sensors are constantly checking each other to ensure each is operating correctly. The two tilt sensors check each other in the same manner. If one of the five rate sensors fails or one of the two tilt sensors fails, the Segway HT will perform a Safety Shutdown.

> Handlebar ElectronicsThe Handlebar contains redundant communication systems and redundant sensors in the Steering Grip and Mode Button. If there is a malfunction in either the Steering Grip or Mode Button sensors, or any of the other electronics in the Handlebar, the Segway HT will perform a Safety Shutdown. Each system in the Handlebar communicates information to the Controller Boards via an independent Control Shaft Cord. If either cord malfunctions, the Segway HT will perform a Safety Shutdown.

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Speed LimiterThe Segway HT will push its Handlebar back to slow the rider down. The speed at which the Segway HT pushes the Handlebar back depends on a variety of factors including riding style, terrain, payload, the Key used to start the Segway HT, Battery Pack condition, and other factors (see list at right). When you reach the maximum allowed speed, based on these factors, the Segway HT will push the Handlebar back to slow you down. This is called Speed Limiter.

If any of these conditions exist, the Display will show the following:

WARNING!

Do not attempt to override this safety feature by continuing to lean forward. (See the Riders’ Guide).

The maximum speed at which the Speed Limiter will tilt the Handlebar back depends upon the Key used to power on the Segway HT. Other conditions may cause the Speed Limiter to tilt the Handlebar back at slower than the maximum allowable Key speeds. 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. (Because of regenerative charging, if the Battery Packs are fully charged, the Segway HT will engage the Speed Limiter to avoid overcharging.)

> The first few seconds after power on.> Inadequate foot pressure on the Platform.> The Battery Packs are too hot or too cold.

Definition The Segway HT is operating at reduced performance levels due to a temporary condition. The speed limit has been lowered until the condition clears.

Display Icon

(green)

User Response If you feel the Speed Limiter push the Handlebar back, stop leaning forward and slow down. You should always leave a gap between yourself and the Handlebar. Riding against the Handlebar can cause loss of control, collisions, falls and injury.

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Stick Shake WarningOne of the ways the Segway HT notifies you that you are at risk of falling is by shaking the Handlebar and making growling noises. This is called the Stick Shake Warning. The Stick Shake Warning will occur if you ride backward too fast or if you demand too much power from the Segway HT, such as by riding on 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

Ease up! Ride more gently, smoothly and slowly.Riding aggressively, accelerating or stopping abruptly.

Ease up! Leave a gap!Riding against the Handlebar.

User Response

The terrain is too demanding or steep. Ride on smoother, flatter terrain. If on a slope, turn perpendicular to the slope, step off, and proceed in Power Assist Mode.

Riding on rough terrain or steep slopes.

Stop pushing against the obstruction. Stop, step off, and proceed in Power Assist Mode.Riding against an obstruction.

Stop, turn in place, and proceed forward.Riding backward.

Come to a controlled stop and safely step off within 10 seconds.During Safety Shutdown.

When moving your Segway HT in Balance Mode with no rider on the Platform, you must move very slowly, or switch to Power Assist Mode. (See Rider Detection on page 17 for more detail.)

Moving a Segway HT with no rider on the Platform while in Balance Mode.

Remove your foot. Level the Platform. Tap the Mode Button to enter Balance Mode. Check the Display for the green smiling face. Move the Handlebar to make sure that the wheels respond. Try stepping on again.

Stepping onto a Segway HT Platform while in Power Assist Mode.

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Safety ShutdownIf the Segway HT detects a fault in any of its redundant subsystems, the Segway HT notifies you by automatically reducing its speed, shaking its Handlebar, making growling and beeping noises, and flashing red in the Display. This is called Safety Shutdown.

If a Safety Shutdown occurs:> Immediately come to a controlled stop.> Carefully step off one foot at a time.> Do not resume use of your Segway HT until the

fault condition is cleared.

Empty Battery ConditionOne of the conditions that can result in a Safety Shutdown is an empty battery condition. The Segway HT will notify 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. This icon will be shown in the Display:

Never restart and ride your Segway HT after it has indicated an empty battery condition or performed a low battery Safety Shutdown. The Segway HT may not have enough power to keep you balanced, especially if you demand a lot of power at once. If you restart and continue riding, you risk falling. Also, you may damage your Battery Packs, resulting in reduced Battery Pack life and capacity.

WARNING!You have approximately 10 seconds from the start of the Safety Shutdown to come to a controlled stop and safely step off before the Segway HT will automatically shut down. During Safety Shutdown, the Segway HT may stop balancing and shut down immediately if you tilt it backward too steeply, and are stopped or moving slowly.

User Response Come to a controlled stop, then safely step off and discontinue operation. You have approximately 10 seconds from the start of the Safety Shutdown to come to a controlled stop and safely step off.

Display Icon

(red)

Definition The system has detected a critical error and is slowing to zero speed before shutdown (full battery charge level indicator shown).

Display Icon

(red)

Definition Pending empty battery condition

User Response Come to a controlled stop and safely step off of the Segway HT prior to commencement of Safety Shutdown.

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Rider DetectionThe 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 than three Rider Detect sensors are depressed while riding, the Segway HT will reduce the top speed limit while moving forward, regardless of the Key used.If the Segway HT is in Balance Mode, but none of the Rider Detect sensors are depressed, and the Segway HT is moved too quickly, the Segway HT will give the Stick Shake Warning after moving some distance, and will switch to Power Assist Mode. This is intended to prevent a riderless Segway HT from traveling on its own. You should never let go of your Segway HT while it is in Balance Mode.

Mode ButtonThere is only one button on the Segway HT Handlebar. It is called the Mode Button and has three distinct functions:1. Change from Power Assist Mode to Balance

Mode.2. Change from Balance Mode to Power Assist

Mode.3. Power off from either Power Assist Mode or

Balance Mode.

See the Riders’ Guide for more information regarding the Mode Button.

WARNING!

You should never place anything on the Platform. Doing so could defeat this safety feature and allow the Segway HT to travel on its own, and run into a person or property and cause injury or damage.

When you are riding the Segway HT, the Mode Button is disabled. This is to prevent accidentally powering off or accidentally switching to Power Assist Mode while riding.

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chapter 2: helpful hints

Check the Tire/Wheel AssemblyBefore each ride, check to make sure the Tire/Wheel Assembly does not wobble and the wheel nuts are tight. Grasp the Tire/Wheel Assembly and attempt to move it side-to-side to check for wheel wobble. It should not move laterally. If you detect wheel wobble, check the wheel nuts and tighten if necessary. See page 38 for additional information regarding the Tire/Wheel Assembly.

Tire Inflation PressureThe tires on the Segway HT serve two important functions, suspension and traction, both of which are affected by the tire inflation pressure.

Check tire inflation pressure regularly. Ensure that tires are properly inflated to the pressure stated on the label attached to the wheel (near the inflation valve). Check that both tires are

inflated equally and are free of debris or contaminates.

SecurityThe best way to deter theft of your Segway HT is to store it in a secure indoor location. If you must leave your Segway HT unattended in a location that is not secure, you may use a cable lock or

U-shaped lock threaded through the wheel and hole provided in the fender. Secure the lock around an appropriate fixed object. However, a thief can always remove the wheel and fender or cut or break the lock and steal your Segway HT. No lock is theft proof.

Also, be sure not to leave your keys with the Segway HT.

WARNING!

The tire pressure stated on the wheel label (near the inflation valve) supersedes any recommended pressure stated on the tires. > Higher pressure reduces suspension

performance and traction, and increases risk of loss of control, collisions, and falls.

> Lower pressure reduces range and increases risk of damage to the Tire/Wheel Assembly.

> Unequal pressure will cause the Segway HT to turn in the direction of the lower pressure tire.

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Lifting and Loading Your Segway HTUse safe and appropriate loading/lifting techniques when lifting your Segway HT. Make sure the Segway HT is powered off prior to lifting. It is recommended that two people work together to lift the Segway HT, with each placing a hand on the Control Shaft (under the Height Adjustment Collar) and a hand under the Platform. Lift with your legs, not your back. Never lift the Segway HT by its tires, fenders, or wheels because your hand could become caught between the tire and the fender, resulting in injury.

Exposure to WaterThe Segway HT is designed to withstand brief exposure to water, but not submersion:> Do not submerge the Battery Packs or

Platform.> Avoid getting water in the Charge Port. > Always close the Charge Port Cover after

charging.> If the Key Port becomes wet, the port may not

recognize the Key. Carefully drying the port and Key will restore normal function.

StorageStore your Segway HT (and its Battery Packs) indoors, in a place that is dry and free of moisture, humidity, and temperature extremes. The specific storage temperature, humidity, and altitude ranges to preserve the full performance capabilities of the Segway HT are listed in the Specifications section (see page 8). Even if you will not be using your Segway HT for an extended period of time, you should leave it plugged into AC power. Otherwise the Battery Packs could fully discharge over time, causing them damage. Do not store your Segway HT or Battery Packs for more than one month without charging. This could cause permanent damage to the Battery Packs resulting in reduced Battery Pack life and capacity.

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Do Not Tow Anything With Your Segway HTAlthough your Segway HT is versatile, you should not attempt to tow or push anything with it. If you try to tow a trailer or other item, you may not be able to stop in a safe manner, turn effectively, or handle various terrain features.

Using the Parking Stand (i Series Only)

To deploy the Parking Stand:> Make sure the power is off.> Tilt the Segway HT back toward you.> Turn the lever at the right front corner of the

Platform to the left until it is perpendicular to the Fender.

> Move the Handlebar forward until the Segway HT rests on the Parking Stand. The Platform will be tilted backward to discourage anyone from stepping on.

To retract the Parking Stand:> Make sure the power is off.> Tilt the Segway HT back toward you.> Turn the lever at the right front corner of the

Platform to the right until it is parallel to the Fender.

Reminders:> Do not tilt the Segway HT back toward you

when in Balance Mode. This could cause the Segway HT to back up into you and could cause injury.

> Retract the Parking Stand before you attempt to stand on or move the Segway HT. The Parking Stand will support only an unloaded Segway HT and may break (or cause a fall) if you attempt to stand on or move the Segway HT with the Parking Stand deployed. This is a safety feature to reduce risk of injury from operating a Segway HT with the Parking Stand deployed.

> Use the Parking Stand on relatively level ground. It will not work on a slope.

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chapter 3: batteriesSafety GuidelinesYour Segway HT is powered by two rechargeable Battery Packs. Take some time to read these guidelines for your own safety and to extend the life of the Battery Packs.

The cells within the Battery Packs contain toxic substances. Do not attempt to open Battery Packs. Do not insert any object into the Battery Packs or use any device to pry at the Battery Pack casing. If you insert an object into any of the Battery Packs’ ports or openings you could suffer electric shock, injury, burns, or cause a fire. Attempting to open the Battery Pack casing will damage the casing and could release toxic and harmful substances.

Use care when handling the Battery Packs. If you are transporting your Segway HT, be sure to protect the Battery Packs to avoid damage during shipment. If the casing of a Battery Pack should

break open, leak any substance, become excessively hot, or if you detect an unusual odor, do not use the Battery Pack. Do not handle a damaged or leaking Battery Pack unless you are wearing disposable rubber gloves. Dispose of the rubber gloves and damaged Battery Pack properly in accordance with regulations governing disposal of toxic materials.

Keep Battery Packs out of reach of children and pets. Ingesting toxic substances and exposure to battery voltage could result in death or serious injury.

ChargingTo maximize battery life and performance, follow this procedure to charge your new Segway HT Battery Packs before the first use and after the first five uses:1. As soon as possible and before your first use,

charge the Battery Packs for at least 12 hours. Charging is best performed at room temperature.

WARNING!

Unplug and disconnect your Segway HT from AC power before removing or installing Battery Packs. It is hazardous to work on any part of your Segway HT when it is plugged into AC power. You risk serious bodily injury from electric shock as well as damage to your Segway HT.

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2. Limit the duration of the first five uses of your Segway HT so that you do not discharge the Battery Packs below the charge level illustrated below. (See Battery Charge Level Display on page 23 for a detailed description of charge levels.)

3. After each of your first five uses, charge the Battery Packs for at least eight hours.

Even if you do not intend to immediately use your new Segway HT, you should still charge the Battery Packs for at least 12 hours as soon as possible. Remember to charge your Segway HT whenever it is not in use. In order to maintain the best performance from your Segway HT Battery Packs, charge your Battery Packs for at least 12 hours once a month, or once every 12 hours of operation— whichever comes first.

You do not need to worry about overcharging, so you should always plug your Segway HT into AC power when it is not in use. Even if you will not be using your Segway HT for an extended period of time, you should leave it plugged into AC power. Otherwise, the Battery Packs could fully discharge over time, causing them permanent damage.

Do not store your Segway HT or Battery Packs for more than one month without charging. This could cause permanent damage to the Battery Packs.

To Charge the Segway HT Battery Packs1. Make sure the Charge Port is dry. Do not

insert the plug if it is wet.2. Plug one end of the Power Cord (provided with

your Segway HT) into the Charge Port in the Control Shaft Base.

3. Plug the other end of the Power Cord into a grounded AC outlet (100 V to 240 V; 50 Hz to 60 Hz). The Power Cord should be properly grounded for charging.

Charging IndicatorsThe Control Shaft Base has two LED (Light Emitting Diode) charging indicators located below the Charge Port.

The left charging indicator corresponds to the front Battery Pack, the right to the rear Battery 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.

"F"front

"R"rear

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Charging ProcessThere are four stages in the charging process:1. Immediately after the Segway HT is plugged

in, the Battery Packs perform a test to determine if it is appropriate to charge at the maximum charge rate. While this test is occurring, the Battery Packs charge slowly at a trickle rate. The charging indicator pulses green every few seconds, giving the Battery Pack short pulses of current.

2. After about two minutes (longer if the Battery Packs are very warm, cold, or completely discharged), the Battery Packs will begin charging at the fast rate, with the charging indicator glowing solid green.

3. The Battery Pack electronics will monitor the Battery Pack voltage and temperature to determine when it is full and will then start pulsing at a rapid rate. This rapid pulsing rate will continue for approximately three hours while a cell balancing process is completed to distribute the energy throughout all the cells in the Battery Packs.

4. At the end of the cell balancing process, the pulse rate will become slow and will continue at the slow rate until the Segway HT is unplugged.

Charging FailuresIf a failure is detected during charging, all charging will stop. Depending on the nature of the failure, a solid red charging indicator light will be displayed or the charging indicator will be off.

If either or both charging indicators are off or red, do this:> If the charging indicators are off (no

illumination), check to make sure that AC power is present.

> If AC power is present and the charging indicators are either red or off, remove and reseat the Battery Pack(s), following the instructions on page 37.

> If this does not resolve the problem, contact Segway Customer Operations at 1-866-4SEGWAY (1-866-473-4929).

Before Each Ride—Remember to Close the Charge Port CoverClose 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 DisplayThe dashed ring around the perimeter of the Handlebar Display indicates the battery charge level. The following series of displays illustrates a gradually depleting battery charge while in Balance Mode:

Slow Pulse

Fast Pulse Cell balancing process,during which the cells are topped off equally.

Slow Pulse Trickle charge to keep Battery Packs fully charged.

Charge Indicator Battery Pack State

Initial test to assess Battery Pack status and amount of charging needed.

Solid LED Fast charge, when approximately 90% of charging takes place.

(green)Full charge Low charge

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This series of displays illustrates the same battery charge levels while in Power Assist Mode:

The Segway HT will display intermediate battery charge levels using flashing segments (e.g., a battery at approximately 90 percent will display a flashing top bar).

If the battery charge level is very low, the Segway HT will notify you of a pending empty battery condition prior to initiating Safety Shutdown (see page 16).

Do not ride your Segway HT if there is inadequate charge in the Battery Packs (indicated by the red unhappy face icon in the Display and no segments around the perimeter). Carefully monitor your Display and be prepared to step off if your battery charge becomes completely depleted.

The battery charge level display shows the relative charge level. No battery gauge is accurate

enough to predict exactly when your battery charge will be totally depleted. It is best to keep track of your battery charge level and recharge whenever possible.

In certain situations, such as riding uphill, the battery charge level display may temporarily drop because you are drawing heavily on the Battery Packs. The battery charge level display should return to the actual charge level once you return to level ground and reduce the load on the Battery Packs.

Surface ChargeSurface charge is a common side effect that results in inaccurate battery charge level information when you have not fully charged batteries.Whenever you do not fully charge the Segway HT’s Battery Packs (i.e., complete the cell balancing process, see page 23), there is a possibility of surface charge affecting the battery charge level display. This could cause the display to falsely show a greater charge level. After you power on, check the battery charge level display, then ride for at least three or four minutes and check the battery charge level display again. If the battery

charge level display shows rapid charge depletion during these three or four minutes, you should conclude that the Battery Packs had only a surface charge. In that case, plug the Segway HT back in and recharge.

Battery Pack Temperature ParametersThe Battery 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 normal, stop riding and allow your Battery Packs

(orange)Full charge Low charge

If the Battery Packs are too hot or too cold, the Segway HT will enter reduced performance mode and limit speed (see page 32). The Display will show the reduced performance icon. (Note that the face is not smiling.)

(green) your

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to warm or cool to within the recommended operating temperature range.Your Battery Packs should be as close as possible to the optimum charging temperature range prior to and during charging (see page 8). If your Battery Packs are too hot or too cold, the charging indicator will continue to blink, indicating a slow or trickle charge, until the battery temperature is within or near the optimum charging temperature range. Once stabilized within this range, the fast charge will begin and the charging indicator will be solid green.

If the charging indicator lights remain blinking throughout the entire time that the Segway HT is plugged in, then the Battery Packs have trickle-charged the entire time. This will provide only a small amount of energy into the Battery Packs.

If You Are Concerned that the Battery Packs May Be Too Cold or Overheated During Charging:> Check the charging indicators to make sure

they show solid green, indicating fast charge.> If the charging indicators do not show solid

green within 15 minutes after the Segway HT is plugged in, move the Segway HT to a location

within or near the optimum charging temperature range (see page 8).

> After the Battery Packs are within the proper temperature range, reconnect the Power Cord.

If the charging indicators still do not show solid green within 15 minutes, contact Segway Customer Operations at www.segway.com or call 1-866-4SEGWAY (1-866-473-4929).

In Hot Conditions, You Can Improve Charging By:> Moving the Segway HT or off board charging

unit out of the sun, or off of hot asphalt. (Into an air-conditioned environment is best!)

> Placing a fan near the Segway HT or off board charging unit to blow air over the batteries.

Regenerative BrakingThe Segway HT has a regenerative braking system that charges the Battery Packs when descending a hill or slowing down.

Replacing Battery PacksBattery Packs should last the equivalent of 300 to 500 full charges. As your Battery Packs near the end of their useful life, you will notice that they need more frequent charging and that your Segway HT has reduced range. You may order replacement Battery Packs by contacting Segway Customer Operations at www.segway.com or calling 1-866-4SEGWAY (1-866-473-4929).

Replace Battery Packs in PairsWhenever you replace a Battery Pack, consider replacing both Battery Packs. Replacing only one Battery Pack will not necessarily increase the performance or range of your Segway HT. This is because the Segway HT is designed to operate at the level allowed by the lower-energy Battery Pack. This is a safety feature.

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Redundancy is a critical safety feature built into the Segway HT. This applies to the Battery Packs. If the Segway HT operated at the level allowed by the stronger Battery Pack, and the other Battery Pack was near depletion or if it was completely depleted, imagine what would happen if the stronger Battery Pack suddenly failed. The rider would be left with little or no electrical power, a dangerous and intolerable result. Therefore, you should replace Battery Packs in pairs (except for the unusual situation where a Battery Pack is replaced because of damage or defect and the other Battery Pack is relatively new).

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chapter 4: troubleshooting

Troubleshooting Procedures

Before contacting Segway Customer Operations, you may attempt to troubleshoot certain problems yourself.

Problem

Segway HT will not power on.

1. If you see a red icon in the display when attempting to power on, refer to the Startup Error Conditions on pages 30-31.

2. Press the Key fully into the Key Port using gentle, constant pressure to keep the Key in contact with the three metal contacts in the Key Port. Do not push down hard on the Key. This could damage the Key and/or the Key Port.

3. Hold the Key against the contacts for at least three seconds.4. If the Segway HT does not power on (beep and Display is lit), try a

variety of Key positions and wait three seconds with the Key held in each position. Do not “rock” the Key in the Key Port.

5. If the Segway HT still will not power on, you may need to reset the system by disconnecting and reconnecting the Control Shaft Cords (see page 36) and then power on. The 5 mm hex wrench is required for this procedure. You may wish to carry this wrench with you in the event a reset is required.

6. If the Segway HT still will not power on, remove and reseat Battery Packs (see page 37), and then power on.

7. If the Segway HT still will not power on, charge the Battery Packs and then power on.

Attempt the following steps in the order listed. If none of these steps solves the problem, call Segway Customer Operations at 1-866-4SEGWAY (1-866-473-4929).

Segway HT will not enter Balance Mode.

1. Make sure you properly powered on into Power Assist Mode (see Riders’ Guide).

2. Make sure you are following all the steps listed in the Riders’ Guide for entry into Balance Mode, including making sure the Platform is level when you tap the Mode Button to switch from Power Assist Mode to Balance Mode.

3. Check the icon in the Display against the messages described on page 31.

4. If a fault message appears, follow the “User Response” described with the message to attempt to clear the fault.

Because of the complex connection between the Handlebar and the top of the Control Shaft, this is not a user serviceable problem. Contact Segway Customer Operations at www.segway.com or call 1-866-4SEGWAY (1-866-473-4929).

The bearing in the Control Shaft is broken. Contact Segway Customer Operations at www.segway.com or call 1-866-4SEGWAY (1-866-473-4929).Tightening the Height Adjustment Collar will not correct this problem.

Handlebar is loose but both sections of the Control Shaft are tight.

Handlebar is tight to the top section of the Control Shaft, but the top section of the Control Shaft turns within the lower section of the Control Shaft.

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Problem

1. Tighten the Wheel Nut (see page 38).2. Remove, clean, and reseat the Tire/Wheel

Assembly (see page 38).

The Tire/Wheel Assembly is loose and wobbles.

The entire Handlebar/ Control Shaft Assembly turns within the Control Shaft Base.

1. Tighten the Control Shaft Clamp Bolt (see page 36).

2. If the Control Shaft Clamp Bolt will not tighten and remain tight, inspect all three Control Shaft Clamp parts for damage.

3. If any part is damaged, contact Segway Customer Operations at www.segway.com or call 1-866-4SEGWAY (1-866-473-4929) to order a replacement Control Shaft Clamp Kit.

4. If none of the Control Shaft Clamp parts are damaged, check to make sure the Control Shaft is properly seated into the Control Shaft Base (see page 36).

Tire is flat or will not maintain air pressure.

1. Check for tire damage. If tire is damaged, contact Segway Customer Operations at www.segway.com or call 1-866-4SEGWAY (1-866-473-4929) to order a replacement Tire/Wheel Assembly.

2. If there is no visible tire damage, check to make sure tire valve stem core is tight. Tighten if necessary.

3. Inflate tire and check for leaks. If tire goes flat or will not maintain air pressure, contact Segway Customer Operations at www.segway.com or call 1-866-4SEGWAY (1-866-473-4929) to order replacement Tire/Wheel Assembly.

This is a tubeless tire. The tire is not easily separated from the wheel. Do not attempt to separate the tire from the wheel to repair a flat tire. You could damage the tire and the wheel.

Segway HT pulls to left or right when riding.

1. Check to make sure tire air pressure is equal.2. Check to make sure Steering Grip returns to

center. If Segway HT turns in place without rider turning the Steering Grip, the Steering Grip is not returning to center. The rider may need to twist the Steering Grip slightly to return it to center.

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Problem

Safety Shutdown while entering or leaving a store, library, or other building.

Theft detection systems may interfere with Segway HT operation. Many libraries, retail stores, and other buildings use theft detection systems to detect protected items as they enter and exit a building. These systems are usually situated at the building entrances and exits so that patrons must pass through on their way in and out. These systems may not always be visible. Some theft detection systems have caused the Segway HT (in Balance Mode) to perform a Safety Shutdown.1. Step off at least 5 feet (1.5 meters) away

from theft detection systems and proceed through the theft detection system in Power Assist Mode or with the Segway HT powered off.

2. Once at least 5 feet (1.5 meters) away from the detectors, riders may return to Balance Mode and step on.

Pressing the Mode Button does not cause the Segway HT to power down or change into Power Assist Mode.

1. Check that your Mat is not sticking to the Platform (see page 38). If the Mat is sticking, lift the Mat to release it, while being careful to hold onto your Segway HT, and not move it forward or backward.

2. Replace the Mat on the Platform3. Press or tap the Mode Button4. If the Segway HT still will not power down

or change into Power Assist Mode, contact Segway Customer Operations at www.segway.com or call 1-866-SEGWAY (1-866-473-4929).

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Display MessagesThe Display on the Handlebar indicates the following information:> The operational mode of the Segway HT (Power Assist Mode or Balance

Mode)> The battery charge level> Whether a fault is detected in any system

It is important to understand all the icon messages that may appear in the Display.

Display ColorsGreen (and only green) means you may step on and ride in Balance Mode. Orange indicates Power Assist Mode. Red means something is wrong.

If the Display is in direct sunlight, it may be difficult to see the color and the icon. Try shading the Display with your hand. If the Display is not illuminated, the Segway HT is not powered on.

Startup Error ConditionsIf 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. All of these icons are red. You may clear these conditions with the user response described:

Startup Error Conditions

WARNING!Do not attempt to step on the Segway HT until you have cleared the error condition and you have confirmed that the Segway HT is in Balance Mode.

The Key being used to start the Segway HT does not contain the correct security code.

Restart using correct Key. If condition continues, contact Segway Customer Operations at www.segway.com or call 1-866-4SEGWAY (1-866-473-4929).

The Segway HT is plugged in.

Unplug the Power Cord and, if the Segway HT has powered off, power on again.

The battery is too low to allow safe operation of the Segway HT.

Charge the Battery Packs; then attempt to power on.

The Steering Grip is turned to the left at startup.

Be sure your hand is not turning the Steering Grip. Gently move the grip to ensure it is in the center (straight-ahead) position.

(red)

(red)

(red)

(red)

The Steering Grip is turned to the right at startup.

(red)

Display Icon User Response Definition

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Startup Error Conditions (continued) Error Condition When Attempting to Enter Balance Mode

The following Display icon will appear if you attempt to enter Balance Mode, but fail to level the Platform.

Normal Operation

The following Display icons should appear each time you power on your Segway HT.

Display Icon

Right front rider detect sensor is on at startup.

Definition User Response

Make sure your foot is not on the Platform when powering on. Check the Mat to ensure it is clear of foreign objects and not sticking to the Platform. If necessary, remove the Mat (see page 38) and inspect beneath it.

Left front rider detect sensor is on at startup.

Left rear rider detect sensor is on at startup.

Right rear rider detect sensor is on at startup.

(red)

(red)

(red)

(red)

Mode Button is depressed at startup

(red)

Make sure the Mode Button is not depressed at startup.

Display Icon

Platform not level when attempting to enter Balance Mode.

Definition User Response

Level Platform, tap the Mode Button to enter Balance Mode.

(red)

Display Icon

Startup test being performed. (All segments should be displayed, with no backlight.)

Definition User Response

Wait before attempting to use the Segway HT.

Segway HT is in Power Assist Mode (full battery charge level shown).

Do NOT attempt to step on the Segway HT. It is not in Balance Mode. Rotate Steering Grip to move the Segway HT forward and back.

(orange)

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Normal Operation (continued) Reduced Performance Mode

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, inadequate foot pressure on the Platform, or the Battery Packs are too hot or too cold.

Display Icon

Segway HT is in Balance Mode (full battery charge level shown).

Definition User Response

You may step on and ride the Segway HT.

Segway HT is powering off (approximately one-half battery charge level shown). This icon should only appear when you power off.

Do not attempt to power on until backlight disappears. (In cold weather, it may take several seconds for this icon to disappear.) Do not step onto the Segway HT.

(orange)

(green) Display Icon

The Segway HT is operating at reduced performance levels due to a temporary condition (full battery charge level shown).

Definition User Response

Do not try to lean past the speed limit, which has been lowered until the condition clears.

(green)

System Faults

If the Segway HT detects a fault in its hardware one of the following icons (which are red and always shown together with a wrench icon) will appear in the Display. The Segway HT cannot be used until the fault is cleared.

Attempt these steps in the order listed to clear the fault. If you are unsuccessful, contact Segway Customer Operations at www.segway.com or call 1-866-4SEGWAY (1-866-473-4929).

Display Icon

There is a fault in the rear Battery Pack.

Definition User Response

1. Remove and reseat the faulted Battery Pack (see page 37).

2. Power on the Segway HT.3. If the same icon appears, remove both Battery

Packs, reverse locations of the Battery Packs (swap front and rear), and reattach both Battery Packs.

4. If, after reversing and reattaching the Battery Packs, the same icon appears (indicating that the fault remains in the same Battery Pack location), check and make sure the two Control Shaft Cord connectors are properly connected (see page 36). Then, power on the Segway HT. If the same icon appears, contact Segway Customer Operations at www.segway.com or call 1-866-4SEGWAY (1-866-473-4929).

5. If, after reversing and reattaching the Battery Packs, the icon changes to indicate that the fault is now in the other Battery Pack location, contact Segway Customer Operations at www.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 Battery Pack (see page 25).

There is a fault in the front Battery Pack.

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System Faults (continued) Critical Faults During Balance Mode

If, during normal riding, the Segway HT detects a fault in any of its redundant subsystems (see page 11), the Segway HT will perform a Safety Shutdown by automatically reducing its speed, shaking its Handlebar, making growling and beeping noises, and flashing red in the Display. At that time, the Display will show one of the following icons:

Display Icon

There is a fault in the Platform.

Definition User Response

1. Check and make sure the two cord connectors are properly connected (see page 36).

2. Power on Segway HT.

3. If same icon appears remove and reseat both Battery Packs (see page 37).

4. Power on the Segway HT. If the same icon appears, contact Segway Customer Operations at www.segway.com or call 1-866-4SEGWAY (1-866-473-4929).

There is an unlocated fault in the Segway HT.

(red)

(red)

Display Icon

The system has detected a critical error, is slowing to zero speed, and is performing Safety Shutdown (full battery charge level shown).

Definition User Response

Come to a controlled stop, then safely step off and discontinue operation. You have approximately 10 seconds from the start of Safety Shutdown to come to a controlled stop and safely step off before the HT will automatically shut down.

Check Segway HT for damage. If no damage, use Key to power on.

The Segway HT shuts down because a forward, backward, or side tilt limit was exceeded or no rider detect sensors were depressed while the Segway HT was moving at speed.

(red)

(red)

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chapter 5: service General InformationSegway Customer Operations can answer your questions about your Segway HT via the web, email, or phone. If you have a question on parts or replacements, please contact us using the information below:

Hours of Support Operation8:00 am - 8:00 pm Eastern TimeMonday - Friday (except Segway observed holidays)Phone: 1-866-4SEGWAY (1-866-473-4929)Fax: (603) 222-6001Email: technicalsupport@segway.com

Parts Diagram1. Handlebar Trim2. Key3. Grips4. Handlebar/Control Shaft Assembly5. Control Shaft Cords6. Mat7. Front Trim8. Control Shaft Clamp Bolt and Clamps (2)9. Parking Stand (i Series models only)10. Platform with Control Shaft Base and

Gearboxes11. Fender12. Battery Packs13. Tire/Wheel Assembly14. Wheel Nut

i Series shown

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Replacing PartsIf a part breaks or needs replacement, contact Segway Customer Operations. Certain parts are owner replaceable and Segway provides replacement parts with installation instructions. Use only Segway-provided replacement parts and fasteners.

Troubleshooting Service ProceduresFollow these procedures when instructed to do so by the Troubleshooting section of this Reference Manual.

Check the Control Shaft Cord Connections; Remove and Install Handlebar/Control Shaft Assembly; Tighten Control Shaft Clamp Bolt Tool required: 5 mm hex wrench.

The two cords at the bottom of the Control Shaft connect to two cords in the Control Shaft Base.

Use the following procedure to check these two connections:1. Make sure the Segway HT is powered off and

not plugged into AC. It is unsafe to perform this procedure while you are charging your Segway HT.

2. Loosen the Height Adjustment Collar and slide the upper portion of the Control Shaft fully into the lower portion of the Control Shaft.

3. Gently tighten the Height Adjustment Collar.4. Using the 5 mm hex wrench, loosen (but do

not remove) the Control Shaft Clamp Bolt.5. Carefully lift the Handlebar/Control Shaft

upwards and out of the Control Shaft Base far enough to expose the two cord connections.

6. Separate the cords at the connections by depressing the tabs and gently pulling the cords apart.

7. Inspect the pins inside each connector to make sure they are not bent or broken. Bent or broken pins could result in a Safety Shutdown. If you observe bent or broken pins, contact Segway Customer Operations.

8. Reattach the two connectors. The connectors are keyed and color-coded to indicate the proper matching. Connect the 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. When you make these connections, you should hear and feel a click.

9. Make sure the Control Shaft Clamp wedges are properly positioned (curved side to the rear).

10. Loosen the Height Adjustment Collar and carefully extend the Control Shaft to approximately one-half its full extended length (to reduce the risk of pinching the cords when reinstalling the Handlebar/Control Shaft in the Control Shaft Base).

11. Tighten the Height Adjustment Collar.12. Insert the Handlebar/Control Shaft fully into

the Control Shaft Base, making certain the cord connections remain attached, the cords are not pinched, and the rubber O-ring (near the bottom of the Handlebar/Control Shaft) is tight against the top of the Control Shaft Base.

13. Lay the Segway HT down forward onto the Handlebar to properly align the Handlebar parallel with the front of the Platform.

14. Use the 5 mm hex wrench to tighten the Control Shaft Clamp Bolt to torque 6.8 N-m.

WARNING!

Always shut down your Segway HT and unplug the Power Cord before performing any maintenance or installing any part or accessory.

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You may wish to disconnect the Handlebar/ Control Shaft from the Control Shaft Base. This may make it easier to transport the Segway HT. To remove the Handlebar/Control Shaft Assembly, follow the procedure described in the previous steps 1 through 6. The Handlebar/ Control Shaft is then disconnected from the Control Shaft Base. To reconnect the Handlebar/Control Shaft to the Control Shaft Base, follow the procedures described in steps 7 through 14.

1.

Remove and Reseat Battery PacksTool Required: 3 mm hex wrench.

1. Make sure the Segway HT is powered off and not plugged into AC. It is unsafe to perform this procedure while you are charging your Segway HT.

2. Tip the Segway HT onto its side so that the outside of one of the wheels lays flat against a clean, smooth surface.

3. Use the 3 mm hex wrench to remove screws (4 per Battery Pack).

4. Pull Battery Packs straight off chassis.

5. Reseat Battery Packs on chassis with curved edge facing outside of chassis.

6. Thread in the socket screws (4 per Battery Pack) and torque to 1.0 N-m.

7.

Handlebar/CS Assembly

Control Shaft Cords

Control Shaft Clamp

WARNING!

The cells within the Battery Packs contain toxic substances. Do not attempt to open Battery Packs. Do not use the Battery Pack if its casing is broken or if it emits an unusual odor or excessive heat or leaks any substance. Do not handle a damaged or leaking Battery Pack unless you are wearing disposable rubber gloves. Dispose of rubber gloves and damaged Battery Pack properly in accordance with regulations governing disposal of toxic materials.

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Remove and Reseat Tire/Wheel Assembly; Tighten Wheel NutTools Required: 16 mm deep socket wrench with 8" (or longer) wrench handle, rubber mallet.

1. Tip the Segway HT onto its side so that the outside of one wheel lays flat against a clean, smooth surface.

2. Remove the Wheel Nut with a 16 mm deep socket wrench. Hold the wheel from rotating and turn the wrench counterclockwise. (This may require considerable force.)

3. Strike the outside edge of the tire with a rubber mallet to unseat the wheel hub taper. (This may require multiple attempts as the wheel hub is seated tightly into the Gearbox taper.)

4. Lift off the wheel.5. Clean any debris from outside of drive shaft

and inside of wheel hub.6. Place the wheel hub opening over the Gearbox

drive shaft; rotate the wheel while pressing down until the wheel seats.

7. Thread on the wheel nut and torque to 50 N-m.

Removal/Reinstallation of MatTool Required: None.

1. Lift Mat off Platform. For i Series only, pull both “ears” of the Mat inward, out of fender channels.

2. Before installing Mat, make sure top 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 Series only, press ears back into the

fender channels.

WARNING!

Always shut down your Segway HT and unplug the Power Cord before performing any maintenance or installing any part or accessory.

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Removal/Reinstallation of GripsTool required: 5 mm hex wrench.

1. Remove grip by removing the bolt using the 5 mm hex wrench.

2. Pull grip off shaft.3. Before installing grip, make sure inside of grip

and outside of shaft are clean, dry, and free of debris.

4. Slide grip onto shaft. Note that it is keyed and will only go on one way.

5. Reinsert bolt and torque with 5 mm hex wrench to 6.8 N-m.

CleaningClean your Segway HT with soap and water and a soft cloth. Do not use a power washer because this could drive water into components that must stay dry.

Do not attempt to open the Platform. There are no user serviceable parts inside. By opening thePlatform, you risk electric shock injury. Also, you could void your limited warranty, damage your Segway HT, and render it unsafe to use. Do not attempt to open the Gearboxes. There are no user serviceable parts inside. You could damage your Segway HT and render it unsafe to use.

AccessoriesYou may be interested in adding accessories to your Segway HT. Please visit www.segway.com to learn what accessories are available.

WARNING!

Never clean the Mat or tires with any specialized cleaners because these products may reduce traction, resulting in injury.

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chapter 6: frequently asked questionsHow often should I check the air pressure in the tires on the Segway HT? Check air tire pressure monthly. Tire condition should be inspected each time you ride. The air pressure in the tires should be set at the pressure stated on the wheel label near the inflation valve (not the pressure stated on the tire sidewall).

What will happen if the Battery Packs on my Segway HT become completely depleted? The HT will not start with depleted Battery Packs. You will need to plug the device into an outlet and let it charge for up to six hours to reach full charge. It is best to keep your Segway HT plugged in when not in use because the Battery Packs can be damaged by self discharging when stored for long periods of time.

What if my Key will not start my Segway HT? See Troubleshooting, page 27.

May the Steering Grip be installed on either the left-hand or the right-hand side? No, the Segway HT is constructed for a left-handed Steering Grip only.

Can the Segway HT climb stairs?You should not attempt to ride the Segway HT up or down stairs. Use Power Assist Mode as described in the Riders’ Guide.

How should I dispose of my old batteries?Segway and The Rechargeable Battery Recycling Corporation encourage you to help preserve our environment by recycling batteries at the nearest recycling collection point. Please check www.rbrc.org/consumer or call 1-800-822-8837 to find the nearest location.

Are there accessories available for my Segway HT such as bags, locks, lights, horns, and reflectors? Yes, there are many accessories available from Segway. Please visit www.segway.com or call Segway Customer Operations at 1-866-4SEGWAY.

Why does my Segway HT jerk to the left or right when I am starting or stopping? The most likely reason for this is a loose Wheel Nut. The Wheel Nut should be tightened with a torque wrench to 50 N-m. If this does not solve the problem, please contact 1-866-4SEGWAY.

Can I charge my Segway HT in countries where the power is at different voltages than the USA? Yes, as long as the voltage is between 100 and 240 V, and 50 to 60 Hz AC (this covers most of Europe and Asia). You might need an adapter at the end of the Power Cord that goes into the wall outlet. Alternatively, you can use a standard International Electrotechnical Commission (IEC) cord (typically used for computers and monitors) designed for the country in which you are residing. The adapters and IEC cables can be found at most electronic stores.

Do I need to change the lubrication in the Gearboxes in my Segway HT?No, the Gearboxes require no maintenance and are sealed.

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What can I use to clean my Segway HT? Soap and water are best. You should not use products that shine rubber, plastic, and vinyl surfaces, as these products may degrade tire traction. You should not use a power washer because it could force water into components that should remain dry.

When I start my Segway HT, the Display turns red and it shuts off. Ensure that your Segway HT has been unplugged and that you are using the correct Key. See pages 30-31 for a list of error conditions.

What is the noise my Segway HT makes while I’m just standing still?This is normal. Just like you hear a fluorescent light buzzing, the effect of the electricity moving through the HT parts (circuit boards, motors) results in the sound you hear.

Why did my Segway HT shut down? When your Segway HT is in Power Assist Mode, it will automatically shut down if 60 seconds elapse without use of the Steering Grip to power the wheels. If this automatic shutdown occurs, reinsert the Key to power on.

Why is my Segway HT rumbling, shuddering, and shaking?If you try to move your Segway HT too quickly while it is in Balance Mode, and you are not on the Platform, the Segway HT will produce the Stick Shake Warning. This Stick Shake Warning alerts you and bystanders that the machine is moving without a rider and that the Segway HT will stop balancing and switch to Power Assist Mode. Stop the Stick Shake Warning by tapping the Mode Button, thus changing to Power Assist Mode.

How do I get a replacement Key?Make a note of your key code and Segway HT serial number. Contact 1.866.4SEGWAY to purchase a replacement Key.

When I received my new Segway HT I noticed that my Mat looked dirty. Why? The Segway HT Mat is molded with a fire retardant. It is normal that a residual amount of this material will leach to the surface of the Mat. You can clean it with soap and water.

While my Segway HT was in Balance Mode, I got the Handlebar jammed underneath a countertop and now I can’t get it out. What should I do?You can loosen the Height Adjustment Collar, lower the Handlebar, and then tap the Mode Button to put the unit into Power Assist Mode. Then, move it out from underneath the countertop.

Why does the Handlebar on my Segway HT rotate left and right? See Troubleshooting, page 27.

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chapter 7: glossaryBalance Sensor Assembly: the central monitoring unit, found in the center of the Platform, that communicates with the Controller Boards and the Motors to balance the Segway HT.

Charge Port and Charge Port Cover: the receptacle on the Control Shaft Base where one end of the AC Power Cord is plugged in during battery charging. The Charge Port Cover is an environmental seal that must be replaced if damaged.

Controller Boards: the two integrated circuit boards located in the Platform.

Control Shaft: the rigid aluminum shaft that houses the connections running between the Handlebar and Platform/Control Shaft Base. It features two-piece construction with a watertight seal.

Control Shaft Base: the aluminum base that connects the Control Shaft to the Platform. It houses the Power Converter.

Control Shaft Clamp: the three-part clamp found in the Control Shaft Base that holds the Control Shaft in place.

Control Shaft Cord: the system of electrical conductors that runs from the Handlebar through the Control Shaft and Control Shaft Base to the Controller Boards.

Display: the circular window on the Handlebar that shows machine conditions through LCD segments and colored backlights.

Handlebar: the handles that connect to the Control Shaft and house the items that allow the user to communicate with the Segway HT and vice versa. These include the circuit board that controls the speaker, the Display that indicates the Segway HT operating condition and Battery Pack levels, the Key Port, the Steering Grip for steering right or left, and the Mode Button that allows the user to turn the machine off or change between Balance Mode and Power Assist Mode.

Height Adjustment Collar: the nut that holds the Control Shaft in place after height adjustments are made.

Hex Wrench: a hexagonal wrench that fits the socket of a hex fastener.

N-m (Newton-meter): measurement units for tightening nuts, bolts, and screws.

Power Converter: the component in the Control Shaft Base that allows the batteries to be charged with an AC electrical connection. An LED display indicates the battery charge status.

Steering Grip: the control grip on the Handlebar that uses an embedded magnet mechanism to steer the Segway HT. It is installed in the factory on the left grip.

Torque: twisting force, often caused by applying a linear force at a radial distance. Torque tends to cause rotation.

Torque Wrench: a wrench that measures the amount of twisting force applied in tightening a nut or bolt.

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chapter 8: contact numbers and legalReport All IncidentsIf you or any other user of your Segway HT is involved in an accident, or if your Segway HT performs in a way that you do not intend or in a way that it is not supposed to, contact Segway Customer Operations at 1-866-4SEGWAY (1-866-473-4929).

Obey All Laws and RegulationsMany states and municipalities regulate use of Segway HTs on public roads and sidewalks. Some states and municipalities prohibit use of Segway HTs on roads and sidewalks. You should consult local and state authorities to identify and become familiar with applicable laws and regulations. (Many of these laws use the term “Electric Personal Assistive Mobility Device” or “Personal Motorized Mobility Device,” which are generally defined to include Segway HTs.) In addition to other requirements, these laws and regulations may prescribe minimum ages for Segway HT riders on public roads and/or sidewalks and may mandate protective gear for riders.

How to Reach UsSegway Customer Operations can answer your questions about your Segway HT via the web, email, or phone. If you have a question on parts or replacements, please contact us using the information below:

Hours of Support Operation8:00 am - 8:00 pm Eastern Time, Monday - Friday (except Segway observed holidays)Phone: 1-866-4SEGWAY (1-866-473-4929)Fax: (603) 222-6001Email: technicalsupport@segway.com

Segway Human Transporter Limited WarrantySegway LLC provides with each Segway HT a “Segway™ Human Transporter Limited Warranty.” This is the only warranty applicable to the Segway HT. Consult the “Segway™ Human Transporter Limited Warranty” delivered with your Segway HT for the specific terms of limited warranty coverage.

FCC PART 15 CLASS B RADIO FREQUENCY INTERFERENCE (RFI) The Segway HT has been tested and found to comply with the limits for Class B digital devices pursuant to Part 15, Subpart B of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential environment. The Segway HT generates, uses, and can radiate radio frequency energy, and, if not installed and used in accordance with the User Materials, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation.If the Segway HT does cause harmful interference to radio or television reception, which can be determined by turning the Segway HT off and on, the user is encouraged to try and correct the interference by one or more of the following measures: > Reorient or relocate the receiving antenna.> Increase the distance between the Segway HT

and the receiver.

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> Connect the Segway HT into an outlet on a circuit different from that to which the receiver is connected.

> Consult the dealer or an experienced radio/TV technician for help.

This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions:> This device may not cause harmful

interference.> This device must accept any interference

received, including interference that may cause undesired operation.

Changes or modifications to this equipment not expressly approved by Segway may void the user’s authority to operate this equipment.

Canadian ICES-003The Segway HT is a Class B digital apparatus that complies with Canadian ICES-003.

European DirectivesThe Segway HT complies with the requirements of European Directives 89/336/EEC, Directive of Electromagnetic Compatibility; 73/23/EEC, Low Voltage Directive; and 98/37/EC, Machinery Directive.

Other StandardsThe Segway HT also complies under the following: Applicable sections of Safety for Information Technology Equipment, IEC950, CAN/CSA C22.2 No. 60950-00, UL 60950. Applicable sections of UL Standard for Safety for Motor-Operated Appliances, UL73. Applicable sections of Motor-Operated Appliances (Household and Commercial), CAN/CSA-C22.2 No. 68-92. Degrees of Protection Provided by Enclosures (IP code), IEC 529.

Segway LLC TrademarksSegway LLC owns a number of trademarks used in this manual, including Segway™ and the Segway Flyer symbol. Failure of a mark to appear in this manual does not mean Segway LLC does not use the mark, nor does it mean that the product is not actively marketed or is not significant within its relevant market.

Patent and Licensing InformationThe Segway HT is covered by US and foreign patents, including one or more of the following:

US Patents: Patent No. 5,701,965; Patent No. 5,971,091Patent No. 5,791,425; Patent No. 6,538,411Patent No. 5,794,730; Patent No. 5,975,225Patent No. 6,332,103; Patent No. 6,062,600Patent No. 6,311,794; Patent No. 6,302,230Patent No. 6,405,816; Patent No. 6,223,104Patent No. 6,367,817; Patent No. 6,288,505Patent No. 6,415,879; Patent No. 6,357,544 Patent No. 6,435,535; Patent No. 6,386,576Patent No. 6,443,250; Patent No. 6,408,240Patent No. 6,443,251; Patent No. 6,343,664Patent No. 6,508,319; Patent No. 6,092,249

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Foreign Patents: Patent No. 130073 (TW); Patent No. 129673 (TW); Patent No. 705704 (AU); Patent No. 205144 (MX); Patent No. 282114 (NZ); Patent No. 2153868 (RU); Patent No. 710104 (AU); Patent No. PI9710331-4 (BR); Patent No. 101929 (TW); Patent No. 330,431 (NZ); Patent No. 728453 (AU); Patent No. 728114 (AU); Patent No. 71497 (SG); Patent No. 129896 (TW); Patent No. 503314 (NZ); Patent No. 118057 (TW); Patent No. 503678 (NZ); Patent No. 129896 (TW); Patent No. 503314 (NZ); Patent No. 118057 (TW); Patent No. 503678 (NZ); Patent No. 72250 (SG); Patent No. 727183 (AU); Patent No. 729781 (AU); Patent No. 726250 (AU); Patent No. 726253 (AU); Patent No. 149599 (TW); Patent No. 738013 (AU); Patent No. PI9710331-4 (BR); Patent No. 83351 (SG); Patent No. 747738 (AU); Patent No. 351082 (KR); Patent No. 2190382 (RU); Patent No. 159151 (TW); Patent No. 157146 (TW); Patent No. 154350 (TW); Patent No. 10-363809 (KR); Patent No. 10-346992 (KR); Patent No. 506785 (NZ); Patent No. 71497 (SG); Patent No. 83351 (SG); Patent No. 2153868 (RU); Patent No. 738013 (AU); Patent No. 729781 (AU); Patent No. 728453 (AU); Patent No. 4474299 (AU); Patent No. 4474199 (AU); Patent No. 4474099 (AU); Patent No. 4473999 (AU); Patent No. 727183 (AU); Patent No. 738013 (AU); Patent No. 726253 (AU); Patent No.

726250 (AU); Patent No. 1225004 (CN); Patent No. 728453 (AU); Patent No. 330431 (NZ); Patent No. 282114 (NZ); Patent No. 1175205 (CN); Patent No. 2211738 (CA); Patent No. 1912395 (AU); Patent No. 6315531 (JP); Patent No. WO9904152; Patent No. WO9623478; Patent No. WO9918907; Patent No. WO9802122; Patent No. WO0054719; Patent No. WO0102920; Patent No. WO0142077; Patent No. WO0115962; Patent No. WO9922966; Patent No. WO0054720; Patent No. WO0073101; Patent No. WO0054721; Patent No. WO729781; Patent No. WO0023315; Patent No. WO03011376; Patent No. WO02094352; Patent No. WO02096491; Patent No. WO0230730; Patent No. WO0211641; Patent No. WO02074220; Patent No. WO0240086; Patent No. EP1161214; Patent No. EP1298041; Patent No. EP1259415; Patent No. EP1237779; Patent No. EP1237489; Patent No. EP1208032; Patent No. EP1200761; Patent No. EP1190283; Patent No. EP1181187; Patent No. EP1161215; Patent No. EP1183163; Patent No. EP1180996

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indexA

accessories, 39adapters, 40angular rate sensors, 13assembly instructions, 4automatic shutdown, 41

BBalance Mode, 17, 27, 30, 32

error while attempting to enter, 31problem entering, 31

Balance Sensor Assembly, 11, 12, 13, 42Battery Packs, 6, 11, 13, 35

casing, 21charge level display, 23, 30charging, 8, 9, 14, 19, 21, 22discharge, 19, 40disposal, 40electric shock, 21empty battery condition, 16initial test, 23interchangeable, 13maximize battery life and performance, 21opening, 21

overheated, 25permanent damage, 22range, 7recycling, 40remove and reseat, 37replacing, 25safety guidelines, 21storage, 19, 22temperature parameters, 8, 24too cold, 25too hot, 14toxic substances, 21useful life, 25

bent pins, 36bumpy terrain, 14

Ccargo weight limits, 7cell balancing process, 23center of gravity, 11changing modes

Balance Mode, 17Power Assist, 17Power Off, 17

charge level display, 23, 24charge port, 22, 23, 42charging indicators, 22charging process, 23

cell balancing, 23fast charge, 23initial test, 23trickle charge, 23

cleaning, 39, 41contact numbers, 43Control Shaft, 6, 42

base, 6, 42clamp, 35, 42clamp bolt, 6, 35cords, 12, 13, 35, 36, 42pins, 36

Controller Boards, 11, 12, 42customer operations, 35, 43

Ddepleted Battery Packs, 40deter, 18dimensions, 7Display, 6, 42

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display colors, 30display messages, 30

battery charge level, 30critical error, 16, 34inadequate battery charge, 24operational mode, 30reduced performance, 14, 24, 32

disposal of Battery Packs, 40dynamic stabilization, 11

Ee Series, 2electric shock, 21, 39empty battery condition, 16error conditions, 41exposure to water, 19

Ffast charge, 23FCC rules, 43Fender, 35fender, 6Fixed Grip, 6flat tire, 28foot pressure, 10, 14foreign patents, 45Front Trim, 35front trim, 6

GGearboxes, 35, 40glossary, 42grips, 35, 39

fixed, 6installing and removing, 39steering, 13, 40, 42

growling noise, 15, 16, 34gyroscopes, 12

HHandlebar, 6, 42

aligning, 36beeping, 16electronics, 11, 13jammed, 41loose, 27rotating, 41shaking, 16, 34trim, 6, 35

Handlebar/Control Shaft Assembly, 35install, 36remove, 36troubleshooting, 28

height, 7Height Adjustment Collar, 6, 42hex wrench, 42horsepower, 12

how the Segway HT works, 11humidity, 19

Ii Series, 35IEC cables, 40incident reporting, 43international usage, 40

KKey, 35

code, 3port, 6will not start HT, 40

Llateral stability, 11laws and regulations, 43LEDs, 22lifting and loading your Segway HT, 19

MMat, 35, 41maximum payload, 7minimum rider weight, 7Mode Button, 6, 13, 17Motors, 11, 12

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NN-m (Newton-meter), 42noise

beeping, 16, 34buzzing, 41growling, 15, 16, 34

note icon, 4

Ooperating altitude level, 8operating humidity range, 8operating temperature, 8operating, charging and storage conditions, 8operational mode, 30

Pparking stand, 6, 20, 35

retract or deploy, 20patent and licensing information, 44pins, 36pitch, 13Platform, 35pollution emissions, 12Power Assist Mode, 17, 31, 40Power Converter, 42power off, 32power on, 27

power washer, 39pulse rates, LEDs during charging, 22

RRadio Frequency Interference (RFI), 43range, 7, 18rapid charge depletion, 24rechargeable Battery Packs, 21red charging indicator, 23red unhappy face, 16, 24reduced performance mode, 32redundant subsystems, 11, 16

Balance Sensor Assembly, 11Battery Packs, 11Controller Boards, 11Handlebar electronics, 11Motors, 11

regenerative braking, 14, 25relative charge level, 24replacement key, 41replacing

Battery Packs, 25parts, 36

replacing Battery Packs, 25Rider Detect sensors, 17rider weight limits, 7Riders’ Guide, 3

SSafety Shutdown, 12, 13, 15, 16, 24, 34Safety Video, 3security, 18serial number, 3service

how to contact, 35procedures, 36

shut down, 41solid state gyroscopes, 13specifications, 7Speed Limiter, 14stairs, use on, 40standards, 44

Canadian ICES-003, 44European directives, 44other, 44

startup error conditions, 30, 41inadequate battery charge, 30incorrect key, 30mode button depressed, 31plugged in, 30rider detect sensor depressed, 31steering grip turned, 30

startup test, 31Steering Grip, 13, 42

left hand only, 40pulls to left or right, 28

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Stick Shake Warning, 15, 17, 41storage, 19submersion, water, 19surface charge, 24suspension, 18system faults, 33

battery pack, 33platform, 34unlocated fault, 34

Ttilt sensors, 13tire inflation pressure, 18, 40tire/wheel assembly, 6, 18, 35

remove and reseat, 38torque, 12, 42torque wrench, 42towing, 20traction, 18, 39, 41trademarks, 44transporting your Segway HT, 21, 37trickle rate, 23troubleshooting, 4, 27, 36troubleshooting icon, 4turning radius, 8

Uunequal tire pressure, 18

US Patents, 44user serviceable parts, 39

Vvoltage, 22, 40

Wwarning icon, 4warranty, 43water, exposure to, 19website, 3weight, 8Wheel Nut, 18, 35

loose, 40tighten, 38

wheel wobble, 18

Yyaw, 13

notes

WARNING!enjoy the ride

farther. quicker. smarter. www.segway.com

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