Replacing The Handlebar/Control Shaft Assembly - Segway Human Transporter i Series Instructor Manual And Participant Workbook

Page 80 of 106

Replacing the Handlebar/Control Shaft Assembly

Tools Required: 4mm or 5 mm hex wrench (depending on the size of the fastener), torque
wrench
Before you begin:
Make sure Segway HT is shut down and not
plugged into an AC outlet. It is unsafe to perform
this procedure while you are charging your
Segway HT.
Directions:
1. Loosen the Height Adjustment Collar and
slide the upper portion of the Control Shaft
fully into the lower portion of the Control
Shaft.
2. Gently tighten the Height Adjustment Collar.
3. Using the appropriate size (4mm or 5mm)
hex wrench, loosen (but do not remove) the
Control Shaft Clamp Bolt.
4. Carefully lift the Handlebar/Control Shaft
upwards and out of the Control Shaft Base
far enough to expose the two cord
connections.
5. Separate the cords at the connections by
depressing the locking tabs and gently
pulling the cords apart.
6. 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.
7. 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. Make sure the
locking tabs engage. When you make these
connections, you should hear and feel a
click.
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 5. 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 6 through 13.
Instructor Guide and Participant Workbook
© Segway LLC 2002
Basic Rider Optimization Training for the Segway HT
8. 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).
9. Tighten the Height Adjustment Collar.
10. 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.
11. Lay the Segway HT down forward onto
the Handlebar to properly align the
Handlebar parallel with the front of the
Platform.
12. Use the appropriate size (4mm or 5 mm)
hex wrench to tighten the Control Shaft
Clamp Bolt to torque 6.8 N-m.
Rev 3.5i - January 2004
P/N 1707100001aa