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 