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Kegel IKON WALKER Operator's Manual

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OPERATORS MANUAL
4:20
KEGEL LLC
1951 Longleaf Blvd.
Lake Wales, FL 33859
863-734-0200 I 800-280-2695

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  • Page 1 OPERATORS MANUAL 4:20 KEGEL LLC 1951 Longleaf Blvd. Lake Wales, FL 33859 863-734-0200 I 800-280-2695...

  • Page 3: Machine Dimensions

    Machine Dimensions Width – 59.5" (151.13 cm) Height – 16.5" (41.91 cm) Length - 44" (111.76 cm) Weight: IKON WALKER - 350 pounds (159 kg) (Without Battery) 158-1634 Red Battery – 24 pounds (10.8 kg) 158-1634B Orange Battery – 29 pounds (13.1 kg) 158-1634C Yellow Battery –...
  • Page 5 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 6 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 7: Safety First

    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 8: Table Of Contents

    Moving & Transporting Your Lane Machine ................... 13 Filling the Conditioner Tank ....................... 13 Filling the Cleaner Supply Tank ......................13 IKON WALKER Sequence of Events- “How it Works” ............. 14 Basic Steps to Operate Your IKON WALKER ..................18 Move Machine ............................ 18 Starting Your Machine ........................
  • Page 9 ..........................52 ROUBLESHOOTING Conditioning System ....................... 52 Conditioning Problems Indicated by Error Messages ..............52 Conditioning System Problems that DO NOT Display Errors ............54 ............................55 ATTERNS Why do we Apply Oil to Bowling Lanes? ............... 55 Troubleshooting Lane Conditions................... 56 Pattern Troubleshooting....................
  • Page 10 Vacuum Motor & Recovery Tank Assembly ..............142 Walker ZTR Left ......................144 Walker ZTR Right ......................146 CHAPTER 9 ..................148 IKON WALKER ELECTRICAL DRAWINGS ..................148 Terminal Block Wiring Layout ..................149 Output Wiring Layout....................150 Input Wiring Layout ....................... 151 Speed Control Wiring Layout ..................

  • Page 11: 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 12 Kegel. The information contained herein is designated only for use with the Kegel IKON WALKER Lane Machines. Kegel is not responsible for any use of this information as applied to other lane machines.
  • Page 13 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 15: Chapter 1

    Machine Serial Number: Battery Serial Number:____________________________ Register Your Lane Machine It is important to register your new IKON WALKER with Kegel in order to receive valuable updates, service bulletins and your Limited Warranty. IMPORTANT: Please take a minute and register at: www.kegel.net...

  • Page 16: 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 17 (and it is heavy when full). 16. 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.
  • Page 18 IP address to the computer. 4. Open up your internet browser and type in the IP address 192.168.11.1 5. Type in the IP address and click on KEGEL WI-FI ONBOARD. 6. The below screen will appear. Press SCAN to see the available networks.
  • Page 19 7. If no connection is made with the WI-FI device an error will display and could be the password was entered incorrectly or poor signal quality below 20%. If the WI-FI device continues to not connect, call Kegel Tech Support. SETTING UP THE USERS DEVICE Setting up Phone app: 1.
  • Page 20 Setting up KOSI app: 1. To use WI-FI with KOSI, go to KOSI Settings and click on Set IP Address. Update KOSI if you have an older version. 2. Click on Scan for IP Address and in a moment the IP Address as well as the machine serial number should appear.
  • Page 21 Now that a thorough overview of the machine has been completed, we are ready to crank it up! 1. When the machine is powered ON, the touchscreen will illuminate. With power applied, press the MOVE MACHINE button on the touchscreen and demonstrate how easy it is to position the machine.
  • Page 22 11. Watch the machine travel from lane to lane. It is possible to customize the travel to each lane and all settings in your center. 12. Be very alert when machine exits the lane, turns 90 degrees, moves to the next lane, turns back 90 degrees and goes forward toward lane.

  • Page 23: 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 24: Ikon Walker Sequence Of Events- "How It Works

    IKON WALKER Sequence of Events- “How it Works” The following steps detail how the Ikon Walker operates. The Walker should be on the approach in the down or operating position behind the first lane with the HOME SCREEN showing.
  • Page 25 5. As the Walker enters the lane, the 10-pin whisker sensor just brushes the foul light which will turn on the steering relay. This will cause the machine to go into its steering function. The 7-pin motor will slow down due to the steering relay opening up the power to the motor.
  • Page 26 14. When the oil distance has been reached, the machine will shift into high speed and continue to travel toward the pin deck. As the Walker approaches the pin deck, the last squirt distance will turn off the cleaner pump and the moving heads will park.
  • Page 27 25. After a short delay, the Walker will turn 90 degrees (the direction of turn will be determined from the starting lane and ending lane) The machine will stop, have a short delay, move to the next lane, stop, have a short delay, turn 90 degrees, and face the next lane.

  • Page 28: Basic Steps To Operate Your Ikon Walker

    Basic Steps to Operate Your IKON WALKER Carefully set the machine in the operating (down) position on the approach. It should be completely on the approach with the cleaning end behind the foul line. Locate the E-Stop and rotate it clockwise which will release the E-Stop button.

  • Page 29: Starting Your Machine

    Starting Your Machine After you have positioned the machine in line with the lane, in the lower right corner of the screen press OIL LANES. The screen will change to the STARTING LANE screen as shown on the right. From the Starting Lane Screen, you can do the following: 1.
  • Page 30 Enter in your Ending Lane and then press START. The screen to the right will appear and the machine will begin to move onto the lane. Pressing Test Clean quickly before the button disappears will cause the machine to Clean Only. When the machine returns, it will move back onto that same lane and continue to Clean and Condition your lanes as programmed.

  • Page 31: 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 32: Day Planner

    PASSWORDS are used to prevent unauthorized operation of the machine. The lane machine will come with the passwords all set to zero allowing you to customize a 4 digit passcode, such as the 1951 shown in the CHANGE PATTERN and PATTERN OVERRIDE lines. By pressing o n the number to the right of CHANGE PATTERN, a keypad will pop up allowing you to create a unique 4-digit passcode.

  • Page 33: Machine Errors

    Machine Errors The machine is equipped with Error Messages that are displayed on the touchscreen in case the machine malfunctions. These messages will indicate the type of operational error that has occurred. Errors are discussed in detail in the appropriate sections. Whenever the machine is powered up and an error is present (such as an Oil...

  • Page 34: Maintenance, Recharging & Storage

    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 35: Recharging

    Recharging For proper charging: It is necessary to plug the charger into the machine first, then power the charger. When the charger is being unplugged, it is necessary to remove power from the charger, allow the charger to shut down, then unplug the charger from the machine.

  • Page 36: Daily, Monthly And Annual Cleaning

    Here are a few time-saving recommendations: 1. More attention can be given to the approaches and the area just past the foul line. 2. Dusting the approaches is much easier without a cord lying around. 3. Adjust foul lights. This is always an on-going task. 4.

  • Page 37: Lid And Guard Removal

    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 38 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. Slide the conditioning compartment lid back as shown in the pic below left. 2.
  • Page 39 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. Rear Cover Removal With the machine in the upright transport position, locate the two screws that are on the inside front panel and below the buffer brush assembly as shown to the left.
  • Page 40 Side Cover Removal With the machine in the upright transport position, locate the two (2) screws on each side that mount the bottom of the side cover as shown to the right. Next, set the machine down in the operating position and slide back the cleaning compartment lid and remove the two (2) screws that fasten the side covers to the side plate of the machine, then do the same for the two in oil compartment.

  • Page 41: 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 43: 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 44: 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 45 To change the program # to test, press the program # and a Keypad will pop up. Simply change the number in the keypad and press ENTER. After the correct program has been selected, press on the line directly below that says ‘Start Oil Volume Test’. Remove the oil tip assembly from the oil head block.

  • Page 46: Oil Calibration Test

    Oil Calibration Test Program number 16 is a hidden program that is intentionally set for 400 boards to calibrate the oil pump. Before performing your Oil Calibration Test, you will need to remove the oil tip assembly from the oil head and place it in the container used for your oil waste.
  • Page 47 Each load can quickly be condensed to a total number of boards by referring to the Board Chart found at the end of this section. Using the Board Chart, we can determine that a load or stream of oil from 2 - 2 covers 37 boards. After converting all the loads, the numbers become very simple.

  • Page 48: Board Chart For Calibrating Oil Pattern (Program) Loads

    Having the total output for the program will ensure that the program values are entered correctly. It will also help you understand each change you make. Although it is not information that will be used daily, it is a way of explaining a lane condition in exact terms.

  • Page 49: 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 50: Change Pattern

    Change Pattern Press CHANGE PATTERN in the Main Menu screen to access the CHANGE PATTERN menu. To the left is the main CHANGE PATTERN screen. From this screen you can choose the pattern to view and make edits. By pressing on VIEW PATTERNS IN STORAGE, you can view what patterns are stored in the machine.
  • Page 51 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 area looking good. This feature is used to reduce the conditioner near the foul line.

  • Page 52: 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 when loads are present. These distances are automatically calculated based on # of loads and Speed.
  • Page 53 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 54: Adjustments

    Adjustments Conditioning System Buffer Brush The buffer brush is made of a long-lasting synthetic bristles, 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 55: Buffer Belt

    Buffer Belt Adjustment of the Buffer Belt is done with the buffer brush in the down position! Loosen the idler pulley and push it all the way down and fasten tight. Do not over tighten belt!! Idler Pulley Transfer Brush The following steps adjust the transfer brush to the buffer brush.

  • Page 56: 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 I/O TEST then press OUTPUT TEST then press BUFFER to turn on the motor.

  • Page 57: Timing Belt

    Timing Belt There are various timing belts that operate in the conditioning system. 1. Oil Head Timing Belt: This belt should not run loose but do not over tighten. To adjust head belt tension, loosen the 3 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.

  • Page 58: Board Counting Target And Proximity Switch

    Board Counting Target and Proximity Switch The timing for the oil head is a precise adjustment. Remove the plastic cover on the 10-pin side to access the sensor assembly. Once the cover is off, you will be able to see the belt tension and head timing assembly.

  • Page 59: 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 60 Take a right-angle flathead screwdriver and remove the buffer motor brush caps. For some, it maybe easier to remove motor for this maintenance. Once both caps have been removed, take the air compressor and blow the motor out freeing it from any potential carbon build up.
  • Page 61 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 62: Troubleshooting

    Troubleshooting 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 63 Normally, the Brush Up Error occurs when Input 0CH04 fails to receive a signal within 3.5 seconds of the motor starting. Below is a list of the possible causes that can produce a BRUSH UP ERROR. If the Brush Lift Motor does not run, menu to the I/O TEST then OUTPUT TEST and press BRUSH LIFT to check relay operation and voltages.

  • Page 64: 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. Blown fuse. c. Motor brushses worn. Remove/inspect and blow out motor. d. Motor unplugged or has a damaged wire. e. PLC output 101CH00 has failed causing no operation. f.

  • Page 65: Oil Patterns

    The Navigation, Landmark and Element 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 66: 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.
  • Page 67 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 chemicals and supplies.

  • Page 68: 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 69: 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 has created the need for improved ways to remove the dirt and conditioners. Proper cleaning of your lanes is very important to the consistency of your playing conditions.

  • Page 70: 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 71 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 0 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 72: Cleaner Pump Volume Adjustment

    Cleaner Pump Volume Adjustment The cleaner pump volume can also be checked in the same menu as the oil. Go to the main menu and press Cleaner oil calib, then press: go to Cleaner Calibration In this screen follow these steps: 1.

  • Page 73: Duster Settings

    Duster Settings From the Home screen, press Main Menu and you will be able to access the Duster Settings menu. Within this menu, you will be able to reset the number of lanes left in a roll of cloth as well as fine tune the amount of cloth usage.
  • Page 74 TECHNICAL NOTE Resetting the DUSTER counter prior to the roll of cloth being empty could reduce the cleaning efficiency of the machine. Cleaning System Changing Duster Cloth The machine uses a patented Dual Motor Ratcheting (DMR) Cloth system. The duster assembly operates by means of two brake motors.

  • Page 75: Recovery Tank

    8. VERY IMPORTANT! After installing the new roll, you must reset the number of lanes in the cloth. Do this by going to your duster settings in the menus and press RESET CLOTH. Recovery Tank To empty the recovery tank the machine must be in the down or operating position. 1.

  • Page 76: 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 77: 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 78: Adjustments

    Adjustments Cleaning System Cleaner Head Timing Belt The machine 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.

  • Page 79: 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 80 With the squeegee down, take a straight edge and rest it on the squeegee blade across the main drive wheels to the LDS wheels. The gap between the straight edge and the drive wheels should be about 1/8" to 3/16" (3.175mm to 4.762mm) Gap should be 1/8”...

  • Page 81: Squeegee Switches

    Squeegee Switches The squeegee switches should have 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 82: Troubleshooting

    Troubleshooting 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 83 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 DUSTER WINDUP ERROR. If the Motor does not run, menu to the I/O TEST then OUTPUT TEST and press DUSTER UP to check relay operation and voltages.
  • Page 84 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 I/O TEST then OUTPUT TEST and press SQU LIFT to check for relay operation and voltages.
  • Page 85 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 86 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. b. The squeegee double wipe function has been turned off. c.

  • Page 87: Chapter 4

    CHAPTER Battery Power and Charging Systems Charger 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 88: E-Stop

    As the machine operates, battery voltage is displayed on the main running screen. Your ProNautic charger is programmed specifically for the battery in your Ikon Walker. The settings will display Calcium Custom for this reason. When charging, the Volts displayed will be constant at 29.2 during the entire length of...
  • Page 89 … 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 battery and the machine control plate. Always turn off E-Stop when inspecting connections. 1.

  • Page 90: Battery

    Battery Battery Cycle Life When running the lane machine only once per day, the maximum amount of lanes that can be done is 40 lanes. When running the machine twice per day, the maximum amount of lanes that can be done is 24 lanes per cycle, 158-1634 or a total of 48 lanes per day.

  • Page 91: Battery Replacement

    Battery Replacement 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 92: Chapter 5

    Press on MAIN MENU then press on MOTOR SPEEDS to advance to the speed setting screen. When setting no load speeds for the Ikon Walker, you must prop the machine up so the wheels will not touch the approach(block of wood under rear panel). Then you can press on the Operate Motor button.

  • Page 93: Approach Adjustments

    Now make sure the machine is positioned to run and press on Start Speed Adjust. The machine will run one lane at 10IPS and adjust the speeds under load. Monitor the speeds while operating the machine to make sure that the speeds are within range. Minor adjustments can be made to speeds without running Speed Adjust.
  • Page 94 There are 4 steps used for each lane to guide the machine across the center: 1, 2, 7, and 8. Steps 3 through 6 are used for ADVANCED lane to lane programming. STEP #1 is used to stop the machine on the approach after it has exited the lane. STEP #2 is used to turn 90 degrees away from the lane.
  • Page 95 Advanced 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 Advanced function. To assist you in determining what the starting values should be, menu to the APPROACH WALKING menus and then press HELP FIND WALKING VALUES.
  • Page 96 Steering Whiskers The Ikon Walker uses “whiskers” to sense when it is too far to the right (or left) when entering the lane. When the machine enters the lane, and the 7-pin whisker contacts the foul light, the 7-pin drive motor will continue to run and the 10-pin drive will slow down.

  • Page 97: Mechanical Adjustments

    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. After the first whisker contact, the add or subtract feature is disabled for that lane.
  • Page 98 Main Drive Motor Chains It is important for the drive chains to stay tight but not too tight. First, determine what adjustment needs to be made. A chain that is too tight means that there is no movement of the chain when you press between Adjusting Screw the sprockets with your finger.
  • Page 99 Adjusting the Lane-Sensing Whiskers Adjusting a whisker is done by simply loosening the two set screws that hold it to its pivot mount and sliding the shaft in or out. The whiskers will be around 6 ¼ inches (15.24 cm) from the side plate of the Walker depending on foul light castings and the lane installation.
  • Page 100 The two drive motors are “balanced” with a long 22 AWG yellow wire, if needed. This wire is used on either the 7-pin or the 10-pin drive motor, depending on which motor needs more resistance. The wire only receives current while the machine is traveling on the approach and it is only creating a small amount of resistance in the circuit to balance the two motors so they will run at the same speed.
  • Page 101 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 102: 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 103 3. Machine drives off into pit giving a Forward Drive Error. a. Forward Cleaning Distance needs to be Decreased by the correct number of counts. b. Lane Distance shaft is not turning freely. c. Lane Distance target is loose. d. Lane Distance Proximity Sensor is too far from target. e.

  • Page 104: Possible Cause

    In a pinch, you may bypass the sensor temporarily in order to finish conditioning the lanes. If the machine is powered down it will reset back to normal operating mode. Problem : 7-pin Approach Motor runs but gives an error. Possible Cause: 1.
  • Page 105 Problem : 10-pin Main Drive Motor does not run. Menu to the MOVE MACHINE screen to test motors. Possible Cause: 1. CR12 (Forward Relay) is loose in socket base or failed. 2. CR13 (Reverse Relay) is loose in socket base or failed. 3.
  • Page 106 The OLS STUCK error is displayed when the LDS wheel has rotated the target in front of the OLS sensor, causing the input to go on. The BUMPER error is displayed on the Walker when the bumper switch contacts close due to a bad switch or running into something while the machine is moving.

  • Page 107: Chapter 6

    CHAPTER Computer and Control Relays Battery Input Terminal Connections Input Indicators KOSI & Touchscreen Wireless Port Port Output Output Terminal Connections Indicators Analog Dip switches Inputs & Status under door Outputs Indicators (Default is OFF)

  • Page 108: Plc Inputs And Testing

    PLC Inputs and Testing The PLC assembly of the machine has 24 inputs, 16 SSR 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 109 The following wiring drawings will show the simplest way a switch and proximity sensor connect to the PLC. Below is an example of a typical input circuit using a switch. One side of the switch goes to the PLC Input and the other side of the switch goes to Negative Voltage. The PLC Input Common is supplied with Positive Voltage.
  • Page 110 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 111: Inputs And Outputs

    Inputs and Outputs PLC Outputs Go to the main menu, select I/O Test then press OUTPUT TEST and the screen will change to show the first 6 OUTPUTS. Press on an output selection to test. Below is an example of the OUTPUT test screen. The outputs marked OIL VALVE, BUFFER and CLEANER PUMP will toggle ON and OFF when pressed but the rest of the outputs are only momentary buttons and are on only as long as you press on the button.

  • Page 112: Analog Variable Speed Control

    Electrical Panel Fuses Mounted on the control plate are several protective devices for your IKON WALKER. IMPORTANT: Do not over-amp fuses. If you can’t find a direct replacement you will cause damage to the smaller motors. In addition to fuses and breakers, the PLC program also protects the machine by “timing out”...

  • Page 113: Control Relays

    Control Relays All of the components on the IKON 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 SSR relays.

  • Page 114: Chapter 7

    CHAPTER Miscellaneous Parts Stickers and Decals...
  • Page 115 164-0014O-714C 164-0015O-714C 164-0024 - Part Number for the “K” only 164-0023W - Part Number for the “ION” only 164-0025...

  • Page 116: 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- 154-0243 154-0256 0225 1/4” NPT x 1/4” Tube - 154- Elbow- Elbow- Elbow- 1/4” Stem x 1/4” Tube 3/8” Stem x 3/8” Tube 1/4”...

  • Page 117: Mechanical Drawings

    CHAPTER Mechanical Drawings Battery and Chargers ......................109 Lid and Guards ........................111 Top View ............................ 113 Bottom View ..........................115 Left Side View ........................... 117 Right Side View......................... 119 Lift Handle Assembly ....................... 121 LDS OLS Assembly ........................123 Whisker Assembly ........................

  • Page 119: 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 120: Lid And Guard Assembly

    SLIDING LID ASSEMBLY - TAIL 164-8802 REAR PANEL 164-8830 FRONT BUMPER 164-8804 164-8233-2133 IKON WALKER RT SIDE GUARD - GRAY 164-8232-2133 IKON WALKER LT SIDE GUARD - GRAY FLUSH MOUNT LID LATCH (WITH LOCK) 153-2232L SPRING PLUNGER THREADED 164-2069 DETENT - SPRING PLUNGER...

  • Page 122: Top View

    TOP VIEW REV. 10/19 INDEX PART DESCRIPTION NUMBER QTY. NUMBER 164-8414 BUFFER MOTOR - 24VDC - 500RPM - STANDARD 164-1254 BUFFER MOTOR BRUSHES (PAIR) 164-9019 BUFFER BELT 164-9012 PULLEY (15 TOOTH 1/2" BORE) 164-8602A RIGHT MAIN DRIVE MOTOR 24V 164-1246 DRIVE MOTOR BRUSHES (PAIR) 153-9044A ZTR CHAIN (40P29) 154-9601 DRIVE CHAIN (40P41) 153-9047 MASTER LINK #40...

  • Page 124: Bottom View

    BOTTOM VIEW REV. 4/20 INDEX PART DESCRIPTION NUMBER QTY. NUMBER 164-8001A BUFFER BRUSH ASSEMBLY 164-9019 BUFFER BELT ASSEMBLY 164-8815 REAR EDGE GUIDE WHEEL ASSEMBLY - BLACK 153-2401 SPRING - COMPRESSION FOR GUIDE WHEEL (NOT SHOWN) 153-2407 BOLT FOR GUIDE ROLLER - FRONT (NOT SHOWN) 153-6417 REAR LANE EDGE GUIDE ROLLER MOUNT 158-8637...
  • Page 125 DETAIL B DETAIL A...

  • Page 126: Left Side View

    LEFT SIDE VIEW REV. 9/19 INDEX PART DESCRIPTION NUMBER QTY. NUMBER 158-8403 ASSEMBLY - DUSTER MOTOR 24VDC 158-8402 BUFFER LOWERING MOTOR 158-8405 HEAD DRIVE MOTOR ASSEMBLY 158-9403 PULLEY FOR HEAD DRIVE (NOT SHOWN) 164-9019 BUFFER BELT ASSEMBLY 153-0001BK CASTER ASSEMBLY 164-8831 BUFFER IDLER PULLEY (TOP ADJUSTABLE) 153-7203 BUMPER WHEEL ASSEMBLY 164-8211 BUFFER IDLER PULLEY (BOTTOM STATIONARY)

  • Page 128: Right Side View

    RIGHT SIDE VIEW REV. 9/19 INDEX PART DESCRIPTION NUMBER QTY. NUMBER 158-8402 SQUEEGEE / BRUSH LIFT MOTOR - 24VDC 158-8403 DUSTER MOTOR ASSEMBLY - 24VDC 154-1220 PROXIMITY SENSOR 153-7203 BUMPER WHEEL ASSEMBLY 153-0001BK CASTER ASSEMBLY...

  • Page 130: Lift Handle Assembly

    FRONT HANDLE ASSEMBLY REV. 10/19 INDEX DESCRIPTION NUMBER QTY. PART NUMBER 164-8073 FRONT HANDLE ASSEMBLY 164-6069 FRONT HANDLE BLOCK (LT) 164-6068 FRONT HANDLE BLOCK (RT) 153-2996 SCREW - FHCS 10-24 X 3/4 BLACK OXIDE 164-6072 FRONT HANDLE PLUG 164-2009 SHCS-1/4-20 153-2004 1/4 FLATWASHER 164-2017...

  • Page 132: Lds Assembly

    LDS/OLS ASSEMBLY REV. 4/20 INDEX PART DESCRIPTION NUMBER QTY. NUMBER LDS SHAFT ASSEMBLY 154-6821 153-7002AA LDS WHEEL ASSEMBLY 153-2819 SET SCREW - 10-32 X 3/8 154-8619 LDS MOUNTING BLOCK ASSEMBLY - LEFT 164-8829 LDS/OLS BLOCK ASSY (BLOCK W/ BUSHING &ROLL PIN ONLY 154-9213 SPROCKET 25B15 (1/2") 154-9211 LDS AND TACH SENSOR DRIVE CHAIN #25 153-9045 MASTER LINK #25 (NOT SHOWN)
  • Page 133 DETAIL A DETAIL B...

  • Page 134: Whisker Assembly

    WHISKER ASSEMBLY REV. 9/17 INDEX PART DESCRIPTION NUMBER QTY. NUMBER RIGHT WHISHER ASSEMBLY 164-8825 153-2023 1/4-20 HEX NUT 153-2014 1/4 LOCKWASHER 153-2004 1/4 FLATWASHER 158-8611 WHISKER BEARING BLOCK ASSEMBLY WITH BUSHING 153-2227A FHMS - 1/4-20 X 1-1/2 153-2739 SHOULDER BOLT 3/8 IN DIA 1" LONG 158-6641 WHISKER SWITCH MOUNT PLATE 153-2231 LOCKNUT - 4-40 153-1203 MICROSWITCH W/ROLLER...

  • Page 136: Plc Plate Assembly

    PLC PLATE ASSEMBLY REV. 9/19 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) 164-8828 SPEED CONTROL ASSEMBLY - DRIVE 164-8806...

  • Page 138: Oil Valve & Pump Assembly

    OIL VALVE ASSEMBLY REV. 4/20 INDEX PART DESCRIPTION NUMBER QTY. NUMBER 154-8682 CONDITIONER TANK ASSEMBLY 164-8081 SUPPLY TANK CAP (NOT SHOWN) 164-0021 GASKET FOR SUPPLY TANK CAP (NOT SHOWN) 158-8401A OIL PUMP MOTOR ASSEMBLY - GROSCHOPP 158-1422G OIL PUMP MOTOR BRUSHES (PAIR) 154-8816 PULSE SUPRESSION TUBE 154-1214 FLUID METERING PUMP-0.05 ML/STROKE 154-8298 OIL CONTROL VALVE (24VDC) WITH EXTENDED WIRES...

  • Page 140: Oil Head Assembly

    OIL HEAD ASSEMBLY REV. 10/19 INDEX PART DESCRIPTION NUMBER QTY. NUMBER 158-8405 OIL HEAD DRIVE MOTOR ASSEMBLY 158-9403 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...
  • Page 141 DETAIL A...
  • Page 142 BRUSH LIFT ROD ASSEMBLY REV. 4/20 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...

  • Page 144: Oil Transfer Assembly

    OIL TRANSFER ASSEMBLY REV. 4/20 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...
  • Page 145 DETAIL A...

  • Page 146: Cleaner Tank & Head Assembly

    CLEANER TANK AND HEAD ASSEMBLY REV. 4/19 INDEX PART DESCRIPTION NUMBER QTY. NUMBER 158-8433C CLEANER SUPPLY TANK ASSEMBLY (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...
  • Page 147 DETAIL A...

  • Page 148: Duster Assembly

    DUSTER ASSEMBLY REV. 10/19 INDEX DESCRIPTION NUMBER QTY. PART NUMBER 158-8403 DUSTER MOTOR ASSEMBLY 164-8839 CUSHION ROLLER WITH WRAP ASSEMBLY 164-6108A DUSTER PLUG CARDBOARD CORE 164-0047EZ K2 SELECT DUSTER CLOTH (BOX OF 4) CASE 154-0052 PVC TAKE UP REEL ASSEMBLY 153-0429 DUSTER ROLL SUPPORT PIPE (40 INCH) 164-6109A...

  • Page 150: Squeegee Assembly

    SQUEEGEE ASSEMBLY REV. 4/20 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 MINIATURE (NOT SHOWN) 153-1203...

  • Page 152: Vacuum Motor & Recovery Tank Assembly

    RECOVERY TANK AND VACUUM MOTOR REV. 5/16 INDEX PART DESCRIPTION NUMBER QTY. NUMBER VACUUM MOTOR ASSEMBLY 158-8407 153-6221M VACUUM HOSE ADAPTER VACUUM MOTOR BRUSHES (NOT SHOWN) 158-1421B 164-8017 RECOVERY TANK 164-8017F RECOVERY TANK FILTER (NOT SHOWN) 158-0405 RECOVERY TANK GASKET (NOT SHOWN) 153-2968 SCREW - 1/4"...

  • Page 154: Walker Ztr Left

    ZTR ASSEMBLY - LEFT REV. 10/19 INDEX QTY. PART NUMBER DESCRIPTION NUMBER 164-6034 KICK UP WHEEL MOUNTING BLOCK 153-2939 NYLON WASHER 3/4" X 1/16" 158-7001 DRIVE WHEEL 4.5 IN 164-6030 KICK-UP WHEEL SHAFT 158-6705 BUMPER WHEEL SIDE POST 164-9005 CHAIN (35P67) ZTR KICKUP 153-2602 HHCS - 5/16-18 X 3/4 153-2015...

  • Page 156: Walker Ztr Right

    ZTR ASSEMBLY - RIGHT REV. 10/19 INDEX PART NUMBER QTY. NUMBER DESCRIPTION 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 KICK-UP WHEEL SHAFT 164-6221 BUMPER WHEEL PLATE 164-9005 CHAIN (35P67) ZTR KICKUP 153-2602 HHCS - 5/16-18 X 3/4 153-2015...

  • Page 159: Chapter 9

    CHAPTER IKON WALKER ELECTRICAL DRAWINGS Terminal Block Wiring Layout ....................149 Output Wiring Layout ......................150 Input Wiring Layout ......................... 151 Speed Control Wiring Layout ....................152 Analog Wiring Layout ......................153 Motor Wiring Layout ........................ 154 Power Contactor Wiring Layout ................... 155 Oil Pump Motor Wiring Layout ....................

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