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L4D/L4KD CPM
Service and Technical Manual

CUSTOMER CONTACT: QAL Medical, LLC (A division of Quality Assembly and Logistics, LLC) 3000 Woleske Road Marinette, Wisconsin 54143 USA 1-888-430-1625; 1-715-735-4727 E-mail: info@QALMedical.com

©2012 QAL Medical, LLC • Printed in the USA • 05070849c • 5/2012

L4D/L4KD Lower Limb CPM Service and Technical Manual

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For Technical Support: 1-888-430-1625; 1-715-735-4727

L4/L4KD Lower Limb CPM Service and Technical Manual

TABLE OF CONTENTS
Specifications and Symbols
Specifications and Operating Limits……………………………………………………………………. Symbols………………………………………………………………………………………………….... General Overview……………………………………………………………………………………….. 1.1 Introduction…………………………………………………………………………………………… 1.2 Power Supply & Power-on Indicator Lights……………………………………………………….. 1.3 Manual Fast Forward/Reverse Controls…………………………………………………………… 1.4 Angle Controls………………………………………………………………………………………... 1.5 Potentiometers (Pot)…………………………………………………………………………………. 1.6 Safety Features………………………………………………………………………………………. 1.6.1 Reverse-on-Load…………………………………………………………………………. 1.6.2 Service Indicator Light & Audible Alarm……………………………………………….. 1.7 L4D Major Components Overview…………………………………………………………………. 1.8 L4KD Major Components Overview……………………………………………………………….. L4D/L4KD Routine Service Guide……………………………………………………………………. 2.1 Mechanical……………………………………………………………………………………………. 2.1.1 Sliders……………………………………………………………………………………... 2.1.2 Wheel bearings…………………………………………………………………………… 2.1.3 Drive chains………………………………………………………………………………. 2.1.4 Drive belt………………………………………………………………………………….. 2.2 Electrical………………………………………………………………………………………………. 2.2.1 Cables……………………………………………………………………………………... 2.2.2 Calibration………………………………………………………………………………… 2.2.3 Connections………………………………………………………………………………. 2.2.4 Digital Motion Controller…………………………………………………………………. Drive Unit…………………………………………………………………………………………………. 3.1 Introduction…………………………………………………………………………………………… 3.2 L4D Drive Unit Assembly……………………………………………………………………………. 3.3 L4KD Drive Unit Assembly………………………………………………………………………….. 3.4 Removing the Drive Unit…………………………………………………………………………….. 3.4.1 Disassembling the Calf Sliders…………………………………………………………. 3.4.2 Reassembling the Calf Sliders………………………………………………………….. 3.5 Calf Slider Assemblies………………………………………………………………………………. 3.6 Lever Adjustment & Replacement…………………………………………………………………. 3.6.1 Lever Removal……………………………………………………………………………. 3.6.2 Lever Replacement………………………………………………………………………. 3.7 Actuator Control Panel & Drive Cover Panel Replacement……………………………………... 3.8 Drive Belt & Pulley Replacement…………………………………………………………………… 3.9 Chain Tightening Procedure………………………………………………………………………... 3.10 Final Drive Disc Removal………………………………………………………………………….. 3.11 Potentiometer (Pot) Replacement………………………………………………………………… 3.12 #15 Chain Replacement…………………………………………………………………………… 3.13 Sprocket Assembly & #10 Chain Replacement…………………………………………………. 5 6 7 7 7 7 8 8 8 8 8 9 10 11 11 11 11 11 11 11 11 11 11 11 12 12 13 14 17 17 18 19 20 20 20 21 22 23 24 25 26 27

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For Technical Support: 1-888-430-1625; 1-715-735-4727

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L4D/L4KD Lower Limb CPM Service and Technical Manual

3.14 Drive Shaft Replacement………………………………………..………………………………… 3.15 Motor Replacement………………………………………………………………………………… 3.16 Trail Replacement………………………………………………………………………………….. 3.16.1 Removal of Calf T Rails:……………………………………………………………….. 3.16.2 Removal of Thigh T Rails:……………………………………………………………... 3.17 Drive Alignment……………………………………………………………………………………... 3.17.1 Checking Drive Alignment:…………………………………………………………….. 3.17.2 New Drive Shaft Alignment Procedure:………………………………………………. 3.17.3 Re-Alignment Procedure………………………………………………………………. 4 L4D Base Disassembly………………………………………………………………………………… 4.1 Introduction…………………………………………………………………………………………… 4.2 L4D Base Overview………………………………………………………………………………….. 4.3 Track Replacement………………………………………………………………………………….. 4.4 Roller Bearing Replacement………………………………………………………………………... 4.5 Ankle Clutch Linkage...
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