Kegel IKON Lane Machine Operation Manual Download Page 1

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IKON Lane Machines

Summary of Contents for IKON Lane Machine

Page 2: ...KEGEL LLC 1951 Longleaf Blvd Lake Wales FL 33859 863 734 0200 I 800 280 2695 ...

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Page 4: ...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 ...

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Page 6: ...ot 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 ...

Page 7: ...er 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 ...

Page 8: ... 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...

Page 9: ...aintenance 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...

Page 10: ...p 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 In...

Page 11: ...nd 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 Sque...

Page 12: ...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 Wi...

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Page 14: ... 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 inclu...

Page 15: ...ou have any questions after reading this manual about proper operation or procedures please contact Kegel at 863 734 0200 or via email at lmc kegel net 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 P...

Page 16: ...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 b...

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Page 18: ...rive 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...

Page 19: ...unction 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 tro...

Page 20: ...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 Whe...

Page 21: ...pen the splash guard and place a rag beneath the tank Open the tank cap and place a rag around the base of the funnel to prevent foam from over flowing into the machine 2 Slowly pour the mixture into the Cleaner Supply Tank using the supplied funnel until the level in the tank is about 1 2 1 3 cm below the top of the tank This will prevent an air pocket from forming and blocking the fluid flowing ...

Page 22: ...4 Press the start button a second time and the moving heads will start and move from left to right or from right to left the heads move in opposite directions The cleaner head will start to apply cleaner instantly to the lane and not stop until the last squirt distance has been reached When the oil head reaches the right board edge proximity sensor the moving heads will reverse and begin to apply ...

Page 23: ... the pin deck As the machine approaches the pin deck the last squirt distance will turn off the cleaner pump and the moving heads will park At the same time the machine will down shift to low speed to reduce its momentum into the pin deck 12 When the machine enters the pin deck the duster wind up motor will turn on at its pre determined distance and start to wind up the cloth and raise the The dus...

Page 24: ...the event one of these errors occurs the machine will need to be re started NOTE If the machine stops and displays the BATTERY VOLTAGE 24VOLTS OR LESS it will need to be returned to the foul line and plugged in This message comes up only if the voltage drops below 17 volts meaning it has a dead battery if the E Stop is pressed or if there is a loose power connection Basic Steps to Operate Your IKO...

Page 25: ...e allows the operator to saturate the cushion roller assembly prior to running the lane machine While this is a good way to get things primed it s also a good opportunity to clean the front part of the lane as well To use this function press the START button and roll the machine onto the lane to where the two front 6 wheels just drop into the gutters By pressing the CLEANER PRESOAK button the clea...

Page 26: ...R UP STOP DELAY function ON The machine will stop at the end of the pattern lift the buffer brush and then continue on VALUE OF 1 TO TURN OFF PLEASE BE AWARE This function can cause more wear on the drive system so it is best to use this when the machine is traveling less than 26 IPS at the end of the pattern before abruptly stopping SET PASSWORDS is used to prevent unauthorized operation of the m...

Page 27: ... 12 Noon will apply that selected conditioner program Program Override To override the preset pattern showing in the START screen press the button that displays the pattern number A keypad will then pop up allowing you to change the program to any of the 15 preset programs Once the current program is changed to a different one it will remain there until the HOME key is pressed or there is a loss o...

Page 28: ...QUEEGEE DOWN Below is an example of how an error messages will appear Troubleshooting methods for this error along will all of the above errors will be explained in Chapter 7 of this manual Operator Menu Selections The machine has a series of menus that are accessed from the Main Menu screen Each of these menus will be explained in detail in the appropriate section of this manual ...

Page 29: ...d the pinsetters If possible the machine should be stored where all of its related Kegel products are kept i e cloth conditioner cleaner and whatever else you use to keep it clean and maintained The storage location is where you will have the charger mounted for charging the batteries There should be a reliable dedicated receptacle for the charger along with a power indicating light to show there ...

Page 30: ... you can do it and not worry about the machine running over the cord when you turn your head 6 Watch the machine do its job Make sure it is conditioning oiling and cleaning properly because it s not much fun when the bowlers know before you do 7 Get your ball out and bowl while you condition and check the lanes out It is always nice to know the strike ability of the lanes 8 It is much easier to ha...

Page 31: ...hine pulls into the conditioning compartment It sounds like a lot of work but so what it makes your life easier the more you run the machine If you want to provide the best conditions it will take time Also it s easier to keep up on a day to day basis 4 Dust your approaches no less than three times a day if not four Some areas of the country or world will require this to just keep them from lookin...

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Page 33: ...able of applying precise amounts of lane conditioner An explanation of how this is accomplished will help you understand the art of oil pattern application When conditioning a lane the oil head travels back and forth applying streams of conditioner onto the Transfer Brush This gives the machine the ability to create patterns like the one below ...

Page 34: ...ic measurement for fluid volume The factory setting for the pump is 50 microliters per board To give you a visual perspective of how much conditioner is being applied in 50 microliters consider that about 20 microliters make up one drop of oil So each time a stream of oil crosses one board it applies almost 2 1 2 drops of conditioner Since this amount of conditioner is too small to measure with th...

Page 35: ...form the test a second time The correct amount of conditioner in the cylinder should match what the program worksheet has for total volume If an oil pump adjustment must be made open the splash guard to access the oil pump assembly Conditioner pump adjustments are done by manually turning the Oil Pump assembly If an increase to the amount of conditioner is needed turn the oil pump towards you If a...

Page 36: ...til the 400 boards have been reached Each time that an Oil Program test or calibration have been performed the numbers in the red circles shown to the right will increase The number in the lower left represents the calibration tests while the number in the lower right shows the number of times the Oil Program has been performed Proving the Oil Pattern We will use generic pattern settings as an exa...

Page 37: ...ads are multiplied and added together the result is the total number of boards that are covered by a stream of oil TOTAL PATTERN BOARDS 37 x 1 37 21 x 3 63 15 x 3 45 13 x 2 26 15 x 4 60 17 x 4 68 19 x 2 38 37 x 1 37 374 Total Boards In our example there are 145 boards covered during Forward travel and 229 boards covered during the Reverse travel This total number 374 can be multiplied by the pump ...

Page 38: ...tment When the math is correct it will tell you if the pump needs adjusting The KOSI software provides a Total volume tab in the Advanced Designer screen that allow you to see the forward reverse total oil volume and boards crossed so you do not have to do the math Having the total output for the program will ensure that the program values are entered correctly It will also help you understand eac...

Page 39: ...9 18 17 16 15 7 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 L 8 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 E 9 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 F 10 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 T 11 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 12 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 13 26 25 24 23 22 21 2...

Page 40: ...exact flow rate to a three way valve known as the Oil Pattern Control Valve The valve in its OFF state routes the conditioner back to the conditioner tank When turned ON the valve routes the conditioner to a line connected to the Oil Head The OIL HEAD travels back and forth across the transfer system at a constant speed much like the printer head on a computer printer The Oil Pattern Control Valve...

Page 41: ...ord to access the CHANGE PROGRAM MENU To the left is the main CHANGE PATTERN screen From this screen you can choose the pattern to view and make edits By pressing on the VIEW PATTERN IN STORAGE button you can select the pattern you wish to change from a list of all the stored programs By pressing the right arrow located in the bottom right corner you will be able to view all 15 stored programs Cha...

Page 42: ...forward Monitor the on times and adjust the Buffer Brush Start Distance to come on sooner or later to avoid potential lane machine shut down This feature is great for open play bowling when it is near impossible to keep customers behind the foul line Another tip that does help is to never turn off foul lights during open play This will make them think twice from going past the line and tripping th...

Page 43: ...hile applying the loads Have the machine start out USING slower speeds and gradually increase through the 6 available conditioning speeds The ability to change speeds while applying these loads is a patented feature of Kegel lane machines Start Distances and End Distances are not adjustable These distances are automatically calculated based on of loads and Speed IPS The first LINE that does not ha...

Page 44: ...l drop wherever the REVERSE DROP BRUSH is set to and buff the lane until the END DIST is reached The END DIST is also where the beginning of where the Reverse oil will start to be applied The rest of the LINES work just like the Forward Screens Row 2 will be the first LINE to have LOADS The DISTANCE will automatically be calculated when the LOADS SPEEDS are entered It is possible to have more than...

Page 45: ...RK AND NAVIGATION PATTERN WORKSHEETS AND DESCRIPTIONS CAN BE FOUND IN THE APPENDIX OF THE MANUAL Go to http www kegel net patternlibrary default asp for additional patterns Troubleshooting Lane Conditions Troubleshooting lane conditions can be very tricky You must first think about what you want to accomplish who the adjustment will affect and if the machine is calibrated correctly We suggest read...

Page 46: ...ut for walk along side the machine while it runs look at the display for speeds and on the way back check the back end for cleanliness Check to see if the pattern looks uniform across the house Do this each day and you may be able to stop and correct problems before they happen 7 A general inspection of the machine should be done whenever there is a concern that something may be wrong Just because...

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Page 48: ...eads to hook In both instances the lane machine should run slower in the heads This is better controlled on the return oil due to the direction of travel and the rotation of the buffer brush Apply oil loads during the return travel that finish closer to the foul line but not less than 4 feet Q What should I do if I have no swing A The amount of oil on the outside boards or adverse lane topography ...

Page 49: ...sequence is started the cleaner pump will turn on and stay on until the last squirt distance has been reached The moving head will apply an equal amount of cleaner across the width of the lane as it travels forward 2 As the machine travels forward the cleaner will pass underneath the cushion roller and will be wiped onto the surface of the lane The special texture of the cushion roller wrap preven...

Page 50: ...rface Good maintenance for your wood lanes is important in protecting the finish and preventing it from glazing in the ball track It is impossible to prevent this completely but it can be slowed down System Cleaning Menu From the Home screen press Main Menu and you will be able to access the System Cleaning menu Within this menu you will be able to control various cleaning features that will help ...

Page 51: ...top traveling forward This is very important to dial in and can cause unnecessary problems when not adjusted properly The default number is 716 and is in counts If this number is set too low the machine will stop short of the tailplank and will leave a line of cleaner mixed with the dirty conditioner This will cause an increase in Out of Ranges as it will smear all over the pindeck Another indicat...

Page 52: ...lane Duster Settings From the Home screen press Main Menu and you will be able to access the Duster Settings menu Within this menu you will be able to reset the number of lanes left in a roll of cloth as well as fine tune the amount of cloth usage The DEFAULT UNWIND TIME will increase by 1 10 one tenth of a second every 35 lanes until the cloth runs out If you install a partial roll you may need t...

Page 53: ... varies from 10 for a fresh roll to 22 for an almost empty roll If accidentally reset use an educated guess on how much of the roll is already used and set your time accordingly EXAMPLE If the roll is about half used set the time to 16 Resetting the DUSTER counter prior to the roll of cloth being empty could reduce the cleaning efficiency of the machine TECHNICAL NOTE When replacing a roll of clot...

Page 54: ...tion to batteries or the lane machine the display on the charger will read BC Once the charger is plugged into the lane machine and a connection is made it will operate as normal ProNautic Charger set for Lithium batteries When the ProNautic charger is used to charge Lithium Batteries it will charge at 29 2 volts the entire length of the charging process The only thing that will drop is the chargi...

Page 55: ... or less for a total maximum of 48 lanes per day When running the machine only once per day the maximum amount of lanes that can be done is 62 lanes When running the machine twice per day the maximum amount of lanes that can be done is 46 lanes per cycle or a total of 92 lanes per day This means that you can run 46 lanes or less recharge the battery at least 4 hours and then run another 46 lanes o...

Page 56: ... will appear To adjust the voltage meters accurately you must have a dependable voltmeter Locate the three pin plug above the fuse bank Put the voltmeter probes in the appropriate pins then add or subtract using the buttons at the bottom of the screen until the Voltage on the screen matches the correct Voltage from the external voltmeter ...

Page 57: ... Programmable Logic Controller PLC Analog Outputs KOSI Port Output Indicators Output Terminal Connections Input Terminal Connections Battery Input Indicators Touchscreen Connection PLC Status Indicators See Chart Battery and CVR Input Voltage ...

Page 58: ...iring drawings will show the simplest way a switch and proximity sensor connect to the PLC Below is an example of a typical input circuit using a switch One side of the switch goes to the PLC Input and the other side of the switch goes to Negative Voltage The PLC Input Common is supplied with Positive Voltage The circuit is shown in the open position so there will be no input light on the PLC The ...

Page 59: ...e Brown to positive and Black is the signal which connects to the appropriate PLC Input The sensor operates when metal passes by the face An LED light located on the sensor will indicate operation The batteries will supply the 24 Volts All of the machine s Proximity Sensor Switches are wired like this the only difference is that the wires will pass though plugs and junction blocks ...

Page 60: ... cause damage to the smaller motors In addition to fuses and breakers the PLC program also protects the machine by timing out after operating motors for a pre determined amount of time DRIVE MOTOR 7 5A BUFFER MOTOR 10A DUSTER UNWIND 3 2A DUSTER WINDUP 3 2A SQUEEGEE MOTOR 3 2A BRUSH LIFT MOTOR 3 2A HEAD DRIVE MOTOR 75A OIL PUMP MOTOR 4A PLC INPUT POWER 5A PLC COMMON 5A TOUCH SCREEN 5A CLEANER PUMP ...

Page 61: ...ol Valve Relay CONTROL RELAY 2 Power Off Relay CONTROL RELAY 3 Dust Windup Motor Relay CONTROL RELAY 4 Dust Unwind Motor Relay CONTROL RELAY 5 Squeegee Motor Relay CONTROL RELAY 6 Brush Lift Motor Relay CONTROL RELAY 7 Oil Pump Motor Relay CONTROL RELAY 8 Cleaner reversing Relay CONTROL RELAY 9 Buffer Motor Relay CONTROL RELAY 10 Oil Head Motor Relay CONTROL RELAY 11 Oil Head Reversing Relay CONTR...

Page 62: ...ge across the front drive wheels and rear drive wheels shown above The buffer brush material should extend approximately 3 32 to 3 16 2 38 mm to 4 76 mm beyond the straight edge for proper adjustment The buffer brush is factory adjusted prior to being shipped at approximately 1 8 3 2 mm If an adjustment is needed loosen the bolts located on the rear panel as shown in the pic This will loosen the L...

Page 63: ...stment bar but keep them snug 3 Using a wrench screw the square headed bolts into the transfer brush to lower Do this until the Transfer brush just contacts the buffer brush assembly Once this happens turn the screws two full turns and tighten them all the way Transfer Roller 1 With the machine in the operating position loosen the roller pivot screws 2 Then loosen the jam nut on the Roller adjusti...

Page 64: ...the Oil Tip as close to the V as possible without actually dispensing oil into the V area The oil tip height is done with the buffer brush in the up position and against the 10 pin wall above the drip pad assembly Adjust the tip by loosening the screw in the tip holder collar and sliding the tip holder up or down Re tighten the set screw when 1 8 height between the tip and the drip pad is achieved...

Page 65: ...sen the 4 screws in the slotted bracket adjust the belt so that when you push the belt down from the top it just touches the head bar assembly as shown in the below figure Fasten all screws when done This belt drives the board counting disk and the cleaner assembly making it important that the belt not run loose A loose belt can cause the machine to lose its oil head timing and the timing that con...

Page 66: ...th of the board counting target should be straight in line with the proximity sensor as shown above If not loosen the set screw in the target and turn until its lined up and tighten 3 Now it is time to make sure that the board counting target is secured and the head assembly is tight Place the side cover back over the right side of the lane machine Replace the fuse for the motor Gap is 0 010 The m...

Page 67: ...ame The proximity sensors have a small amount of adjustment so they can also move if necessary Brush Lift Switches The Brush Lift Switches are mounted to a plate that has adjusting slots The switch plate adjustment should be checked when each switch is on the cam lobe The switch rollers should not bottom out and have only between 0 005 and 0 010 over travel of the roller about 0 127 mm to 0 254 mm...

Page 68: ...that is needed Keep in mind that these are only guidelines temperature greatly affects viscosity and may change these results An ideal oil pressure is between 15 20 PSI To purchase stock tubing for adjusting the regulator lengths order the following part numbers 154 0202A 1 4 OD Tubing Stock Inch 154 0202B 3 16 OD Tubing Stock Inch Pressure Regulator Tubing ...

Page 69: ...ou have this problem Momentary Wheel Adjustment We like to call this The Forgotten Adjustment because no one does much with these wheels To adjust the momentary wheels the machine will have to be stopped on the lane Once the machine is on the lane loosen do not remove the bolts that hold the momentary wheels to the machine Slide the momentary wheel housings up or down until the gap between the whe...

Page 70: ...ntil there is some over travel of the switch lever Tighten the nut s and make sure the cushion roller moves up and down freely Squeegee Blades Replace the squeegee blades and follow the below information for the proper adjustment The Squeegee Assembly is adjusted at the factory to ensure proper cleaning This adjustment should be checked when the machine is installed The factory zero point is measu...

Page 71: ...gee Down Switch With the squeegee down take a straight edge and rest it on the squeegee blade across the main drive wheels to the rear drive wheels The gap between the straight edge and the drive wheels should be about 3 16 to 1 4 3 18 mm to 4 76 mm on each side If the distance is more or less loosen the bolts two on each side that hold the squeegee pivot in place Move the pivot mount until the sq...

Page 72: ...he rod end as needed to increase or decrease the pitch DO NOT make the linkage too short 5 Re install and tighten the bolt to connect the rod end to the cam 6 Re check the gap between the straight edge and the drive wheels 7 Tighten the rod end to the rod with the jam nut 8 Check cleaning to ensure adjustment is adequate Squeegee Switches The squeegee switches should have a little over travel in t...

Page 73: ...lue to the right of the 10 IPS By pressing on the number a keypad display will show allowing you to change the value to either increase or decrease Important On the approcch speed 1 is the only speed to be set at its actual speed All remaining speeds will be adjusted to run 1 speed below the actual IPS For example 14 IPS will operate at 13 18 IPS will operate at 17 IPS and so on This is done so th...

Page 74: ...nt for the drive chain to stay tight but not too tight First determine what adjustment needs to be made A chain that is too tight means that there is no movement of the chain when you press between the sprockets with your finger A chain that is too loose is when you can move the drive wheels back and forth without engaging the motor To adjust Lane Drive Chain 1 Loosen the three screws that secure ...

Page 75: ...e color to yellow To test an input you will need to physically operate the switch by pressing on it or pass metal by a proximity sensor Here is a list of the OUTPUT numbers for the PLC along with their wire color and designations OUTPUT DESCRIPTION WIRE COLOR 100 00 OIL CONTROL VALVE ORANGE 100 01 POWER OFF RELAY NOT A TEST GRAY YELLOW 100 02 FORWARD DRIVE GREEN ORANGE 100 03 REVERSE DRIVE YELLOW ...

Page 76: ...OX SENSOR RED WHITE 002 LEFT OIL HEAD REVERSING PROX SENSOR RED ORANGE 003 RIGHT OIL HEAD REVERSING PROX SENSOR ORANGE BLACK 004 BUFFER BRUSH UP SWITCH GREEN WHITE 005 BUFFER BRUSH DOWN SWITCH VIOLET YELLOW 006 DRIVE SHAFT TACHOMETER PROX SENSOR BLACK BLUE 007 LANE DISTANCE PROXIMITY SENSOR LDS WHITE PINK 008 RESUME BUTTON HANDLE BUTTON IKON ONLY VIOLET 009 LIGHTS WHEN IN OIL ONLY 010 DUSTER UP SW...

Page 77: ... Lift Motor does not run menu to the INPUT OUTPUT TEST and press BRUSH LIFT to check the relay operation and voltages 1 The brush lift motor runs but the down switch failed to operate and send a signal to PLC Input 005 a Check and inspect the microswitch manually operate switch to see if Input 005 will illuminate b Possible broken wire or loose connection in either the yellow 24 VDC wire or the Vi...

Page 78: ...ppears when Input 001 fails to receive a signal within 0 5 seconds of the head motor starting or if there is not a continuous pulsing signal as the motor runs This makes the machine think that the motor is not running causing the machine to stop Here are the possible causes that can produce a MOVING HEAD TRAVEL ERROR If the Motor does not run menu to the INPUT OUTPUT TEST and press HEAD MOTOR to c...

Page 79: ...here are a number of things that can go wrong even if the machine appears to operate correctly Most of these problems can be caught before the bowlers notice them but only if the operator is paying attention Doing a calibration test every day will eliminate many problems from turning into disasters 1 Oil Pump fails to run a Motor is unplugged or has a damaged or open connection b Motor has failed ...

Page 80: ...ioner oil loads not ending at correct footage a Oil Head not running at correct speed Check Oil and Cleaner Heads for lubrication b Machine speeds are not set correctly 6 Oil Valve time has increased a Oil Head is not running at correct speed check oil and cleaner heads for lubrication b Board counting target loose c Wrong program was run or someone has changed the program 1 culprit d Belts are to...

Page 81: ...ok closely This error normally happens when Duster Input 0CH 10 fails to open meaning the input light does not turn off Below are a few things that can cause an UNWIND error If the Motor does not run menu to the INPUT OUTPUT TEST and press DUSTER to check relay operation and voltages 1 Duster cloth is empty Replace cloth 2 One or both of the Duster Up Switches are stuck Check if Input 0CH 10 has a...

Page 82: ...hin 3 5 seconds of the motor starting A few things that can cause this SQUEEGEE DOWN ERROR are shown on the next page If the Motor does not run menu to the INPUT OUTPUT TEST and press SQUEEGEE LIFT to check relay operation and voltages 1 The Squeegee motor runs but the down switch failed to operate and a send signal to PLC Input 1CH 00 a Check and inspect the microswitch Manually operate the switc...

Page 83: ...ror can also happen if the squeegee down Input 1CH 00 is stuck on 2 Squeegee motor does not run when tested in the Output Test You will need to determine if power is getting to the motor a Fuse is blown b Squeegee linkage is in a bind c Relay came loose in socket base or has failed d Motor has failed e Bad connection to the motor Check all power and wiring to the motor f PLC Output 101CH 03 failed...

Page 84: ...ubing has closed up internally Remove the tubing and roll in your hand to loosen any potential blockage 3 Machine leaves water on the lane after a test clean in various spots but cleans everywhere else a Squeegee not low enough to the lane 1 cause b The lane has bad depressions possibly more than 1 100th of and inch mostly around screw holes c Squeegee has a damaged area d Squeegee is worn out and...

Page 85: ...ose after the squeegee head d Applying too much volume while the machine is traveling too fast 9 Machine is leaking cleaner a Tubing in pump failed or has come loose and needs to be replaced b Tubing connector failed or came loose c Tank is leaking around fittings d Operator over filled machine and made a mess 10 Duster cloth hangs down on one side and sometimes touches the lane when the machine e...

Page 86: ...he drive motor runs but gives a Forward or Reverse Travel Error a Machine is not seated on the lane there are high gutters or the drive wheels are slipping b LDS signal has failed or the LDS shaft is binding c Wire is loose or broken for the 0CH 07 Input circuit d Turn the LDS shaft and see if Input 0CH 07 is flashing on the PLC as the wheels rotate e Machine Acceleration trimpot needs to be adjus...

Page 87: ...ane Distance shaft is not turning freely d Lane Distance target is loose e Lane Distance Proximity Sensor is too far from target f Lane Distance Proximity Sensor is damaged g Operator needs more training and is starting the machine too far past the foul line h Tail plank is missing from pin deck Check for missing tail planks Q If there is a definite failure of the Lane Distance Sensor is it possib...

Page 88: ...Machine runs but the number of lanes has been reduced or is reducing Any time this occurs the charging voltage should be monitored daily to determine if the charger is working 100 of the time 1 The charger voltage is incorrect 2 Charger operates intermittently Battery charger has internal bad connection 3 Vacuum is drawing more amps 4 Machine run times are longer 5 Possible bad connection between ...

Page 89: ...ack as shown in the pic below left 2 Reach your hand under the lid and locate the Lid Pin and pull the spring loaded pin from the pin guide 3 Do the same for both the 7 pin and 10 pin sides 4 Tilt the lid assembly up and slide the rear lid pins up and out of the middle guides Cleaning Compartment Lid Removal To remove the lid set the machine down in the operating position 1 In the operating positi...

Page 90: ...oval To remove the front cover simply unfasten the 4 screws that secure the top of the cover and remove from the attaching pins located on the bottom Rear Cover removal With the machine in the up right transport position locate the two screws that are on the inside front panel and below the buffer brush assembly As shown to the right After removing these set the machine down into the operating pos...

Page 91: ... attaching hardware and set aside for reassembly Side Cover Removal With the machine in the up right transport position locate the two 2 screws on each side that mount the bottom of the side cover as shown to the right Next set the machine down in the operating position and slide back the cleaning compartment lid Remove the two 2 screws that fasten the side covers to the side plate of the machine ...

Page 92: ...here the conditions are sometimes worse than bowling in a parking lot It is the only place on the planet where the lane man gets no grief from the players since no one cares if two lanes play the same Keeping your machine clean also helps you find potential problems Loose fasteners or wires can be found and fixed before they interfere with normal lane maintenance A good cleaning program is worth a...

Page 93: ...he cleaning compartment 3 Inspect buffer belt and its tension 4 Oil buffer belt idler 5 Check and inspect sliding head belts 6 Clean and inspect the compartment that contains the conditioner oil tank and pump 7 Clean the transfer brush Take an air compressor and blow out the transfer brush while loosening up the dirt with your hand Annual Maintenance If you are a real neat freak you could do thing...

Page 94: ...he buffer motor brush cap Once both caps have been removed take the air compressor and blow the motor out freeing it from any potential carbon build up Procedure for Cleaning Oil Control Valve The following steps outline the procedure for disassembling the conditioner metering valve Be careful when removing the oil lines from the fittings since they will leak Block off the stem elbows to prevent t...

Page 95: ...ol can also be used to remove any build up of sediment Do not use an air compressor to blow out the valve water in the air lines may be forced into the manifold 7 The bottom section contains a plunger and spring Make sure the three grooves on the sides of the plunger are clean This part should be cleaned with a cotton swab and alcohol to remove the debris IMPORTANT If a valve is found to have only...

Page 96: ... E 9 154 8889E Size C 10 154 8889C When installing the cushion roller wrap into the machine make certain that the arrows on the underside of the wrap are both facing outward towards the side panels Ten pin side Seven pin side If the Cushion Roller shows excessive wear it will be necessary to replace the entire assembly Changing Duster Cloth The machine uses a patented Dual Motor Ratcheting DMR Clo...

Page 97: ...he motor button in the cleaner compartment this button is always enabled to operate the duster unless the cleaner volume is being checked Press the button once and the duster will unwind press again and it will wind up cloth The cloth should be rolled up tight and evenly across the assembly 8 VERY IMPORTANT After installing the new roll you must reset the number of lanes in the cloth You can do th...

Page 98: ...may be discharged from the vacuum exhaust and onto the lane until the line is cleared 4 Transporting the machine with waste in the recovery tank is one of the worst things that an operator can do It should be strictly forbidden to allow any of your employees to do this The vacuum will get trashed out and begin to have problems and it will also affect the battery life Expensive PLC replacement is a...

Page 99: ...bing if a complete assembly is not being installed 4 Separate the end bells the pump head valves shown as A in diagram Hold the end bell containing the rotor as shown on opposite page with tubing retainer grooves pointing down Remove old tubing 5 Place new tubing which is broken in at the factory before shipping in the right groove and against the first two rollers Hold tubing with your thumb Near...

Page 100: ... 2 Place a drop of oil on the adjusting link end fittings and the squeegee pivots once every 6 months 3 Flip squeegee blades every 6 months and replace blades once a year 4 Change filter in recovery tank once a month or when needed 5 Check vacuum housing once a week and clean if any debris is present 6 Check vacuum hose from squeegee head to tank for clogs at least once a year in high lineage cent...

Page 101: ... that the Drive Motor is in need of service Slide back the oil compartment lid to gain access to the drive motor located under the Vacuum motor assembly With a flathead screwdriver remove the drive motor brush cap and remove the brush It may be necessary to pry this out with small screwdriver Battery Replacement Replacing the battery is simple but with the center compartment hinged open great care...

Page 102: ... remove the battery Given the weight of the battery care should be taken when removing 6 After carefully replacing the battery and mounting hardware plug the battery back into the connector 7 Close the center compartment and tighten fasteners 8 Turn machine ON to check charger and battery voltage ...

Page 103: ...90 CHAPTER 9 Miscellaneous Parts Stickers and Decals ...

Page 104: ...91 164 0014o 714C 164 0015o 714C 164 0024 Part Number for the K only 164 0023o 714C Part Number for the ION only ...

Page 105: ... 3 8 NPT x 3 8 Tube 154 0223 Elbow 1 4 Stem x 1 4 Tube 154 0222 Elbow 3 8 Stem x 3 8 Tube 154 0258 Elbow 1 4 Stem x 1 4 Hose Barb 154 0226 Elbow 3 8 Stem x 5 16 Hose Barb 154 0227 Female Connector 1 4 Tube x 1 8 FPT 154 0257 Union 1 4 x 1 4 154 0241 Reducing Union 1 4 x 3 16 154 0248 Male Lure 1 8 Hose Barb 154 0863 ...

Page 106: ...ide View 102 Right Side View 104 LDS Assembly 106 Handle Assembly 108 PLC Plate Assembly 110 Oil Valve Assembly 112 Oil Head Assembly 114 Oil Transfer Assembly 116 Brush Lift Rod Assembly 118 Cleaner Tank and Head Assembly 120 Duster Assembly 122 Squeegee Assembly 124 Recovery Tank and Vacuum Motor Assembly 126 ...

Page 107: ...94 ...

Page 108: ...34 K2 LITHIUM 25 6 Ah 164 8471 EXTERNAL BATTERY CHARGER ASSEMBLY 115V EXTERNAL BATTERY CHARGER ASSEMBLY 230v 164 8471 E 158 1634C K2 LITHIUM 51 2 Ah 158 1634B K2 LITHIUM 38 4 Ah Battery Quick Disconnects Red 158 1407 Blue 158 1408 DC Power Cord Assembly 6FT External 164 8475 ...

Page 109: ... BUMPER EA 5 1 164 8809 IKON RT SIDE GUARD LOWER 6 1 164 8810 IKON LT SIDE GUARD LOWER EA 7 1 164 8811 IKON RT SIDE GUARD UPPER EA 8 1 164 8812 IKON LT SIDE GUARD UPPER 9 2 153 2232L FLUSH MOUNT LID LATCH WITH LOCK EA 10 2 164 2069 SPRING PLUNGER THREADED EA 11 2 164 2002 DETENT SPRING PLUNGER EA 12 2 164 6164 LID LATCH BUMPER EA 13 2 164 2044 STANDOFF FEMALE THREADED 8 32 X 3 8 EA 14 2 164 2071 S...

Page 110: ...1 2 3 4 5 7 8 6 9 10 11 13 14 12 ...

Page 111: ...1 2 BORE EA 2 1 158 8406 DRIVE MOTOR EA 1 158 1405B DRIVE MOTOR BRUSHES PAIR PR 1 154 9601 CHAIN FOR 153 9002 SPROCKET EA 1 153 9047 MASTER LINK 40 EA 1 153 9048 OFFSET LINK 40 EA 1 153 9002 SPROCKET 40B13 5 8 IN EA 3 1 158 8407 VACUUM MOTOR 24VDC EA 4 1 158 8404D CLEANER PUMP ASSEMBLY EA 1 154 0861B NORPRENE TUBING FOR CLEANER PUMP ASSEMBLY EA 5 1 158 8404 CLEANER PUMP MOTOR 24VDC EA ...

Page 112: ...5 4 1 2 3 ...

Page 113: ... EA 4 2 153 6417 REAR LANE EDGE GUIDE ROLLER MOUNT EA 2 153 2407 BOLT FOR GUIDE ROLLER REAR NOT SHOWN EA 5 2 153 7005R MOMENTARY WHEEL ASSEMBLY WHEEL ONLY EA THE BELOW ATTACHED PARTS ARE NOT SHOWN 2 153 6006 MOMENTARY WHEEL SHAFT EA 2 153 6029 MOMENTARY WHEEL HOUSING ASSEMLBY EA 2 153 2049 SET SCREW NOT SHOWN EA 6 1 164 8012 HANDLE ASSEMBLY COMPLETE EA 7 2 158 6645 SKID GUIDE EA 8 2 153 7002AA LDS...

Page 114: ...DETAIL A DETAIL B A B 7 8 9 1 4 3 2 5 6 ...

Page 115: ... DUSTER MOTOR 24VDC EA 2 1 158 8402 BUFFER LOWERING MOTOR EA 3 1 158 8405 HEAD DRIVE MOTOR ASSEMBLY EA 154 9607 PULLEY FOR HEAD DRIVE NOT SHOWN EA 4 1 164 9019 BUFFER BELT ASSEMBLY EA 5 2 164 0022 L TO L CASTER ASSEMBLY EA 6 2 158 7002 6 WHEEL ASSEMBLY EA 7 1 153 8039 BUFFER IDLER PULLEY EA ...

Page 116: ...6 3 5 4 7 1 2 ...

Page 117: ...UMBER QTY PART NUMBER DESCRIPTION UOM 1 2 158 8402 SQUEEGEE BRUSH LIFT MOTOR 24VDC EA 2 2 158 8403 DUSTER MOTOR ASSEMBLY 24VDC EA 3 1 154 1220 PROXIMITY SENSOR EA 4 2 153 7002 6 WHEEL ASSEMBLY EA 5 2 164 0022 L TO L CASTER ASSEMBLY EA ...

Page 118: ...5 3 4 1 2 ...

Page 119: ...LOCK ASSEMBLY LEFT EA 4 1 154 8621 LDS MOUNTING BLOCK ASSEMBLY RIGHT EA 5 1 154 9213 SPROCKET 25B15 1 2 EA 6 1 154 9211 LDS AND TACH SENSOR DRIVE CHAIN 25 EA 1 153 9045 MASTER LINK 25 NOT SHOWN EA 7 1 153 9010 SPROCKET 25B15 3 8 EA 8 1 154 8320 LDS MOUNTING BLOCK ASSEMBLY CENTER EA 9 1 154 1220 PROXIMITY SENSOR EA 10 1 154 6264 SHAFT FOR TIMING DISK ASSEMBLY EA 11 1 154 6717 5 TOOTH SENSOR DISK EA...

Page 120: ...DETAIL A A 1 4 3 2 8 9 10 11 6 7 5 ...

Page 121: ...64 8013 HANDLE BUTTON REPLACEMENT ASSEMBLY W WIRES EA 3 1 164 6083 BUTTON COLLAR EA 2 158 2003 SCREW 8 32 X 1 2 FHCS BLK OXIDE EA 4 2 164 6057 HANDLE CATCH EA 5 2 164 6084 HANDLE MOUNT ASSEMLBY EA 6 2 164 6058 HANDLE SPACER EA 7 4 164 2001 UNTHREADED CURVED SPACER BLACK EA 2 164 2028 BHSCS 5 16 18 X 3 FULL THREAD EA ...

Page 122: ...3 4 5 6 7 1 2 ...

Page 123: ...LEANER PUMP EA 5 1 164 6815 CLEAR PC PLATE COVER EA 6 2 158 1460 RELAY SOLID STATE EA 7 6 158 1458 RELAY OMRON 24DC DPDT GENERAL PURPOSE EA 8 6 158 1462 24 V RELAY DPDT 10A W DIODE EA 9 2 164 1231 LY3 RELAY EA 10 2 164 1207 LY3 RELAY CLIP EA 11 13 153 1028 PANEL MOUNT FUSE HOLDER UL COMPLETE EA 12 1 153 1209 BUTTON GUARD EA 13 1 158 8439 PUSH BUTTON RED NORMALLY OPEN EA 14 1 164 6161 E STOP BOX EA...

Page 124: ...9 8 7 6 10 14 15 11 12 13 5 17 18 1 2 3 4 16 ...

Page 125: ...P 0 05 ML STROKE EA 5 1 154 8298 OIL CONTROL VALVE 24VDC WITH EXTENEDED WIRES EA EA 6 1 154 0248 REDUCING UNION CONNECTOR 1 4 X 3 16 EA 7 1 154 9607 PULLEY 24XL 5 16 BORE EA 8 1 154 9202A CONDITIONER PUMP BELT EA 9 1 154 9404 PULLEY 16XL037 X 1 4 BORE EA 10 16 5 154 0202 PUMP TUBING STOCK 3 8 OD X 1 4 ID IN 11 1 154 0257 FEMALE CONNECTOR 1 4 TUBE X 1 8 FPT EA 12 1 158 1613 PRESSURE GAUGE 60PSI EA ...

Page 126: ...12 11 1 1 13 14 15 10 6 7 9 8 1 2 3 4 5 6 ...

Page 127: ...154 6647A SLIDING HEAD BAR ASSEMBLY EA 5 1 154 0206 SPRING FOR OIL HOSE TIP ASSEMBLY EA 6 2 154 0220 PROXIMITY SENSOR EA 7 2 164 6280 HEAD BAR MOUNTING BLOCK EA 8 1 154 0202A PENCIL TUBING STOCK IN 9 1 153 2713 OIL HEAD SPRING EA 10 1 154 6893 OIL HEAD ASSEMBLY EA 11 1 154 6646 HEAD MOUNT PLATE ASSEMBLY EA 12 1 154 9201 OIL HEAD DRIVE BELT ASSEMBLY EA 13 1 154 6832 OIL PENCIL TIP ASSEMBLY EA ...

Page 128: ...DETAIL A A 8 3 7 6 5 4 11 10 9 12 1 2 13 ...

Page 129: ...46 BEARING MOUNT ASSEEMBLY LEFT EA 6 1 164 8045 BEARING MOUNT ASSEEMBLY RIGHT EA 7 1 158 6735 BRUSH TRACK MOUNT SUPPORT EA 8 1 158 6732 SINGLE BRUSH TRACK MOUNT ASSEMBLY EA 9 1 164 8008 TRANSFER ROLLER ASSEMBLY EA 10 1 158 9402 BUFFER BRUSH PULLEY ASSEMBLY EA 11 1 153 9816 FLANGED BUFFER BRUSH BEARING EA 12 1 154 8640 FLANGED BUFFER BRUSH BEARING ROTATED EA 13 2 164 6051 TRANSFER ROLLER IDLER BELT...

Page 130: ...1 9 5 11 4 10 7 2 8 3 6 17 16 13 12 14 ...

Page 131: ...GHT EA 3 1 154 8638 BUFFER BRUSH LOWER LINK LEFT EA 4 1 154 8837 BRUSH LIFT ROD TO CAM LINK EA 5 1 154 6243 MOTOR CAM DUAL LOBES STACKED SWITCHES EA 6 1 154 8637 BRUSH LIFT ROD ASSEMBLY EA 7 1 154 6824 CAM SWITCH PLATE EA 8 2 153 1203 MICROSWITCH W ROLLER EA 9 1 158 8634 SQUEEGEE BRUSH MOUNT PLATE ASSEMBLY EA 1 158 9614 BALL BEARING MINITURE NOT SHOWN EA ...

Page 132: ...DETAIL A A 6 2 3 1 7 8 5 4 9 ...

Page 133: ...Y EA 4 1 154 8852 CLEANER HOSE AND TIP ASSEMBLY EA 4 1 1 154 0863 LURE HOSE BARB EA 4 2 1 164 0012M CLEANER TIP WITH CHECK VALVE EA 4 3 1 153 2804 COLLAR 3 8 X 3 4 X 3 8 EA 4 4 1 153 2902 COLLAR 1 2 X 1 1 8 X 1 2 EA 5 1 154 8867A IN LINE FILTER ASSEMBLY EA 6 1 154 6646 CLEANER HEAD BELT MOUNT PLATE EA 7 1 154 6882 CLEANER HEAD ASSEMBLY EA 8 1 153 2713 SPRING FOR CLEANER HEAD ASSEMBLY EA 9 1 154 92...

Page 134: ...DETAIL A A 1 1 1 2 1 3 14 13 12 11 10 9 4 2 4 1 8 4 4 4 3 7 6 1 4 1 5 2 3 4 ...

Page 135: ...OVER SIZE C EA 154 8839D CUSHION ROLLER COVER SIZE D EA 154 8839E CUSHION ROLLER COVER SIZE E EA 3 1 164 6108 DUSTER PLUG CARDBOARD CORE EA 4 1 153 0047EZ K2 SELECT DUSTER CLOTH BOX OF 4 CASE 5 1 154 0052 PVC TAKE UP REEL ASSEMBLY EA 6 1 153 0429 DUSTER ROLL SUPPORT PIPE 40 INCH EA 7 1 164 6109 UHMW DUSTER PLUG FOR PVC TAKE UP REEL EA 8 2 153 8420 CUSHION ROLLER PIVOT ARM EA 9 1 153 8202B DUSTER S...

Page 136: ...1 6 3 8 10 1 9 6 7 8 10 5 2 1 4 2 1 5 4 2 ...

Page 137: ...03 GASKET NOT SHOWN EA 3 2 154 8802 SQUEEGEE ADJUSTMENT ARM EA 4 1 154 6677A SQUEEGEE HOSE ADAPTER NYLON EA 5 1 158 8634 SQUEEGEE BRUSH MOUNT PLATE ASSEMBLY EA 1 158 9614 BALL BEARING MINITURE NOT SHOWN EA 6 2 153 1203 MICROSWITCH W ROLLER EA 7 1 154 6824 SQUEEGEE CAM SWITCH PLATE EA 8 1 154 6339 2850 SQUEEGEE MOUNT ANGLE EA 9 1 154 6243 MOTOR CAM DUAL LOBES STACKED SWITCHES EA ...

Page 138: ...8 4 3 7 6 5 9 1 2 ...

Page 139: ...COVERY TANK GASKET NOT SHOWN EA 12 153 2968 SCREW 1 4 X 3 4 FHSHCS NOT SHOWN EA 4 2 153 8827T 1 1 4 PVC ELBOW TANK INLET NO THREADS EA 5 1 164 6120 FLEX RECOVERY TANK COVER PLATE EA 6 1 154 0607 PVC ELBOW 1 1 2 BARB X 1 1 2 BARB EA 7 40 154 0260 FLEXIBLE HOSE SOLD BY THE INCH IN 8 6 153 2406 HOSE CLAMP 2 INCH EA WHEN ATTACHING PART NUMBER 153 6221M USE A TWO 2 PART EPOXY AND ALLOW TO DRY ACCORDING...

Page 140: ...3 1 1 1 5 6 7 8 4 2 ...

Page 141: ...127 ...

Page 142: ...otor Wiring Layout 138 L R R L Head Proximity Sensor Wiring Layout 139 Oil Valve Wiring Layout 140 Buffer Motor Wiring Layout 141 Brush Lift Motor Wiring Layout 142 Vacuum Wiring Layout 143 Squeegee Motor Switch Wiring Layout 144 Duster Unwind Motor Switch Wiring Layout 145 Duster Windup Motor Switch Wiring Layout 146 Cleaner Pump Speed Control Wiring Layout 147 Start Button Duster Presoak Button ...

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