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Kegel FLEX 17-5801 Operator's Manual

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OPERATORS MANUAL
Edition 03:18

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Summary of Contents for Kegel FLEX 17-5801

  • Page 1 OPERATORS MANUAL Edition 03:18...
  • Page 3 FLEX Walker Specifications 17-5801 FLEX Walker - Red 17-5803 FLEX Walker – Black 17-5805 FLEX Walker – White 17-5807 FLEX Walker – Blue (24VDC) Class I - Single Phase 115 Volts, 50/60 Hz, 7 Amps 230 Volts, 50/60 Hz, 3.5 Amps FLEX Specifications 17-5701 FLEX - Red 17-5703 FLEX - Black...
  • Page 4 ("Warranty Item") which, within ONE YEAR after the date of installation by an authorized KEGEL Distributor, has been determined to be defective upon examination by KEGEL. For FLEX Lane Machines, KEGEL shall repair or replace, at its factory or authorized service station, any lane machine or replacement part ("Warranty Item") which, within eighteen...
  • Page 5 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 and is exclusive for FLEX lane machines.
  • Page 6 Make sure to bend at the knees and use a back support or mechanical lift if needed. Kegel does offer 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 7: 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 .........................
  • Page 8 Oil Tip .................................. 61   Timing Belts ................................ 61   Oil Pump Belt ..............................62   Board Counting Target and Proximity Switch ....................63   Oil Head Target ..............................64   Brush Lift Switches ............................. 65   Stepper Motor Controls ............................. 65  ...
  • Page 9 Chargers ............................121   Constant Voltage Regulator – CVR ....................... 122   E-Stop ..............................122   Batteries ............................123   Replacing Batteries ........................... 124   Troubleshooting Battery & Charging Problems ................125   CHAPTER 5 ....................129   ............................129  ...
  • Page 10 Flex Walker Left View ......................... 196   Flex Walker Right View ........................198   Flex Walker LDS Assembly ......................... 200   Flex Walker Front Handle Assembly ....................202   Flex Walker Whisker Assembly ......................204   PLC Plate Assembly ........................... 206   Oil Valve Assembly ..........................
  • Page 11 Flex Walker Oil Pump Driver & Motor Wiring Layout ................ 271   Flex Walker Oil-Cleaner Head Driver & Motor Wiring Layout ............272   Flex L-R & R-L Proximity Sensor Wiring Layout ................273   Flex Oil Valves Wiring Layout ......................274   Flex Buffer Motor Wiring Layout .......................

  • Page 13: 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 14 Kegel. The information contained herein is designated only for use with the Kegel FLEX Walker and the Kegel FLEX Lane Machines. Kegel is not responsible for any use of this information as applied to other lane machines.
  • Page 15 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 original concepts including, 12 adjustable topography lanes, and advanced coaching tools like Specto, and the Torch.
  • Page 16 “Wah-lah…I did them the same!”...

  • Page 17: Chapter 1

    Machine Serial Number: ______________________ Battery Serial Number: Register your Lane Machine It is important to register your new FLEX with Kegel in order to receive valuable updates, service bulletins and your Limited Warranty. Fill out the card or go on-line. www.kegel.net/kegel-lane-machine-warranty-registration-form...

  • Page 18: Machine Installation Procedures For The Distributor

    Machine Installation Procedures for the Distributor When using this manual make note that ALL fonts that are in BLUE contain information that pertain to the FLEX Walker ONLY. All other documentation will be used for both FLEX model lane machines. Also, 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.
  • Page 19 Motor controls. On the Walker, also show the resistance wire box and explain how to balance the motors. Make sure they call Kegel for advice on balancing the motors. 10. Inspect all the relays and describe their function. Make sure all are seated properly in the socket bases.
  • Page 20 Please read more on this in Chapter 3. 19. 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. 20. Point out the KOSI software located on the USB storage key that was provided for their PC.
  • Page 21 Watch the machine as it enters the lane. Describe the function of the Whiskers as they operate to steer the machine. Watch how the machine will continue to move on one side and slow down on the other to steer if one of the Whiskers hits the foul light cover. As the machine enters and sets itself onto the lane describe how the On Lane Switch changes the machine from approach functions to on-lane functions.

  • Page 22: Daily Setup And Operation

    16. After operation, review proper steps to transport, clean, and charge the machine for its next use. Tell them to read this Operators Manual and show them how the manual is organized to help them find what they are looking for. Daily Setup and Operation Moving &...

  • Page 23: Filling The Cleaner Supply Tank

    When finished, be sure to refill your conditioning cartridges if necessary. DO NOT OVERTIGHTEN THE CAP FOR THE CARTRIDGE! Filling the Cleaner supply Tank With separate water and cleaner tanks 1. To fill the Cleaner Supply Tank, the machine should be in the down or operating position on the lane.
  • Page 24 Not using a funnel with a filter may cause the tank's internal filter to become clogged frequently and reduce the cleaner output, resulting in inadequate cleaning. This may lead to customer complaints, ball calls and an excess of out-of-range pins. When necessary, the supply tank can be removed for cleaning.
  • Page 25 FLEX Walker Sequence of Events - “How it Works” The following steps detail how the Walker operates. Skip to Page 15 for the FLEX. The Walker should be on the approach in the down or operating position behind the first lane with the HOME SCREEN showing.
  • Page 26 6. The moving heads will start and move in opposite directions. The cleaner head will start to apply cleaner when signaled and not stop until the last squirt distance has been reached. When the oil head reaches the right board edge proximity sensor, the moving heads will reverse and begin to apply the first stream of oil.
  • Page 27 duster up switch’s normally open contacts will close to turn off the duster wind-up motor. If the contacts do not close there will be a DUSTER WINDUP error displayed. 16. There are two ways to reverse the Walker or Flex. In this scenario, the LDS sensor stops the machine and the alarm buzzer will sound to alert the operator.

  • Page 28: Flex Sequence Of Events - "How It Works

    26. As the Walker approaches the foul line the 7-pin side motor will turn on and the buzzer will begin to sound. When both motors turn on they are once again monitored by their respective sensors to confirm they are in motion. The Walker will drive up on the approach and stop at the preset distance past the foul line.
  • Page 29 to a screen that will ask you to double check your info. If it’s correct press YES and the screen will change to the run screen and it will be ready to run. 2. Press the start button on the handle one time and the machine will lower the duster cloth which is monitored by the duster up switch.
  • Page 30 be a BRUSH UP error displayed. If the brush up switch sticks closed when it should be open it will give a BRUSH DOWN error. 10. When the oil distance has been reached the machine will shift into high speed and continue to travel toward the pin deck.

  • Page 31: Basic Steps To Operate Your Flex Or Flex Walker

    20. As the machine continues to travel in reverse it will be down-shifting to lower speeds. After the machine applies the last reverse load the moving head will park. The machine will continue to the foul line then stop. 21. If the oil float contacts open, an OIL EMPTY error will be displayed after the machine has completed its run.

  • Page 32: Machine Setup I

    If you enter the wrong password, the touchscreen will display a notification. Press CONTINUE and try again. Machine Setup I From the Home Screen, press the icon for the MAIN MENU. A series of sub-menus appear on the screen. To access the MACHINE SETUP menus, press MORE MENUS and then select the MACHINE SETUP icon.
  • Page 33 The NUMBER OF LANES button allows you to set the size of the center. Press on the number and a keypad will appear to update the program with the correct number of lanes. To lock in the setting press ENTER. To exit the keypad press CANCEL. The NUMBER OF READ ONLY PATTERNS will allow the user to set which patterns are able to be edited.
  • Page 34 Press on the day of the week to choose the proper DAY and the button will change color to show the selected day. SELECT LANGUAGE is used to choose which language is displayed on the touchscreen. English, Chinese and Japanese are available. Pressing the yellow Forward Arrow (in the lower right corner of the screen) will advance the menu to the MACHINE SETUP II options for the Walker.

  • Page 35: Positioning Your Flex Walker

    VACUUM DISABLED ON THE APPROACH can be activated by pressing that button and the ENABLE BUTTON at the same time. These two buttons pressed at the same time will toggle the function ON and OFF. Setting this ON will cause the vacuum to turn on as it exits the lane.
  • Page 36 The buttons will disappear after they are pressed and a STOP MACHINE screen will take their place. The buttons will re-appear when the machine stops or after the stop button is pressed. It is not unusual to start then stop the machine quickly to obtain the exact position desired.
  • Page 37 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 38: Toggle Monitor Screens

    The screen is very informative! It will show the pattern name and number, what lanes the machine is going to run, the number of lanes that are left in the conditioner cartridges, both A and B, the number of lanes left in the Pindeck Treatment can, and the mode of operation.

  • Page 39: Keypad And Menus

    The last two monitor screens allow the user to see exactly what inputs are turning ‘off’ and ‘on’ as the machine is in operation. These screens are very helpful in troubleshooting of the lane machine. Keypad and Menus Machine Error Messages The machine is equipped with Error Messages that are displayed on the touchscreen in case the machine malfunctions.

  • Page 40: Operator Menu Selections

    ADDITIONAL ERROR LIST FOR FLEX WALKER OLS SENSOR TOO LATE OLS SENSOR STUCK ON APPROACH 7-PIN SIDE APPROACH 10-PIN SIDE 7/10 PIN WHISKER BUMPER SWITCH Below is an ‘example’ of how an error messages will appear along with its help screen. Refer to Chapter When the machine loses battery power, or if the E-STOP is pressed while operating on the lane, the machine will...

  • Page 41: History Selections

    Technical support on the machine is available at any time, day or night. To reach a technician, press the CONTACT KEGEL button and several ways to access Kegel is displayed. History Selections From the MAIN MENU screen, press the MORE MENUS button, then HISTORY MONITOR, and you will be able to view the OPERATING HISTORY of the Lane Machine.
  • Page 42 The OIL VALVE TIME screen (shown to the right) will display 30 consecutive valve times to the screen, each count is 1/50 of a second. To ensure consistency in conditioner application, frequently check the valve times. A button on the menu screen allows the times to be reset, when desired.
  • Page 43 The machine will record the Day, Month, Hour, User #, Pattern #, Start Lane, End Lane and Number of Lanes Run each time the machine completes one lane or more. The main function of this feature is to keep track of the centers conditioning program.

  • Page 44: Maintenance, Recharging & Storage

    Maintenance, Recharging & Storage Maintenance Reminder Pop Ups There are 7 Maintenance Reminders that will appear on start up when maintenance or inspection is needed to be done. These are for the Drive Motors, Cushion Roller, Squeegee, Buffer Brush and Cleaner &...

  • Page 45: Charger Location & Storing Of The Machine

    Some centers build dog houses for their machine next to the approach or behind the pinsetters. If possible, the machine should be stored where all of its related Kegel products are kept (i.e. cloth, conditioner, cleaner, and whatever else you use to keep it clean and maintained).

  • Page 46: Lid And Side Cover Removal

    from the charger, allow the charger to shut down then unplug the charger from the machine. When charging, the volts will be below 29.2 volts and the amps will be high teens to 20.8 amps, when fully charged the amps will go to 0.02 or 0.00 and the voltage will go up to 29.2 volts.
  • Page 47 1. While in the operating position, stand facing the lane machine from the cleaner compartment side and push the lid all the way away from you. 2. Standing in rear of the machine, lift the cleaner lid assembly up and out of the rear guide opening.
  • Page 48 Warning: When removing the rear cover, be extra careful to unplug the LED light located on the inside of the cover! Side Cover Removal With the machine in the up-right transport position, locate the two (2) screws that mount the bottom of the side cover as shown, on a Flex Walker.

  • Page 49: 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 50: 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 52: Chapter 2

    CHAPTER Conditioning Overview How Conditioner is Metered and Controlled Sanction Technology™ is patented and 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 form of oil pattern application. When conditioning a lane, the oil head travels back and forth across the transfer brush applying streams of conditioner.

  • Page 53: Calibrating The Oil Pump

    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. The accuracy of the pump is ...

  • Page 54: Matching The Oil Pumps

    Conditioner pump adjustments are done through the touchscreen. Press on the + or – symbols to select the MIC per microliter (µl) selection to highlight the button and check the pump volume for that setting. In this example, we will use the 50 µl PUMP SETTING. The OIL VALVE TIME will be displayed on the screen.

  • Page 55: Manual Adjustment Of The Oil Pumps

    4. Clean out the graduated cylinder using the long felt wick that is provided with the machine. A thorough cleaning is important because any oil left clinging to the sides of the cylinder will give inaccurate readings. NOTE: When felt gets soaked with oil it can be cleaned by squeezing it in a g or towel just use strips of...
  • Page 56 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 to the Board...
  • Page 57 The special thing about Sanction Technology is that this total pattern 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 you should perform it whenever conditioning lanes for competition.

  • Page 58: 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. 10 11 12 13 14 15 16 17 18 19 20 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18...

  • Page 59: 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 60: Change Pattern

    Change Pattern Press CHANGE PATTERN in the main menu screen and the screen will change to the password screen. Enter the password, and press “CONTINUE”. The factory default is 000. To the left is the main CHANGE PATTERN screen. From this screen you will choose the pattern to view and then you can check the settings in SYSTEM SETTINGS or LANE PATTERN DESIGN.

  • Page 61: System Settings Menus

    System Settings Menus Located at the bottom of the Change Program home screen is the System Settings button. Press on the mode to set the machine to perform the desired operation. When pressed, the button will turn yellow and the text will change indicating what mode the pattern is set to perform.

  • Page 62: Distance From Fouline When Brush Turns On

    Distance from Fouline When Brush Turns on The default settings do not allow the machine to oil the first 27 inches of the lane. This area will need to be maintained by hand to keep the oil in the area to a smudge and the area looking good.

  • Page 63: Drop Brush In Reverse Location

    Drop Brush in Reverse Location This feature is used to choose where you want the brush to turn on in reverse. The upper limit is the oil distance and the lower limit is where the oil starts in reverse. When the oil distance is changed, this value will default to that same distance and this feature will need adjusted back to your desired setting.

  • Page 64: Fine Tuning Buffer Brush Settings

    Hidden within the SYSTEM SETTINGS menu, there are special adjusting features to help in fine tuning the Buffer Brush to the lane. Please contact Kegel to learn how to access these menus as well as fully understanding the benefit of each feature.

  • Page 65: Tank Selection

    Tank Selection This new feature will allow the pattern designer to blend two compatible lane conditioners on each of the program lines in the forward or reverse screens. By pressing the TANK SELECTION LOCKED button, the screen will be highlighted in yellow and changed to UNLOCKED. You will now be able to choose either Tank A, Tank B or both within each program line.
  • Page 66 With the ability to change the oil pump volume output on each load screen, also comes some mechanical limitations. While the lane machine is in motion, and going from one pump setting (µL per board volume output) to a different pump setting, it will require the oil pump motor to change speeds.

  • Page 67: Variable Speed Buffer (Upgraded Machines Only)

    Variable Speed Buffer (Upgraded Machines only) One of the available factory upgrades is the Variable Speed Buffer feature. This allows the programmer to change the RPM of the buffer brush allowing for more FLEX ability with the taper within an oil pattern. To change the buffer brush’s RPM within the pattern, press on the BUFFER SPEEDS button located above the speed IPS.

  • Page 68: Designing The Oil Pattern

    USING slower speeds and gradually increase through the 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 69 Whenever the OIL DISTANCE is increased the last BUFF LINE will need to be adjusted to the OIL DISTANCE. When this change is made, the program will automatically change the OIL DISTANCE to the 15th Forward BUFF LINE (F15). You will need to fix this. After the forward screens are complete, through F15, the screen will advance to REVERSE SCREEN I.

  • Page 70: Auto Programming (7 Day Planner Program)

    Auto Programming (7 Day Planner Program) Go to the main menu and press 7 DAY AUTO PLANNER and the password screen will appear, enter password and press CONTINUE. You will be given the option to choose one of the days to edit, or select PINDECK TREATMENT PLANNER to set up your Pindeck treatment program The day selection will appear press MONDAY and the screen will change to MONDAY AM.

  • Page 71: Adjustments

    Adjustments 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 Front wheel season is recommended to ensure consistency throughout the year. To check the buffer brush adjustment, the brush must first be Rear wheel...

  • Page 72: 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 up and fasten tight, do not over tighten belt. Idler Pulley This idler roller is used to keep belt from jumping cogs.

  • Page 73: 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 74: Oil Pump Belt

    2. Oil Head Timing Belt: This belt should be adjusted a little on the tight side. Unplug the head motor fuse before attempting to work on this belt to disable the braking circuit. 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 the top it just touches the head bar assembly as shown in the below figure.

  • Page 75: Board Counting Target And Proximity Switch

    Board Counting Target and Proximity Switch (look for tutorial video on KOSI) 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 76: Oil Head Target

    7. If on the 10-pin side the board counting sensor comes on too soon and the 7-pin side comes on late, the board counting target will need to be turned in a counter-clockwise direction and vice-versa if they are off in the other direction. NOTE: When determining the direction to turn the target, look at the face of the target for the clockwise rotation.

  • Page 77: Brush Lift Switches

    Brush Lift Switches Adjusting Slots The Brush Lift Switches are mounted to a plate that has adjusting slots. The switch plate adjustment should be checked when each switch is on the cam lobe. The switch rollers should not “bottom out” and have only between 0.005”...
  • Page 78 Use the chart below as reference: SPEED 1 60 RPM SPEED 2 200 RPM SPEED 3 500 RPM SPEED 4 700 RPM Speed Control board settings: The above speed pots are held in place by electric tape after being adjusted in factory.

  • Page 79: Pressure Regulator Tubing

    A viscosity cup, thermometer, and a stopwatch are valuable tools if you are mixing your own blend of conditioner. Call Kegel for more information on how to obtain Pressure this equipment. Regulator...

  • Page 80: Maintenance

    Maintenance It is very important to maintain a clean environment in the conditioning compartment. Not doing this will result in oil migrating through the entire machine causing damage to wiring and making a mess of things. The following procedures should be followed in order to keep your machine healthy.

  • Page 81: Buffer Motor Brushes

    Buffer Motor Brushes When the lane machine has been in operation for 300 hours, this screen will pop up indicating that the Buffer Motor is in need of service. This is an indication that the Buffer Motor brushes should be inspected and/or replaced. The Buffer brush motor is located in the center compartment under the electrical panel.

  • Page 82: Procedure For Cleaning Oil Control Valve

    Procedure for Cleaning Oil Control Valve The following steps outline the procedure for disassembling the conditioner metering valve. Be careful when removing the oil lines from the fittings since they will leak. Block off the stem elbows to prevent them from leaking all over the machine (do not split the stem).
  • Page 83 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 contact KEGEL for an immediate replacement. All machines should have the "high flow" valves which are machined with three grooves.

  • Page 84: Troubleshooting The Conditioning System

    Troubleshooting the Conditioning System Conditioning Problems Indicated by Error Messages Problems that display errors are normally corrected easily and happen for definite reasons. Usually, a stuck or out of adjustment switch (and possibly loose or damaged wires) will cause most problems when the machine is old. If an input fails to go off completely and still displays a dim light, the PLC will still consider that as a good input, so look very closely.
  • Page 85 Problem Brush Lift motor does not run when tested in the Output Test. You will need to determine if power is getting to the motor. Possible Cause  Fuse is blown or fuse holder is bad.  Brush bearings are causing a bind not allowing free movement up and down. ...
  • Page 86 Problem Brush Lift motor does not run when tested in the Output Test. You will need to determine if power is getting to the motor. Possible Cause  Fuse is blown or fuse holder is bad.  Brush bearings are causing a bind not allowing free movement up and down. ...
  • Page 87 Problem Oil Head Motor runs, but Input 001 does not operate when oil head is moving or it was interrupted. Possible Cause  Board counting sensor has failed.  Wire between sensor and PLC is damaged or loose causing an open connection. ...
  • Page 88 Each Driver Board has a switch at terminals 10 and 11. Terminal 10 is the Common and terminal 11 is Normally Open. The switches are wired in series back to Input 009. Possible Cause  Turning power off, then back on quickly, will send the driver into fault. ...

  • Page 89: Conditioning System Problems That Do Not Display Errors

    This error lets you know that the machine is low on conditioner (oil). Simply inspect each of the conditioning cartridges and replace the one or both of the empty cartridges. If this does not clear the error the float may have a problem.
  • Page 90 Board counting target loose. c. Wrong program was run or someone has changed the program (#1 culprit). d. Belts are too tight on one or both of the moving heads. e. Shaft bushings need lubricated. KEGEL’s Original Mission By: John Davis...

  • Page 91: Oil Patterns

    Kegel, which utilizes the groundbreaking technology of the FLEX lane machine. With the innovative features in the Kegel FLEX lane machine, three of the patterns in each series will use a combination of the variable buffer speed, multi-mic stream, and dual lane conditioner features.
  • Page 92 John Davis, the Founder of Kegel, was from Missouri and used to have a saying; “they always like ‘em easy in St. Louis.” The Gateway Arch pattern is a tribute to that saying and yes, the composite shape is one large arch…from 9R-9L!
  • Page 93 CHALLENGE 3.1:1 to 4.9:1 Known as the Crown of Palaces, this Challenge Series pattern is also a wide crown-shaped pattern at 38’ in length. Because of the “not too long and not too short” length of this oil pattern, along with being dome like in shape, this jewel can wash away all past sins if you decide to visit it.
  • Page 94 SPORT 3.0:1 or Less 38’ patterns can often handcuff players because they are too short to play inside, but too long to play outside. However, within the Alcatraz oil pattern there looks to be an escape route, and many have tried to use it, but very few have succeeded.
  • Page 95 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 winning technical support department, Lane Maintenance Central, will also be available for questions and to assist in setting up these patterns in your bowling center for your customers.

  • Page 96: Troubleshooting Lane Conditions

    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. However, mixing cleaner stronger than a 4 to 1 ratio is not good either.
  • Page 97 10. Did someone put the wrong conditioner in the oil tank or use the wrong cleaner? Always make sure that your KEGEL lane machine uses KEGEL products. We have thoroughly tested and established recommendations for all of our lane maintenance...

  • Page 98: 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 carry down? A: Shorten the applied oil distance.
  • Page 99 Q: What should I do if the track dries up too quickly? A: Many bowling centers do not apply enough oil to the track on both forward and return passes. The volume (in units) at the end of the pattern should be slightly more than the outside boards.

  • Page 100: Chapter 3

    CHAPTER Cleaning System Theory of Operation The cleaning system is the result of years of experience with automated lane care. The changes that the game has gone through over the years have created the need for improved ways to remove the dirt and conditioners.

  • Page 101: 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 102: System Settings Cleaning Menus

    System Settings Cleaning Menus The following are the Change Pattern/System Settings that relate to the cleaning of the lane. All System Settings adjustments are individual to the pattern selected and the below information will vary based on whether the lane machine has the Cleaner Tank upgrade or not.

  • Page 103: With Standard Cleaner Tank System (Single Tank)

    To turn the backend Cleaning ratio off, simply increase the Change Mix Distance to the max value of 59 feet and this function will be turned off. Choosing the same ratio for backend cleaning as front end cleaning will also act as if this feature is turned off. With Standard Cleaner Tank system (single tank) Within the Flex System Settings screens the operator has the ability to reduce the cleaner volume output on the...
  • Page 104 This adjustment should be monitored and checked. The Sensor on the WALKER or FLEX located on the Squeegee assembly is used to stop the machine any time needed. It works when the Sensor goes passed end of the Pindeck. When the machine is stopped by the Sensor there is no buzzer sound from the touchscreen.

  • Page 105: Fine-Tuning For Stopping The Machine At The End Of Lane

    Machine overview showing maximum distance for Forward Travel. The drive wheels cover 7-pin & 10-pin spots when squeegee is off the pin deck Fine-Tuning for Stopping the Machine at the End of Lane It really does not matter which function stops the lane machine, just as long as it stops and the squeegee completely clears the tail plank.

  • Page 106: Pindeck Treatment Settings

    Pindeck Treatment Settings THE OPERATOR MUST FULLY UNDERSTAND THE CARE NEEDED TO USE THIS FUNCTION!! THE MAINTENANCE AND UPKEEP OF THIS PART OF THE MACHINE SHOULD ONLY BE PERFORMED BY THE MOST TRUSTED PLAYER ON THE TEAM!!! The Pindeck Treatment feature is a new item as of the 2016 FLEX and FLEX Walker model lane machines and is used to help eliminate sliding pins causing out-of-ranges and other issues.

  • Page 107: Programming The Pindeck Feature

    When the Pindeck Treatment mode is ‘on’, you will have screens pop up that will remind you to be certain that you are ready to go. This would include removal of the Tip Cover and the tip assembly firmly in place in the head block. DO NOT LOSE THE TIP COVER ASSEMBLY!!! Programming the Pindeck Feature The Pindeck Treatment has two ways it can be used, one is...

  • Page 108: Adjustments

    Adjustments The tip height to the bowling lane should be equal to the tip height of the cleaner tip assembly, which is flush with the frame. Adjusting the tip up or down from the default height (flush with the frame) will change the start and stop points of the treatment stream.
  • Page 109 4. Place the cap and hose assembly on top of the new bottle and push firmly on the outside portion of the cap to attach it to the stem. Even though the protective cap is in place, be careful to not press the center button during this process, you will have a sticky mess to clean up! If replacing the entire cap, remove the protective cap after installing the actuator cap and press down to break the plastic on...

  • Page 110: Duster Settings

    Duster Settings Go to the Main Menu and press on DUSTER SETTINGS and the screen will change. Press on a function and the screen will go to an adjustment screen. If resetting the duster cloth counter, press RESET CLOTH. The lane machine will always be set to have the duster operate during all conditioning modes.
  • Page 111 DEFAULT # OF LANES ON ROLL is used to trigger the “Almost Out of Cloth Warning” that pops up in the HOME screen. 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.

  • Page 112: Special Functions

    The unwind time varies from 10 for a fresh roll to 22 for an almost empty roll. If accidentally reset, use an educated guess on how much of the roll is already used and set your time accordingly. EXAMPLE: If the roll is about half used, set the time to 16. TECHNICAL NOTE Resetting the DUSTER counter prior to the roll of cloth being empty could reduce the cleaning efficiency of the machine.

  • Page 113: Mechanical Adjustments

    Mechanical Adjustments Cleaner Pump Volume Adjustment with standard Cleaning System The cleaner pump volume will be checked in the same menu as the oil volume. Go to the Main Menu and press TEST OIL CLEANER PUMP VOLUME, then press: CLEANER PUMP CALIBRATION AND ADJUSTMENT In this screen follow these steps: 1.

  • Page 114: Cleaner Pump Volume Adjustment With Cleaner Mixing System Upgrade

    Cleaner Pump Volume Adjustment with Cleaner Mixing System Upgrade The cleaner pump volume can also be checked in the same menu as the oil. Go to the Main Menu and press TEST OIL CLEANER PUMP VOLUME, then press CLEANER PUMP CALIBRATION AND ADJUSTMENT In the Cleaner Pump Calibration screen, you can test the water volume output, the concentrate volume output or...
  • Page 115 Below is a chart to determine the amount of Water and the amount of Cleaner that should be dispensed during testing. REGULAR CONCENTRATE: (example Defense C) If you were to test the water output at 5:1, you would see by the chart that a total volume of 25.00mL would be dispensed.

  • Page 116: Cleaner Head Timing Belt

    When testing Super Concentrate it will be 8 times the normal run compared to the water test because of the low volume used. Press More Ratio Info to see comparisons with normal concentrate and super concentrate when it comes to how many caps of super concentrate to 2.5 gallons of water.

  • Page 117: Duster Switches

    The wheels need to be as close to the lane as possible without touching. For proper adjustment the lanes need to be relatively flat lengthwise. Tighten the bolts in the housing once the desired gap is achieved. Both momentary wheel housings should have the same height adjustment on both sides.

  • Page 118: Squeegee Blades

    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. The switches on both sides should clearly actuate before the cushion lever screws hit the stops and there should be a small amount of over-travel of the switch levers.
  • Page 119 Press the SQUEEGEE LIFT TEST BUTTON once. The squeegee motor will activate and rotate 180°, this will lower the squeegee. If the squeegee does not stop in the down position, check the condition of the Squeegee Down Switch. With the squeegee down, take a straight edge and rest it on the squeegee blade across the main drive wheels to the rear drive wheels.

  • Page 120: Squeegee Switches

    Squeegee Switches The squeegee switches should have a little over-travel in the lever of about 0.015 (0.381 mm). To adjust, loosen the mounting screws a little (but not too much) so the assembly can be tapped to a fine adjustment using feeler gauges. When the proper adjustment is made you can tighten the screws.

  • Page 121: Changing Duster Cloth

    If the Cushion Roller shows excessive wear, it will be necessary to replace the entire assembly. Changing Duster Cloth The machine uses a patented Dual Motor Ratcheting (DMR) Cloth system. The duster assembly operates by means of two brake motors. The first unwinds cloth and sets the cushion roller down on the lane surface.

  • Page 122: Filling The Cleaner Supply Tank

    Filling the Cleaner Supply Tank With separate water and cleaner tanks: 1. To fill the Cleaner Supply Tank, the machine should be in the down or operating position on the lane. 2. Add water to the supply tank located on the left or the 7 pin side. Add water until you reach ½”...
  • Page 123 accumulates between baffles on the opposite side of the tank dirty cleaner may be discharged from the vacuum exhaust and onto the lane until the line is cleared. 4. Transporting the machine with waste in the recovery tank is one of the worst things that an operator can do.
  • Page 124 shown as "A" in the diagram). Hold the end bell containing the rotor (as shown on opposite page) with tubing retainer grooves pointing down. Remove old tubing. Place new tubing (which is broken in at the factory before shipping) in the right groove and against the first two rollers.

  • Page 125: Secondary Pump Tubing Replacement (Upgraded Machine Only)

    Secondary Pump Tubing Replacement (Upgraded machine only) For the FLEX machines that are equipped with the Cleaner Mixing System upgrade, it will be necessary to replace the tubing inside the cleaner pump motor periodically. Because of the availability of two types of cleaner, standard concentrated cleaner and super concentrated, different tubing will be used for each.

  • Page 126: Troubleshooting The Cleaning System

    5. Check vacuum housing once a week and clean if any debris is present. 6. Check vacuum hose from squeegee head to tank for clogs at least once a year in high lineage centers. We have seen clogs you would not believe, some look like bath tub drains with dirty, hairy clogs the size of dead rats.
  • Page 127 Problem Duster Motor UNWIND motor does not run. Possible Cause  Duster cloth is empty. Replace cloth.  One or both of the Duster Up Switches are stuck. Check if Input 0CH 10 has an LED light showing on the PLC with the cushion roller adjusting screws off the switches. ...
  • Page 128 This error is generated when the present unwind time reaches 25, which it should never reach. The only way to see this error is to forget to reset the cloth after changing it or putting half a roll in the machine and guessing too high for the present unwind time. Normally, this error screen occurs when Input 1CH 00 fails to receive a signal within 3.5 seconds of the motor starting.
  • Page 129 Problem Squeegee motor does not run when tested in the Output Test. You will need to determine if power is getting to the motor. Possible Cause:  Fuse is blown.  Squeegee linkage is in a bind.  Relay came loose in socket base or has failed. ...

  • Page 130: Cleaning System Problems That Do Not Display Errors

    Machine is low on cleaner or water. Fill and restart machine to clear the error from the screen. If this does not clear the error the float may have a problem. In a pinch you may temporarily bypass the float allowing you to finish cleaning.
  • Page 131 3. Machine leaves water on the lane after a test clean in various spots but cleans everywhere else. a. Squeegee not low enough to the lane (#1 cause). b. The lane has bad depressions, possibly more than 1/100 of an inch (mostly around screw holes).
  • Page 132 10. Duster cloth hangs down on one side and sometimes touches the lane when the machine exits from of the lane. a. Duster switches are out of adjustment; contacting one switch too soon. b. Duster plug bolt is loose from the side of the machine. c.

  • Page 133: 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. The charger provides a display of the charging voltage, charging AMP’s and the percentage of what the charger is charging at.

  • Page 134: Constant Voltage Regulator - Cvr

    approximately 1-2 hours depending on the beginning voltage. After the Charging stage is complete, the charger will then go into the Conditioning stage. During this stage the output voltage will drop to around 28 to 28.8 volts during this time. This process will take approximately 2 hours.

  • Page 135: Batteries

    Batteries Battery Cycle Life When running the lane machine only once per day, the maximum amount of lanes that can be done with this battery is 40 lanes. When running the machine twice per day, the maximum amount of lanes that can be done is 24 lanes per cycle, or a total of 48 lanes per day.

  • Page 136: Replacing Batteries

    Replacing Batteries Replacing the battery is simple, but with the center compartment hinged open, great care should be used whenever this job is done. 1. First turn the E-Stop OFF. Power to the machine must be turned off 2. Refer to Chapter 1 and remove the Lids and side covers. 3.

  • Page 137: Troubleshooting Battery & Charging Problems

    Troubleshooting Battery & Charging Problems Battery problems are no fun no matter what piece of equipment you are using. It is a fact of life you will experience battery problems but to have a lane machine that has no cord … well it may just be something you are willing to deal with.
  • Page 138 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 on the screen matches the correct Voltage from the external voltmeter.
  • Page 139 Battery connections can be very deceiving when there is a bad connection. You can read fully charged battery voltage but just as soon as a load is introduced it is gone. When it comes to 24-Volt battery connections, you must have nothing less than perfect connections or you may be dead in the water.
  • Page 140 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 141: Chapter 5

    CHAPTER Drive Systems Manual Walker Operation From this screen on the Walker you can position your machine, test the motors, and return the machine back to the foul line in the event of an error. While in the Home Screen press MOVE MACHINE and the following screen appears: To move your FLEX Walker like a pro you should practice and pay close attention to your main approach drive wheels.

  • Page 142: Approach Adjustments

    To turn the machine use the two turning buttons, the one on the left is Counter-Clockwise direction the button to the right is Clockwise. Like the other buttons, they will disappear while the machine is moving. If the machine is parallel to the foul line and the main drive wheels are on the center board, the machine will be lined up with the lane when turned 90 degrees.
  • Page 143 The machine will not enable Super Advance function if steps 1, 2, 5, 6, 7, and 8 are used, only the above 6 Step method will work. Call Kegel for help when using the Super Advance function. To assist you in determining what the starting values should be menu to the INPUT/OUTPUT TEST and then press DRIVE MOTORS.
  • Page 144 You must first have an idea what path the machine is going to take. First, make sure the machine is parked on the lane behind the foul line where it will normally stop after running a lane and reset the counter. If the machine needs to back-up farther than where it normally stops, then press the reverse button and stop the machine at the new location and write down the number in the counter.

  • Page 145: Automatic Lane To Lane Adjustments

    Automatic Lane to Lane Adjustments The FLEX Walker is equipped with automatic lane to lane adjusting. The two whiskers mounted in the front of the machine not only steer the machine into the lane but they also detect if the machine is traveling too far or too short. When the machine is programmed to travel left to right if the 7-pin whisker hits first, it will indicate the machine has traveled short and will add one count to the value for that lane.
  • Page 146 The machine will clean and condition 6 lanes while adjusting its speeds using pattern 31 (calibration pattern). Press Start Speed Adjust and the machine will start operating. The machine sets 10 IPS first for the Forward and Reverse settings. The number to the left of Analog Speed Value is the Step Number; 1 is 10 IPS Forward and 2 is 10 IPS Reverse, 3 is 14 IPS Forward and 4 is 14 IPS Reverse.

  • Page 147: Adjustments

    Basically, the bumper wheels need to be set to prevent the guide roller on the opposite side from sitting on top of the lane. If the adjustment is too wide the machine may get wedged between the foul lights. Safety Stop Bumper Left Bumper Switch The machine is equipped with a front bumper in case the machine comes in...

  • Page 148: Rear Approach Wheel Chains

    To adjust 10-pin Approach Drive Chain: 1. Loosen the three screws that secure the center compartment and hinge it back. 2. Locate the chain idler adjustment and loosen the main pivot and adjusting jam nut. 3. Adjust the idler until there is no play in the approach wheel. Make sure the sprockets not come in contact with each other after the adjustment is made.

  • Page 149: Guide Rollers

    Guide Rollers REAR GUIDE WHEEL FRONT GUIDE WHEEL Adjustment of the front guide rollers may be needed if the bowling center has lanes that have been injected or if the gutters are even with the lane surface causing the machine to not track properly.

  • Page 150: Adjusting The On Lane Sensor (Ols)

    The goal is when the machine enters the lane and the whiskers just miss the guide rollers never have a chance to high-center the machine and cause a travel error. The whisker should just miss the foul lights and seat the machine on the lane correctly without hearing a guide roller snap over the edge of the lane.
  • Page 151 decrease the ACCEL time (which could cause the machine to make sudden speed changes). This function can cause travel errors in the pit if the acceleration time is too slow. Deceleration trim pot is adjusted for smooth decelerations from one speed to the next. Decelerating too quickly will possibly cause the drive board to shut down from an over- voltage fault when going from a higher speed to a lower speed.
  • Page 152 The above speed pots are sealed in place after being adjusted in factory using liquid tape. Balancing the Two Walker Drive Motors The two drive motors are “balanced” with a long 22 AWG yellow wire. This wire is used on either the 7-pin or the 10-pin drive motor, depending on which motor needs more resistance.

  • Page 153: Maintenance

    Maintenance There are a few things that the operator should do to maintain the Drive System. Here are some suggestions that should be done to keep your machine in proper working order. 1. Keep all of the bushings oiled on the drive shaft (one or two drops is plenty). Do not allow chains to get dry but do not over-oil.
  • Page 154 With a flathead screwdriver remove the drive motor brush cap and remove the brush. It may be necessary to pry this out with small screwdriver. Next, with the machine standing up, remove the opposite side drive motor brush. With the machine in the upright, transport position, you will have access through the bottom plate of the lane machine.

  • Page 155: Troubleshooting

    Troubleshooting 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 156 Problem The drive motor does not run Possible Cause:  Forward Relay is loose in socket or failed.  Reverse Relay is loose in socket or failed.  Motor control plugs is loose or unplugged. Check speed control and drive motor plugs.
  • Page 157 Whisker errors are generated when the whisker is already pulled away from the switch when the machine is started. A whisker or switch that is damaged or just out of adjustment can cause this error. Input 109 is for the 7 pin and input 110 is for the 10 pin. Normally this Walker error screen appears when Input 1CH 06 fails to receive a signal within 1.5 seconds of the 7-pin Approach Motor starting.
  • Page 158 Problem 7-pin Approach Motor runs but gives an error. Possible Cause:  Sensor has failed.  Bad connection between sensor and PLC.  Chain is broken that drives sensor target.  Main drive chain to rear wheel is off.  Sensing target is loose or has fallen off. Problem 7-pin Approach Motor does not run, menu to MOVE MACHINE screen to test motors.
  • Page 159 Problem 10-pin Main Drive Motor runs but gives an error. Possible Cause:  Sensing target is loose or has fallen off.  Sensor has failed.  Bad connection between sensor and PLC.  Chain has broken that drives sensor target. ...
  • Page 160 The OLS LANE error is enabled when the machine begins its movement toward the lane. If the machine takes more than 8 seconds to close the normally open contacts, it will display the error. The machine could either be high-centered on the lane by a guide roller or the speed is set too slow.

  • Page 161: Drive System Problems That Do Not Display Errors On Lane Or Approach

    Drive System Problems that Do Not Display Errors on Lane or Approach There are a number of things that can go wrong with the Drive System and the Walker will appear to operate poorly. Most of these problems can be corrected before the machine fails, but only if the operator is paying close attention.

  • Page 162: Chapter 6

    CHAPTER Computer and Control Relays Programmable Logic Controller (PLC) Battery Input Terminal Connections Input Indicators KOSI & Wireless Port Output Indicators Output Terminal Connections Analog Dip switches Touchscreen under door Status Inputs & (Default is OFF) Indicators Outputs...
  • Page 163 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 WIRE COLOR...
  • Page 164 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 165 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 166: Plc Outputs

    PLC Outputs Here is a list of the OUTPUT numbers for the PLC along with their, wire color, and designations. OUTPUT DESCRIPTION WIRE COLOR 100.00 OIL PUMP MOTOR 100.01 POWER OFF RELAY GRAY / YELLOW 100.02 FORWARD MAIN DRIVE GREEN / ORANGE 100.03 REVERSE MAIN DRIVE YELLOW / VIOLET...
  • Page 167 INPUT / OUTPUT TEST 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. The Brush Lift test also shows the inputs that control the motor to stop in the proper position.

  • Page 168: Fuses

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

  • Page 169: Analog Controls

    Analog Controls The variable speeds for the Cleaner pump and Drive Motor(s) in the machine are controlled by a built in analog output. The signal comes from the green junction on the PLC first, then onto the Motor Speed Control Boards located on the left side of the electrical compartment.

  • Page 170: Control Relays On The Flex / Flex Walker

    Control Relays on the FLEX / FLEX Walker All of the components on the FLEX and FLEX Walker 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 172: Chapter 7

    CHAPTER Miscellaneous Parts Stickers and Decals...

  • Page 175: Fittings

    Fittings Elbow- Elbow- Elbow- 1/4” Tube x 1/4” 3/8” Tube x 3/8” 3/8” NPT x 1/4” Tube - Tube Tube 154-0225 Elbow- Elbow- Elbow- 1/4” Stem x 1/4” 3/8” Stem x 3/8” 1/4” Stem x 1/4” Hose Tube Tube Barb Elbow- Reducing Union- Union-...

  • Page 177: Chapter 8

    CHAPTER Mechanical Drawings Battery and Chargers ......................161 Flex Lid and Cover Assembly ....................163 Flex Panel Exploded View ..................... 165 Flex Top View ........................167 Flex Bottom View ........................169 Flex Left Side View ........................ 171 Flex Right Side View ......................173 Flex LDS Assembly ........................

  • Page 179: 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 184: Flex Panel Exploded View

    REV. 1/17 TOP VIEW - FLEX INDEX PART DESCRIPTION NUMBER QTY. NUMBER 158-8414 BUFFER MOTOR - 24VDC - 500RPM - STANDARD 158-1406B BUFFER MOTOR BRUSHES (PAIR) 164-9016 BUFFER BELT STANDARD 158-9401 PULLEY (14 TOOTH 1/2" BORE) 164-8014 BUFFER MOTOR - 24VDC - 700RPM - VARIABLE BUFFER 158-1405B BUFFER MOTOR BRUSHES (PAIR) 164-9017 BUFFER MOTOR BELT VARIABLE 164-9014A BUFFER MOTOR PULLEY ASSEMBLY...

  • Page 194: Flex Lds Assembly

    REV. 3/16 FRONT HANDLE ASSEMBLY - FLEX INDEX DESCRIPTION NUMBER QTY. PART NUMBER 153-2052 HHCS - 1/4-20 X 7/8 153-2014 1/4 LOCKWASHER 153-2004 1/4 FLATWASHER 164-8073F FRONT HANDLE - COMPLETE ASSY 153-2996 SCREW - FHCS 10-24 X 3/4 BLACK OXIDE 164-6072 FRONT HANDLE PLUG 164-6087...
  • Page 199 10 12 9 10 2 13 8...

  • Page 202: Flex Walker Panel Exploded View

    REV. 1/18 TOP VIEW ‐ FLEX WALKER INDEX  PART  DESCRIPTION NUMBER QTY. NUMBER 158‐8414 BUFFER MOTOR ‐ 24VDC ‐ 500RPM ‐ STANDARD 158‐1406B BUFFER MOTOR BRUSHES (PAIR) 164‐9016 BUFFER BELT 158‐9401 PULLEY (14 TOOTH 1/2" BORE) 164‐8014 BUFFER MOTOR ‐ 24VDC ‐ 700RPM ‐ VARIABLE BUFFER 158‐1405B BUFFER MOTOR BRUSHES (PAIR) 164‐9017 BUFFER MOTOR BELT 164‐9014A BUFFER MOTOR PULLEY ASSEMBLY 164‐8217M RIGHT MAIN DRIVE MOTOR 24V 158‐8602 LEFT DRIVE MOTOR 24V 158‐1405B DRIVE MOTOR BRUSHES (PAIR) 154‐9601 CHAIN (FOR 153‐9002, INSIDE AND OUTSIDE SPROCKET) 153‐9444 CHAIN (FOR 153‐9003, MIDDLE SPROCKET) 153‐9047 MASTER LINK #40 153‐9048  OFFSET LINK #40 153‐9002 SPROCKET ‐ 40B13 (5/8 IN) INSIDE AND OUTSIDE SPROCKET 153‐9003 SPROCKET ‐ 40B10 (5/8 IN) INSIDE AND OUTSIDE SPROCKET 158‐8407 VACUUM MOTOR ‐ 24VDC 158‐8404D CLEANER PUMP ASSEMBLY...

  • Page 206: Flex Walker Bottom View

    REV. 1/16 LEFT SIDE - FLEX WALKER INDEX PART DESCRIPTION NUMBER QTY. NUMBER 158-8403 ASSEMBLY - DUSTER MOTOR 24VDC 164-8027 CLEANER PUMP ASSEMBLY - CONCENTRATE (UPGRADE ONLY) 164-8025 CLEANER TUBING #14 FOR SUPER CONCENTRATE 164-8026 CLEANER TUBING #16 FOR REG CONCENTRATE 158-8402 BUFFER LOWERING MOTOR 164-8032 HEAD DRIVE MOTOR ASSEMBLY 153-0001BK CASTER ASSEMBLY (3 INCH DUAL WHEEL)- BLACK...

  • Page 208: Flex Walker Left View

    REV. 1/16 RIGHT SIDE - FLEX WALKER INDEX PART DESCRIPTION NUMBER QTY. NUMBER 158-8402 SQUEEGEE/BRUSH LIFT MOTOR - 24VDC 158-8403 DUSTER MOTOR ASSEMBLY - 24VDC 153-7203 BUMPER WHEEL 154-1220 PROXIMITY SENSOR 153-0001BK CASTER ASSEMBLY (3 INCH DUAL WHEEL)- BLACK...

  • Page 210: Flex Walker Right View

    REV. 1/16 FRONT HANDLE ASSEMBLY - FLEX WALKER INDEX DESCRIPTION NUMBER QTY. PART NUMBER 164-8073 FRONT HANDLE ASSEMBLY 164-6069 FLEX FRONT HANDLE BLOCK (LT) 164-6068 FLEX FRONT HANDLE BLOCK (RT) 153-2996 SCREW - FHCS 10-24 X 3/4 BLACK OXIDE 164-6072 FRONT HANDLE PLUG 164-2009 SHCS-1/4-20...

  • Page 218: Plc Plate Assembly

    REV. 2/16 OIL VALVE ASSEMBLY INDEX PART DESCRIPTION NUMBER QTY. NUMBER 154-8298 OIL CONTROL VALVE (24VDC) WITH EXTENEDED WIRES 154-0613 ELBOW - 1/8 NPT X 3/16 TUBE 154-0224 MALE CONNECTOR - 1/4" TUBE X 1/8 NPT 158-8632 OIL STEPPER MOTOR ASSEMBLY 164-8021 FLEX PULSE SUPRESSION TUBE 154-1214 FLUID METERING PUMP-0.05 ML/STROKE 158-9403 PULLEY - 26XL037 X 5/16"...

  • Page 220: Oil Valve Assembly

    REV. 3/16 SUB TANK CARTRIDGE ASSEMBLY INDEX PART DESCRIPTION NUMBER QTY. NUMBER 164-8015 FLEX 1.5L CARTRIDGE 164-8015A CARTRIDGE ONLY (NO PLUNGER ASSEMBLY) 164-6015A FLEX CONDITIONER SUB TANK A 164-6015B FLEX CONDITIONER SUB TANK B 154-0212 CONDITIONER TANK FILTER ASSEMBLY 154-8693 FLOAT SWITCH ASSEMBLY 164-8007 OIL VENT VALVE ASSEMBLY 164-6124 OIL PLATE ASSEMBLY 153-2019 LOCKNUT - 8-32 (NYLOK)

  • Page 222: Oil Head Assembly

    REV. 2/16 OIL HEAD ASSEMBLY INDEX PART DESCRIPTION NUMBER QTY. NUMBER 164-8051 DUAL OIL TIP WITH FITTINGS 164-6046 FLEX HEAD BAR SUPPORT 164-6104 OIL TIP HOSE ANGLE 153-2806 FLAT HEAD PHILLIPS - 8-32 X 5/8 153-2231 LOCKNUT - 4-40 153-2724 FHMS PHILLIPS - 4-40 X 1/2 164-8023 OIL TUBE SLEEVE 154-9201 BELT FOR HEAD DRIVE 153-2937 SHAFT COLLAR 3/4"...

  • Page 226: Brush Lift Rod Assembly

    REV. 2/16 BRUSH LIFT ROD ASSEMBLY INDEX PART DESCRIPTION NUMBER QTY. NUMBER 158-8402 MOTOR ASSEMBLY - 24VDC 158-8634 SQUEEGEE/BRUSH MOUNT PLATE ASSEMBLY 158-9614 BALL BEARING MINITURE 164-8218 FLEX BRUSH LIFT ROD - 2016 164-6011 FLEX BRUSH LIFT ROD TO BEARING LINK 153-2027A JAM NUT - 5/16-18 153-2801 SHOULDER BOLT-3/8 X 3/8 (5/16-18) 153-9803 FLANGED BUSHING (3/8 X 1/2 X 1/4)

  • Page 228: Oil Transfer Assembly

    REV. 1/16 VACUUM MOTOR ASSEMBLY INDEX QTY. PART NUMBER DESCRIPTION NUMBER 158-8407 VACUUM MOTOR ASSEMBLY (COMPLETE) 158-1421B VACUUM MOTOR BRUSHES 153-0204F FAN BLADE 153-0204H FAN BLADE COVER 1.4* 153-6221M VACUUM WALL PLASTIC ADAPTER (See Below) 158-8618 VACUUM MOTOR HOUSING 154-0228S STOCK - 1/8 IN GRAY FELT 153-2830 HEX HEAD SELF TAP #10 X 5/8 SCREW...

  • Page 230: Cleaner Tank Assembly

    REV. 9/14 CLEANER TANK ASSEMBLY INDEX PART DESCRIPTION NUMBER QTY. NUMBER 164-8042 CLEANER SUPPLY TANK (COMPLETE) 164-6016 CLEANER SUPPLY TANK ONLY 154-8693 CLEANER SUPPLY TANK FLOAT ASSEMBLY 164-8041 FLEX UPGRADED WATER TANK ASSEMBLY (COMPLETE) 164-6740 UPGRADED WATER TANK (TANK ONLY) 164-8043 FLEX UPGRADED CLEANER TANK ASSEMBLY (COMPLETE) 164-6741 UPGRADED CLEANER TANK (TANK ONLY) 164-8081 SUPPLY TANK CAP WITH GASKET...

  • Page 232: Cleaner Head Assembly

    REV. 3/16 CLEANER HEAD ASSEMBLY INDEX PART NUMBER QTY. DESCRIPTION NUMBER 154-8852 CLEANER HOSE AND TIP ASSEMBLY (COMPLETE) 164-0012M CLEANER TIP WITH CHECK VALVE FITTING - MALE LUER TO 1/8 IN HOSE BARB 154-0863 SPRING - TIP RETAINER 153-2713 COLLAR - 3/8 X 3/4 X 3/8 153-2804 153-2902 COLLAR - 1/2 X 1 1/8 X 1/2...

  • Page 236: Recovery Tank Assembly

    REV. 2/16 RECOVERY TANK INDEX PART DESCRIPTION NUMBER QTY. NUMBER 164-8017 FLEX RECOVERY TANK 164-8017F RECOVERY TANK FILTER 153-2968 SCREW - 1/4-20 X 3/4 FHSHCS 164-6120 FLEX RECOVERY TANK COVER PLATE 153-8827T 1-1/4 PVC ELBOW-TANK INLET (NO THREADS) 153-2406 HOSE CLAMP (2 INCH) 154-0260 FLEXIBLE HOSE - SOLD BY THE INCH 154-0607...

  • Page 240: Vacuum Motor Assembly

    REV. 3/16 PINDECK TREATMENT ASSEMBLY INDEX PART DESCRIPTION NUMBER QTY. NUMBER 156-8310 SPOT ON PINDECK TREATMENT (CASE OF 4) 164-8226 PINDECK SPRAY SOLENOID 154-0248 REDUCING UNION 154-0222 ELBOW 1/4" STEM X 1/4" TUBING OD 164-2065 SHAFT COLLAR 3/16" 164-1227 SOLENOID SPRING ASSEMBLY 164-6242 SOLENOID BRACKET ASSEMBLY 164-6245 DRIP TRAY ASSEMBLY 164-6241 CAN CLIP BRACKET...
  • Page 242 REV. 3/16 ZTR ASSEMBLY - LEFT INDEX QTY. PART NUMBER DESCRIPTION NUMBER KICK UP WHEEL MOUNTING BLOCK 164-6034 153-2939 NYLON WASHER 3/4" X 1/16" 158-7001 DRIVE WHEEL 4.5 IN 164-6030 FLEX KICK-UP WHEEL SHAFT 158-6705 BUMPER WHEEL SIDE POST CHAIN (35P67) ZTR KICKUP 164-9005 153-2602 HHCS - 5/16-18 X 3/4...

  • Page 244: Flex Walker Left Ztr Assembly

    REV. 3/16 ZTR ASSEMBLY - RIGHT INDEX PART NUMBER QTY. DESCRIPTION NUMBER 164-8219 KICK UP WHEEL MOUNTING BLOCK 153-2939 NYLON WASHER 3/4" X 1/16" 158-7001 DRIVE WHEEL 4.5 IN 164-6030 FLEX KICK-UP WHEEL SHAFT 164-6221 BUMPER WHEEL PLATE 164-9005 CHAIN (35P67) ZTR KICKUP 153-2602 HHCS - 5/16-18 X 3/4 5/16 LOCKWASHER...

  • Page 247: Chapter 9

    FLEX ELECTRICAL DRAWINGS The following diagrams show wiring schematics for the Kustodian Walker. Detailed diagrams for the Ion follow this section. If you have any questions please call 863-734-0200 or email tech@kegel.net . Flex Motor Wiring Layout Flex Output Wiring Layout...

  • Page 275: Flex Walker Electrical Drawing

    The following diagrams show wiring schematics for the Kustodian Walker. Detailed diagrams for the Ion follow this section. If you have any questions please call 863-734-0200 or email tech@kegel.net . Flex Walker Motor Wiring Layout Flex Walker Output Wiring Layout...

This manual is also suitable for:

Flex 17-5803Flex 17-5805Flex 17-5807Flex 17-5701Flex 17-5703Flex 17-5705 ... Show all

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