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KLC FLEX-MATE K500 Service Manual

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TABLE OF CONTEXT
Section Title
1.0
2.0
3.0
4.0
5.0
6.0
7.0
7.1
7.2
7.2.1
7.2.2
8.0
8.0.1
8.1
8.1.1
8.1.2
8.2
8.2.1
8.2.2
8.2.3
8.2.4
8.2.5
8.2.6
8.2.7
8.3
8.3.1
8.3.2
8.3.3
8.4
8.4.1
8.4.2
8.5
8.5.1
8.5.2
8.5.3
8.6
8.6.1
8.6.2
8.7
8.7.1
8.7.2
8.8
8.8.1
P/N 1.00060 Revision A
4038 Weaver Ct. East
Columbus, OH 43026
FLEX-MATE K500
SERVICE MANUAL
WARRANTY
(614) 921-8866
(866) 532-3534
FX: (800) 329-2734
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June 7, 2025

Can’t get flexing past 60 degrees

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Summary of Contents for KLC FLEX-MATE K500

  • Page 1: Table Of Contents

    Basic Troubleshooting During Warranty Period Basic Troubleshooting Out of Warranty Period The Flex-Mate K500 Motor PCB Cable Connections Test Points and Variable Resistors Calibration Processes For The Flex-Mate K500 Knee CPM Range Limit Calibration Limits of Reversing Load 7.2.1 Calibration of older model PCBs 7.2.2...

  • Page 2: Serviceability Limitations

    Primary (input): 120VAC 60Hz 25W The FLEX-MATE K500 is a CLASS 1 device based on its type of protection against electric shock. It is a TYPE B APPIED PART device based on the degree of protection against electric shock. The degree of protection against ingress of water is ordinary.

  • Page 3: Warranty Information

    No other warranties, express or implied, are given and no affirmation of or by KLC Services, Inc., by words or action, will constitute a warranty. In no event shall KLC Services, Inc. be liable for any incidental, special or consequential damages, including...

  • Page 4: Basic Troubleshooting During Warranty Period

    Cannot change pendant settings. Refer to User’s Manual regarding locking feature. NOTE: If the above solutions do not work or for other problems not listed, call KLC Services, Inc. Any actions taken other than those listed above will void the Warranty.

  • Page 5: The Flex-Mate K500 Motor Pcb

    - If under user end and the color is reddish brown or black, inspect the rod ends. Replace if necessary. All other problems. Call KLC Services, Inc. for assistance. Section 4 The Flex-mate K500 Motor PCB Due to modifications in both the electronic hardware and software for the K500 Knee CPM, there are 2 different calibration processes.

  • Page 6: Test Points And Variable Resistors

    4 Figure 1 - Motor PBC is the earlier model PCB for the Flex-mate K500. Most CPM units with a serial number that begins with ‘1’ will have this board installed, unless it is a demo unit, or has been updated.

  • Page 7: Limits Of Reversing Load

    LIMITS OF REVERSING LOAD In order to properly calibrate the Reversing Load Limits of the Flex-mate K500 Knee CPM, and digital multi- meter should be used. It is also recommended that probe clips be utilized to ensure proper connectivity and allow easier adjusting of the calibration settings.

  • Page 8: Calibration Of Older Model Pcbs

    Sec 7.2.1 Calibration of older model Motor PCBs (fig 3) A. To set the reversing load limit bring the CPM to the -10º position, then find TP2, TP3 and R6 on the Motor PCB. B. Using a voltmeter attach the positive lead to TP2, the negative lead to TP3 and set the voltmeter for volts.

  • Page 9: Servicing And Repair Instructions

    Section 8.0 SERVICING AND REPAIR INSTRUCTIONS This section includes the instructions that are contained in the repair kits. Section 8.0.1 AVAILABLE KITTED PARTS LISTS Kit Description Kit Part Number *** indicates kit is universal in use Serial Number 1XXXX Serial Number 2XXXX Softgoods Pad Set K500 06490 Pulley Replacement Kit...

  • Page 10: Bearing Replacement Instructions

    2. Place dual pulley onto pulley shaft. The larger portion of the pulley is to be next to the motor plate. Using the retaining ring pliers, install the retaining ring onto the shaft, assuring the ring is seated into the groove on the shaft.

  • Page 11: Flange Bearing/Pulley Installation

    Sec 8.2.3 Configuration Two (Nylon Lock Nut) 9. To remove the nylon lock nut from the leadscrew, place the 7/16 open-end wrench onto the nut. Grasp the large pulley to secure the leadscrew in place and remove the nut. Place the nut aside and discard the spring washer, if any are installed.

  • Page 12: Potentiometer Replacement Instructions

    10. Grasp the large pulley with one hand and tighten the nylon nut with the 7/16” wrench. To assure that the unit will not bind during operation, allow for approximately 1/16” play. 11. Replace upper housings and push rivets. Section 8.3 POTENTIOMETER REPLACEMENT/CALIBRATION INSTRUCTIONS (For use with kit number 71190 or 76524) NOTE:...

  • Page 13: Potentiometer Calibration

    3. Thread the cable through the opening for the potentiometer. For CPM units with a serial number beginning with the number ‘1’, compress the Heyco strain relief and insert it into the opening to secure the potentiometer cable. For CPM units with a serial number that begin with the number ‘2’, insert the molded strain relief into the key-hole and turn it 90°...

  • Page 14: Lead Screw Replacement Instructions

    7. If the 0° position is verified, complete the installation process above. If 0° position cannot be verified, repeat the calibration process. Section 8.4 LEAD SCREW REPLACEMENT INSTRUCTIONS (For use with kit number 71200) Tools required; Rubber Mallet Slip Lock Pliers Diagonal Cutters Retaining Ring Pliers 1/64”...

  • Page 15: Nut Housing Replacement Instructions

    9. Wipe down nut housing, yoke area, and inside of the aluminum extrusion/rail with clean towel to remove all debris from the yoke of the calf support. Sec 8.4.2 Installation of the Leadscrew: NOTE: Note that if the pulley is black and has teeth (such as a gear) and the belt being removed also has teeth, this pulley is of the original configuration and cannot be used with the new leadscrew.

  • Page 16: Nut Housing Installation

    #0 Phillips Screwdriver 7/16” Open-End Wrench Sec 8.5.1 To remove the existing nut housing: 1. Turn unit on and start into complete flexion (120°). Using the lightweight rope or string, secure calf support to thigh support. 2. Switch unit to off and unplug the transformer from the wall. 3.

  • Page 17: Reinstalling The Leadscrew

    5. Place a small drop of serviceable lock tight onto the ends of each screw. 6. Insert the assemblies through the holes in the yoke and secure tightly to the nut housing. NOTE: Assure that the ACME nut is not locked in place by the screws. If the nut cannot move in a reasonably free motion, it may cause binding of the leadscrew or premature failure of the coating on the leadscrew.

  • Page 18: Rod End / Ball Joint Replacement Instruction

    3. Disconnect the existing membrane switch from the controller circuit board. 4. Peel membrane switch from front controller housing and discard. If necessary, use a small flathead screwdriver to lift the edge of the switch. Sec 8.6.2 To replace the membrane switch: 1.

  • Page 19: Brush Removal

    2. Remove the push rivets from the front half of the upper housing of the unit by lifting head of rivet with a small screwdriver, remove smaller cover and set aside. Be sure to place rivets where they will not be lost. 3.

  • Page 20: Optical Sensor Replacement Instructions

    SECTION 8.10 OPTICAL SENSOR REPLACEMENT INSTRUCTIONS (For use with kit number 71270) Tools required; #1 Phillips Screwdriver Small Flathead Screwdriver Sec 8.10.1 To remove the existing Optical Sensor: Switch unit to off and unplug the transformer from the wall. Remove the push rivets from the lower end of the unit (portion with labeling near power cord) by lifting head of rivet with a small screwdriver and remove cover.

  • Page 21: Motor Replacement Instructions

    12. Replace the cover and secure with push rivets SECTION 8.11 MOTOR REPLACEMENT INSTRUCTIONS (For use with kit number71280) Tools required; #0 Phillips Screwdriver #1 Phillips Screwdriver Small Flathead Screwdriver 7/64" Allen Wrench NOTE: Before the replacement of the motor assembly, view the pulleys installed into the unit. These pulleys should incorporate the use of 3 round belts connecting the pulleys.

  • Page 22: Transformer Replacement Instructions

    SECTION 8.12 TRANSFORMER REPLACEMENT INSTRUCTIONS (For use with kit number 71290 and kit number 76520) Tools required; Slip-lock Pliers Small Flathead Screwdriver Small Diagonal Cutters Adjustable Wrench NOTE: Due to modifications of the CPM housings, there are different processes for the removal and reinstallation of the transformer into the housing.

  • Page 23: Housing Replacement Instructions

    16. Connect DC plug to the PCB and secure it with the 4” cable tie. NOTE: For connecting to a newer PCB, plug the DC plug onto the jumper that was included in kit number 71290. Plug the other end of the jumper into the PCB. *For units with serial numbers beginning with’2’...

  • Page 24: Housing Installation

    8. Remove the Motor PC Board from its mountings. Set screws aside for reinstallation of board. 9. Using the small diagonal cutters, clip the wire tie that is securing the switch into the housing. 10. Disconnect the flag connectors from the power switch. With the diagonal cutters, cut the cable tie that is securing the switch to the housing and remove the switch from the housing.

  • Page 25: Electronics Removal

    Tools Required: #1 Phillips Screwdriver #2 Phillips Screwdriver Flathead Screwdriver 5/64” Allen Wrench 3/32” Allen Wrench Needle Nose Pliers Straight Edge Slip Lock Pliers Strain Relief Pliers 6” Ruler or Tape Measure Small Diagonal Cutters 8.14.1 Removal of the electronics from the Flexmate K500 1.

  • Page 26: Miscellaneous Parts List

    Optical Sensor - J5 6. Secure each of the controller and potentiometer cables into the housing with a Heyco strain relief. 7. Secure the wires into the black wire clips located on either side of the new motor PCB and snap clips closed. 8.

  • Page 27: 8.15.1 Electronic Replacement Parts List

    Retaining Compound 4.00780 Retaining RNG, External .352" GRV .025" thick 5.01270 Rivet, Plastic .200 OD 5.01460 Screw, #10 x 5/8 L S. T. 5.01430 Screw, #8-32 x .318SS 5.01420 Screw, #8-32 x 7/8 Flat Head 5.01470 Screw, Carriage 1/4"-20x1.5" SS 5.01990 Screw, Set #8-32 x .50"...

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