KM 360-drive User manual

Technical Manual
360-drive
Konga Mekaniska Verkstad AB
Dång 2
SE 362 93 TINGSRYD
Tel: +46 (0) 477 – 549 90
Fax: +49 (0) 477 – 549 99
E- mail: [email protected]
Internet: www.kongamek.se

Technical manual 360-drive page 2 of 26
Version 1, November 2011
The machine is delivered by:
Konga Mekaniska Verkstad AB
Dång 2
SE 362 93 TINGSRYD
Tel: +46 (0) 477 – 549 90
Fax: +49 (0) 477 – 549 99
E- mail: [email protected]
Internet: www.kongamek.se

Technical manual 360-drive page 3 of 26
1. Statements
1.1 Copyright
No part of this documentation may be reproduced and / or made public by means of print,
photocopy, film or any other means, without the prior written consent of Konga Mekaniska.
Except for parts of the manual that are meant to be reproduced for the use of this
documentation as shortened instructions and/or indications on the machine.
1.2 Liability
Konga Mekaniska is not liable for unsafe situations, accidents and damages that result from
ignoring warnings or instructions, as shown on the machine or in this manual, for example:
- Improper or incorrect use or maintenance;
- Use for other purposes or under conditions other than those specified in this
documentation;
- The use of other than specified parts;
- Repairs without the consent of Konga Mekaniska;
- Changes to the machine. These include, among others;
- Changes in the control or programming
- Welding, mechanical processing, etc.
- Enhancements to the machine or operator.
Konga Mekaniska is not liable:
- If the customer does not meet all its obligations to Konga Mekaniska (financial or otherwise)
as satisfied;
- For consequential damage caused by faults or defects in the machine (eg damage
(processed) products, work interruption, delays, etc.).

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1.3 Warranty
During a period of 12 months (unless otherwise agreed) after delivery Konga Mekaniska
grants to the client warranty on material and errors in manufacturing which occur during
normal use. Konga Mekaniska’s guarantee does not apply if the errors are caused by
improper use or other causes than of material and errors of manufacturing.
Warranty does not apply if material used or used goods are supplied or if the cause of errors
cannot be clearly demonstrated.
All goods and materials Konga Mekaniska does not manufacture, Konga Mekaniska grants
no warranty, other than by the given supplier. Warranty is provided only for delivered
materials, but not on wages or hours, this will be charged.
For goods sold and delivered with factory, importers or wholesalers guarantee applies only
by the suppliers guarantee provisions. Regarding warranty on batteries should always
charging scheme to be submitted, mentioned in Chap. 7.2.

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2. Foreword
In this manual, the 360 electric drive is described.
This manual provides you with information on safety, a description of the 360 drive and
working principle and instructions, operation and maintenance of the 360 drive.
It will highlight the potential dangers and directions to these hazards.
It is important to read this manual carefully to learn how the machine should be operated and
how it should be maintained. By reading this manual, you and others are helped to use the
machine the right way and to avoid personal injury and damage to the machine as far as
possible.
Konga Mekaniska produces as safe as possible. These machines are designed to the latest
standards, according to the CE marking. The user is responsible for the proper use and
maintenance of the machine.

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Table of contents
1. STATEMENTS …………………………………………………………………… 3
1.1 COPYRIGHT ……………………………………………………………………………………….. 3
1.2 LIABILITY …………………………………………………………………………………………... 3
1.3 WARRANTY………………………………………………………………………………………… 3
2. FOREWORD ……………………………………………………………………… 4
3. OVERVIEW SAFETY …………………………………………………………………………. 6
3.1 MARKINGS IN TEXT……………………………………………………………………………….. 6
3.2 MARKS USED………………………………………………………………………………………. 6
3.3 GENERAL SAFETY MEASURE ………………………………………………………………….. 7
4. GENERAL DESCRIPTION OF THE 360-DRIVE ……..……………………………. 9
4.1 INTENDED USE ……………………………………………………………………………………. 9
4.2 MAIN COMPONENTS OF THE 360-DRIVE ……………………………………………………. 10
4.3 CONTROL ………………………………………………………………………………………….. 11
5. OPERATING INSTRUCTIONS …………………………………………………. 13
5.1 INSPECTION BEFORE USING THE 360-DRIVE……………………………………………….. 13
5.2 REVERSE OF THE 360-DRIVE ........................................................................................... 14
5.3 OPERATION OF THE 360-DRIVE………………………………………………………………… 14
5.5 USING THE SAFETY SWITCH…………………………………………………………………….. 15
5.6 SHUTDOWN 360-DRIVE……………………………………………………………………………. 15
5.7 CLEANING PROCEDURE………………………………………………………………………….. 15
5.8 SOUND MACHINE …………………………………………………………………………………… 16
5.9 DRIVING ON VARIOUS SURFACES AND SLOPES .............................................................. 16
6. TRANSPORT, INSTALLATION AND DISPOSAL………………………………. 17
6.1 TRANSPORT…………………………………………………………………………………………… 17
6.2 STORAGE 360- DRIVE ………………………………………………………………………………. 17
6.3 DISPOSAL OF THE MACHINE……………………………………………………………………… 17
7. MAINTENANCE INSTRUCTIONS……………………….…………………………………… 18
7.1 BATTERIES…………………………………………………………………………………………….. 18
7.2 CHARGING THE BATTERY…………………………………………………………………………….18
7.3 REPAIRS………………………………………………………………………………………………… 19
8. SPECIFICATIONS…………………………………………………..………………………………. 20
ANNEX I EC DECLARATION OF CONFORMITY …………………………………………….21
ANNEX II ELECTRICAL DIAGRAM 360-DRIVE ………………………………………………23
ANNEX III TECHNICAL DRAWING ………………………………………………………………...24

Technical manual 360-drive page 7 of 26
3. Overview security
3.1 Markings in the text
IMPORTANT: Indicates strong influence on the machine, maintenance and
working with the machine
WARNING: Indicates a potentially hazardous situation which, if not avoided,
could result in serious injury or death.
DANGER: Indicates a potentially hazardous situation which, if not avoided, will
result in serious injury or death.
3.2 Used markings
Risk of electric shock

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3.3 General safety measure
- Read the manual always carefully prior to starting work, and follow the instructions
- Use this 360-drive only for the purpose for which it was intended and designed.
- Ensure that the recommendations on voltage (V) and frequency (Hz) are followed. The charger of the
360 drive must only be connected to a grounded AC outlet.
- Keep the 360 drive in good working condition by periodic safety inspections. Rectify immediately any
unsafe situations, or tag unsafe for use.
- The 360-drive may only be used after it has been reviewed and found to be correct with regard to
damage, functioning and completeness.
- Switch off the 360-drive for the servicing and transport and disconnect the battery terminals.
- Allow only qualified, properly trained personnel to operate the 360-drive or attempt maintains the
360-drive. The 360 drive may only be operated by one person.
- The user must have sufficient visibility on the road which should be free of obstacles and people.
- The user must choose speed and distance, in the unlikely event that its path is blocked, he must
always be able to stop the 360-drive and hold it in place.
- The user must be sure that he or others cannot be trapped.
- The 360-drive should not be left with the key in the ignition. In this way, unauthorized use is
prevented.
- The 360 drive should be left with the parking brake applied when not in use.
- Work on mounting, installation, adjustment, electrical connection, maintenance and repairs should
only be performed by qualified personnel.
- Stay out of the path of the moving and / or rotating parts of the 360 drive when it is in operation and
be careful of sharp edges and corners.
- When driving with the 360 drive any load should be properly plugged and / or fixed.
Activities not included in this documentation, should be carried out by staff or
in consultation with Konga Mekaniska.
This documentation is part of the machine!
Keep this documentation carefully. It contains information, which later can be
useful or necessary for example for repair and maintenance.
Konga Mekaniska can optionally supply an extra copy.

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4. General description of the 360 drive
The 360 drive is electrically powered and has two drive wheels and two steering wheels.
Inside the chassis are the 2 drive electric motors, including a reduction gearbox, electronic
speed control and power batteries. The 360 drive is operated via a tillerhead attached to the
chassis.
On the tiller controls are applied, as well as a safety switch.
The 360 drive is equipped with batteries that ensure that the 360-drive is independent of
continuous 220V AC power. Whenever the 360 drive connected to AC power charges the
battery. When the power plug is removed, it automatically switches to "battery operation”.
Customer-oriented systems can have different sizes, allowing the supplied 360-drive different
from the illustrations in this manual.
4.1 Intended use
This 360-drive is intended for the low physical effort in a controlled manner horizontally
moving goods with a maximum weight and performance (see Chapter 8: Specifications)
and/or a person.
For other applications, Konga Mekaniska proper operation of the 360 drive is
not guaranteed.
If the 360 drive is be used for other applications, please contact Konga Mekaniska.
Konga Mekaniska can determine whether (or not) changes to the 360 drive should be done
so that the operation can be guaranteed.

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4.2 Main Components of the 360 drive
The main components of the drive 360 are illustrated in Figure 1
Figure 1
Tiller:
Step less speed control forward and backward through butterfly buttons on both sides of the
tiller, for both right and left hand operation. The tiller is equipped with a safety switch. When
this switch is pressed, the 360 drive stops motor / drive wheel.
Stabilization blocks:
To drive the 360 additional "stable" to keep the vehicle stabilized at all times. These blocks
are located under the chassis.
Manual brake:
This brake can be used as a parking brake. Squeeze the handle and move the metal lock on
and the brake is permanently pressed. By squeezing the brake further, it will release metal
lock and the parking brake is now disengaged.

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You can also use the brake in an emergency such as a power failure and electronic
brake failures.
4.3 Operating parts
Emergency brake
Butterfly buttons
Warning Beeper
Magnetic key
BDI Battery condition meter
Battery Condition Meter:
The 360 drive is equipped with a battery condition meter. The capacity of the battery can be
read. Caution, do not use it as a guide for loading. The 360-drive should be recharged as
many times as possible, preferably after each workday If the BDI ends up in the red field
batteries are already damaged.
Travel speed
Use the potentiometer to set the desired maximum speed to a maximum of 6 km / h
(optional, not standard)
Warning Beeper:
In case of danger, the operator can warn the environment using the the warning beeper/
alarm.
Butterfly Buttons:
With the aid of the butterfly buttons on both sides of the tiller head, the 360 drive can be
moved either forwards or backwards when the butterfly buttons are pushed.
Safety switch:
The 360 drive is equipped with a safety switch. This safety switch is clearly recognizable by
its red color. In case of entrapment, this switch is pressed, after which the 360-drive stops.
Ignition switch:
Using the magnet supplied key the 360 drive can be switched off.

Technical manual 360-drive page 12 of 26
5. Operating Instruction
This chapter contains instructions for operating the 360 drive.
The vehicle can be operated by any adult person if the contents of these operating
instructions are followed. A special training is not required; some experience in working with
this type of equipment is required.
You may only drive with the 360 drive after you made sure that there are no
persons in the danger zones.
Allow only qualified, properly trained personnel operate this 360-drive or
attempt maintenance on. The 360 drive may only be operated by one person.
5.1 Inspection for use of the 360 drive
Before driving the 360 drive the following actions are performed:
1. Perform a visual inspection for signs of damage to the 360 drive. The 360 drive should
only be used after it has been reviewed and found to be correct with regard to damage,
functioning and completeness.
2. Enter the required maintenance. (see 7. Maintenance rules)
3. Verify the battery voltage is present. This is done by placing the magnetic key on contact.
The battery indicator lights up. (see 7.1.1 Battery Charging)
4. Determine the desired speed by turning the butterfly knobs. (see chapter 4.3)
5. Stand on the platform and lay both hands on the handles. Push with your right or left
thumb the upper ridge of the butterfly buttons slowly and gradually downhill. The 360 drive
will now move forward. Release the butterfly button again. Now pull the thumb or finger the
butterfly buttons toward you. The 360 drive will move backwards.
6. Squeeze the handle and move the metallic lock so the brake is permanently pressed. By
squeezing the brake further release the parking brake. Squeeze the handbrake while driving
and simulate an emergency. The handbrake turns the throttle off. Use on slopes always the
manual brake if necessary. When stationary on slopes, always lock the parking brake with
the metallic part on the brake.
Do not use the butterfly buttons at once to the extreme position to push. Push
the butterfly buttons slowly away from you or towards you and give more "gas"
as you know the 360-drive is under control.
1. 1. If 360 drive is equipped with a horn, the operation must be checked by
pressing the button.

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2. If all these things work properly, the 360 drive is ready for use. Should that not
be the case, please contact the technical department of Konga Mekaniska, before
using the 360 drive.
When 360 drive is not in use, remove the key from the ignition switch magnet
to exclude unauthorized persons driving the 360-drive. In addition put the 360
drive on the handbrake and disconnect any loads. .
The driver should only be on the 360 drive to take place at the appropriate
platform in the raised edges. The height of the platform is 130 mm. In the
driving routes, the minimum height of frames and / or ceilings or obstructions
on ceilings and / or frames to the floor have to be measured. Of this
measurement must be subtracted 130mm, this is the length allowed for
employees to be able to stand on the platform. If an employee is longer than
the allowed length of 360 he must drive and step on the floor temporarily until
the right height allows him to drive on the platform again.
5.2 Reversing the 360 drive.
Always keep in mind when reversing maintains a creep speed. Your control of
the machine is less when reversing.
5.3 Operation of 360 drive
When all inspections have been done as described in 5.1 you’re ready to drive.
While driving with 360 drive, always use two hands on the tiller for safe steering.
5.5 Use of the safety switch
The safety switch is located on the tiller and is clearly recognizable by its red color. (see
chapter 4.3 Control device) When the switch is pressed (in case of entrapment), the 360
drive stops.
5.6 Shutdown 360 drive
Turn off the 360 drive after use by taking off the magnetic key at the tillerhead.
Turn the machine off and remove the magnet key always from the ignition
switch before servicing the 360 drive to prevent dangerous situations or
serious injury.
When 360 drive is not in use, remove the magnetic key off the tillerhead to
avoid unauthorized persons driving the 360 drive.

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5.7 Cleaning Procedure
The 360 drive must be disabled during the cleaning. Electrical components
must not come into contact with water or other liquids or acids.
IIf the cleaning work is done by others than the operating personnel of 360
drive one should be ensured that such persons have the correct instructions
to clean safely carry.
The 360-drive should be cleaned regularly. Depending on the circumstances, you can use
the following tools:
- DO NOT CLEAN WITH Hot or cold water high pressure cleaner
- Compressed air (specially inside the machine every 3 months)
- Suitable scrapers, brushes or abrasive sponges.
- Suitable detergents.
Before using a detergent, make sure that is suitable for the materials of the
machine.
5.8 Machine Vision
Unusual sounds usually indicate wear, loose or broken parts, or incorrect adjustment of 360
drive. These defects must be fixed as soon as possible to prevent further deterioration or
damage to the drive 360 and / or surrounding equipment.
If the drive 360 is used in accordance with the requirements, the noise level will be less than
70 dB.5.8
5.9 Driving on different surfaces and slopes
Although we in the technical specifications indicate that a slope of 5% with 800 pounds
towing grip is possible it depends much of the subsurface. The customer must independently
determine what is safe. On an outer slope a drive can be safe with a heavy load in summer
but in bad weather or frost in winter, the situation is quite different. This also applies to
situations in the house with ramps or floors that are rough or smooth. A slope with a kitchen
on slippery tiles is very different from a slope in a house with carpet. Decisive is not so much
the pulling speed or incline, but the braking ability to incline or braking in general.

Technical manual 360-drive page 15 of 26
6. Transportation, installation, discard
6.1 Transport
The loading and unloading and transporting the 360 drive should be done with great care to
avoid damage and accidents.
When transporting 360 drive key must first be removed from the ignition and
battery terminals should be decoupled.
6.2 Storage of the 360-drive
When 360-drive is storaged for a long time, take the magnetic key off the
tillerhead and disconnect the batteries.
If 360 drive is not used for a long period of time due to long transport and / or storage, and
the battery is not recharged regularly, it may be that this is over-discharged. For proper
functioning, the battery should first be fully charged again.
6.3 Disposal of the machine
If 360 drive are disassembled, the requirements for waste observed have to be in force at the
place and at the time of disassembly.
In 360 drive are only made of generally known materials. At the time of the construction
waste disposal options exist for this and there were no special risks known for the persons
responsible for the dismantling work.
.
Batteries should be at a collection point for chemical waste to be returned.

Technical manual 360-drive page 16 of 26
7. Maintenance instructions
During work on the 360-drive the electrical supply should be switched off by means of the
magnetic key.
In order to avoid unintentional starting, the magnetic key should be taken off from the
tillerhead. Furthermore, the poles of the batteries should be disconnected.
Turn off the 360 drive always and remove the magnetic key of the tiller before
servicing the 360 drive to avoid dangerous situations or serious injury.
Furthermore, the poles of the batteries are disconnected.
7.1 Batteries
To prolong the life of the battery as long as possible, observe the following points in mind
and charge the gastight batteries only with the supplied charger.
1. The connection between the batteries and charging equipment must be undamaged;
2. Batteries should be clean and dry;
3. Regularly check the pools of battery connections before servicing;
4. Do not charge with damaged battery cables;
5. The batteries can be recharged at any time without problem. Empty driving should be
avoided.
6. Batteries have a limited life. The capacity (the time of discharge) lowers in time. If the
battery no longer has the desired discharge time it needs replacing.
7.2 Charging batteries
To magnetic key needs to be removed of the tillerhead during charging. The
360-drive should be put on the handbrake during charging.
Keep the charger out of dusty and wet areas. During charging any type of
moisture should be avoided
The 360 drive must only be recharged in a ventilated area.

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Too much charge cannot hurt the batteries, too little charge and deep-
discharge will damage batteries.
During charging, it is forbidden to touch the throttle.
The 360 drive is equipped with a portable charger. The 360- drive can be
charged everywhere where there is a drive socket (230 Volt).
With a proper working charger damaging of the battery is not possible during
charging, the battery charger decides when the charging process is
completed. Then it switches to trickle charge. A charging procedure is about 7
hours, depending on the (remaining) capacity of the batteries.
Within the organization a person should be held responsible for
a proper loading of the device. At starting the charging process he / she must
check whether the two red lights on the charger lights up and the fan starts. This
needs to be listed on a schedule that is kept. On that schedule should also be
the case if the machine is loaded and how many hours he has been on the
charger. If the batteries are fully charged a burning a red and a green light show
up.
When 360 drive is purchased, the battery has to be charged/discharged a few times before it
reaches it’s maximum capacity.
1. Insert 360-drive near a 230 V outlet.
2. Turn off the 360-drive by taking the magnetic key off the tillerhead.
3. Then insert the plug on/into the 230 volt outlet. Insert the key on the front position (red
coloured) of the chassis (Figure 1 page 11) the batteries are being recharged. Note that both
red lights on the charger and the fan starts running. If not, repeat the procedure.
4. When the batteries are fully charged, unplug the charger from the socket.
5. The 360 drive is now ready for use.
7.3 Repairs
During the warranty time repairs should be done under the direction of Konga Mekaniska.
All replaced parts should at least meet the specifications of the original parts.
The machine consists of standard components (commercially available) and specific
components. (Only for this machine produced)
Standard Parts:
Is preferable to use the original manufacturer.
If any doubt exists about the specifications: call Konga Mekaniska.
Specific components:
Only by Konga Mekaniska supplied replacement parts may be used.
A Deviate from the above rules may affect the safety of the machine. Konga
Mekaniska can accept no liability.

Technical manual 360-drive page 18 of 26
8. Specifications
Design data
Type of machine: Electric hand-operated by a driver
Length 800mm
Width 670 mm
Platform Height 130mm
Height 160mm low part
Height of tiller vertical 1310 mm
Speed 6 km / h maximum speed limit
Batteries 60 Ah at 24 V
Charger 10 A
Pulling force 1500 kg on a flat floor.
Maximum axle load on the machine 150 kg.
Range.
Watts: 800 watts peak, 500 watts continuous
Weight: 105 lbs. / 47,6 kg
About 60 km away without tensile load.
Approximately 30 km away by cargo.
Inclination 5 degrees with 800 pounds / 363 kg
See power Requirements:
Batteries: 6 x 12 Volt gas tight
Charger: 24 Volt / 10 or 15 ah / h
Physical conditions of use
Ambient temperature, operating: +5 to +40 degrees Celsius
Rel. Humidity (RH): 30% to 85%, non condensing

Technical manual 360-drive page 19 of 26
Lighting: Normal ambient lighting. Lighting is not installed on the machine.
Altitude: up to 1000 meters above sea level.
The machine is not intended for outdoor use.
The machine is not suitable for hazardous areas.

Technical manual 360-drive page 20 of 26
Annex I EC-Declaration of Conformity
Konga Mekaniska Verkstad AB, Dång 2, SE 362 93 TINGSRYD
Declaration of conformity:
client:
Job Number:
Date of award:
Date of delivery:
We, Konga Mekaniska,
Declare under our sole responsibility that the product:
WO No.:
Product Description: 360 Drive
to which this declaration relates, is in conformity with the standard (s) or other (e)
normative (f) (ve) document (s):
EN ISO 12100-1
(Safety of machinery-Basic concepts, general principles for design-Part 1:
Basic terminology, methodology)
EN ISO 12100-2
(Safety of machinery-Basic concepts, general principles for design-Part 2:
Technical principles)
EN ISO 14121-1
(Safety of machinery - Risk assessment - Part 1: Principles)
EN 614-1
(Safety of machinery - Ergonomic design principles - Part 1: Terminology and
general principles)
EN 1175-1
(Safety of industrial trucks - Electrical requirements - Part 1: General
requirements for trucks with battery)
EN 1726-1
(Safety of industrial trucks - Industrial trucks
with capacity up to and including 10000 kg capacity and tractors with a drawbar pull
up to and including 20000
N - Part 1: General requirements)