KLC FLEX-MATE K500 User manual

P/N 1.00060 Revision A
1
4038 Weaver Ct. East [phone]
Columbus, OH 43026 [phone]
FX: [phone]
FLEX-MATE K500
SERVICE MANUAL
WARRANTY
TABLE OF CONTEXT
Section Title Page
Serviceability Limitations 2
WarrantyInformation 3
1.0 Routine Maintenance Schedule 3
2.0 Basic Troubleshooting During Warranty Period 4
3.0 Basic Troubleshooting Out of Warranty Period 4
4.0 The Flex-Mate K500 Motor PCB 5
5.0 Cable Connections 5
6.0 Test Points and Variable Resistors 6
7.0 Calibration Processes For The Flex-Mate K500 Knee CPM 6
7.1 Range Limit Calibration
7.2 Limits of Reversing Load
7.2.1 Calibration of older model PCBs 8
7.2.2 Calibration of current model PCBs 8
8.0 Servicing and Repair Instructions 8
8.0.1 Available Kitted Parts List 8
8.1 Pulley Replacement Instructions
8.1.1 Pulley / Belt Removal 9
8.1.2 Pulley / Belt Installation 9
8.2 Bearing Replacement Instructions
8.2.1 Bearing Removal 10
8.2.2 Cotter Pin Removal 10
8.2.3 Nylon Lock Nut Removal 10
8.2.4 Flange Bearing / Pulley Installation 11
8.2.5 Flange Bearing / Thrust Bearing Installation 11
8.2.6 Cotter Pin Installation 11
8.2.7 Nylon Lock Nut Installation 11
8.3 Potentiometer Replacement Instructions
8.3.1 Potentiometer Removal 11
8.3.2 Potentiometer Installation 12
8.3.3 Potentiometer Calibration 13
8.4 Lead screw Replacement Instructions
8.4.1 Leadscrew Removal 14
8.4.2 Leadscrew Installation 14
8.5 Nut Housing Replacement Instructions
8.5.1 Nut Housing Removal 15
8.5.2 Nut Housing Installation 16
8.5.3 Reinstalling the Leadscrew 17
8.6 Membrane Switch Replacement Instructions
8.6.1 Membrane Switch Removal 17
8.6.2 Membrane Switch Installation 17
8.7 Rod End / Ball Joint Replacement Instruction
8.7.1 Rod End Removal 18
8.7.2 Rod End Installation 18
8.8 Brush / Rod Replacement Instructions
8.8.1 Weather Stripping Removal 18

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8.8.2 Brush Removal 19
8.8.3 Brush Installation 19
8.9 Handle Replacement Instructions
8.9.1 Handle Removal 19
8.9.2 Handle Installation 19
8.10 Optical Sensor Replacement Instructions
8.10.1 Sensor Removal 19
8.10.2 Sensor Installation 20
8.11 Motor Replacement Instructions
8.11.1 Motor Removal 21
8.11.2 Motor Installation 21
8.12 Transformer Replacement Instructions
8.12.1 Transformer Removal 22
8.12.2. Transformer Installation 22
8.13 Housing Replacement Instructions
8.13.1 Housing Removal 23
8.13.2 Housing Installation 24
8.14 Electronics Upgrade / Replacement Instructions
8.14.1 Electronics Removal 25
8.14.2 Electronics Upgrade Installation 25
8.15 Miscellaneous Parts List 26
8.15.1 Electronic Replacement Parts List 27
SERVICEABILITY LIMITATIONS
06500 Flexmate K500 (domestic) 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. It primary mode of use is continuous.
FLEX-MATE K500 can be transported and stored in an environment of – 40°F to 158°F (–40°C to 70°C), with a
relative humidity between 10% and 100% non-condensing. The FLEX-MATE K500 can operate between 50°F to
95°F (10°C to 35°C) under the same humidity levels, and 700 hPa to 1060 hPa atmospheric pressure.
Any service requirements beyond the scope of this service manual are to be performed by the factory or an
authorized service/repair representative.
Units returned to the factory for repair are not to be modified. Such modification include, but are not limited to, (a)
modifications that restrict the accessibility to critical components, (b) modifications that bypass any safety features
originally designed into the Flex-Mate K500 Knee CPM unit, (c) or modifications that may cause further damage
to the Flex-Mate K500 Knee CPM unit or the end user.
Replacement of any modified components will be made at the customer’s expense.

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SECTION 1
ROUTINE MAINTENANCE SCHEDULE
NOTE: The bearings that are located at each end of the leadscrew are sealed and do not require oiling
Before each use –
To be performed by
user or service
personnel
Every Month –
To be performed by user
or service personnel
Every 3 Months –
To be performed by authorized service
personnel
Inspections General condition General condition Frayed power cord
Housing integrity
Check belt wear
Grease
Lubrication
Grease1the outside edges of Thrust
Bearing at lower end of Drive Screw.
Use a white lithium based grease
Oil Lubrication
NOTE: Never
lubricate any
belts or pulleys
with oil.
Apply 3 drops of oil2to
the oiling felt located in
the nut housing.
Apply 3 drops of oil2to
the oiling felt located in
the nut housing.
The oiling felt of the nut housing is to be
inspected and replaced if necessary.
Using oil2add a drop to the Knee Joints,
Rod Ends, ‘S’ Brackets and Clevis
connections.
Cleaning Clean housing & leg
carriage with a mild
soap solution and dry
thoroughly.
Wipe the belt(s) & both
pulleys with alcohol and
allowed to dry thoroughly
before installing belts.
Wipe pulleys with alcohol and replace
belt if required.
1. Christo-Lube grease from Lubrication Technology, Inc., 310 Morton Street, Jackson, Ohio 45640, (740)
286-2644.
2. 3-in-1 Oil or equivalent sewing machine oil.
FLEX-MATE K500 WARRANTY
KLC Services, Inc. warrants the Flex-Mate K500 to be free from defects in materials and workmanship
under normal and proper use under the direct supervision of a licensed health care practitioner during
the warranty period of one year, commencing from the date of purchase. Date of Purchase will be the
date your payment is processed by our Bank and funds are received by KLC Services, Inc. This warranty
extends only to the original purchaser and is not transferable to anyone who subsequently purchases,
leases or otherwise obtains the K500 from the original purchaser. This Warranty is void if within the
warranty period, the K500 has been serviced, parts removed, tampered with or replaced or any other
actions taken beyond the scope of Routine Maintenance and Basic Troubleshooting as specified in the
service manual by any party other than KLC Services, Inc.
In the event the K500 exhibits a defect in material or workmanship during the warranty period, KLC
Services, Inc. will at no additional charge repair or replace defective parts or the entire unit at KLC
Service’s option.
Except for the warranties and conditions set forth herein, KLC Services, Inc. disclaims all other
warranties, express or implied, or statutory, including but not limited to the implied warranties of
merchantability or fitness for a particular purpose. Any implied warranties that may be imposed by
applicable law are limited to the terms of this limited warranty. 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
but not limited to loss of business, revenue, profits, data or use, whether in an action in contract or tort or
based on a warranty arising out of or in connection with the use or performance of the K500 or any
software supplied by KLC Services, Inc. that accompanies the K500, even if KLC Services, Inc. has been
advised of the possibility of such damages. Purchaser understands, acknowledges and agrees that repair
or replacement, as applicable, under the warranty services described herein are your sole and exclusive
remedies with respect to any breach of the warranty set forth herein.

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SECTION 2
BASIC TROUBLESHOOTING DURING WARRANTY PERIOD
No pendant display. Check that the wall outlet has power.
Check power switch-on.
Pendant displays “Err”. Turn power off, wait 5 seconds, and turn power back on.
Pendant adjustments inoperative, but
display is on.
Check all connections at the P.C. Board.
Unit will not start, or it starts then stops. Check pendant settings.
Check belts.
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.
SECTION 3
TROUBLESHOOTING OUT OF WARRANTY PERIOD
No pendant display. Check that the wall outlet has power.
Check power switch-on.
Use a multi-meter to check voltage before and after switch:
- If no voltage before switch, replace transformer. (See voltage chart Pg27)
- If voltage before but not after switch, replace switch.
- If voltage after switch, check all P.C. Board and pendant connections.
- If still no display, replace pendant.
- If still no display, replace P.C. Board. (Note: If this solves the problem, test the
original pendant; it may be okay.)
Pendant
adjustments
inoperative, but
display is on.
Check to see if the settings are locked.
- If locked, a dot will appear in the lower right hand corner of the display. To
remove lock, press both the ‘UP’ and ‘DOWN’ arrows at the same time.
Check all connections at the P.C. Board.
Replace pendant.
- If still no display, replace P.C. Board. (Note: If this solves the problem, test the
original pendant; it may be okay.)
Unit will not start, or
it starts then stops.
Check pendant settings. Ensure settings are greater than 10°apart.
Check belts. Ensure that no oil has gotten onto the belts.
- If oil is present, remove all belts and wipe the clean both the belts and
pulleys with alcohol to remove oil. Allow the components to dry thoroughly
before installing belts.
Remove the belts and turn each of the pulleys by hand.
- If any of the pulleys do not turn freely, this could be the cause of the issue.
- If the Large Pulley does not turn freely, inspect the thigh adjustment knobs for
alignment, the condition of the leadscrew and nut, and the amount of slack/play in the
driveline. Also inspect the tightness of the screw at the knee joint.
- If the Dual Pulley/Transfer Pulley does not turn freely, replace pulley.
- If the motor pulley does not turn freely, replace motor.
Remove the Motor Connector from J3 on the Motor PCB. Using a knife blade carefully push
the red and black wires deeper into the connector. Reattach connector and turn on power.
Use a multi-meter to test voltage at motor after pressing the Start/Stop button. (See voltage
chart Pg27)
- If there is voltage to the motor, but the motor is not running, replace motor.
- If there is no voltage to the motor, replace P.C. Board.
- If still no voltage to the motor, replace the pendant. (Note: If this solves the
problem, test the original P.C. Board, it may be okay.)
Cannot change
pendant settings.
Check to see if settings are locked. If locked, a dot will appear in the lower right hand corner of
the display. To remove lock, press both the ‘UP’ and ‘DOWN’ arrows at the same time.
- If unlocking does not work, replace pendant.
- If this still does not work, replace the P.C. Board (Note: If this solves the
problem, test the original pendant; it may be okay.)
Angle does not
appear to read
correctly on
pendant.
Start unit. Set extension limit to 0°. Stop unit when 0°is displayed on the pendant. Visually
check to see that the Leg Carriage is perfectly straight.
- If the carriage is not aligned properly, calibrate the range of motion as
dictated in Section 7.1 of this manual.
Loud grinding
screeching sounds
present when in
Inspect the position of the encoder wheel within the optical sensor.
- If it is contacting the sensor, reposition the encoder wheel.
Inspect the area just below the rear of the motor for debris.

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motion / with or
without load
- If a black powder is evident, replace motor.
Inspect the inside of the extrusion/rail for contact between the wheel screw and sidewall.
- If contact has been made. Remove upper carriage assembly as dictated in
Section 8.5 - Nut Housing Replacement Instructions and ensure the proper
assembly.
Inspect the condition of the leadscrew.
- If the operational portion of the leadscrew appears dry, apply oil to the oiler felt and
leadscrew.
- If the operational surface of the leadscrew appears to be dry but shiny, the
Teflon coating has been worn off. It is recommended that the leadscrew is
replaced at this time.
Powdery substance
developing under
unit
Determine area of development.
- If under the foot end of the unit and the color is whitish, inspect the motor,
pulleys, and belts for excessive wear. Replace if necessary.
- 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. Determination of the Motor PCB will be required to employ the correct calibration process.
The earlier model boards (fig 3) calibration process requires adjustment to R5 for Range Limit and R6 for Load
Limit. The load limit on the earlier is bi-directional which means one setting of both flexion and extension.
Calibration adjustments for the current model board (fig 4) includes R5 for the Range limit, as with the earlier
model, but splits the Load Limit settings for the Flexion (R1) and the Extension (R6).
It is recommended that if either an earlier model Motor PCB (fig3) is being replaced in the CPM unit, the controller
board/chip be replaced at the same time.
Section 5 Cable Connections
fig 1 fig 2
J2 Power Connector
J5
J3
J1
J4 J5
J1
J4
J3

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Section 6 Test Points and Variable Resistors
fig 3 fig 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.
Figure 2 – Motor PCB is the ‘newer’ UL60601 approved board. This board will be in use with all K500 CPM units
that have a serial number beginning with ‘2’, unless it is a demo unit, or has been updated during routine
maintenance.
Identification of the boards may be achieved in a number of ways. Easiest means is to identify the (J2) ‘power
connector’ (see fig 1 and fig 2). The earlier motor board will have a ‘black’ DC plug (fig 1), while the UL60601
version will have a white connector (fig 2). The second means of identification is to scan the board for the number
of variable resistors mounted to the board. On the Fig 3 PCB, there are 2 variable resistors (R5, R6). On the Fig
4,UL PCB, there are 3 (R1, R6, R5).
Section 7 CALIBRATION PROCESSES FOR THE
FLEX-MATE K500 KNEE CPM
Sec 7.1
RANGE LIMIT CALIBRATION
For the calibration Range Limit, the CPM unit is to be plugged in and turned on. The thigh support of the carriage
must also be set at its lowest setting (below 35 on the scale). This process is for either the older or current model
boards.
During the process of repairing and reinstallation of a potentiometer, calibration will be required.
If, in the case of a broken wire to the potentiometer, the display will give a false reading to what the
physical angle of the carriage actually is. This reading will normally be evident with a display reading of
less than –10. To repair and recalibrate the potentiometer, follow this process.
Remove the 3 Goniometer cover screws and cover.
Check the rear of the Goniometer for any broken wires. If there are multiple wire disconnected from the
potentiometer, re-solder the wire to the posts indicated in the Fig 5
R5
R6R1
R6
R5
TP2
TP3
TP2
TP3

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On the joint coupling, remove the first setscrew and tighten the second one, then replace the first setscrew. This
will insure the coupling is tight to the shaft.
Using the control pendant, move the leg carriage until the thigh and calf support bars on either side of the hinges
align in a straight line. This can be checked visually or with a straight edge.
Loosen the 2 screws, using a 3/32” Allen wrench that hold the Goniometer in position. Rotate the Goniometer
until the control pendant displays reads 0º. Tighten the 2 screws.
Start the CPM in flexion and stop it when the rear of the calf support nut yoke is 1-1/4" + 1/8” from the rear end of
the extrusion (figure 7).
Check the control pendant display, if it does not read 120º then adjust R5 on the Motor PCB with a small
screwdriver until it does.
Make sure all screws and set screws are tight and replace the Goniometer cover.
Check -10º again, if it does not read -10º change the Motor PCB.
Sec 7.2 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. Below are 2 examples of the clips that can be used.
End of
extrusion
Yoke
Rear of yoke is
1 ¼ + 1/8” from
end of extrusion
BLACKRED
Fig
5
F
ig.
7
NOTE: Should the wires of the potentiometer break and require to
be soldered onto the post, assure that the wires are attached to the
proper post of the potentiometer. See figures 5 and 6
WIRING DIAGRAM
DEFINITION
On the side of the Potentiometer is a
wiring diagram. When viewing the
components as indicated in the Fig 6
photo, the numbers of the diagram will
be aligned with the proper post. The
number/wire combinations are;
Post 1 – White
Post 2 – Black
Post 3 – Red
Fig
6
WHITE

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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.
C. With CPM power ON, the meter should read about .450 volts (450 mV).
D. The CPM should be able to lift about 40 pounds before the load reverse limit is
activated. If it fails to lift the weight, adjust R6 counter-clockwise to increase the voltage and
the weight is not activating the load reverse limit.
WARNING!!!! Under no circumstances should the R6 voltage setting exceed the maximum of .450
volts at the -10º position. Exceeding the .450v rating may damage the motor and
motor driver over time.
Sec 7.2.2 Calibration of Current model Motor PCBs (fig 4)
A. Set the Extension Limit at -10°position and Flexion Limit at 120°positions on the controller.
B. Locate TP2, TP3, R1, and R6 on the Motor PCB.
C. Attach the positive lead of a Voltmeter to TP2 and the negative lead to TP3.
D. Press the Start/Stop key on the keypad to start the motor.
E. Stop the unit by pressing the Start/Stop key when the unit is extending and -8°has been reached.
Adjust R6 so that the voltage on the Voltmeter reads 0.125±0.002 Volt. Turn the trim pot counter-
clockwise to increase the voltage, clockwise to decrease the voltage.
F. Press Start/Stop button again to turn on the motor. The unit will start flexing. Stop the motor and start
again. The unit will start extending and when it reaches -10°it will reverse and begin flexing. When the
unit is flexing and -8°appears on the keypad, stop the motor. Adjust R1 so that the Voltmeter shows a
reading of 0.425±0.002 Volt. As with the R1 adjustment, turn the trim pot counter-clockwise to increase
the voltage, clockwise to decrease the voltage.
G. With these adjustments, CPM must cycle without reversal when loaded with a 40 pound weight.
H. Do not re-adjust these limits if reversal occurs. Be sure the unit is properly aligned since misalignment
would cause excessive surge currents during start- ups and result in motor reversal. Also, make sure
the track is properly oiled. Excessive friction may also cause motor reversal.

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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 71160 ***
Bearing Replacement Kit 71170 ***
Potentiometer Replacement Kit 71190 76524
Lead Screw Replacement Kit 71200 ***
Nut Housing Replacement Kit 71205 ***
Membrane Switch Replacement 71220 ***
Rod End Replacement Kit 71230 ***
Brush / Rod Replacement Kit 71240 ***
Handle Replacement Kit 71250 ***
Optical Sensor Replacement Kit 71270 ***
Motor Assembly Replacement Kit 71280 ***
Transformer Replacement Kit 71290 76520
Controller Replacement Kit 71300 76522
Power Switch Replacement Kit 71310 ***
Footplate Assembly Replacement Kit 71330 ***
Housing Replacement Kit 71480 76521
Electronics Upgrade Package 73616 not required
SECTION 8.1 PULLEY REPLACEMENT INSTRUCTIONS
(FOR USE WITH KIT NUMBER 71160)
Tools required;
Small Flathead Screwdriver Retaining Ring Pliers 3/32” Allen Wrench
Sec 8.1.1 To remove the pulleys and belts:
1. Switch unit to off and unplug the transformer from the wall.
2. 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. Be sure to place rivets where they will not be lost.
3. Remove belts from the large pulley and discard.
4. To remove the large pulley, loosen the set screw(s) with a 3/32” Allen Wrench and remove pulley from lead
screw shaft, Discard pulley and setscrew(s).
5. Remove spring washer and discard.
6. Remove the 3 belts from the Dual Pulley and discard.
7. To remove dual pulley, first remove the retaining ring from the pulley shaft with retaining ring pliers. Discard
pulley.
8. Remove nylon washer and wave washers (2) and discard
9. Wipe away any excess residue that may have accumulated on both shafts.
Sec 8.1.2 To install the new pulleys and belts:
1. Place small spring washer onto pulley shaft.

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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.
3. Install the three smaller diameter belts to the motor pulley and the larger portion of the dual pulley.
4. Place nylon washer and wave washers (2) onto lead screw shaft.
5. Install the large pulley onto the lead screw shaft. When installing, assure that the set screw is aligned with the
1/8” diameter hole on the shaft. The pulley should be flush with the end of the shaft.
6. Install the Full-dog setscrew into the pulley and tighten, assure that the ‘Full-dog point’ is properly seated into
the hole on the shaft. Install the ¼” setscrew into the pulley and tighten.
7. Install the three larger diameter belts to the large pulley and the smaller portion of the dual pulley.
8. Replace housing onto unit and secure with push rivets.
Note: This pulley/belt system is to be used with units that have a ‘grooved’ pulley on the motor assembly. If the system being repaired has
a non-grooved pulley, then an upgraded motor assembly kit (BREG P/N – 71280) will need to be installed.
Section 8.2 BEARING REPLACEMENT INSTRUCTIONS
(For use with kit number 71170)
Tools required;
Rubber Mallet Slip Lock Pliers ¼” Drive Pin Punch
Diagonal Cutters Retaining Ring Pliers 3/32” Allen Wrench
Small Flathead Screwdriver 7/16” Open End Wrench
Note: Due to upgrades in the system that allow for better adjustment of the leadscrew, there are two (2) leadscrew configurations. To
determine which configuration is installed into the unit being repaired, examine the fastening system for the thrust bearing. This is
the end of the leadscrew opposite the pulley and belts. Configuration One will have a collar and cotter pin attachment* and
Configuration Two will incorporate a ¼-28 nylon lock nut. The removal and installation instructions for both are detailed below.
(* obsolete component no longer offered in repair kits)
Sec 8.2.1 To remove the bearings:
1. Switch unit to off and unplug the transformer from the wall.
2. Remove the push rivets from 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. Remove belts from the large pulley and set aside.
4. Remove the large pulley loosening the set screw with a 3/32” Allen Wrench, also remove spring washer and
set them aside. (Perform steps 4 & 5 at this time, only if the Configuration One attachment (cotter pin/collar) is
in use. Otherwise, leave this pulley/flange bearing on the leadscrew to assist in the removal of the nylon lock
nut defined is Step 9.
5. Separate extrusion weather stripping / brushes with fingers and place drive punch against flanged bushing.
Gently tap with rubber mallet until bearing is free from the motor plate. Remove old bearing from lead screw
and discard.
6. To remove the thrust bearing, move the upper housing to reduce interference while working.
Sec 8.2.2 Configuration One (Cotter Pin / Collar Removal)
7. To remove the cotter pin from the leadscrew, rotate lead screw shaft to expose the tail ends of cotter pin and
bend ends with the pliers until straightened. Rotate shaft to expose the opposite end of the pin and pull it out
of the collar. Set aside for later installation.
8. Remove the collar and set it aside for later installation. Remove the thrust bearing, and thrust bushing and
discard.