Kegel FLEX 17-5801 User manual

OPERATORS MANUAL
Edition 03:18

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
17-5705 FLEX - White
17-5707 FLEX –Blue
(24VDC) Class I - Single Phase
115 Volts, 50/60 Hz, 7 Amps
230 Volts, 50/60 Hz, 3.5 Amps
Machine Dimensions
Width – 59.5" (151.13 cm)
Height – 16.5" (41.91 cm)
Length - 44" (111.76 cm)
Weight: FLEX Walker - 370 pounds (167.8 kg)
Weight: FLEX - 350 pounds (150.1 kg)
(Without Batteries)
158-1634 Red Battery – 24 pounds (10.8 kg)
158-1634B Orange Battery – 29 pounds (13.1 kg)
158-1634C Yellow Battery – 39 pounds (17.6 kg)
Manual Part Number: 164-5718

WARRANTY
KEGEL warrants that lane machines and replacement parts will be manufactured free from
defects in material and workmanship under normal use and service. Except as stated below, KEGEL
shall repair or replace, at its factory or authorized service station, any lane machine or replacement
part ("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 (18)MONTHS after the date
of installation by an authorized KEGEL Distributor, has been determined to be defective upon
examination by KEGEL. In no event shall the Warranty coverage be more than twenty-four (24)
months from the date of shipment from KEGEL's factory.
In the contiguous United States, the bowling center or end-user will be responsible for
requesting Warranty Items from KEGEL and must return Warranty Items directly to KEGEL, following
the required procedures. KEGEL will pay reasonable freight charges to deliver and receive Warranty
Items from the bowling center. KEGEL will not be responsible for any "expedited" shipping charges.
Customer will be invoiced for Warranty Items that are not promptly returned per the required
procedures.
Outside the contiguous United States, the bowling center or end-user will be responsible for
requesting Warranty Items from the DISTRIBUTOR and must return Warranty Items directly to the
DISTRIBUTOR, following the required procedures. KEGEL will compensate the DISTRIBUTOR for
reasonable freight charges to deliver and receive the Warranty Items from bowling center and to
return them to KEGEL. Under no circumstances will KEGEL be responsible for any "expedited"
shipping charges or taxes and duties.
This Warranty shall not apply to any lane machine repaired or altered outside of KEGEL's
factory, or authorized service station, in any way, or where replacement parts have been installed in
the lane machine other than KEGEL approved replacement parts, or where the lane machine has
been subjected to misuse, negligence, accident or abuse.
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.
KEGEL DISCLAIMS ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

KEGEL KOMFORT BONUS WARRANTY PROGRAM
The KEGEL Komfort Bonus Warranty program
provides Sanction Technology™ customers,
additional protection on costly components
after the initial standard Warranty expires. By
accepting the KEGEL Komfort Program, the
owner will receive an additional eighteen (18)
month Warranty by committing to use KEGEL
Chemical Products exclusively in their lane
machine. This includes Conditioner, Cleaner
and Cloth for the first three (3) years of
operating the machine. To accept the program,
simply check the box on the front of the
Warranty card.
In the event that a selected part should fail, a verification process will be initiated with the
cooperation of the assigned Distributor to confirm that the requirements of the program have been
met. 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.

Safety First
This Class I Single Phase lane cleaning/conditioning machine shall be grounded while charging to
protect the operator from electric shock. The machine is provided with a three-conductor charger
cord for use in a properly grounded receptacle. Machines rated at 115 Volts A.C. are for use on a
nominal 120-volt circuit and machines rated at 230 Volts A.C. are for use on a nominal 240-volt
circuit.
This product is intended for COMMERCIAL USE. To reduce the risk of fire, use only commercially
available bowling lane cleaners & conditioners intended for machine application.
This is a HEAVY piece of equipment, and care should be taken when lifting it into the transport
position. Use the proper technique to lift and lower the machine, and get a partner to help lift it up
and set it down whenever possible. 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. Large centers might consider getting
one for each end of the center for more convenience.
DO NOT; operate the machine while standing up in the transport position. There is a POTENTIAL
FOR INJURY due to moving parts. Refer all servicing to qualified personnel. This machine is
designed and manufactured for many years of dependable service. To ensure the durability of this
equipment please handle it carefully. Do NOT drop or bang the machine around.
Disconnect power BEFORE filling the Supply Tank or the Conditioner Tank. Be careful not to overfill
the tanks. Do not allow excess fluid to enter the electrical compartment or come into contact with
any electrical components. WIPE UP spills immediately, and make sure all components are dry
before applying power to the machine.
Replace fuses with the same type (Slow Blow) and Amp rating as indicated on the original fuse (or
refer to the wiring diagram). Failure to do so may result in DAMAGE to the machine.
NEVER use any batteries, other than the type supplied with the machine. Mixing battery types or
using batteries that are different from what is supplied with the machine may damage the machine
and cause serious injury or death to the operator. Use of alternate battery or charger types will void
the machine’s warranty.
Please make sure the WARRANTY CARD is filled out and returned immediately. This will allow the
manufacturer or distributor to notify you of potential problems and/or offer upgrades to machine as
they become available. Register your machine on line at www.kegel.net.
If you need assistance or more information about this equipment please contact Kegel in Lake
Wales, Florida USA at [phone].
Warning of Potential Injury: Moving Parts – To Reduce the Risk of Injury Always
Disconnect Power Before Servicing!

TABLE OF CONTENTS
PREFACE........................................................................................................ 1
CHAPTER 1 ................................................................................................... 5
INSTALLATION &SETUP ................................................................................................................................... 5
Machine Inspection...............................................................................................................................5 
Register your Lane Machine .................................................................................................................5 
Machine Installation Procedures for the Distributor ...........................................................................6 
Daily Setup and Operation ................................................................................................................. 10 
Moving & Transporting your Lane Machine...................................................................................................... 10
Replacing the Conditioner Cartridge ................................................................................................................ 10
Filling the Cleaner supply Tank......................................................................................................................... 11
FLEX Sequence of Events - “How it Works” ...................................................................................................... 16
Basic Steps to Operate Your FLEX or FLEX Walker ........................................................................................... 19
Machine Setup I.................................................................................................................................................. 20
Positioning Your FLEX Walker............................................................................................................................ 23
Toggle Monitor Screens ..................................................................................................................................... 26
Keypad and Menus.............................................................................................................................. 27 
Machine Error Messages .................................................................................................................................... 27
Operator Menu Selections ................................................................................................................................. 28
History Selections .............................................................................................................................................. 29
Maintenance, Recharging & Storage .................................................................................................. 32 
Maintenance Reminder Pop Ups....................................................................................................................... 32
Cleaning Guidelines ........................................................................................................................................... 32
Charger Location & Storing of the Machine...................................................................................................... 33
Lid and Side Cover Removal.............................................................................................................................. 34
Things You Can Do with No Cord Attached!........................................................................................ 37
LANE MAINTENANCE 101............................................................................................................................... 38
CHAPTER 2 ................................................................................................. 40
CONDITIONING OVERVIEW .............................................................................................................................. 40
How Conditioner is Metered and Controlled .....................................................................................40 
Calibrating the Oil Pump ................................................................................................................................... 41
Matching the Oil Pumps..................................................................................................................................... 42
Manual Adjustment of the Oil Pumps ............................................................................................................... 43
Proving the Oil Pattern ...................................................................................................................................... 43
Board Chart for Calibrating Oil Pattern (Program) Loads ............................................................................... 46
CONDITIONING SYSTEM ................................................................................................................................. 47
Theory of Operation............................................................................................................................ 47 
Change Pattern ................................................................................................................................... 48 
System Settings Menus....................................................................................................................... 49 
Distance from Fouline When Brush Turns on.......................................................................................... 50
Stop Machine and Lift Buffer Brush .......................................................................................................... 50
Drop Brush in Reverse Location................................................................................................................. 51
Start Applying Oil to the Brush as Machine Moves onto Lane........................................................ 51
Fine Tuning Buffer Brush Settings................................................................................................................ 52
Tank Selection................................................................................................................................................. 53
Adjustable Pump Volume........................................................................................................................... 53
Variable Speed Buffer (Upgraded Machines only)............................................................................ 55
Tank Selection (continued) ........................................................................................................................ 55
Designing the Oil Pattern ............................................................................................................................ 56
Auto Programming (7 Day Planner Program) .................................................................................... 58 
Adjustments ........................................................................................................................................ 59 
Buffer Brush....................................................................................................................................................... 59
Buffer Belt........................................................................................................................................................... 60
Transfer Brush .................................................................................................................................................... 60
Transfer Roller .................................................................................................................................................... 60

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
Variable Speed Buffer ........................................................................................................................................ 65
Pressure Regulator Tubing ............................................................................................................67 
Maintenance........................................................................................................................................68 
Buffer Motor Brushes...................................................................................................................................... 69
Procedure for Cleaning Oil Control Valve............................................................................................. 70
Troubleshooting the Conditioning System ........................................................................................72 
Conditioning Problems Indicated by Error Messages...................................................................................... 72
Conditioning System Problems that DO NOT Display Errors .......................................................................... 77
OIL PATTERNS.............................................................................................................................................79
Why do we Apply Oil to Bowling Lanes? .............................................................................................79 
Landmark Pattern Settings.................................................................................................................79 
Troubleshooting Lane Conditions ......................................................................................................84 
Pattern Troubleshooting.....................................................................................................................86 
CHAPTER 3 ..................................................................................................88
CLEANING SYSTEM ........................................................................................................................................88
Theory of Operation ............................................................................................................................88 
Why do we Clean Lanes? .....................................................................................................................89 
System Settings Cleaning Menus........................................................................................................90 
With Cleaner Mixing System upgrade (dual tank) ............................................................................................ 90
With Standard Cleaner Tank system (single tank) ........................................................................................... 91
Fine-Tuning for Stopping the Machine at the End of Lane .............................................................................. 93
Pindeck Treatment Settings ...............................................................................................................94 
Application Tip Cover......................................................................................................................................... 94
Programming the Pindeck Feature................................................................................................................... 95
Adjustments........................................................................................................................................................ 96
Pindeck Treatment Can Replacement .............................................................................................................. 96
Duster Settings ....................................................................................................................................98 
Special Functions ..............................................................................................................................100 
Squeegee Wipe ................................................................................................................................................. 100
Cleaner Pump Reversing.................................................................................................................................. 100
Mechanical Adjustments...................................................................................................................101 
Cleaner Pump Volume Adjustment with standard Cleaning System......................................... 101
Cleaner Pump Volume Adjustment with Cleaner Mixing System Upgrade.............................. 102
Cleaner Head Timing Belt ................................................................................................................................ 104
Momentary Wheel Adjustment........................................................................................................................ 104
Duster Switches............................................................................................................................................. 105
Squeegee Blades ........................................................................................................................................ 106
Squeegee Switches .......................................................................................................................................... 108
Maintenance......................................................................................................................................108 
Cushion Roller Assembly............................................................................................................................ 108
Changing Duster Cloth.............................................................................................................................. 109
Filling the Cleaner Supply Tank....................................................................................................................... 110
Recovery Tank .................................................................................................................................................. 110
Secondary Pump Tubing Replacement (Upgraded machine only) .............................................................. 113
General Maintenance ....................................................................................................................................... 113
Troubleshooting the Cleaning System .............................................................................................114 
Cleaning System Problems Indicated by Error Messages.............................................................................. 114
Cleaning System Problems that Do Not Display Errors ................................................................................. 118
CHAPTER 4 ................................................................................................121
BATTERY POWER AND CHARGING SYSTEMS......................................................................................................121

Chargers ............................................................................................................................................ 121 
Constant Voltage Regulator – CVR....................................................................................................... 122
E-Stop................................................................................................................................................ 122 
Batteries ............................................................................................................................................ 123 
Replacing Batteries........................................................................................................................... 124 
Troubleshooting Battery & Charging Problems............................................................................... 125 
CHAPTER 5 ............................................................................................... 129
DRIVE SYSTEMS .......................................................................................................................................... 129
Manual Walker Operation................................................................................................................. 129 
Approach Adjustments ..................................................................................................................... 130 
Automatic Lane to Lane Adjustments............................................................................................................. 133
Motor Speeds .................................................................................................................................... 133 
Adjustments ...................................................................................................................................... 135 
Main Drive Motor Chains........................................................................................................................... 135
Rear Approach Wheel Chains .......................................................................................................................... 136
Approach Sensor Chains.................................................................................................................................. 136
Guide Rollers .................................................................................................................................................... 137
Adjusting the Lanes Sensing Whiskers............................................................................................................ 137
Adjusting the On Lane Sensor (OLS) ............................................................................................................... 138
Drive Board Adjustments................................................................................................................................. 138
Maintenance...................................................................................................................................... 141 
Drive Motor Brushes......................................................................................................................................... 141
Troubleshooting ............................................................................................................................... 143 
Drive System Problems Indicated by Error Messages.................................................................................... 143
Drive System Problems that Do Not Display Errors on Lane or Approach ................................................... 149
CHAPTER 6 ............................................................................................... 150
COMPUTER AND CONTROL RELAYS ................................................................................................................ 150
Programmable Logic Controller....................................................................................................... 150 
PLC Outputs...................................................................................................................................................... 154
Fuses.................................................................................................................................................. 156 
Analog Controls................................................................................................................................. 157 
Control Relays on the FLEX / FLEX Walker........................................................................................ 158 
CHAPTER 7 ............................................................................................... 160
MISCELLANEOUS PARTS............................................................................................................................... 160
Stickers and Decals........................................................................................................................... 160 
Fittings............................................................................................................................................... 163 
CHAPTER 8 ............................................................................................... 165
MECHANICAL DRAWINGS .............................................................................................................................. 165
Batteries and Chargers ..................................................................................................................... 168 
Flex Lid and Cover Assembly ............................................................................................................ 170 
Flex Panel Exploded View ................................................................................................................. 172 
Flex Top View .................................................................................................................................... 174 
Flex Bottom View .............................................................................................................................. 176 
Flex Left Side View ............................................................................................................................ 178 
Flex Right Side View .......................................................................................................................... 180 
Flex LDS Assembly ............................................................................................................................ 182 
Flex Front Handle Assembly ............................................................................................................. 184 
Flex Handle Assembly....................................................................................................................... 186 
Flex Walker Lid and Cover Assembly................................................................................................ 188 
Flex Walker Panel Exploded View..................................................................................................... 190 
Flex Walker Top View ........................................................................................................................ 192 
Flex Walker Bottom View .................................................................................................................. 194 

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 ............................................................................................................................208 
Sub Tank Cartridge Assembly...........................................................................................................210 
Oil Head Assembly.............................................................................................................................212 
Brush Lift Rod Assembly ...................................................................................................................214 
Oil Transfer Assembly .......................................................................................................................216 
Cleaner Tank Assembly.....................................................................................................................218 
Cleaner Head Assembly ....................................................................................................................220 
Duster Assembly................................................................................................................................222 
Recovery Tank Assembly ..................................................................................................................224 
Squeegee Assembly ..........................................................................................................................226 
Vacuum Motor Assembly...................................................................................................................228 
Pindeck Treatment Assembly ...........................................................................................................230 
Flex Walker Left ZTR Assembly .........................................................................................................232 
Flex Walker Right ZTR Assembly.......................................................................................................234 
CHAPTER 9 .................................................................................................236
FLEX ELECTRICAL DRAWINGS ................................................................................................................236
Flex Motor Wiring Layout ..................................................................................................................236 
Flex Output Wiring Layout ................................................................................................................237 
Flex Input Wiring Layout ...................................................................................................................238 
Flex Speed Control Wiring Layout ....................................................................................................239 
Flex Analog Wiring Layout.................................................................................................................240 
Flex Terminal Block Wiring Layout ...................................................................................................241 
Flex Power Wiring Layout..................................................................................................................242 
Flex Voltage Regulator Wiring Layout...............................................................................................243 
Flex Oil Pump Driver & Motor Wiring Layout ....................................................................................244 
Flex L-R & R-L Proximity Sensor Wiring Layout ................................................................................245 
Flex Oil Valves Wiring Layout ............................................................................................................246 
Flex Buffer Motor Wiring Layout .......................................................................................................247 
Flex Variable Buffer Motor Wiring Layout.........................................................................................248 
Flex Brush Lift Motor Wiring Layout..................................................................................................249 
Flex Vacuum Motor Wiring Layout ....................................................................................................250 
Flex Squeegee Motor & Switch Wiring Layout..................................................................................251 
Flex Duster Unwind Motor & Switch Wiring Layout..........................................................................252 
Flex Duster Windup Motor & Switch Wiring Layout..........................................................................253 
Flex Cleaner Pump #1 Wiring Layout................................................................................................254 
Flex Cleaner Pump #2 Wiring Layout................................................................................................255 
Flex Start Button & Duster Presoak Button Wiring Layout ..............................................................256 
Flex Oil Float & Cleaner Float Wiring Layout ....................................................................................257 
Flex Speed Tach & LDS Wiring Layout ..............................................................................................258 
Flex LED Tank Light Wiring Layout ...................................................................................................259 
FLEX WALKER ELECTRICAL DRAWING ....................................................................................................262
Flex Walker Motor Wiring Layout ......................................................................................................263 
Flex Walker Output Wiring Layout ....................................................................................................264 
Flex Walker Input Wiring Layout .......................................................................................................265 
Flex Walker Speed Control Wiring Layout ........................................................................................266 
Flex Walker Analog Wiring Layout ....................................................................................................267 
Flex Walker Terminal Block Wiring Layout.......................................................................................268 
Flex Walker Power Wiring Layout .....................................................................................................269 
Flex Walker Voltage Regulator Wiring Layout ..................................................................................270 

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....................................................................................................... 275 
Flex Variable Buffer Motor Wiring Layout......................................................................................... 276 
Flex Brush Lift Motor Wiring Layout ................................................................................................. 277 
Flex Vacuum Motor Wiring Layout.................................................................................................... 278 
Flex Squeegee Motor & Switch Wiring Layout.................................................................................. 279 
Flex Duster Unwind Motor & Switch Wiring Layout ......................................................................... 280 
Flex Duster Windup Motor & Switch Wiring Layout ......................................................................... 281 
Flex Cleaner Pump #1 Wiring Layout................................................................................................ 282 
Flex Cleaner Pump #2 Wiring Layout................................................................................................ 283 
Flex Start Button & Duster Presoak Button Wiring Layout.............................................................. 284 
Flex Oil Float & Cleaner Float Wiring Layout.................................................................................... 285 
Flex Speed Tach & LDS Wiring Layout.............................................................................................. 286 
Flex LED Tank Light Wiring Layout ................................................................................................... 287 
Flex 7 Pin & 10 pin Side Approach Distance Sensor Wiring.............................................................. 288 
Flex Walker Bumper & Whisker Switch Wiring ................................................................................. 289 

PREFACE
The Kegel FLEX Lane Cleaning and Conditioning Machine represents advanced technology
in automated lane care. Clean and consistent bowling conditions are accessed from an on-
board touchscreen linked to an industrial Programmable Logic Controller (PLC).
Battery-operated FLEX machines operate like no other lane maintenance machines.
Cordless operation of the FLEX and automatic lane to lane advancement of the Walker
allows for fewer operating problems and increased customer satisfaction.
A patented fluid metering transfer system, along with the vacuum/squeegee cleaning
system and duster system, allow the machine to maintain clean and consistent bowling
conditions.
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.
KOSI includes programs and instructional videos which should be used as a supplement to
this manual.
IT IS VERY IMPORTANT THAT THE OPERATOR THOROUGHLY READ AND UNDERSTAND THIS
OPERATING MANUAL BEFORE USING THE MACHINE. WHEN ALL ELSE FAILS...READ THE
MANUAL AGAIN OR WATCH TRAINING VIDEOS FOUND IN KOSI.

2
Copyright Notice
All Rights Reserved. No part of this manual may be reproduced, stored in a retrieval system,
or transmitted in any form or by any means, electronic, mechanical, photocopying,
recording, or otherwise, without the prior written permission of 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.
About This Manual
This manual was prepared by the engineering, graphics & documentation departments of
Kegel to provide detailed information and technical support about this lane machine and its
operation. This manual was specially designed to educate the operator and ensure your
investment is maintained properly.
The Intended User / Operator
Although every attempt has been made to make this manual easy to understand and use,
the operator should have basic electrical, mechanical and technical understanding to
operate and maintain the FLEX. Should you have any questions after reading this manual
about proper operation or procedures, please contact Kegel at [phone] or via email at
[email protected] for technical support.
Disclaimer
The identification of individuals, companies and products in this manual is provided for
technical informational purposes only and does not constitute endorsement by Kegel of any
business entity, service or products. Product brand names mentioned in this manual are
trademarks or registered trademarks of their respective holders. Kegel disclaims any and all
rights in those marks.
Trademark(s)
Kegel, FLEX Walker, FLEX, Sanction Technology, Lane Maintenance Central, Navigation
Series, Navigate, Offense, Defense, Prodigy, Infinity, Crossfire, Fire, ICE, Fizzion, Curve, Pure,
Spot On, Balance and K2 EZ Core Cloth are registered trademarks or service marks of Kegel.
All Rights Reserved.
Conformity
This lane machine has been independently tested to comply with applicable standards for
the equipment.
For additional copies of this or any other Kegel product manuals contact:
KEGEL www.kegel.net
1951 Longleaf Blvd. [phone] (Toll Free in the U.S.)
Lake Wales, FL 33859 [phone]
USA
© 2008 KEGEL

3
Kegel Company Background
Kegel was founded in 1981 by John Davis, Linda Davis, and David Jennings. At that time,
Kegel had designed a small hand operated cleaning tool named “The Key”, which they
manufactured at a time in David’s garage.
In 1983, Kegel purchased Ridge Lanes in Sebring, Florida and the crew moved south to run
the bowling center and start Research & Development of lane maintenance and machines.
The Sanction Machine®was soon developed and marketed as Kegel’s first fluid metering
lane machine.
In the following years many more machines were designed, such as the DBA LaneWalker,
followed by the innovative LCM, Excel, Arrow, Phoenix, Phoenix-S, Standard, Kustodian,
Sanction Walker, Kustodian Plus, ION Sport, Walker Sport, FLEX / FLEX Walker and IKON.
Manufacturing – Our core division designs and manufactures the world’s best lane
conditioning and cleaning machines, replacement parts, and other specialized machinery
products.
Kegel Bowling Technologies – This division develops and blends conditioners and cleaners
that are used in our lane conditioning machines, as well as other areas in bowling and
beyond. Lane Maintenance Central (LMC) – Regarded by many as the best in the industry,
LMC provides 24 hour telephone support, educational seminars, workshops, and on-site
support to bowling centers and distributors throughout the world.
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.
Kegel has grown into a worldwide organization with several product divisions, over 100
employees, and a specially designed 72,000 sq. ft. state-of-the-art facility and a 33,000 sq. ft.
facility located in Lake Wales, Florida. Kegel has done this with a simple philosophy of
researching the problems that exist in the bowling industry, developing a product or service
to solve that problem, and making sure to support the customer with the highest of
standards.

4
“Wah-lah…I did them the same!”

5
CHAPTER 1
Installation & Setup
Machine Inspection
It is important to identify all of the parts included with your lane machine and inspect its
condition before you begin. Use the following list to make sure all parts are accounted for:
Fill in the following Check Boxes and Information:
□FLEX Walker Lane Machine
□FLEX Lane Machine
□Cleaner Funnel – 158-8252
□Accessory Kit
□Operators Manual – 164-5718
□KOSI PRO FLEX Software on USB drive & PLC Cable – 154-8781
□Extra Roll of EZ Core Cloth - 153-0047EZ
□Maintenance Supplies Starter Kit - 154-8866
□External Charging Assembly
□K2 Battery Assembly
Date Unpacked: __________________________________
Unpacked by: ____________________________________
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

6
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. Please read the description to fully
understand what the setting should be for your particular lane machine.
1. Decide on the storage area for machine, which is where the charger will be mounted. It is
strongly suggested to use only a dedicated circuit. The light may prevent the machine
from not being charged due to a tripped breaker (a simple night light works fine).
2. Unpack and inspect machine for shipping damage; make sure all the extra items are
included in the shipping crate. Put batteries on charge as soon as possible after
inspecting. See Chapter 5 for instructions.
3. Menu to the ‘ABOUT’ screen and enter the install date.
4. Remove the lid and the side guards to reveal all of the components.
5. Inspect all of the switches and sensors and describe the function of each one:
a. 7-pin & 10-pin Whiskers Switches - adjusting screw is hard to see (FW only);
b. Bumper Switches (FW only);
c. On Lane sensor (OLS) – it is very important to show this sensor since it is hard to see.
d. Duster up Switches (FLEX & FW);
e. Cleaning Compartment Button - both functions should be explained;
f. 7-pin & 10-pin Approach Sensors (FW only);
g. Lane Distance Sensor (LDS);
h. Tachometer Sensor (Tach);
i. Right & Left Board Edge Sensors;
j. Board Counting Sensor;
k. Brush and Squeegee Lift Switches;
l. Handle Button (FLEX) - explain the functions of this button;
m. Recovery Tank Switch – explain that this switch will produce a an error message
when the recovery tank is not present;
n. Oil & Cleaner Floats Switches. Explain the purpose as outlined in the conditioning
and cleaning troubleshooting in the respective chapter.
o. Stop by Sensor mounted on Squeegee channel (FLEX & FW);
6. On the Walker, examine the Zero Turn Radius (ZTR) Wheels and explain how these
wheels, plus the approach casters, are the only wheels on the approach when the
machine is turning and moving to next lane. The rear black wheels help the machine out
of the lane and also help steer the machine just before they leave the approach as the

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machine is going into lane. Also mention that the 7-pin drive wheels turn off after the
machine enters the lane.
Discuss how important it is to have a good transition to the approach. The adapters from
gutter to approach must be the same for the machine to come out as straight as possible, it
is up to the center to make this happen. Extra dusty approaches are not good. This is very
important for the Walker lane machine.
7. On the Walker, describe how the black Bumper Wheels function and make certain that
adjustment is not too wide for center (always run the machine first before making any
adjustments). The factory adjustment will typically work just fine.
8. On the Walker, show the Whisker adjustment and make sure they are not adjusted too
wide for center (run the machine before adjusting). Factory adjustment usually works
well. Describe how the Whiskers self-adjust when machine is moving onto the lane.
9. Show the Motor Controls for the Drive Motor, Cleaner Pump Motor and the two Stepper
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.
11. On the Walker, show the two steering relays (CR15 & CR16) and notice that both input
lights come on when just one whisker switch is operated (when machine is not in
motion). When both drive motors are on while traveling forward, the Whiskers will only
turn on their input. When both input lights come on it is due to the Negative DC power
feeding back through the coil of the relays. Positive DC power for the coils of CR15 &
CR16 is routed through the Whisker Control Relay (CR14).
12. Show the PLC and how the Inputs light up when a sensor or switch is actuated. Explain
the channel designations and which Inputs are 0CH and which are 1CH; Outputs are
100CH and 101CH. This can be confusing for both the Inputs and Outputs since it is not
clearly printed this way on the PLC (i.e. 2 connections are labeled 00, but one is 0CH 00
and the other is 1CH 00).
13. Describe the CVR and what components have controlled voltage: Oil Pump; Drive
Motors; Buffer Motor; Moving Head Motor; Oil Valve; and all of the Relays.
14. Loosen the fasteners for the Main Control Plate to lift it out of the way and show the
batteries and the motor chain adjustments.
15. Open the Splash Guard and describe all of the components behind it.

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16. Discuss how the cleaner tank can do up to 50 lanes depending on cleaner volume
settings and show how this adjustment is made (Chapter 3). The recovery tank holds
what the cleaner supply tank dispenses (and it is heavy when full).
17. Explain the Conditioner cartridges and how they work (Chapter 2).
18. Discuss the operation of the Pindeck treatment function. Explain how the duster
functions during the application, and how important the tip cover is to be in place when
not in use! 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. Some may want to install it right away. (The CP1H PLC requires a different cable
than the other Omron PLCs.)
21. View all of the menus on the touchscreen.
1. When the machine is powered ON the touchscreen will illuminate. With power applied,
press the MOVE MACHINE icon on the touchscreen and demonstrate how easy it is to
position the machine. Line the machine up with lane as if you are ready to operate.
When starting the machine on the first lane it is important to position it the correct
distance from the foul line. The front bumper should be about 20” to 22” (51 to 56 cm)
away from the foul line. This is required so the machine functions will happen at the
proper location relative to the foul line of the first lane.
2. Have the operator(s) practice moving the machine and provide tips on what to look for.
3. Using the touchscreen, perform the starting sequence to run the machine. On the
Walker, if you are just checking lane to lane settings choose program 30, it is set to run
for 10 feet at oil only.
Now that a thorough overview of the machine has been completed, we are ready to
crank it up. Keep in mind that some steps only apply to the Walker.