Kegel IKON Lane Machine User manual

IKON Lane Machines

KEGEL LLC
1951 Longleaf Blvd.
Lake Wales, FL 33859
863-734-0200 I 800-280-2695

Lane Machine Manual
2017
IKON Specifications
17-5900 –115v
17-5950 –230v
(24VDC) Class I - Single Phase
115 Volts, 50/60 Hz, 7 Amps
230 Volts, 50/60 Hz, 3.5 Amps
UMachine Dimensions
Width –59.5" (139.7 cm)
Height –16.5" (40.64 cm)
Length - 44" (107.95 cm)
Weight: IKON - 331 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: 158-5900
First Edition

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 IKON 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 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.

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 sell an optional piece of equipment that can assist the operator when lifting and
lowering the machine. It can be mounted next to the end pairs of lanes to significantly reduce the
transitional weight of the machine. 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!

UTABLE 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..............................................................................................................................8
Moving & Transporting your Lane Machine.............................................................................................................. 8
Filling the Cleaner supply Tank ....................................................................................................................................... 8
Basic Steps to Operate Your IKON...............................................................................................................................11
Starting Your Machine......................................................................................................................................................11
Keypad and Menus .......................................................................................................................................... 12
..................................................................................................................................................................................................12
The HOME Screen..............................................................................................................................................................12
Machine Settings................................................................................................................................................................12
7 Day Planner.......................................................................................................................................................................14
Program Override...............................................................................................................................................................14
Machine Error Messages .................................................................................................................................................14
Operator Menu Selections..............................................................................................................................................15
Maintenance, Recharging & Storage.................................................................................................... 16
Charger Location & Storing of the Machine............................................................................................................16
Recharging............................................................................................................................................................................16
Things You Can Do with No Cord Attached! ...........................................................................................................17
LANE MAINTENANCE 101............................................................................................................................................... 18
CHAPTER 2.........................................................................................20
CONDITIONING OVERVIEW.............................................................................................................................................. 20
How Conditioner is Metered and Controlled..................................................................................... 20
Program Volume Test.......................................................................................................................................................21
Oil Calibration Test ............................................................................................................................................................23
Proving the Oil Pattern.....................................................................................................................................................23
Board Chart for Calibrating Oil Pattern (Program) Loads....................................................................................26
CONDITIONING SYSTEM ................................................................................................................................................. 27
Theory of Operation.......................................................................................................................................... 27
Change Pattern .................................................................................................................................................. 28
Designing the Oil Pattern................................................................................................................................................30
OIL PATTERNS................................................................................................................................................................... 32
Why do we Apply Oil to Bowling Lanes?.............................................................................................. 32
Troubleshooting Lane Conditions.............................................................................................................. 32
Pattern Troubleshooting.................................................................................................................................. 35
CHAPTER 3..........................................................................................36
CLEANING SYSTEM ........................................................................................................................................................... 36
Theory of Operation.......................................................................................................................................... 36
Why do we Clean Lanes? ............................................................................................................................. 37
System Cleaning Menu................................................................................................................................... 37

Duster Settings.......................................................................................................................................................39
CHAPTER 4 ........................................................................................ 41
BATTERY POWER AND CHARGING SYSTEMS ..................................................................................................................41
Chargers...................................................................................................................................................................41
Constant Voltage Regulator –CVR..............................................................................................................................41
E-Stop .........................................................................................................................................................................42
Batteries ....................................................................................................................................................................42
CHAPTER 5 ........................................................................................ 44
COMPUTER AND CONTROL RELAYS ................................................................................................................................44
Programmable Logic Controller.................................................................................................................44
Electrical Panel.....................................................................................................................................................47
Fuses .......................................................................................................................................................................................47
Control Relays......................................................................................................................................................................48
CHAPTER 6 ........................................................................................ 49
ADJUSTMENTS ...................................................................................................................................................................49
Conditioning System..........................................................................................................................................49
Buffer Brush..........................................................................................................................................................................49
Buffer Belt..............................................................................................................................................................................50
Transfer Brush......................................................................................................................................................................50
Transfer Roller......................................................................................................................................................................50
Oil Tip .....................................................................................................................................................................................51
Timing Belt...........................................................................................................................................................................52
Board Counting Target and Proximity Switch..........................................................................................................53
Oil Head Target...................................................................................................................................................................54
Brush Lift Switches .............................................................................................................................................................54
Oil Pressure Tubing............................................................................................................................................................55
Cleaning System..................................................................................................................................................56
Cleaner Head Timing Belt................................................................................................................................................56
Momentary Wheel Adjustment.....................................................................................................................................56
Duster Switches...................................................................................................................................................................57
Squeegee Blades ................................................................................................................................................................57
Squeegee Switches ............................................................................................................................................................59
Drive System ...........................................................................................................................................................60
Drive Speeds ........................................................................................................................................................................60
Main Drive Motor Chain ..................................................................................................................................................61
CHAPTER 7 ........................................................................................ 62
TROUBLESHOOTING...........................................................................................................................................................62
Inputs and Outputs.............................................................................................................................................62
PLC Outputs..........................................................................................................................................................................62
PLC Inputs and Testing.....................................................................................................................................................63
Conditioning System..........................................................................................................................................64
Conditioning Problems Indicated by Error Messages...........................................................................................64
Conditioning System Problems that DO NOT Display Errors.............................................................................66
Cleaning System..................................................................................................................................................68
Drive System ...........................................................................................................................................................73

CHAPTER 8.........................................................................................76
PREVENTIVE MAINTENANCE ............................................................................................................................................ 76
Lid and Guard Removal................................................................................................................................. 76
Daily, Monthly and Annual Cleaning...................................................................................................... 79
Cleaning Guidelines...........................................................................................................................................................79
Conditioning System......................................................................................................................................... 81
Cleaning System ................................................................................................................................................. 83
Cushion Roller Assembly.................................................................................................................................................83
Changing Duster Cloth.....................................................................................................................................................83
Filling the Cleaner supply Tank .....................................................................................................................................84
Recovery Tank .....................................................................................................................................................................85
Pump Tubing Replacement ............................................................................................................................................86
General Maintenance........................................................................................................................................................87
Drive System .......................................................................................................................................................... 87
Drive Motor Brushes .........................................................................................................................................................88
Battery Replacement....................................................................................................................................... 88
CHAPTER 9.........................................................................................90
MISCELLANEOUS PARTS................................................................................................................................................... 90
Stickers and Decals ........................................................................................................................................... 90
Fittings........................................................................................................................................................................ 92
CHAPTER 10.......................................................................................93
MECHANICAL DRAWINGS................................................................................................................................................ 93
Batteries and Chargers ................................................................................................................................... 95
Lid and Cover Assembly................................................................................................................................. 96
Top View.................................................................................................................................................................. 98
Bottom View........................................................................................................................................................100
Left Side View .....................................................................................................................................................102
Right Side View ..................................................................................................................................................104
LDS Assembly ......................................................................................................................................................106
Handle Assembly..............................................................................................................................................108
PLC Plate Assembly.........................................................................................................................................110
Oil Valve & Pump Assembly .......................................................................................................................112
Oil Head Assembly...........................................................................................................................................114
Brush Lift Rod Assembly .................................................................................................................................116
Oil Transfer Assembly ......................................................................................................................................118
Cleaner Tank & Head Assembly..............................................................................................................120
Duster Assembly ................................................................................................................................................122
Squeegee Assembly.......................................................................................................................................124
Vacuum Motor & Recover Tank Assembly........................................................................................126
CHAPTER 11.................................................................................... 128
IKON ELECTRICAL DRAWINGS .............................................................................................................................128
Motor Wiring Layout........................................................................................................................................129
Output Wiring Layout .....................................................................................................................................130
Input Wiring Layout..........................................................................................................................................131
Speed Control Wiring Layout.....................................................................................................................132
Analog Wiring Layout.....................................................................................................................................133

Terminal Block Wiring Layout ..................................................................................................................... 134
Power Contactor and Relay Wiring Layout ...................................................................................... 135
Voltage Regulator Wiring Layout............................................................................................................ 136
Oil Pump Motor Wiring Layout.................................................................................................................. 137
L-R & R-L Proximity Sensor Wiring Layout ............................................................................................. 138
Oil Valve Wiring Layout................................................................................................................................. 139
Buffer Motor Wiring Layout.......................................................................................................................... 140
Brush Lift Motor Wiring Layout ................................................................................................................... 141
Vacuum Motor Wiring Layout................................................................................................................... 142
Squeegee Motor & Switch Wiring Layout .......................................................................................... 143
Duster Unwind Motor & Switch Wiring Layout.................................................................................. 144
Duster Windup Motor & Switch Wiring Layout ................................................................................. 145
Cleaner Pump Wiring Layout .................................................................................................................... 146
Start Button & Duster Presoak Wiring Layout .................................................................................... 147
Oil Float & Cleaner Float Wiring Layout .............................................................................................. 148
Speed Tach & LDS Wiring Layout............................................................................................................ 149
LED Tank Light Wiring Layout ..................................................................................................................... 150

PREFACE
The Kegel IKON 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 IKON machines operate like no other lane maintenance
machines. Cordless operation of the IKON 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.

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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 IKON 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 IKON. Should you have any questions
after reading this manual about proper operation or procedures, please contact
Kegel at [phone] or via email at [e-mail] 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, IKON, 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
Kegel is an ISO 9001 Certified Manufacturer. 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

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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 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
and the Flex Walker and the 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 several original concepts including C.A.T.S. on every
lane, adjustable topography lanes, and advanced coaching tools.
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 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.

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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:
□ IKON Lane Machine
□ Cleaner Funnel –158-8252
□ Accessory Kit
□ Operators Manual - 158-5900
□ KOSI PRO IKON 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 IKON with Kegel in order to receive valuable
updates, service bulletins and your Limited Warranty. Fill out the card or go on-
line.
IMPORTANT: Please take a minute and register at:
www.kegel.net .

6
Machine Installation Procedures for the Distributor
Please be aware that the screen shots are for illustration purpose only and the settings
within may or may not be the exact factory setting. Please read the description to
fully understand what the setting should be for your particular lane machine.
1. 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 with a
receptacle that has a power indicating light. 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 4 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. Duster Up Switches
b. Cleaning Compartment Button - both functions should be explained
c. Lane Distance Sensor (LDS);
d. Tachometer Sensor (Tach);
h. Right & Left Board Edge Sensors;
i. Board Counting Sensor;
j. Brush and Squeegee Lift Switches;
k. Handle Button - explain the functions of this button;
l. Oil & Cleaner Floats Switches. Explain the purpose as outlined in the
conditioning and cleaning troubleshooting in the respective chapter.
6. Discuss how important it is to have a good transition to the approach.
7. Show the Motor Controls for the Drive Motor and Cleaner Pump Motor.
8. Inspect all the relays and describe their function. Make sure all are seated
properly in the socket bases.
9. 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).
10. 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.

7
11. Loosen the fasteners for the Main Control Plate to lift it out of the way and show
the batteries and the motor chain adjustments.
12. Open the Splash Guard and describe all of the components behind it.
13. 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).
14. Explain how the duster functions during the application.
15. Stop and take a break…let some of the information sink in and consider getting
something to drink. Reassure them that Kegel provides many resources with this
information.
16. Point out the KOSI software located on the USB storage key that was provided
for their PC. Some may want to install it right away. (The CP1H PLC requires a
different cable than the other Omron PLCs.)
17. View all of the menus on the touchscreen.
1. When the machine is powered ON the touchscreen will illuminate. Line the
machine up with lane as if you are ready to operate.
2. Using the touchscreen, perform the starting sequence to run the machine.
3. Watch the machine operate on the lane and monitor the speeds. Make
certain they are in the proper range for each speed.
4. When the machine enters the pin deck check to see if the squeegee
completely clears the pin deck.
5. Explain the squeegee wipe function when the machine enters the pin deck
and how this is meant to remove any excess drips of cleaner that could fall off
on the lane or approach.
6. Monitor the machine back to the foul line.
7. After operation, review proper steps to transport, clean, and charge the
machine for its next use. Tell them to read this Operators Manual and show
them how the manual is organized to help them find what they are looking for.
Now that a thorough overview of the machine has been completed,
we are ready to crank it up!