Kegel IKON Lane Machine Operation Manual
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Kegel IKON Lane Machine Operation Manual

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Do you have a question about the IKON Lane Machine and is the answer not in the manual?

Questions and answers

louis
January 24, 2025

i'm having problems with the ikon lane machine stopping under pin deck not coming back to foul line. sometime ikon come back most of the time it stops under pindeck

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1 comments:
Mr. Anderson
May 14, 2025

The Kegel Ikon Lane Machine may stop under the pin deck instead of returning to the foul line if it is not in “clean and oil mode” during operation. This mode is required for the correct sequence of events, including the machine returning after reaching the end of the lane.

This answer is automatically generated

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Gary gilbert
May 31, 2025

Need the master code

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Summary of Contents for Kegel IKON Lane Machine

  • Page 1 IKON Lane Machines...
  • Page 2 KEGEL LLC 1951 Longleaf Blvd. Lake Wales, FL 33859 863-734-0200 I 800-280-2695...
  • Page 4 Lane Machine Manual 2017 IKON Specifications 17-5900 – 115v 17-5950 – 230v (24VDC) Class I - Single Phase 115 Volts, 50/60 Hz, 7 Amps 230 Volts, 50/60 Hz, 3.5 Amps Machine Dimensions Width – 59.5" (139.7 cm) Height – 16.5" (40.64 cm) Length - 44"...
  • Page 6 KEGEL reserves the right to inspect and make the final decision on any claim under Warranty which it deems questionable. KEGEL's liability under the Warranty expressed above is limited to repair or replacement; KEGEL shall have no liability for any and all incidental or consequential damages or costs.
  • Page 7 If sufficient documentation cannot be provided, the customer shall be responsible for the cost of the replaced components. This Warranty program will follow the same guideline as our standard Warranty that accompanies the purchase of a KEGEL lane machine.
  • Page 8 Make sure to bend at the knees and use a back support or mechanical lift if needed. Kegel does sell an optional piece of equipment that can assist the operator when lifting and lowering the machine. It can be mounted next to the end pairs of lanes to significantly reduce the transitional weight of the machine.

  • Page 9: Table Of Contents

    TABLE OF CONTENTS PREFACE ....................1 CHAPTER 1 ................... 5 & S ..............................5 NSTALLATION ETUP Machine Inspection ..............................5 Register your Lane Machine ........................... 5 Machine Installation Procedures for the Distributor ................6 Daily Setup and Operation ..........................8 Moving &...
  • Page 10 Duster Settings ............................... 39 CHAPTER 4 ..................41 ........................41 ATTERY OWER AND HARGING YSTEMS Chargers ................................... 41 Constant Voltage Regulator – CVR ..........................41 E-Stop ..................................42 Batteries ..................................42 CHAPTER 5 ..................44 ..........................44 OMPUTER AND ONTROL ELAYS Programmable Logic Controller .........................
  • Page 11 CHAPTER 8 ..................76 ............................76 REVENTIVE AINTENANCE Lid and Guard Removal ..........................76 Daily, Monthly and Annual Cleaning ...................... 79 Cleaning Guidelines ................................79 Conditioning System ............................81 Cleaning System ..............................83 Cushion Roller Assembly ..............................83 Changing Duster Cloth ..............................83 Filling the Cleaner supply Tank .............................
  • Page 12 Terminal Block Wiring Layout ........................134 Power Contactor and Relay Wiring Layout ..................135 Voltage Regulator Wiring Layout ......................136 Oil Pump Motor Wiring Layout ........................137 L-R & R-L Proximity Sensor Wiring Layout ..................... 138 Oil Valve Wiring Layout ..........................139 Buffer Motor Wiring Layout..........................

  • Page 14: Preface

     In addition to this manual, Kegel has developed an On-line Support Interface called KOSI. This software is provided free with the machine. KOSI allows the operator to access additional functions that are otherwise not available to the operator through the keypad.
  • Page 15 Kegel. The information contained herein is designated only for use with the Kegel IKON Lane Machines. Kegel is not responsible for any use of this information as applied to other lane machines.
  • Page 16 Kegel Training Center – Located on-site, we custom built this 12-lane bowling center for serious bowlers to train to be the best. Kegel is proud to host educational clinics in various forms for bowlers, coaches and pro shop operators. The first of its kind, the Kegel Training Center boasts several original concepts including C.A.T.S.

  • Page 18: Chapter 1

    Machine Serial Number: Battery Serial Number:____________________________ Register your Lane Machine It is important to register your new IKON with Kegel in order to receive valuable updates, service bulletins and your Limited Warranty. Fill out the card or go on- line.

  • Page 19: Machine Installation Procedures For The Distributor

    Machine Installation Procedures for the Distributor Please be aware that the screen shots are for illustration purpose only and the settings within may or may not be the exact factory setting. Please read the description to fully understand what the setting should be for your particular lane machine. 1.
  • Page 20 14. Explain how the duster functions during the application. 15. Stop and take a break…let some of the information sink in and consider getting something to drink. Reassure them that Kegel provides many resources with this information. 16. Point out the KOSI software located on the USB storage key that was provided for their PC.

  • Page 21: Daily Setup And Operation

    Daily Setup and Operation Moving & Transporting your Lane Machine Be careful when moving the machine. Ramps that are used for moving the machine to and from the approach should also be “machine friendly”. These ramps should be no less than 12 feet long with no bump on either end of the transition.
  • Page 22 TECHNICAL NOTE If the lanes are going to be cleaned, make sure the Cleaner Supply Tank is filled, the Recovery Tank is empty, and an adequate supply of Lane Cleaning Cloth is installed before beginning operation. Always empty the recovery tank when filling the supply tank or standing the machine to transport position.
  • Page 23 7. As the machine travels forward down the lane the moving heads will continue to operate applying oil and cleaner. The board counting proximity sensor monitors the motion of the moving heads. If the motion is interrupted, a MOVING HEAD TRAVEL error will be displayed. 8.

  • Page 24: Basic Steps To Operate Your Ikon

    17. The brush will begin buffing at the pre-determined distance as the IKON travels in reverse. The oil head will start back up again when it reaches the first reverse load distance. 18. As the machine continues to travel in reverse it will be down-shifting to lower speeds.

  • Page 25: Keypad And Menus

    This will help prevent the first lane and pair from being different (drier) than the rest. This is critical for league and tournament play conditions. Kegel has recommended this procedure to be done with every machine we have produced.
  • Page 26 By pressing MACHINE SETTINGS, you will arrive at the screen to adjust your buffer brush functions. ADVANCE BUFFER DROP is used to fine tune where the buffer brush starts to lower in reverse on the way back to apply the reverse oil. Ideally, if the ‘buffer brush start in reverse location’...

  • Page 27: Day Planner

    7 Day Planner This feature allows the machine to store specific conditioning programs to be used for each day of the week, within each time period of the day. The "real time" clock in the machine's PLC keeps track of the time of day and will run the program selected for that specific time period.

  • Page 28: Operator Menu Selections

    LIST OF MACHINE ERRORS FORWARD TRAVEL CLEANER EMPTY REVERSE TRAVEL OIL EMPTY OIL HEAD TRAVEL ERROR DUSTER NOT RESET DUSTER WIND-UP DUSTER UNWIND BRUSH UP SQUEEGEE UP BRUSH DOWN SQUEEGEE DOWN Below is an ‘example’ of how an error messages will appear. Troubleshooting methods for this error along will all of the above errors, will be explained in Chapter 7 of this manual.

  • Page 29: Maintenance, Recharging & Storage

    Recharging To recharge your IKON Lane machine, simply plug the cord from the charger into the receptacle on the bottom side of the machine. Always put the machine on charge when not in use. The charging voltage should be monitored each day when the machine is ready for charging.

  • Page 30: Things You Can Do With No Cord Attached

    Things You Can Do with No Cord Attached! Now that there is no cord to manage you have the freedom to do many things you couldn’t do with previous lane machines. In the past, you had to hold the cord whenever operating the lane machine.

  • Page 31: Lane Maintenance 101

    Lane Maintenance 101 Overview Bowling lane maintenance is more than just pushing a button on a lane machine and applying oil to the surface. It also requires giving attention to the approaches, gutters and capping which all get dusty. Maintaining all of this area on a daily schedule is important to provide the best service to your customers.

  • Page 33: Chapter 2

    CHAPTER Conditioning Overview How Conditioner is Metered and Controlled The patented Sanction Technology™ is the ONLY measurable method capable of applying precise amounts of lane conditioner. An explanation of how this is accomplished will help you understand the ‘art’ of oil pattern application. When conditioning a lane, the oil head travels back and forth applying streams of conditioner onto the Transfer Brush.

  • Page 34: Program Volume Test

    The size of the stream can be set to an exact amount, or volume. We achieve this exact stream and volume by using a ‘highly’ accurate fluid metering pump. This pump, running at a constant speed, gives absolute positive displacement of the conditioner.
  • Page 35 To change the program # to test, press the top line and a numbered Keypad will be displayed. Simply change the number in the keypad that will pop up and tap on OK. After the correct program has been selected, press on the line directly below that says ‘Start Oil Volume Test’.

  • Page 36: Oil Calibration Test

    Oil Calibration Test Program number 16 is a hidden program that is intentionally set for 400 boards, to be used to calibrate the oil pump. To perform an Oil Calibration test, you must first ‘Purge’ the line by removing the oil tip assembly from the oil head and place inside a disposable cup, such a Styrofoam coffe cup.
  • Page 37 PATTERN STRUCTURE 2 - 2 x 1 (Forward Loads) 10 - 10 x 3 13 - 13 x 3 Zero Loads are ignored going forward and reverse. 14 - 14 x 2 (Reverse Loads) 13 - 13 x 4 12 - 12 x 4 11 - 11 x 2 2 - 2 x 1 Each load can quickly be condensed to a total number of boards by referring...
  • Page 38 The special thing about Sanction Technology is that the patterns total volume amount can be confirmed by running the pattern and performing a PATTERN VOLUME TEST. This step is the most important element in the PVP (Process Verification Procedure) and should be performed whenever conditioning lanes for competition.

  • Page 39: Board Chart For Calibrating Oil Pattern (Program) Loads

    Board Chart for Calibrating Oil Pattern (Program) Loads This chart shows the total number of boards the head travels across when distributing conditioner. This will make it much easier to determine the amount of oil that is used for your pattern, on paper, before it is measured by the machine during a Calibration Test.

  • Page 40: Conditioning System

    Conditioning System Theory of Operation This machine uses proven SANCTION TECHNOLOGY patented by Kegel. This ® exclusive technology, perfected over the past 3 decades, is the only way to measure the volume of conditioner (oil) that is applied to a bowling lane.

  • Page 41: Change Pattern

    Change Pattern Press CHANGE PATTERN in the main menu screen and the screen will change to the password screen. By pressing on PRESS HERE TO ENTER PASSWORD a keypad will display that will allow you to enter the correct password to access the CHANGE PROGRAM MENU.
  • Page 42 Start Brush Distance The default settings do not allow the machine to oil the first 24 inches of the lane. If the factory setting is increased, the area with no conditioner will need to be maintained by hand to keep the oil in the area to a smudge and the area looking good.

  • Page 43: Designing The Oil Pattern

    6 available conditioning speeds. The ability to change speeds while applying these loads is a patented feature of Kegel lane machines. Start Distances and End Distances are not adjustable. These distances are automatically calculated based on # of loads and Speed IPS.
  • Page 44 It is possible to have more than one BUFF LINE during the return trip to the foul line, by entering lines until you hit zero footage as the lower limit. It’s a good rule of thumb to have at least 7 feet of buff on the last reverse oil line. KEGEL’s Original Mission By: John Davis...

  • Page 45: Oil Patterns

    It is important to monitor your playing conditions to keep them consistent and provide the best customer service The Landmark and Navigation Pattern series are available in Kegel’s Pattern Library on www.kegel.net and they are available to view and download for free. Kegel’s award...
  • Page 46 4. Who mixed the cleaner last? Concentration of the cleaner is very important and must stay consistent. At Kegel, we have seen mixed diluted cleaner mistaken as the concentrate. Then it was diluted again making a very, very weak solution.

  • Page 48: Pattern Troubleshooting

    Pattern Troubleshooting Now that you have determined the machine is in perfect working order, here are some tips to common questions about lane conditioning, which should help you make proper adjustments. Q: What should I do if I have too much carrydown? A: Shorten the applied oil distance.

  • Page 49: Chapter 3

    CHAPTER Cleaning System Theory of Operation The cleaning system is the result of years of experience with automated lane care. The evolution that the game has gone through over the years, have created the need for improved ways to remove the dirt and conditioners. The proper cleaning of your lanes is very important to the consistency of your playing conditions.

  • Page 50: Why Do We Clean Lanes

    Why do we Clean Lanes? There are many reasons for cleaning lanes. One is to protect your investment. Not having a good lane maintenance program will not allow you to achieve the best results. It’s also just good customer service. Another good reason would be to have your center create high scoring conditions (but that can also be achieved with poor maintenance).
  • Page 51 The Lift Duster feature is used to lift the duster off the lane prior to reaching the end of the lane, or what is called the tailplank. The default number is set to 20 and is in inches from the end of the lane. If you are using a lot of cleaner, or your last squirt distance is set high, you may want to set this number to 20.

  • Page 52: Duster Settings

    The Squeegee Wipe function allows the machine to make its forward travel pass at the distance set for Forward Travel. However, prior to returning to the fouline, the lane machine will raise the squeegee assembly up off the lane and travel in reverse at the preset distance and then lower the squeegee a second time and move forward gathering up any residue that may have been left...
  • Page 53 TECHNICAL NOTE When replacing a roll of cloth, try not to wrap any more on the take-up reel than needed, it is easy to waste 10 lanes worth of cloth by making extra wraps. After the Duster Cloth is installed, press the RESET CLOTH button in the lower right corner and the ‘# OFLANES’...

  • Page 54: Chapter 4

    CHAPTER Battery Power and Charging Systems Chargers Proper Location and Mounting of Charger It is recommended that the Charger be mounted in a secure, cool dry place and plugged into a dedicated circuit. Before using any outlet, be sure to double check the connections inside the outlet.

  • Page 55: E-Stop

    E-Stop By pressing the red E-Stop breaker, power will be removed from the lane machine. To resume power, simply turn the breaker clockwise. The machine should always be turned off by the E- Stop during charging or maintenance. When the E-Stop is pressed during operation, the machine program will be zeroed and the machine will need to be returned to the foul line and re- started.
  • Page 56 Using the screen to the left, press on the Voltage you want to adjust; the buttons will become enabled and an adjustment reference number will appear. To adjust the voltage meters accurately you must have a dependable voltmeter. Locate the three-pin plug above the fuse bank. Put the voltmeter probes in the appropriate pins then add or subtract using the buttons at the bottom of the screen until the Voltage...

  • Page 57: Chapter 5

    CHAPTER Computer and Control Relays Programmable Logic Controller (PLC) Battery Input Terminal Connections Input Indicators PLC Status Indicators See Chart KOSI Touchscreen Connection Port Output Indicators Output Terminal Connections Analog Battery and CVR Outputs Input Voltage...
  • Page 58 Inputs and Testing Continued… Testing inputs is very simple, like the flick of a light switch. To test proximity sensors pass a metal object across the face of any sensor. Lights on both the proximity sensor and PLC Input should light up. To test inputs operated by switches, depress the lever on the switch and the appropriate input should light up.
  • Page 59 Inputs and Testing Continued… Below is a wiring example of a typical input circuit using a Proximity Sensor Switch. The Proximity Switch has three wires. Blue will connect to negative, Brown to positive, and Black is the signal which connects to the appropriate PLC Input. The sensor operates when metal passes by the face.

  • Page 60: Electrical Panel

    Electrical Panel Fuses Mounted on the control plate are several protective devices for your IKON. From the Input/Output Test Menu press the Machine Fuse List and the below screen will appear. IMPORTANT: Do not over-amp fuses. If you can’t find a direct replacement you will cause damage to the smaller motors.

  • Page 61: Control Relays

    Control Relays All of the components on the IKON are isolated from the PLC. When we say isolated, it means there is a control relay between the PLC and the motor or device. This is to protect the PLC against power spikes from motor amp loads that can cause damage to the smaller internal PLC relays.

  • Page 62: Chapter 6

    CHAPTER Adjustments Conditioning System Buffer Brush The buffer brush is made of a long-lasting synthetic bristle, which under normal circumstances, can be expected to last approximately 18 months. However, changing this annually before each league season is recommended to ensure consistency throughout the year. To check the buffer brush adjustment, the brush must first Front drive wheel be in the down position.

  • Page 63: Buffer Belt

    Buffer Belt Adjustment of the Buffer Belt is done with the buffer brush in the down position! Loosen up the idler pulley and push it all the way down and fasten tight. Idler Pulley Transfer Brush The following steps adjust the transfer brush to the buffer brush. 1.

  • Page 64: Oil Tip

    Oil Tip Correct adjustment of the Oil Tip is very important and is a determining factor in applying a consistent pattern. This adjustment should be checked with the buffer brush running. To operate the brush, go to your test INPUT/OUTPUT screen and press the BUFFER MOTOR then press the button in the center that says BUFFER TEST to turn on the motor.

  • Page 65: Timing Belt

    Timing Belt There are various timing belts that operate in the conditioning system. Refer to the KOSI videos to see if the below videos are available, to set the proper amount of tension required for each belt. 1. Oil Head Timing Belt: This belt should be adjusted a little on the tight side. To adjust head belt tension, loosen the 4 screws in the slotted bracket, adjust the belt so that when you push the belt down from...

  • Page 66: Board Counting Target And Proximity Switch

    Board Counting Target and Proximity Switch The timing for the oil head is a precise adjustment. Before making an adjustment, the Head Motor Fuse will need to be removed to disable the braking circuit. Remove the plastic cover on the 10-pin side to access the sensor assembly.

  • Page 67: Oil Head Target

    Oil Head Target Proximity Sensor Target Oil Head The moving Oil Head uses a flat head screw as a target for the Board Edge Sensors to “see”. The screw should be adjusted to 0.010” (0.254 mm) from the face of the proximity sensors.

  • Page 68: Oil Pressure Tubing

    Oil Pressure Tubing A wide range of conditioner viscosity has been tested in the machine to determine the size and length of the pressure regulator tubing that is needed. Keep in mind that these are only guidelines; temperature greatly affects viscosity and may change these results.

  • Page 69: Cleaning System

    Cleaning System Cleaner Head Timing Belt The machine also uses a timing belt to drive the cleaner head back and forth. To check this adjustment, move the oil head to the middle of the machine. When the oil head is in the center, the cleaner head should also be in the center. Before loosening the idler, place a reference mark on the belt and drive pulley.

  • Page 70: Duster Switches

    Duster Switches Adjust the duster switches only when the machine is standing up in the transport position. 1. Unwind some cloth so there is free movement of the cushion roller. 2. Check the Wind-Up Switches first by lifting the cushion roller up and holding it against the stop bolts.
  • Page 71 To lower the squeegee, apply power to the machine and press MAIN MENU. Next, press the I/O TEST, and this screen will pop up. Press the SQU LIFT test button once. The squeegee motor will activate and rotate 180°, this will lower the squeegee.

  • Page 72: Squeegee Switches

    The tilt or pitch of the squeegee may also Need adjustment to ensure that both blades are contacting the lane squarely. If a pitch adjustment is necessary, follow the steps below to make the adjustment. Make sure the squeegee motor does not bind up when making an adjustment.

  • Page 73: Drive System

    Drive System Drive Speeds Go to the Main Menu and select MOTOR SPEEDS and the screen will advance to the Motor Speeds. The following adjustment is to be made on the approach! The drive motor will activate during this test. To adjust the speeds you must first dial in the first speed which is 10 IPS (Inches per second).

  • Page 74: Main Drive Motor Chain

    After going through and adjusting each of the speeds, press the SET SPEED button in the lower right corner and the RUN SCREEN will appear. Start the machine as you normally would by pressing the handle button once on the approach and a second time after placing the lane machine on the lane.

  • Page 75: Chapter 7

    CHAPTER Troubleshooting Inputs and Outputs PLC Outputs Go to the main menu and select INPUT/OUTPUT TEST and the screen will change to the first test screen. Press on an output selection to test, below is an example of the BRUSH LIFT test.

  • Page 76: Plc Inputs And Testing

    PLC Inputs and Testing The PLC assembly of the machine has 24 inputs, 16 relay outputs, and two analog outputs. Inputs accept data from various sensors or switches in the machine and then use that information to control functions of the machine through its outputs. Here is a list of the INPUT numbers for the PLC along with their wire color and designations: INPUT DESCRIPTION...

  • Page 77: Conditioning System

    Conditioning System Please go over this section if there is any kind of problem with your conditioning system. Reviewing this before calling for Technical Support will help in correcting any problems you may have and allow you to communicate more clearly with a technician on the phone.
  • Page 78 If the Brush Lift Motor does not run, menu to the INPUT/OUTPUT TEST and press BRUSH LIFT to check relay operation and voltages 1. The Brush Lift motor runs but the up switch failed to operate and send the signal to PLC Input 004.

  • Page 79: Conditioning System Problems That Do Not Display Errors

    2. Oil Head Motor does not run in one or both directions. a. Motor has failed. b. Motor brushses worn. Remove/inspect and blow out motor. c. Motor unplugged (CN3) or has a damaged wire. d. PLC output 101CH 00 has failed causing no operation. e.
  • Page 80 4. Machine fails to dispense oil from tip. a. Oil pump motor has failed. b. Pump has failed. c. Pump belt is broken. d. Oil control valve has failed. e. PLC oil control valve output 100CH 00 failed. f. Filter is clogged. g.

  • Page 81: Cleaning System

    Cleaning System Please go over this section if there is any kind of problem with your cleaning system. Reviewing this before calling for Technical Support may help in correcting any problems you have. Cleaning System Problems Indicated by Error Messages Problems that display errors are usually easily corrected and happen for a definite reason.
  • Page 82 This error screen normally happens when the duster fails to wind-up the cloth and actuate the duster up switch, failing to turn on Input 0CH 10 on the PLC. Below are a few things that can cause a WINDUP error. If the Motor does not run, menu to the INPUT/OUTPUT TEST and press DUSTER to check relay operation and voltages.
  • Page 83 Normally this error occurs when Input 1CH 01 fails to receive a signal within 3.5 seconds of the motor starting. The following list will cover a few things that can cause a SQUEEGEE UP ERROR. If the Motor does not run, menu to the INPUT/OUTPUT TEST and press SQUEEGEE LIFT to check for relay operation and voltages.
  • Page 84 Cleaning System Problems that Do Not Display Errors There are a number of things that can go wrong when cleaning, but the machine will appear to operate correctly. Most of these problems can be caught before the bowlers notice them but only if the operator is paying attention. Doing a cleaner test and checking the cleaning system every day will eliminate many problems from turning into disasters.
  • Page 85 6. Machine strips only ‘where’ cleaner is applied on the lane. a. The duster is definitely not touching the lane. 7. Machine drips dirty cleaner and oil off of the squeegee. a. Rear squeegee blade is not clearing the tail plank. It is very important that the rear squeegee blade clears the pin deck completely.

  • Page 86: Drive System

    Drive System Drive System Problems Indicated by Error Messages Problems that display errors are easily corrected and happen for definite reasons. Forward and Reverse Travel Errors normally happen when LDS Input 0CH 07 fails to go off and on as the lane distance wheels turn. When the motor is turned on an error counter is also activated at the same time.
  • Page 87 Drive Motor does not run. a. Forward Relay is loose in socket or failed. b. Reverse Relay is loose in socket or failed. c. One of the motor control plugs is loose or unplugged. Check the speed control and drive motor plugs. d.
  • Page 88 The last thing you want your machine to have is … loose connections Loose connections are the number one cause of charging and operating problems. Here are all of the locations between the batteries and the machine control plate. Always turn off E-Stop when inspecting connections. 1.

  • Page 89: Chapter 8

    CHAPTER Preventive Maintenance Lid and Guard Removal In some cases it may be necessary to remove the Lid and/or side covers to access certain areas of the lane machine. Conditioner Compartment Lid Removal To remove the lid, set the machine down in the operating position. 1.
  • Page 90 2. Standing in front of the machine, lift the cleaner lid assembly up and out of the guides. Pull the back of the lid towards you and lift the rear portion up and out of the guides as well. Front Cover removal To remove the front cover, simply unfasten the 4 screws that secure the top of the cover, and remove from the attaching pins located on the bottom.
  • Page 91 Locate the single mounting screw that is under the cleaner splash guard and above the cleaner supply tank, as shown in the image to the left. Remove this screw along with the hardware and set aside. Next, remove all four of the transport casters including the attaching hardware and set aside for reassembly.

  • Page 92: Daily, Monthly And Annual Cleaning

    Oil Compartment 7-pin side Cleaner Compartment 7-pin side Daily, Monthly and Annual Cleaning Cleaning Guidelines Cleaning is the single most important thing the operator can do for this lane machine and it is not hard. Not taking the time to do simple cleaning will result in the downward spiral of your conditioning program.
  • Page 93 Daily Maintenance 1. The felt in the compartment must be wiped down and the drip pads on each side of the machine must be wiped off. 2. Wipe around the moving head and check each end of the head bar. 3.

  • Page 94: Conditioning System

    Conditioning System Once the lids have been removed, remove the three screws on the back side of the hinged electrical panel. Tilt the electrical panel up towards you to view the top of the drive motor brush cap. Remove the drive motor cap followed by the drive motor brush.
  • Page 95 This part should be cleaned with a cotton swab and alcohol to remove the debris. IMPORTANT: If a valve is found to have only one groove please call KEGEL for an immediate replacement. All machines should have the "high flow" valves which are machined with three grooves.

  • Page 96: Cleaning System

    11. Return the oil assembly to the machine and plug in the connections. Run the OIL VOLUME test once to clear the lines out. Then check the volume of conditioner output for a typical program and adjust the pump if necessary. Cleaning System Cushion Roller Assembly It may be possible to replace the cushion roller wrap only.

  • Page 97: Filling The Cleaner Supply Tank

    Lane Cleaning Cloth should be loaded into the machine using the following procedure: 1. Remove the cleaner dispensing tip from the holder and then remove the old cloth (make sure the spring in the tip holder block doesn’t fall out). 2.

  • Page 98: Recovery Tank

    Recovery Tank To empty the recovery tank the machine must be in the down or operating position. 1. Disconnect the inlet from the side of the recovery tank and the outlet hose from the vacuum motor by removing the PVC elbows. It is best to have a rag in each hand to hold over the fittings to help prevent drips.

  • Page 99: Pump Tubing Replacement

    Pump Tubing Replacement It is recommended that the pump tubing be replaced every year. When the cleaner pump’s maximum volume output is a problem, follow these instructions to disassemble the pump and replace the tubing. To perform the following steps you will need to use the tubing loading key.

  • Page 100: General Maintenance

    Position the other end bell on top and press the end bells together. Be careful not to pinch the tubing. If the end bells do not snap tightly together you need to reload the tubing. If necessary, turn the key in the slot on rotor shaft to adjust tubing.

  • Page 101: Drive Motor Brushes

    5. Keep the LDS shaft bushings oiled, one drop of oil every 4 to 6 months is sufficient. 6. Inspect the drive wheels for tightness and free rotation each time you clean the machine. 7. Inspect the drive chain adjustment whenever the wheels are checked or cleaned.
  • Page 102 4. Remove the mounting strap across the top of the battery. 5. Unplug the battery and carefully remove the battery. Given the weight of the battery, care should be taken when removing. 6. After carefully replacing the battery and mounting hardware, plug the battery back into the connector.

  • Page 103: Chapter 9

    CHAPTER Miscellaneous Parts Stickers and Decals...
  • Page 104 164-0014o-714C 164-0015o-714C 164-0024 - Part Number for the “K” only 164-0023o-714C - Part Number for the “ION” only...

  • Page 105: Fittings

    Fittings Elbow- Elbow- Elbow- 1/4” Tube x 1/4” Tube 3/8” Tube x 3/8” Tube 3/8” NPT x 1/4” Tube - 154-0225 154-0243 154-0256 3/8” NPT x 3/8” Tube - 154-0223 Elbow- Elbow- Elbow- 1/4” Stem x 1/4” Tube 3/8” Stem x 3/8” Tube 1/4”...

  • Page 106: Chapter 10

    CHAPTER Mechanical Drawings Battery and Chargers ..........................95 Lid and Guards ............................96 Top View ..............................98 Bottom View ............................100 Left Side View ............................102 Right Side View ............................104 LDS Assembly ............................106 Handle Assembly ........................... 108 PLC Plate Assembly ..........................110 Oil Valve Assembly ..........................

  • Page 108: Batteries And Chargers

    BATTERIES AND CHARGERS Rev. 12/13 158-1634 – K2 LITHIUM – 25.6 Ah 158-1634B – K2 LITHIUM – 38.4 Ah 158-1634C – K2 LITHIUM – 51.2 Ah Battery Quick Disconnects Red - 158-1407 Blue - 158-1408 ProNautic® Charger and Accessories 164-8471 - EXTERNAL BATTERY CHARGER ASSEMBLY –...

  • Page 109: Lid And Cover Assembly

    REV. 5/16 LID AND GUARDS INDEX  NUMBER QTY. PART NUMBER DESCRIPTION 164‐8801 SLIDING LID ASSEMBLY ‐ CONDITIONER SIDE 164‐8802 SLIDING LID ASSEMBLY ‐ CLEANER COMPARTMENT SIDE 164‐8808 REAR PANEL  164‐6725A‐2133 FRONT BUMPER  164‐8809 IKON RT SIDE GUARD ‐ LOWER 164‐8810 IKON LT SIDE GUARD ‐ LOWER 164‐8811 IKON RT SIDE GUARD ‐ UPPER 164‐8812 IKON LT SIDE GUARD ‐ UPPER 153‐2232L FLUSH MOUNT LID LATCH (WITH LOCK) 164‐2069 SPRING PLUNGER THREADED 164‐2002 DETENT ‐ SPRING PLUNGER 164‐6164  LID LATCH BUMPER 164‐2044 STANDOFF FEMALE THREADED 8‐32 X 3/8 164‐2071 STANDOFF FEMALE THREADED 8‐32 X 5/8...

  • Page 111: Top View

    REV. 5/16 TOP VIEW  INDEX  PART  DESCRIPTION NUMBER QTY. NUMBER 158‐8414 BUFFER MOTOR  158‐1406B BUFFER MOTOR BRUSHES (PAIR) 164‐9019 BUFFER BELT  158‐9401 PULLEY (14 TOOTH 1/2" BORE) 158‐8406 DRIVE MOTOR  158‐1405B DRIVE MOTOR BRUSHES (PAIR) 154‐9601 CHAIN (FOR 153‐9002 SPROCKET) 153‐9047 MASTER LINK #40 153‐9048  OFFSET LINK #40 153‐9002 SPROCKET ‐ 40B13 (5/8 IN)  158‐8407 VACUUM MOTOR ‐ 24VDC 158‐8404D CLEANER PUMP ASSEMBLY 154‐0861B NORPRENE TUBING FOR CLEANER PUMP ASSEMBLY 158‐8404 CLEANER PUMP MOTOR ‐ 24VDC...

  • Page 113: Bottom View

    REV. 5/16 BOTTOM VIEW INDEX  PART  DESCRIPTION NUMBER QTY. NUMBER 164‐8001A BUFFER BRUSH ASSEMBLY 164‐9019 BUFFER BELT ASSEMBLY   153‐8410 LANE EDGE GUIDE ROLLER 153‐2401 SPRING ‐ COMPRESSION FOR GUIDE WHEEL (NOT SHOWN) 154‐6651 FRONT LANE EDGE GUIDE ROLLER MOUNT 153‐2527 BOLT FOR GUIDE ROLLER ‐ FRONT (NOT SHOWN) 153‐6417 REAR LANE EDGE GUIDE ROLLER MOUNT 153‐2407 BOLT FOR GUIDE ROLLER ‐ REAR (NOT SHOWN) 153‐7005R MOMENTARY WHEEL ASSEMBLY (WHEEL ONLY) THE BELOW ATTACHED PARTS ARE NOT SHOWN  MOMENTARY WHEEL SHAFT 153‐6006 MOMENTARY WHEEL HOUSING ASSEMLBY 153‐6029 SET SCREW (NOT SHOWN) 153‐2049 164‐8012 HANDLE ASSEMBLY (COMPLETE) 158‐6645 SKID GUIDE 153‐7002AA LDS/DRIVE WHEEL (NO SET SCREW) 153‐2819 SET SCREW (NOT SHOWN) 153‐7013 DRIVE WHEEL  (NO SET SCREW)
  • Page 114 DETAIL A DETAIL B...

  • Page 115: Left Side View

    REV. 5/16 LEFT SIDE VIEW INDEX  PART  DESCRIPTION NUMBER QTY. NUMBER 158‐8403 ASSEMBLY ‐ DUSTER MOTOR 24VDC 158‐8402 BUFFER LOWERING MOTOR 158‐8405 HEAD DRIVE MOTOR ASSEMBLY 154‐9607 PULLEY FOR HEAD DRIVE (NOT SHOWN) 164‐9019 BUFFER BELT ASSEMBLY  164‐0022 L TO L CASTER ASSEMBLY 158‐7002 6" WHEEL ASSEMBLY  153‐8039 BUFFER IDLER PULLEY...

  • Page 117: Right Side View

    REV. 5/16 RIGHT SIDE VIEW INDEX  PART  DESCRIPTION NUMBER QTY. NUMBER 158‐8402 SQUEEGEE / BRUSH LIFT MOTOR ‐ 24VDC 158‐8403 DUSTER MOTOR ASSEMBLY ‐ 24VDC 154‐1220 PROXIMITY SENSOR 153‐7002 6" WHEEL ASSEMBLY  164‐0022 L TO L CASTER ASSEMBLY ...

  • Page 119: Lds Assembly

    REV. 5/16 LDS ASSEMBLY  INDEX  PART  DESCRIPTION NUMBER QTY. NUMBER 154‐6821 LDS SHAFT ASSEMBLY 153‐7002AA LDS WHEEL ASSEMBLY 153‐2819 SET SCREW ‐ 10‐32 X 3/8 154‐8619 LDS MOUNTING BLOCK ASSEMBLY ‐ LEFT 154‐8621 LDS MOUNTING BLOCK ASSEMBLY ‐ RIGHT 154‐9213 SPROCKET 25B15 (1/2") 154‐9211 LDS AND TACH SENSOR DRIVE CHAIN #25 153‐9045 MASTER LINK #25 (NOT SHOWN) 153‐9010 SPROCKET ‐ 25B15 (3/8") 154‐8320 LDS MOUNTING BLOCK ASSEMBLY ‐ CENTER 154‐1220 PROXIMITY SENSOR 154‐6264 SHAFT FOR TIMING DISK ASSEMBLY 154‐6717 5 TOOTH SENSOR DISK...
  • Page 120 DETAIL A...

  • Page 121: Handle Assembly

    REV. 5/16 HANDLE ASSEMBLY INDEX  PART  DESCRIPTION NUMBER QTY. NUMBER 164‐8012 HANDLE ASSEMBLY (COMPLETE) 164‐8013 HANDLE BUTTON REPLACEMENT ASSEMBLY (W/WIRES) 164‐6083 BUTTON COLLAR 158‐2003 SCREW 8‐32 X 1/2 FHCS BLK OXIDE 164‐6057 HANDLE CATCH 164‐6084 HANDLE MOUNT ASSEMLBY 164‐6058 HANDLE SPACER 164‐2001 UNTHREADED CURVED SPACER BLACK 164‐2028 BHSCS 5/16‐18 X 3 FULL THREAD...

  • Page 123: Plc Plate Assembly

    REV. 5/16 PLC PLATE ASSEMBLY INDEX  DESCRIPTION NUMBER QTY. PART NUMBER 158‐1610P PLC FOR IKON ‐ SPECIFY SOFTWARE VERSION 158‐1610S SERIAL CONVERTER FOR FLEX  164‐1235 CABLE TO TOUCHSCREEN ‐ 24IN  (NOT SHOWN) 164‐8803 TOUCH SCREEN ASSEMBLY 164‐1234 SCREEN PROTECTOR (NOT SHOWN) 164‐8807 SPEED CONTROL ASSEMBLY ‐ DRIVE 164‐8806 SPEED CONTROL ASSEMBLY ‐ CLEANER PUMP 164‐6815 CLEAR PC PLATE COVER 158‐1460  RELAY SOLID STATE 158‐1458 RELAY ‐ OMRON 24DC DPDT GENERAL PURPOSE 158‐1462 24 V RELAY DPDT 10A W/DIODE 164‐1231 LY3 RELAY 164‐1207 LY3 RELAY CLIP 153‐1028 PANEL‐MOUNT FUSE HOLDER ‐ UL (COMPLETE) 153‐1209  BUTTON GUARD 158‐8439 PUSH BUTTON (RED = NORMALLY OPEN) 164‐6161 E‐STOP BOX 164‐1223 E‐STOP SWITCH ASSEMBLY...

  • Page 125: Oil Valve & Pump Assembly

    REV. 5/16 OIL VALVE ASSEMBLY INDEX  PART  DESCRIPTION NUMBER QTY. NUMBER 154‐8682 CONDITIONER TANK ASSEMLBY 164‐8081 SUPPLY TANK CAP (NOT SHOWN) 164‐0021 GASKET FOR SUPPLY TANK CAP (NOT SHOWN) 158‐8401A OIL PUMP MOTOR ASSEMBLY 154‐8816 PULSE SUPRESSION TUBE 154‐1214  FLUID METERING PUMP‐0.05 ML/STROKE 154‐8298 OIL CONTROL VALVE (24VDC) WITH EXTENEDED WIRES 154‐0248 REDUCING UNION CONNECTOR‐1/4" X 3/16" 154‐9607 PULLEY ‐ (24XL 5/16" BORE) 154‐9202A CONDITIONER PUMP BELT 154‐9404 PULLEY 16XL037 X 1/4" BORE 16.5 154‐0202 PUMP TUBING STOCK (3/8" OD X 1/4"ID) 154‐0257 FEMALE CONNECTOR ‐ 1/4" TUBE X 1/8" FPT 158‐1613  PRESSURE GAUGE ‐ 60PSI 154‐8817 MANUAL VENT VALVE ASSEMLBY 154‐0212 OIL TANK FILTER ASSEMBLY 154‐6287 GUARD FOR PUMP...

  • Page 127: Oil Head Assembly

    REV. 5/16 OIL HEAD ASSEMBLY  INDEX  PART  DESCRIPTION NUMBER QTY. NUMBER 158‐8405 OIL HEAD DRIVE MOTOR ASSEMBLY 154‐8851 OIL HEAD HOSE AND TIP ASSEMBLY 154‐9607 PULLEY  154‐6647A SLIDING HEAD BAR ASSEMBLY 154‐0206 SPRING FOR OIL HOSE TIP ASSEMBLY 154‐0220 PROXIMITY SENSOR 164‐6280 HEAD BAR MOUNTING BLOCK 154‐0202A PENCIL TUBING STOCK 153‐2713 OIL HEAD SPRING  154‐6893 OIL HEAD ASSEMBLY 154‐6646 HEAD MOUNT PLATE ASSEMBLY 154‐9201 OIL HEAD DRIVE BELT ASSEMBLY 154‐6832 OIL PENCIL TIP ASSEMBLY...
  • Page 128 DETAIL A...

  • Page 129: Brush Lift Rod Assembly

    REV. 5/16 OIL TRANSFER ASSEMBLY INDEX  QTY. PART NUMBER DESCRIPTION NUMBER 164‐8001A BUFFER BRUSH ASSEMBLY 164‐0866 SINGLE TRANSFER BRUSH ASSEMBLY 164‐8805 DRIP PAD ASSEMBLY (SOLD IN PAIRS) 164‐8805 DRIP PAD ASSEMBLY (SOLD IN PAIRS) 164‐8046 BEARING MOUNT ASSEEMBLY ‐ LEFT 164‐8045 BEARING MOUNT ASSEEMBLY ‐ RIGHT 158‐6735 BRUSH TRACK MOUNT SUPPORT 158‐6732 SINGLE BRUSH TRACK MOUNT ASSEMBLY 164‐8008 TRANSFER ROLLER ASSEMBLY  158‐9402 BUFFER BRUSH PULLEY ASSEMBLY  153‐9816 FLANGED BUFFER BRUSH BEARING FLANGED BUFFER BRUSH BEARING ‐  ROTATED 154‐8640 164‐6051 TRANSFER ROLLER IDLER BELT BLOCK 158‐6742 TRANSFER ROLLER BELT IDLER ROLLER ASSEMBLY...

  • Page 131: Oil Transfer Assembly

    REV. 5/16 BRUSH LIFT ROD ASSEMBLY INDEX  PART  DESCRIPTION NUMBER QTY. NUMBER 158‐8402 MOTOR ASSEMBLY ‐ 24VDC 154‐8639 BUFFER BRUSH LOWER LINK ‐ RIGHT 154‐8638 BUFFER BRUSH LOWER LINK ‐ LEFT 154‐8837 BRUSH LIFT ROD TO CAM LINK 154‐6243 MOTOR CAM‐DUAL LOBES (STACKED SWITCHES) 154‐8637 BRUSH LIFT ROD ASSEMBLY 154‐6824  CAM SWITCH PLATE 153‐1203 MICROSWITCH W/ROLLER  158‐8634 SQUEEGEE/BRUSH MOUNT PLATE ASSEMBLY 158‐9614 BALL BEARING MINITURE (NOT SHOWN)
  • Page 132 DETAIL A...

  • Page 133: Cleaner Tank & Head Assembly

    REV. 5/15 CLEANER TANK  AND HEAD ASSEMBLY INDEX  PART  DESCRIPTION NUMBER QTY. NUMBER 158‐8433C CLEANER SUPPLY TANK ASSEMLBY (COMPLETE) 164‐8081 CLEANER SUPPLY TANK CAP 154‐8817 MANUAL VENT VALVE ASSEMBLY 154‐8693 CLEANER FLOAT SWITCH ASSEMBLY 154‐0212B FILTER ASSEMBLY 164‐0021 CLEANER SUPPLY CAP GASKET (NOT SHOWN) 158‐8404 CLEANER PUMP MOTOR ASSEMBLY 158‐8404D CLEANER PUMP ASSEMBLY 154‐8852 CLEANER HOSE AND TIP ASSEMBLY 154‐0863 LURE HOSE BARB  164‐0012M CLEANER TIP WITH CHECK VALVE 153‐2804 COLLAR ‐ 3/8 X 3/4 X 3/8 153‐2902 COLLAR ‐ 1/2 X 1 1/8 X 1/2 154‐8867A IN LINE FILTER ASSEMBLY  154‐6646 CLEANER HEAD BELT MOUNT PLATE 154‐6882 CLEANER HEAD ASSEMBLY 153‐2713 SPRING FOR CLEANER HEAD ASSEMBLY 154‐9201 ...
  • Page 134 DETAIL A...

  • Page 135: Duster Assembly

    REV. 5/16 DUSTER ASSEMBLY INDEX  DESCRIPTION NUMBER QTY. PART NUMBER 158‐8403 DUSTER MOTOR ASSEMBLY 153‐8839 CUSHION ROLLER WITH WRAP ASSEMBLY 154‐8839A CUSHION ROLLER COVER ‐ SIZE A 154‐8839B CUSHION ROLLER COVER ‐ SIZE B 154‐8839C CUSHION ROLLER COVER ‐ SIZE C 154‐8839D CUSHION ROLLER COVER ‐ SIZE D 154‐8839E CUSHION ROLLER COVER ‐ SIZE E 164‐6108 DUSTER PLUG CARDBOARD CORE 153‐0047EZ K2 SELECT DUSTER CLOTH (BOX OF 4) CASE 154‐0052 PVC TAKE UP REEL ASSEMBLY 153‐0429 DUSTER ROLL SUPPORT PIPE (40 INCH) 164‐6109 UHMW DUSTER PLUG FOR  PVC TAKE UP REEL 153‐8420 CUSHION ROLLER PIVOT ARM 153‐8202B DUSTER SOLID DRIVE HUB (PVC) 154‐1603 MICROSWITCH WITHOUT ROLLER (LARGE)

  • Page 137: Squeegee Assembly

    REV. 5/16 SQUEEGEE ASSEMBLY INDEX  DESCRIPTION NUMBER QTY. PART NUMBER 158‐8402 MOTOR ASSEMBLY ‐24VDC 164‐8038K SQUEEGEE BLADE AND GASKET REPLACEMENT (1 SET) 164‐0003 GASKET (NOT SHOWN) 154‐8802 SQUEEGEE ADJUSTMENT ARM 154‐6677A  SQUEEGEE HOSE ADAPTER NYLON 158‐8634 SQUEEGEE/BRUSH MOUNT PLATE ASSEMBLY 158‐9614 BALL BEARING MINITURE (NOT SHOWN) 153‐1203 MICROSWITCH W/ROLLER  154‐6824  SQUEEGEE CAM SWITCH PLATE 154‐6339‐2850 SQUEEGEE MOUNT ANGLE 154‐6243 MOTOR CAM‐DUAL LOBES (STACKED SWITCHES)

  • Page 139: Vacuum Motor & Recover Tank Assembly

    REV. 5/16 RECOVERY TANK AND VACUUM MOTOR INDEX  PART  DESCRIPTION NUMBER QTY. NUMBER 158‐8407 VACUUM MOTOR ASSEMBLY 153‐6221M VACUUM HOSE ADAPTER 158‐1421B VACUUM MOTOR BRUSHES (NOT SHOWN) 164‐8017 RECOVERY TANK 164‐8017F RECOVERY TANK FILTER (NOT SHOWN) 158‐0405 RECOVERY TANK GASKET (NOT SHOWN) 153‐2968 SCREW ‐ 1/4" X 3/4" FHSHCS (NOT SHOWN) 153‐8827T 1‐1/4 PVC ELBOW‐TANK INLET (NO THREADS) 164‐6120 FLEX RECOVERY TANK COVER PLATE 154‐0607 PVC ELBOW ‐ 1‐1/2 BARB X 1‐1/2 BARB 154‐0260 FLEXIBLE HOSE ‐ SOLD BY THE INCH 153‐2406 HOSE CLAMP (2 INCH) TECHNICAL NOTE WHEN ATTACHING PART NUMBER 153-6221M, USE A TWO (2) PART EPOXY AND ALLOW TO DRY ACCORDING TO DIRECTIONS.

  • Page 142: Chapter 11

    CHAPTER IKON ELECTRICAL DRAWINGS Motor Wiring Layout ..........................129 Output Wiring Layout .......................... 130 Input Wiring Layout ..........................131 Speed Control Wiring Layout ......................132 Analog Wiring Layout .......................... 133 Terminal Block Wiring Layout ......................134 Power Contactor Wiring Layout ...................... 135 Voltage Regulator Wiring Layout ....................

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