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Caster Forks and Stems

Frog Legs Ultra Sport Fork Polymer Replacement
NOTE: The Ultra Sport fork has different polymers that can be used based on the chair user’s weight
and preferred ride. The Phase 2 fork has one polymer that works for any configuration. If ever
needed, the replacement procedure is the same for a Phase 2, but no coin is needed.

1.   Remove the pivot pin screw (D) using a 4mm Allen wrench.
2.   Use a punch or small screwdriver and a rubber mallet to push the pivot pin (A) out.
3.   Open the fork assembly and remove the polymer (C) and coin (B).
4.   Install the new polymer (C) and coin (B).
5.   Insert the pivot pin (A) back into the fork assembly. A punch or small screwdriver can be used to help

align holes if needed.

6. Secure the assembly by reinstalling the pivot pin screw (D) using a 4mm Allen wrench.
7. Repeat steps on opposite side.

Assembled View

A

B

C

D

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Содержание ROGUE 2

Страница 1: ...THIS TECHNICAL MANUAL HAS BEEN DEVELOPED FOR AND INTENDED TO BE USED BY A QUALIFIED TECHNICIAN WORKING FOR AN AUTHORIZED KI MOBILITY DEALER ...

Страница 2: ...e performed by an Assistive Technology Practitioner ATP or clinical professional trained to do wheelchair repairs adjustments and retrofits Additional information can be found in the Rogue 2 User Instruction Manual The user instruction manual can be found on the Ki Mobility website If you have any questions or concerns about any aspect of this wheelchair this manual or the service provided by us o...

Страница 3: ...drim Configurations 25 P Handrim Construction 26 Q Seat Pan 27 R Seat Upholstery 28 S Side Guards 29 T Transit 33 U Hybrid Angle Adjustable Footrest 34 V Angle Adjustable Footrest 35 W Angle Adjustable Flip Under Footrest 36 X High Mount Angle Adjustable Footrest 37 Y High Mount Angle Adjustable Flip Under Footrest 38 Z Adjusting the Footrest 39 AA Anti Tips 40 AB Wheel Locks 41 AC Reversing Wheel...

Страница 4: ...hments Tools Needed 2 5mm Allen Wrench Two 8mm Wrenches 3mm Allen Wrench Two 10mm Wrenches 4mm Allen Wrench 13mm Wrench 5mm Allen Wrench 17mm Wrench 5 5mm Allen Wrench 19mm Wrench 6mm Allen Wrench 24mm Wrench Utility Blade Phillips Screwdriver Torque Wrench Punch or small screwdriver Rubber Mallet Rogue 2 Frame Tube Frame Tube 1 3 8 Camber Tube 1 1 8 Back Canes Fixed Height Back Canes 1 Rigidizer ...

Страница 5: ... 5 13 5 11 5 13 5 11 5 19 16 5 14 5 12 5 14 5 12 5 20 17 5 15 5 13 5 15 5 13 5 F Front Seat Height See Diagram 1 Measured from ﬂoor to top of seat tube at front of seat sling G Footrest Width See Diagram 1 Measured from inside of front tube to inside of front tube on other side Footrest width is listed below for each seat width and taper E Footrest Taper See Diagram 1 Indicates bend of front frame...

Страница 6: ...a 4mm Allen wrench 3 Install the caster lock threaded barrel B into the caster lock barrel D with hole facing upward 4 Install the M6 bolt I through the washer G caster lock saddle H caster housing opening caster lock barrel D caster lock threaded barrel B and second washer G Secure with nut F using a 4mm Allen wrench and a 10mm wrench 5 Close the caster housing assembly by installing the caster w...

Страница 7: ...ork assembly NOTE Based on your configuration the caster may need to be removed first to allow clearance for wrench See step 3 2 Remove the caster wing covers by removing the M4 bolt with a 2 5mm Allen wrench Remove the caster stem by removing the M5 bolt with a 4mm Allen wrench Regular Caster Fork Single Sided Caster Fork ...

Страница 8: ...t F using a 16mm wrench 2 Install caster wheel H into fork B with two screws C a threaded barrel D and two spacers G using two 4mm Allen wrenches NOTE There is one size of caster stem standard and three sizes of forks tall standard and short that can be used The image below shows the stem and forks The installation process is the same for whichever stem and fork you use 3 Install assembly to caste...

Страница 9: ...using a wrench 2 Install caster wheel F onto fork B with a screw E the axle shaft G and secure with E Ring H NOTE There are two sizes of caster stems standard and 3 4 and two sizes of forks short and tall that can be used The installation process is the same for whichever stem and fork you use A B C D E F G H ...

Страница 10: ...9 Caster Forks and Stems Frog Legs Ultra Sport Fork Assembly 1 Install Frog Leg Ultra Sport Fork A onto caster wheel E with axle B screw C and two spacers D using two 4mm Allen wrenches A B C D D E ...

Страница 11: ...0 Caster Forks and Stems Frog Legs Phase 2 Carbon Fork Assembly 1 Install Frog Leg Phase 2 Carbon Fork A onto caster wheel E with axle B screw C and two spacers D using two 4mm Allen wrenches A B C D D E ...

Страница 12: ... but no coin is needed 1 Remove the pivot pin screw D using a 4mm Allen wrench 2 Use a punch or small screwdriver and a rubber mallet to push the pivot pin A out 3 Open the fork assembly and remove the polymer C and coin B 4 Install the new polymer C and coin B 5 Insert the pivot pin A back into the fork assembly A punch or small screwdriver can be used to help align holes if needed 6 Secure the a...

Страница 13: ...ss caster flutter first ensure all fasteners in the caster fork and stem assembly have been appropriately tightened down and there is no excessive play between any of the parts If the issue remains ensure the caster is square by adjusting the caster angle as demonstrated below Lastly if the flutter still remains open the caster angle You can open the caster angle 1 at a time up to 2 forward or 2 r...

Страница 14: ...ith two bolts F and two washers E per side using a 5mm Allen wrench 3 Repeat on the opposite side ensuring both sets of index clamp assemblies are set in the same location on both sides of the frame 4 Install the upper base mount B onto the rear index clamps with two bolts D two washers C and two square nuts A per side using a 5mm Allen wrench Repeat on opposite side Rear tower dimple should face ...

Страница 15: ...assembly and sleeve into the anti tip mount and ensure index button clicks and locks into one of the holes in the anti tip mount 7 Install the camber tube F into the opening in the anti tip mount 8 When user activated anti tips are present Install the anti tip spacer C and anti tip assembly B onto the upper base mount with bolt A and nut D using a 4mm Allen wrench and a 2 5mm wrench Do not fully t...

Страница 16: ...using a 4mm Allen wrench 2 Tighten the four bolts to 50 in lbs in the sequence shown below 1 2 3 4 3 Slide the tower index clamp assembly along the dimple track to the the desired CG position CG is measured from the front of the back cane to the center of the camber tube axle receiver 4 Tighten all tower clamp bolts D to 70 in lbs to secure in the desired position A B C D 1 2 3 4 ...

Страница 17: ...stalled up through the bottom of the back post The compression spring F is installed up through the bottom of the back post also but the bolt doesn t pass through it Repeat steps on opposite side of back post 2 Secure the relax bumper C to the relax saddle B with the screw A using a 4mm Allen wrench There are three index slots that the screw can be installed in the top 9 middle 4 and bottom 0 Inst...

Страница 18: ... plug cap adjustment screw H over the top and the 5 8 retaining ring I over the top of both plug cap pieces See the zoomed in image below for details of this procedure 6 Install the bolt D through the backrest plate into the strike G 7 Repeat steps on opposite side of the backpost 8 Install the backrest assembly onto the chair with the hardware shown below A 10mm wrench and a 4mm Allen wrench are ...

Страница 19: ...ounterclockwise increases the angle Each angle indicator mark on the back plate is 3 and 3 of angle change takes roughly 2 5 turns NOTE Ensure both sides of the backrest are set in the same position Use the angle indicator marks as a guide Use angle indicator marks to align both sides of the backrest Indica tor marks are separated by 3 Use 5mm Hex drive to adjust back rest angle to desired positio...

Страница 20: ...ng two 3mm Allen wrenches NOTE The straight upper back standard push handle and fold down push handle upper backs are shown in the image below NOTE The hole patterns on the lower section of the tubes differ between designs but the process of installation and adjustment is the same Straight Upper Back Fold Down Push Handle Standard Push Handle A B C C D E F G ...

Страница 21: ...s NOTE The fixed height back post standard push handle and fold down push handle upper backs are shown in the image below The standard push handle and fold down push handle upper backs also require sleeves upper post assemblies and the handle hardware See image below for details Fixed Height Back Post Fold Down Push Handle Standard Push Handle A B C D E E ...

Страница 22: ...me with two bolts D and two nuts A using a 5mm Allen wrench and a 10mm wrench 2 Install the T Arm assembly into the receiver Ensure the latch B clicks into place Adjust the height by loosening the height lever A and sliding the T Arm post up or down Repeat steps on opposite side A B C D A B ...

Страница 23: ...west hole will provide the highest setting 4 Install the swing away arm assembly into the receiver G with the sleeve F 5 Install the swing away arm assembly onto the outside of the backplates with three bolts D E F four saddles B 2 inside of frame 2 outside of frame two nuts A and a strike C A 4mm Allen wrench and a 10mm wrench are needed for the install If existing hardware is present on the back...

Страница 24: ...en wrench and an 8mm wrench 2 Install the crutch holder tube assembly onto the camber tube with the clamps D E and two bolts C using a 5mm Allen wrench 3 Install the crutch holder velcro strap A onto the back post ensure the crutch holder cup and velcro strap are on the same side of chair with a screw B using a 3mm Allen wrench A B C D E F H G I J ...

Страница 25: ...clamp and fork using two 4mm Allen wrenches 2 Secure the clamp in the desired location by installing and tightening the screw F and nut D on the backside of the clamp using a 5mm Allen wrench NOTE The nut for the backside screw goes into a recess in the clamp Ensure that nut stays in place 3 Repeat on opposite side Using the Luggage Carrier 1 Operating position for the luggage carrier is when the ...

Страница 26: ...112821 112825 100793 200202 24 Superlight 101159 100754 101161 100836 100830 100828 25 Superlight 101160 101160 101091 101464 101460 20 Spinergy Spox 103125 103179 22 Spinergy Spox 100827 100808 100889 100888 24 Spinergy Spox 100766 101161 100615 100830 100828 25 Spinergy Spox 100767 101160 100765 101464 101460 26 Spinergy Spox 101477 101148 200200 100950 22 Spinergy LX 100827 100808 100889 100888...

Страница 27: ...26 ...

Страница 28: ... sequencing of hardware for the three styles of handrims is shown below The specific hardware used is determined in the chart on the previous page based on the tire and handrim being used Spacer Style Detached Tab Style Tab Style ...

Страница 29: ... already done install the tape onto the seat as shown in the image below The tape should cover as much area as possible without hanging over the edge or covering one of the screw holes Part Number Tape Size Seat Pan Depth 004458 3 X 4 10 11 004458 004459 3 X 4 3 X 5 12 004459 3 X 5 13 004460 3 X 6 14 22 19 22 Seat Depth Screw Qty 10 12 6 13 15 8 16 18 10 19 21 12 22 14 Screw Qty Per Chair A B C ...

Страница 30: ...lstery C Repeat on opposite side The seat rail is shown outside of the sleeve to show the hole alignment in the image below 2 Secure the seat rail and seat upholstery onto the chair frame with screws A using a Phillips screwdriver Seat sling used on 10 13 wide Seat sling used on 14 22 wide ...

Страница 31: ...ide guard receiver it just has two additional rubber buttons J installed into the receiver Repeat on opposite side Removable Adult Side Guard 1 Install the adult side guard D onto the side guard post C with two screws A using a 4mm Allen wrench On the opposite side install the side guard post stop B with a screw A using a 4mm Allen wrench NOTE There are two sets of holes that the side guard post C...

Страница 32: ...31 Side Guards 2 Install the side guard assembly into the receiver so the side guard post stop faces the outside of the chair ...

Страница 33: ...nder in the desired position for the occupant This can be adjusted again later 2 Set the height of the back post by installing the post stop B with a screw A using a 4mm Allen wrench The height of the post can also be adjusted later if needed 3 Install the fender assembly into the receiver by dropping the post into the receiver slot Adjust the fender if needed 4 Repeat steps on opposite side Mediu...

Страница 34: ...olts from the post mount with a 3mm Allen wrench 2 Rotate the fender either way to align the fender with the profile of the tire 3 Rotate the post mount plate so the four holes align with the desired holes on the fender 4 Reinstall the the four bolts securing the fender to the post and post mount plate using a 3mm Allen wrench Medium Tall Short A B C D ...

Страница 35: ...section of this technical manual for full instructions on how to install the transit back plate An exploded image is shown below as reference but the full instructions are found in the Backrest section Transit Back Plate Hardware Right ...

Страница 36: ...stable Footrest Angle Adjustment of Your Footrest 1 Loosen the two set screws A on the bottom of the footrest using a 4mm Allen wrench 2 Rotate footrest to desired angle and secure in place by retightening the two screws A ...

Страница 37: ... used to elevate the footrest platform install between the footrest platform and the footrest adjustable clamp 3 Install the footrest protectors C by peeling the backing off of the tape B and sticking the tape inside the footrest protector Peel the remaining backing off of the tape and snap footrest protectors onto the footrest as seen below A B C G H Apply tape to the inside of the footrest prote...

Страница 38: ...be offset are shown below The installation process is the same for both footrest tubes 2 Install two screws C into the footrest flip stop clamp to secure the footrest tubes using a 5mm Allen wrench Install the footrest platform B onto the footrest flip stop clamp with two screws A and two nuts D using a 5mm Allen wrench Footrest Tube Footrest Tube Offset A B B C D A B C D ...

Страница 39: ...ling the footrest platform C onto the clamp with two screws D and two nuts E using a 5mm Allen wrench 2 Install the two clamps C D one end on the footrest tube and the other end around the frame tube with two screws A and two lock washers B using a 5mm Allen wrench A A E B C D Shown assembled without frame tube in place A B C D ...

Страница 40: ... bracket with two screws I and two saddles G using a 4mm Allen wrench 4 Install foot platform C onto pivots with two screws B using a 5mm Allen wrench While installing the foot platform slide the flip foot strap A onto frame tube 5 Install the top and bottom footplate clamps E F onto the footrest tubes and the frame tubes with three screws D G using a 4mm Allen wrench and a 5mm Allen wrench A B B ...

Страница 41: ...shown below Height Adjustment of Footrest 1 Locate the set screw on each side of the frame 2 Loosen the set screw on each side of the frame using a 3mm Allen wrench Do not remove set screws all the way 3 Adjust footrest tube up or down to achieve the desired height B 4 Ensure both sides are adjusted equally 5 Retighten each set screw to 40 in lbs A B ...

Страница 42: ...th a bolt C and nut A using two 10mm wrenches 3 The anti tip receivers are installed on the base mounts and the camber tube runs through the receivers The standard and user activated configurations are shown below For more specific information refer to the Index Towers and Camber Tube section in this technical manual A A B C C B A D D Standard Anti Tip User Activated Anti Tip A B B C Standard Anti...

Страница 43: ...the next page The Under Seat Scissor Lock always comes assembled so it is not shown below Push to Lock Flush Mount Short Thro Scissor Locks Low Profile Scissor Lock Extension Bar Assembled View Grade Aids Wheel Lock Extension Push and Pull to Lock Wheel Locks Extended Bar Wheel Lock Extension Push Pull Extended Bar 112048 112049 ...

Страница 44: ...d chair frame in position using a 5mm Allen wrench and a 6mm Allen wrench Once installed ensure wheel lock engages at least 1 8 into tire and locks properly prevent the chair from moving when engaged NOTE Always tighten wheel lock hardware by alternating between hardware while tightening a little at a time This prevents overclamping on one set of hardware which can lead to binding of the fasteners...

Страница 45: ...below The process of removing the clamp is the same for all of the wheel locks NOTE Always loosen wheel lock hardware by alternating between the two bolts while loosening a little at a time This prevents overclamping on one set of hardware which can lead to binding of the fasteners and increased difficulty in removal Short Thro Scissor Lock Low Profile Scissor Lock Push and Pull to Lock Wheel Lock...

Страница 46: ...0mm wrench For the push and pull to lock loosen and remove the top lock nuts and then grasp the assembly so the spring does not come out of the linkage hole when sliding off the arbors 4 Rotate the wheel lock bar 180 Low Profile Scissor Lock Short Thro Scissor Lock Push to Lock Flush Mount Wheel Lock Push and Pull to Lock Wheel Locks Low Profile Scissor Lock Short Thro Scissor Lock Push to Lock Fl...

Страница 47: ...lock pull the spring arm end into the wheel lock bar hole thin screwdriver will help with this Place and tighten the top lock nuts to secure See image below NOTE Always tighten wheel lock hardware by alternating between the two bolts while tightening a little at a time This prevents overclamping on one set of hardware which can lead to binding of the fasteners and increased difficulty in removal 6...

Страница 48: ...ust all of these settings as necessary NOTE Adjusting your chair s center of gravity will require readjusting the location of the wheel locks if provided See the Wheel Lock section for instructions on adjusting the wheel locks To adjust the center of gravity location a Remove both rear wheels b Loosen the two bolts at the top of the rear index clamps on both sides of the chair using a 4mm Allen wr...

Страница 49: ...unt 4 Repeat on both sides of the wheelchair 5 When the desired height is reached tighten the bolts D to 70 in lbs NOTE Height adjustments are in increments NOTE A front caster adjustment should be made to correspond with any change in seat angle Front Seat Height The front seat height can be adjusted in increments by repositioning the caster wheel within the fork 1 Use two 4mm Allen wrenches to r...

Страница 50: ...is optimally minimized when the wheel toe is set to zero To Set Toe to Zero 1 Remove the lower base mounts by removing two bolts per side using a 3mm Allen wrench If anti tips are present the image will look different but the process is the same 2 Adjust the camber tube so it is centered in the mounts and rotate the tube until the camber is facing upward relative to the ground if the chair is upri...

Страница 51: ...ximize pushing efficiency To Adjust the Wheelbase Width 1 Remove the lower base mounts B by removing two bolts A per side using a 3mm Allen wrench If anti tips are present the image will look different but the process is the same 2 Move the dimple clip C to the dimple on the camber plug D that provides the desired spacing 3 Repeat on opposite side 4 When both sides are spaced equally tighten the b...

Страница 52: ...the camber tube mount clamps F onto the camber towers A using three bolts D B and three nuts E using a 4mm Allen wrench and an 8mm wrench The holes used to install the camber mount clamp onto the camber tower determines seat heat Use the holes that provide the desired seat height for the user 4 The axle mount C must be mounted reverse of how it is shown in the image below when using 2 degrees or g...

Страница 53: ... Some configurations require one wheel to be installed then the drive shaft then the opposite wheel These configurations are called out in the Shaft Reference at the end of these instructions 5 Install the OAD wheels on both sides of chair Install the OAD wheel with the handrim A on the desired drive side The OAD wheel with no handrim B is the following side and is installed opposite the drive whe...

Страница 54: ...UNIVERSAL DRIVE SHAFT 220 280MM 111498 0 75 1 4 QUICK RELEASE OAD UNIVERSAL DRIVE SHAFT 220 280MM 111498 1 1 25 0 QUICK RELEASE OAD ZERO CAMBER DRIVE SHAFT 177 255MM 111503 1 5 0 QUICK RELEASE OAD ZERO CAMBER DRIVE SHAFT 225 295MM 111504 1 75 0 QUICK RELEASE OAD ZERO CAMBER DRIVE SHAFT 225 295MM 111504 0 75 1 1 25 2 QUICK RELEASE OAD UNIVERSAL DRIVE SHAFT 220 280MM 111498 1 5 2 QUICK RELEASE OAD U...

Страница 55: ...FT 350 460MM 111501 1 75 2 QUICK RELEASE OAD UNIVERSAL DRIVE SHAFT 350 460MM 111501 0 75 4 QUICK RELEASE OAD UNIVERSAL DRIVE SHAFT 295 370MM 111500 1 4 QUICK RELEASE OAD UNIVERSAL DRIVE SHAFT 350 460MM 111501 1 1 25 1 5 0 QUICK RELEASE OAD ZERO CAMBER DRIVE SHAFT 330 440MM 111506 1 75 0 QUICK RELEASE OAD ZERO CAMBER DRIVE SHAFT 330 440MM 111506 0 75 2 QUICK RELEASE OAD UNIVERSAL DRIVE SHAFT 220 28...

Страница 56: ...55 One Arm Drive OAD ...

Страница 57: ...11500 1 75 0 QUICK RELEASE OAD ZERO CAMBER DRIVE SHAFT 260 370MM 111505 1 75 2 QUICK RELEASE OAD UNIVERSAL DRIVE SHAFT 350 460MM 111500 1 75 0 QUICK RELEASE OAD ZERO CAMBER DRIVE SHAFT 330 440MM 111506 1 75 2 QUICK RELEASE OAD UNIVERSAL DRIVE SHAFT 350 460MM 111501 1 75 0 QUICK RELEASE OAD ZERO CAMBER DRIVE SHAFT 330 440MM 111506 1 75 2 QUICK RELEASE OAD UNIVERSAL DRIVE SHAFT 350 460MM 111501 1 75...

Страница 58: ...Ki Mobility 5201 Woodward Drive Stevens Point Wisconsin 54481 715 254 0991 www kimobility com DCN1032 1 ...

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