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KI CR45 Technical Manual

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

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Summary of Contents for KI CR45

  • Page 1 THIS TECHNICAL MANUAL HAS BEEN DEVELOPED FOR AND INTENDED TO BE USED BY A QUALIFIED TECHNICIAN WORKING FOR AN AUTHORIZED KI MOBILITY DEALER.
  • Page 2 This technical manual is designed to aid in the different procedures that may be needed for the CR45 wheelchair. This technical manual does not replace, but aids the user instruction manual, adjustment guides and instructions. The procedures shown in this technical manual should only be performed by an Assistive Technology Practitioner (ATP) or clinical professional trained to do wheelchair repairs, adjustments and retrofits.

  • Page 3: Table Of Contents

    Table of Contents Tools........................ 3 Frame Tube Size Guide................... 3 Seat Height - Configuration Charts..............4 Frame Setup by Depth Charts ................ 10 Frame Setup Charts..................12 Axle Diagram References................26 Frame Depth and CG Position References............. 27 Fork Diagram References ................28 Base Frame &...

  • Page 4: Tools

    Tools Please see the list below to identify the tools needed throughout this tech manual. Always check tools to ensure the ends are not stripped and that the tool can perform it’s function properly without damaging any parts or hardware on the chair. Tools Needed •...

  • Page 5: Seat Height - Configuration Charts

    Seat Height - Configuration Charts Select wheels and casters based on desired seat height. Make adjustment of axle sleeves, caster arms and caster stems based on the subsequent sections. Subsequent sections define these activities and provide guidance for fastener locations. Tire Type Caster Size Seat Height...
  • Page 6 Seat Height - Configuration Charts Tire Type Caster Size Seat Height Axle Position Base Frame Caster Fork Caster Stem Fork Hole Short 14.5 Short Short 15.5 Short Short Tall 17.5 Short Short 18.5 High Short High Short 17.5 High Short High Short 18.5...
  • Page 7 Seat Height - Configuration Charts Tire Type Caster Size Seat Height Axle Position Base Frame Caster Fork Caster Stem Fork Hole Short 14.5 Short 16.5 High Short Tall 16.5 High Short High Short 17.5 High Short High Short 16.5 Short Short 16"...
  • Page 8 Seat Height - Configuration Charts Tire Type Caster Size Seat Height Axle Position Base Frame Caster Fork Caster Stem Fork Hole High Short 16.5 High Short Short 16.5 Short High Short 17.5 High Short 19.5 High Tall High Tall 20.5 High Tall Short...
  • Page 9 Seat Height - Configuration Charts Tire Type Caster Size Seat Height Axle Position Base Frame Caster Fork Caster Stem Fork Hole Not Available 16.5 Tall Tall 17.5 Short Short 18.5 Short 20.5 High Tall High Short 17.5 High Short High Short 18.5 High...
  • Page 10 Seat Height - Configuration Charts Tire Type Caster Size Seat Height Axle Position Base Frame Caster Fork Caster Stem Fork Hole Not Available 17.5 High Tall High Tall 18.5 High Tall High Tall 17.5 High Short High Short 18.5 High Short High Short...

  • Page 11: Frame Setup By Depth Charts

    Frame Setup by Depth Charts Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Roller Frame Depth Frame Width CG Position Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...
  • Page 12 Frame Setup by Depth Charts Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Roller Frame Depth Frame Width CG Position Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...

  • Page 13: Frame Setup Charts

    Frame Setup Charts - Setup by Ki, Backrest Offset: -2 Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Frame Frame Roller Seat Depth CG Position Width Depth Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...
  • Page 14 Frame Setup Charts - Setup by Ki, Backrest Offset: -2 Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Frame Frame Roller Seat Depth CG Position Width Depth Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...
  • Page 15 Frame Setup Charts - Setup by Ki, Backrest Offset: -1 Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Frame Frame Roller Seat Depth CG Position Width Depth Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...
  • Page 16 Frame Setup Charts - Setup by Ki, Backrest Offset: -1 Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Frame Frame Roller Seat Depth CG Position Width Depth Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...
  • Page 17 Frame Setup Charts - Setup by Ki, Backrest Offset: 0 Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Frame Frame Roller Seat Depth CG Position Width Depth Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...
  • Page 18 Frame Setup Charts - Setup by Ki, Backrest Offset: 0 Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Frame Frame Roller Seat Depth CG Position Width Depth Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...
  • Page 19 Frame Setup Charts - Setup by Ki, Backrest Offset: +1 Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Frame Frame Roller Seat Depth CG Position Width Depth Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...
  • Page 20 Frame Setup Charts - Setup by Ki, Backrest Offset: +1 Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Frame Frame Roller Seat Depth CG Position Width Depth Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...
  • Page 21 Frame Setup Charts - Setup by Ki, Backrest Offset: +2 Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Frame Frame Roller Seat Depth CG Position Width Depth Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...
  • Page 22 Frame Setup Charts - Setup by Ki, Backrest Offset: +2 Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Frame Frame Roller Seat Depth CG Position Width Depth Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...
  • Page 23 Frame Setup Charts - Setup by Ki, Backrest Offset: +3 Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Frame Frame Roller Seat Depth CG Position Width Depth Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...
  • Page 24 Frame Setup Charts - Setup by Ki, Backrest Offset: +3 Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Frame Frame Roller Seat Depth CG Position Width Depth Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...
  • Page 25 Frame Setup Charts - Setup by Ki, Backrest Offset: +4 Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Frame Frame Roller Seat Depth CG Position Width Depth Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...
  • Page 26 Frame Setup Charts - Setup by Ki, Backrest Offset: +4 Axle Plate Position for Axle Sleeve Position (See Page 30 & 31) Frame Frame Roller Seat Depth CG Position Width Depth Position Recline *-indicates sub-optimum CG positioning +-indicates not available w/Long seat frame...

  • Page 27: Axle Diagram References

    Axle Diagram References With the correct configuration determined from the charts above, use the diagrams below to identify parts and hole locations. See the next page for actual hardware and assembly instructions after identifying parts and hole locations. Sleeve Position 1 Sleeve Position 2 Sleeve Position 3 Sleeve Position 4...

  • Page 28: Frame Depth And Cg Position References

    Frame Depth and CG Position References See below for diagrams of the Frame Depth and CG Position references. The front hole of the adapter plate defines the CG Position, as shown below, and hardware is installed/adjusted using a 5mm Allen wrench and a 10mm wrench.

  • Page 29: Fork Diagram References

    Fork Diagram References Fork Size, Fork Hole Location and Stem Height 7" & 7W Stem Height 6" Standard 3.5" 5" & 6W Tall 4.8" 4" Base Frame & Roller Plate References Align front hole of roller plate with hole to set roller position (shown in position 4, 4 3 2 1 wheel lock mount removed for clarity).

  • Page 30: Caster Construction

    Caster Construction Caster assemblies are shown below. Securing the caster wheel to the fork requires two 13mm wrenches. Securing the stem to the fork requires an 19mm wrench. Caster Assembly - Standard Stem Caster Assembly - Tall Stem Use the Use the spacers and spacers and...

  • Page 31: Caster Seat Height Matrix

    Caster Seat Height Matrix = Default Seat Height Master Matrix = Op onal 4" Caster 5" Caster Caster Base High High Fork Stem Short Short Tall Short Tall Short Tall Short Tall Short Tall Short Tall Fork Hole 1 2 2 3 4 1 2 2 3 4 2 3 4 2 3 4 3 4 5 6 3 4 5 6 2 3 4 5 2 3 4 5 2 3 4 2 3 4 3 4 5 6 3 4 5 6 2 3 4 5 2 3 4 5 Seat Ht.
  • Page 32 Caster Seat Height Matrix = Default Seat Height Master Matrix = Op onal 6" Caster Caster Base High Fork Stem Short Tall Short Tall Short Tall Short Tall Fork Hole 3 4 5 6 3 4 5 6 1 2 3 4 5 1 2 3 4 5 3 4 5 6 3 4 5 6 1 2 3 4 5 1 2 3 4 5 Seat Ht.
  • Page 33 Caster Seat Height Matrix = Default Seat Height Master Matrix = Op onal 6"x2" Wide Caster Caster Base High Fork Stem Short Tall Short Tall Short Tall Short Tall Fork Hole 1 2 3 4 1 2 3 4 1 2 3 4 5 1 2 3 4 5 1 2 3 4 1 2 3 4 1 2 3 4 5 1 2 3 4 5 Seat Ht.
  • Page 34 Caster Seat Height Matrix = Default Seat Height Master Matrix = Op onal 7" Caster 8" Caster Caster Base High High Fork Stem Short Tall Short Tall Short Tall Short Tall Short Tall Short Tall Fork Hole 4 5 6 4 5 6 1 2 3 4 5 1 2 3 4 5 4 5 6 4 5 6 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 1 2 3 4 5 Seat Ht.

  • Page 35: Chair Width

    Chair Width To adjust chair width, use two 10mm wrenches and a 5mm Allen wrench to remove the two sets of hardware on each strut tube. Reinstall hardware with new width struts. The struts correspond with the desired frame width which is available from 14" - 22". NOTE: Anything that may be on a strut tube, such as a foot tilt mount or an attendant foot lock mount, would need to be transferred to the new struts.

  • Page 36: Hand Tilt Mechanism Installation

    Hand Tilt Mechanism Installation NOTE: Remove any seating / cushion on the chair along with the seat pan for access in later steps. 1. Fully thread the cable (G) onto the housing plunger (F) until the ball end of the cable emerges from the end of the plunger (F).
  • Page 37 Hand Tilt Mechanism Installation 2. Route the cable as shown in the images below. Leave sufficient Fixed Height Fixed Height slack in cable to Height Adjustable Height Adjustable Stroller Stroller Adjustable Push Adjustable Push Recline Recline allow full range of Handle Handle motion of angle...

  • Page 38: Foot Tilt Mechanism Installation

    Foot Tilt Mechanism Installation NOTE: Remove any seating / cushion on the chair along with the seat pan for access in later steps. 1. Fully thread the cable (G) onto the housing plunger (F) until the ball end of the cable emerges from the end of the plunger (F).
  • Page 39 Foot Tilt Mechanism Installation Foot Tilt Cable Routing Route cable as shown below. The alternative mounting location of the foot pedal (left configuration) is also called out. Always test and adjust the locking and unlocking of the tilt mechanism with no user in the chair. NOTE: When the foot pedal is mounted on the left side, opposite of what is shown below, the pedal mount is flipped so the the bolts still install from the inside of the chair with the nuts installed on the outside of the chair.

  • Page 40: Transit

    Transit See the below diagram for transit bracket installation. Two 2.5mm Allen wrenches, a 4mm Allen wrench, a 5mm Allen wrench, a 10mm wrench and a 13mm wrench are needed for this assembly. NOTE: The Transit Hook decals must be installed in the correct locations shown below. NOTE: The No Transit label must be removed if transit is being installed, see image below for location of the label.

  • Page 41: Anti-Tips

    Anti-Tips 1. Anti-tip receiver is installed with two bolts and two nuts using a 5mm Allen wrench and a 10mm wrench. NOTE: The chart and diagram below are used to determine if the anti-tip receiver is installed in the up or down configuration. 2.

  • Page 42: Back Height

    Back Height Stroller Handle Backrest - Not Adjustable - Available in Fixed Height with Adjustable Handle Backrest - Not STD ( 20”) or Tall ( 24”). Adjustable - Available in STD (22”) or Tall (26”). Adjustable Height with Adjustable Handle Backrest - Reclining Back with Adjustable Handle Backrest - Not Available in STD (18-25”) and Tall (20-27”).
  • Page 43 Back Height Height Back Post Back Height Range Short Stroller Handle Back Post Tall Short Fixed Height with Adjustable Handle Tall Short Adjustable Height with Adjustable Handle Tall Short Reclining Back with Adjustable Handle Tall The Adjustable Height with Adjustable Handle backrest is adjustable using an 8mm wrench. See the diagram below.

  • Page 44: Backrest Angle Adjustment

    Backrest Angle Adjustment 1. Use a 4mm Allen wrench and a 10mm wrench to remove the button head screw and nut on the backrest. 2. Rotate backrest to desired angle. Each hole represents 5° of rotation. See diagram below for the angle for each hole.

  • Page 45: Seat Pan

    Seat Pan Front Seat Pan Rear Seat Pan Seat Pan Size Frame Depth Dimension A Mounting Holes Mounting Holes 1 & 5 1 & 5 15.0" 2 & 5 1 & 4 16.0" Short 3 & 5 1 & 3 17.0"...

  • Page 46: Center Of Gravity (Cog)

    Center of Gravity (COG) COG Fully Rearward COG Fully Forward Check your current COG by retracting levers or pressing on the foot tilt pedal and letting the chair (with user seated) settle into it’s natural resting point. Read the degree on the rotary frame (shown below). 20° is the desired resting angle position.

  • Page 47: Adjusting The Cog

    Center of Gravity (COG) If the chair COG needs adjusting use the diagrams and chart below to correct. System Resting Position Adjustment Required System Rests Between 44 and 35 2 Holes Foward System Rests Between 34 and 25 1 Hole Forward System Rests Between 24 and 16 Acceptable System Rests Between 15 and 7...

  • Page 48: Wheel Lock Configurations

    Wheel Lock Configurations FRAME SETUP Axle Position (Shown in 12) Roller Position (Shown in 4) DIM A DIM A *If Dimension A causes the short wheel lock channel to interfere with the long wheel Wheel Dimension A lock channel, position the short wheel lock channel directly behind the long short 12"...
  • Page 49 Wheel Lock Configurations Wheel Lock Mount Direction (FWD/REV) for Wheel Size Roller Axle Plate 16" Low Position Position 12" 12" Poly 16" 20" 22" 24" Poly FWD* FWD* FWD* FWD* FWD* FWD* FWD* FWD* FWD* FWD* FWD* FWD* FWD* FWD* FWD* FWD* FWD*...
  • Page 50 Wheel Lock Configurations Wheel Lock Assembly 1. Slide the head of the bolts (B) into the channel (A). 2. Install the channel onto the frame using the holes determined in the earlier charts and diagrams with two bolts (C & I) and two washers (J) which requires a 13mm wrench. 3.

  • Page 51: Attendant Foot Lock

    Attendant Foot Lock Attendant Foot Lock Reference Diagrams and Charts Wheel Size Axle Sleeve Position Wheel Lock Mount Configuration Mount Angle 12" 5 - 8 DOWN 25° 12" Poly 5 - 8 DOWN 25° 1 - 4 25° 16" 5 - 8 DOWN 25°...
  • Page 52 Attendant Foot Lock Attendant Foot Lock Reference Diagrams and Charts Axle Position (Shown in Position 12) Roller Position (Shown in Position 4) FRAME SETUP DIM A If Dim A causes the short wheel lock channel to interfere WHEEL DIM A 12”...
  • Page 53 Attendant Foot Lock Attendant Foot Lock Assembly 1. Slide the head of the bolts (I) into the channel (A). 2. Install the channel onto the frame using the holes determined in the earlier charts and diagrams with two bolts (B & J) and two washers (K) which requires a 13mm wrench. 3.
  • Page 54 Attendant Foot Lock Attendant Foot Lock Pedal Assembly 1. Install the foot lock cables (B) and spool (A) into the foot lock pedal (J) and pedal mounts (C & E) with three bolts (K & G), three spacers (I & F) and three nuts (D & H) using a 5mm Allen wrench, a 10mm wrench and a 4mm Allen wrench.
  • Page 55 Attendant Foot Lock 3. Install P-Clips for cable routing as shown below using two 10mm wrenches or a 10mm wrench and a 5mm Allen wrench (if foot mount tilt is present). Left Foot Tilt Mount Right Foot Tilt Mount P-Clips are installed on the front side of the mounts.
  • Page 56 Attendant Foot Lock 4. Route cable as shown below. The cable is attached the lock assembly by inserting the cable barrel into the hole called out below from the opposite side of the lock. The keyhole barrel nut is installed into the slot called out below.

  • Page 57: Height Adjustable T-Arm

    Height Adjustable T-Arm Installation 1. Install the arm pad onto the armrest with two screws using a Philips head screwdriver. 2. Install the T-Arm receiver onto the outside of the seat frame with the T-Arm bracket, two bolts, two washers and two nuts using a 4mm Allen wrench and a 10mm wrench. 3.

  • Page 58: Side Guard

    Side Guard 1. Install the side guard post (C) onto the side guard panel (B) with two screws (A) using a Philips head screwdriver. 2. Install the post stop (D) onto the side guard post (C) with a screw (F) using a Philips head screwdriver. 3.

  • Page 59: Handrim Configurations

    Natural Connection Aluminum Plastic Natural Flex Wheel Part Spacer Screw Superlight Projection Points Anodized Coated Fit LT Number Standard 18" Ki 200529 100206 101106 Spoke 20" Ki 200530 200536 200542 Spoke Aluminum, Plastic 22" Ki Coated, 200531 100560 100576 100569...

  • Page 60: Aa. Handrim Construction

    Handrim Construction The 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...

  • Page 61: Ab. Footplate And Heel Loops

    Footplate and Heel Loops For additional footplate information, see pages 16 - 20 for the Caster - Footplate Compatibility Charts. Strap Length Heel Loop (Reference image above) Standard Hanger Offset Hanger Composite Composite Size Part Number Strap Length Angle Angle Composite Angle Composite...

  • Page 62: Ac. Rotating 4-Way Latch

    Rotating 4-Way Latch The 4-Way latch has eight possible configurations, four with the curve of the lever facing outward and four with the curve of the lever facing inward. See diagram below. Eight Possible Configurations Standard Position Lever Facing Outward Lever Facing Inward Rotating 1.

  • Page 63: Ad. Pro Elr Adjustment

    Bearing Construction There are two sets of bearings used within the tilt function of the CR45 chair. Use two 13mm wrenches to remove and/or assemble the bearings. See diagram below for sequencing of parts. NOTE: The positioning of the roller plate is shown in the Base Frame & Roller Plate References...

  • Page 64: Af. Angle Adjustable Locking Flip Up Extendable Armrest

    Angle Adjustable Locking Flip Up Extendable Armrest 1. Set the angle of the armrest. There are five holes that can be used to set the angle. Tighten the bolt using a 10mm wrench once angle is set. 3 4 5 2.

  • Page 65: Ag. Iv Holder

    IV Holder 1. Place the two hole clamps (A) with the barrel nut (B) and screw (C) using a 5mm Allen wrench. Ensure the sides of the clamp with the flats are used on the backrest tube. Turn the screw (C) finger tight into the barrel nut (B).

  • Page 66: Ah. Pediatric Pro Elr

    Pediatric Pro ELR Installing Pediatric Pro Elevated Leg Rest Assembly 1. Remove current hangers from chair if applicable. Install latch blocks (A) if not present. 2. Install the Pediatric Pro ELR the same way as a swing away hanger. Place the swing away pivot saddle into the receiver on the front frame tube with the leg rest facing either inward or outward from the frame (B).
  • Page 67 Pediatric Pro ELR Removal (Refer to first image in Pediatric Pro ELR Section) 1. To remove leg rest, push or pull release latch. 2. Lift the leg rest straight upward to remove. You may also swing the leg rest inward or outward before lifting it off.
  • Page 68 Pediatric Pro ELR Adjusting Length of Footrest 1. Remove bolt (A), washer (B), footplate assembly (C), washer (D), saddle (E), nut (G) and ensure footrest tube insert (F) stays in tube using a 5mm Allen wrench and a 10mm wrench. 2.
  • Page 69 Pediatric Pro ELR Extension Mount Configuration Some configurations may require an extension mount to avoid interference with the footplate. Use a 5mm Allen wrench, a 4mm Allen wrench and a 10mm wrench to attach your footplate to the extension mount and the extension mount to the hanger assembly.
  • Page 70 Pediatric Pro ELR Replacing Pediatric Pro Elevated Leg Rest Parts 1. See figure below for a parts diagram of the Pediatric Pro ELR (Not all parts are sold individually, refer to parts manual for additional information at www.kimobility.com). NOTE: Parts chart located on next page.
  • Page 71 Pediatric Pro ELR Item Number Part Number Description Quantity 003853 Hanger Assy, Pro ELR, FM, R 003854 Hanger Assy, Pro ELR, FM, L 003843 Insert, Footrest Tube 003344 Calf Pad Bracket Assembly 101585 Calf Pad - Large 101470 Calf Pad Pediatric - Medium 003844 Calf Pad, 84mm X 120mm - Small 003643...

  • Page 72: Ai. Canopy

    Canopy Installation 1. Install tube mount (C), inner clamp (B), outer clamp (D), barrel nut (A), spherical washer (E) and bolt (F) onto backrest tube using a 5mm Allen wrench. Repeat on opposite side. NOTE: The clamps may need to be rotated to accomodate the chair width while remaining in the correct distance for the stems.
  • Page 73 Canopy 3. To remove just the canopy, push in the latch on both stems and lift up and out of tube mount. Push latch in to clear the tube mount.
  • Page 74 Ki Mobility 5201 Woodward Drive Stevens Point, Wisconsin 54481 715-254-0991 www.kimobility.com DCN0912.0...

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