Tug Smart
Operating Manual
Tug Smart Operating Manual—OM0025E/1
This manual contains important safety, installation and operating instructions for this
unit. Read this manual thoroughly and completely, and retain for future reference. This
unit can cause serious injury to personnel or damage to property if used incorrectly,
therefore do not use this machine for any other purpose apart from its intended use.
Using this unit incorrectly may void warranty.
Any damage audible or visible to this unit should be addressed at the time of discovery.
Electrodrive Pty Ltd can provide parts and service support on request through its
service partner company:
Serviced Equipment Pty Ltd
p: 1300 934 471
e: service@fallshaw.com.au
Made in Australia by:
Electrodrive Pty Ltd
2A Ayton Street, Sunshine North VIC Australia 3020
p: 1800 333 002 (within Australia)
p: +61 (03) 9300 8521 (International)
e: sales@electrodrive.com.au
w: www.electrodrive.com.au
© Electrodrive
Tug Smart—Operating Manual
Contents
Introduction ..................................................................................................................... 4
Features ....................................................................................................................... 4
Operating instructions ................................................................................................... 5
Controls ........................................................................................................................ 5
Driving instructions ........................................................................................................ 8
Safety Check ................................................................................................................ 8
Hitching to a trolley ....................................................................................................... 8
Unhitching .................................................................................................................... 9
Steering ........................................................................................................................ 9
Charging ....................................................................................................................... 9
Maintenance ................................................................................................................. 10
Batteries ..................................................................................................................... 10
Tyres ........................................................................................................................... 10
Brakes ........................................................................................................................ 10
Motor .......................................................................................................................... 10
Motor controller .......................................................................................................... 10
Throttle lever ............................................................................................................... 10
Fuses and circuit breakers ......................................................................................... 10
Park brake release switch .......................................................................................... 11
Warranty ........................................................................................................................ 12
Unauthorised maintenance ........................................................................................ 12
Misuse ........................................................................................................................ 12
General wear items not covered under warranty ........................................................ 12
Appendix 1: Machine rating conditions ..................................................................... 13
Appendix 2: Charging procedures for SLA batteries ................................................ 14
Appendix 3: Spare parts list......................................................................................... 15
Service log .................................................................................................................... 16
3
Introduction
Move your existing manual trolleys with the battery powered Tug Smart.
The Tug Smart simply hooks on to your existing trolley with your chosen hitch. This
converts your heavy trolley into a powerful, easy to move motorised unit. Productivity is
greatly increased, and back or shoulder strain is eliminated.
Features
§ Rated to tow up to 5000 kg
§ Power steering
§ 1800 W motor power
§ 24 Volt DC power
§ Variable speed drive unit
§ Electro-magnetic park brake
§ Travel speed—up to 5 km/h
§ Robust steel chassis
§ Programmable motor controller
§ Automatic charger
4
Operating instructions
Controls
Tiller arm
Tiller post
Optional safety lights
Tug Smart—Operating Manual
Optional strobe light
Hitch
Controls
Emergency stop
Battery level indicator
Speed selector
Direction selector
Optional horn
Emergency back-off
button
Throttle lever
5
Controls
Key switch
The key switch must be turned clockwise to switch the unit on. When ON, the LED
status indicator will be illuminated. It is located next to the charger socket on the body
of the machine. It is important to note that the unit should be switched off and the key
removed, whenever it is not in use. This eliminates the risk of unauthorised movement
and also prevents an unnecessary use of battery power.
Use this key switch to reset the machine by switching it off and on again. Note that
upon reset, the machine will always default to slow speed and in the direction of towing.
Emergency stop and back-off button
The controls have two emergency buttons.
1. Emergency stop button—in an emergency, push this button to stop the unit.
LED lighting on the tiller handle will blink. The machine must be reset in order to
operate after the emergency button has been pressed. To do this, slightly twist the
emergency stop button for it to pop back up. Turn the key switch off and on again,
and the machine will now be ready again.
2. Emergency back-off button—when pressed, the unit will travel backwards until
released, to avoid pinning the operator against an obstacle.
Only use the emergency buttons in an emergency.
Using emergency buttons frequently in unnecessary situations will harm
the machine.
Direction selector
This determines the direction of travel. Push the button corresponding to the desired
travel direction (forward/reverse).
Throttle lever
This lever provides variable speed control from zero up to 100% of the selected speed.
Releasing the lever stops the unit.
Note: As a safety precaution, the throttle lever must be squeezed in order to steer the
machine. Moving the tiller handle without throttling will not steer/move the machine.
Speed selector
The speed selector will always start in the SLOW position. Select a speed that you are
comfortable using. The speed can be changed whilst driving. It is advisable that you
operate this unit at a slow speed when entering a conned area. For safety reasons, the
tug will always be in slow speed when travelling in reverse.
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Tug Smart—Operating Manual
Battery level indicator
The battery level indicator indicates the amount of charge left in the batteries. When it
appears to be running low, return the unit to the closest charging station to charge the
batteries. Being aware of the level of charge of the batteries will eliminate the possibility
of running low on power whilst away from the charging station.
Red light only indicates no usable battery power remaining.
The battery level indicator may blink from time to time. This is normal as battery voltage
is frequently monitored.
Horn (where tted)
Push to sound the horn, release to turn off.
Charger socket
The charger socket is located on the body panel of the unit, below the tiller post.
The machine is disabled whenever the charger is plugged in.
Brakes
When the speed control lever is released, the unit is slowed electrically by dynamic
braking until the machine and load comes to a complete stop. The electromagnetic
brakes (park brakes) will then be applied. These brakes are also applied shortly after the
speed control lever is released.
Load capacity
Refer to the serial plate for the unit’s safe working load, located on the body adjacent to
the tiller post.
7
Driving instructions
Safety Check
Before using the Tug Smart the operator should complete the following check:
1. The battery charger is not connected.
2. The direction selector works.
3. The emergency stop button is released.
4. The brakes operate correctly when the throttle lever is released.
5. The battery indicator shows adequate charge.
6. There is no visible damage to the unit.
7. Back-off button works correctly.
Hitching to a trolley
This Tug Smart is tted with a tow ball hitch. Other
hitches are also available.
Ensure that the trolley being attached to has its brakes
engaged (or chocked) and is free from obstruction.
Inspect the trolley and ensure that the trolley castors
are in good condition.
Always ensure you are hitching on level ground.
It is STRONGLY RECOMMENDED that the operator lead the Tug Smart
and trolley, rather than using the Tug Smart to “push” the trolley.
This will ensure that the operator has a safe unobstructed view ahead,
and ensures the Tug Smart and trolley are easy to manoeuvre.
Towing a trolley with castors in poor condition can overload the
Tug Smart, and cause damage not covered under warranty.
This Tug Smart is not designed for use on inclined surfaces at
full load, and doing so may pose a risk of accident or injury.
Use on level ground only, unless assessed by Electrodrive.
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Tug Smart—Operating Manual
Contact Electrodrive for further information on rated loads for hitches.
Contact Electrodrive for advice on maximum loads when towing on
ramps and slopes.
Unhitching
Always make sure the trolley is on a at level surface and apply the castor brakes
(if tted) or chock the trolley wheels.
Release the hitch and carefully drive the Tug Smart forward away from the trolley.
Steering
The Tug Smart has a dual motor drive system which allows for power steering.
Therefore minimal force on the tiller handle is required to steer the tug. To steer, push
the tiller handle into the desired direction of travel whilst squeezing the throttle lever. To
pivot the tug on its own axis, simply push the tiller handle sideways whilst only slightly
squeezing the throttle.
The Tug Smart with an attached trolley can be manoeuvred through tight areas.
Charging
Plugging in the charger cord will disable the machine whether it is turned on or not. If
the machine is turned on whilst charging, then the lights on the tiller handle will blink.
When disconnecting the charger, the machine must be reset by turning the key off
and on.
Ensure regular recharging of batteries (charging overnight after a day’s usage is
recommended). Irregular charging may cause the batteries to prematurely fail.
Leaving a machine in storage without charge for periods greater than a month can also
lead to premature battery failure. This is not covered under warranty.
For detailed charging procedures refer to Appendix 2. Misuse of the battery will void
warranty.
Only use the battery charger supplied with this Tug Smart.
The automatic features of the supplied charger ensures that the sealed gel
batteries are not overcharged, and only a minimum amount of gas, if any at
all, are expelled during charging.
9
Maintenance
Batteries
If this unit is not being used for an extended period of time, it should be connected to
the battery charger to check the battery level on a regular basis, and placed on charge
overnight if required. This will ensure the batteries are kept in good condition.
The batteries are sealed and maintenance free. DO NOT attempt to open these
batteries. If the unit is not charged as above, the batteries may be exhausted and have
dropped below the charging threshold of the battery charger. The supplied charger
cannot begin to charge the batteries unless they have a small amount of charge. If this
occurs, contact Electrodrive or your local service agent.
A sign that the batteries need replacing is when they no longer hold charge.
Tyres
The tyres are polyurethane, giving it punture-proof characteristics. For replacement
tyres, contact Electrodrive or your local service agent.
Brakes
The dynamic braking system does not require regular maintenance.
Motor
Motor brushes should be inspected every six months and replaced every 2 years.
Remove the brush retaining cover for access to the brushes, should they need
replacing.
Motor controller
This unit is not serviceable. Any difculties experienced with speed control should be
referred to Electrodrive.
Throttle lever
The throttle lever and cable do not require maintenance. Should the lever or cable suffer
damage they should be replaced. If the handle loosens with wear, the hinge nut can
be gently tightened. However, rst conrm that the lever is in the correct position as it
may need to be reset. (Test by squeezing the lever slightly. The Tug Smart should slowly
move, release and the Tug Smart should completely stop).
Fuses and circuit breakers
The control circuits and power circuits are protected against inadvertent current overloads. These fuses are located adjacent to the controller under the top cover.
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Tug Smart—Operating Manual
Park brake release switch
In the unlikely event of a failure, the park brake can be disengaged, allowing it to be
towed by another machine.
To disengage the park brake, remove maintenance panel take the key from the key
switch and insert it into the park brake switch, and turn clock-wise.
The park brake will not release if the battery is at.
Do not use a duplicate key to unlock the park brake.
You must use the same key from the tiller handle key switch.
11
Warranty
Electrodrive Pty Ltd warrants that this product is free from defects in materials and
workmanship for a period of twelve months from the date of dispatch from the
Electrodrive plant. The battery has a six month warranty.
If a defect is reported, Electrodrive will repair or replace the defective part, at its own
discretion. This warranty does not apply if this unit has been misused, damaged, or
modied in any way.
Please be aware that modications and misuse will void your warranty. The following
activities (including, but not limited to) are examples of these:
Unauthorised maintenance
§ The machine is re-wired by an unauthorised service agent
§ The motor controller is re-programmed by an unauthorised service agent
§ There are modications to the body or frame of the machine
§ Use of non-specied parts
§ The machine is serviced by an unauthorised service agent
Misuse
§ Shunting loads at speeds in excess of 2 km/h
§ Overloading the unit either during towing or lifting
§ Carrying people or other foreign objects
§ Exposed to rain or other precipitation, unless weatherproof option is installed
§ Using the emergency back-off system to change direction regularly
§ Exposed to a corrosive environment
§ Driven off road—potholes, gravel, etc.
§ Driven on slopes which don’t comply with Electrodrive’s recommendations
§ Not being charged adequately
§ Using the emergency stop button as an ON/OFF button
General wear items not covered under warranty
§ Tyres, tubes and castors
§ Drive wheels and motor brushes
§ Hand grips
12
Tug Smart—Operating Manual
Appendix 1: Machine rating conditions
875
548
1875
Model Working Load Limit Max Load
TUGSMART4TNH 4000 kg 4000 kg
TUGSMART5TNH 5000 kg 5000 kg
TUGSMART6TNH 6000 kg 6000 kg
The Tug Smart has been designed to move the rated weight capacity on a level rm
surface. Variations in the working environment may impede the performance of this unit.
Such parameters include (but are not limited to) the following:
• Ramps and sloped surfaces
• Soft surfaces (for example carpet)
• Slippery surfaces (gravel, water, oil on the ground, etc.)
It is important that the Tug Smart IS NOT to be operated outside of the
recommended conditions.
Contact Electrodrive for advice on maximum loads when towing on
ramps and slopes.
747
13
Appendix 2: Charging procedures for
SLA batteries
§ Always charge batteries when work is complete and the equipment is not required for
use.
§ Opportunity charging is NOT recommended. This can also shorten battery life.
§ Never leave batteries in a discharged state as this will shorten the batteries life.
§ For maximum battery life, a battery must be recharged to 100% capacity. Recharging
less than 100% may result in premature battery failure. Batteries are not covered
under warranty if they are not recharged properly.
§ If batteries are disconnected from the machine and not used for lengthy periods of
time, it is recommended to give them a maintenance charge once every two months.
Charging setup
§ Ensure you have the correct charger for the batteries. The correct voltage and current
is important to ensure the full life of the batteries.
§ Check all connections are tight and in good condition.
§ The green charger LED will illuminate to conrm charging is in progress.
§ If charger lights do not come on, call your service technician.
§ When charger is plugged in, drive function of machine is automatically inhibited.
During charging
§ Ensure there is enough airow to help keep the batteries as cool as possible.
§ If the batteries are swollen turn off immediately and call your service technician.
§ Always leave batteries on charge until the charge is COMPLETE. This is indicated
when charger LED turns off.
Charger manual
Please read BA1105—Battery Charger Operating Manual for more information.
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Tug Smart—Operating Manual
Appendix 3: Spare parts list
Part Description
EDROB2CH120A30V Motor controller XDC2430
EDMOTHUB900W250 Hub motor 900W
EDBATGEL12V100AH 12V Gel battery 100Ah
EDGSTRUT30X100 Gas strut 100N
EDGSTRUT30X150 Gas strut 150N
EDEL3100 Brake relay
EDREL24V150A Main contactor
EDWP1890 Tiller handle membrane
EDBATCHA25A Charger 24V 25A
EDPOT5KOHM Throttle potentiometer
EDEL3015 Steering potentiometer
EDFUS325A80VDC Main fuse 325A
EDEL2460 Fuse 1A Blade
EDEL2465 Fuse 3A Blade
EDPCBRUGDUINO RUGGEDUNO UNO
EDPCBRUGSERIAL Rugged Serial breakout board
EDSWTESTOP2NCTWIST Emergency stop button complete
EDLHTAMBER24V Beacon 24V amber
EDST-CV-W-01 Back cover
EDST-CV-W-02 Front cover
EDST-CV-W-03 Top cover
EDST-CV-L-01 Service cover
EDST-BA-L-02 Top ballast plates
15
Service log
Service recommendations
To ensure this equipment is kept in a safe and reliable condition, it is important to
follow a preventative maintenance program. Maintain a log of the service work on the
cards below, and always use an approved Electrodrive service agent to conduct the
works. Approved service personnel will be provided with all necessary documents and
components in service repair, including but not limited to, circuit diagrams, component
part lists, descriptions, service checklists and spare parts.
6 month service
Date of service Service agent
Machine serial number
Summary of works
Next service due
16
12 month service
Date of service Service agent
Machine serial number
Summary of works
Next service due
18 month service
Tug Smart—Operating Manual
Date of service Service agent
Machine serial number
Summary of works
Next service due
17
24 month service
Date of service Service agent
Machine serial number
Summary of works
Next service due
30 month service
Date of service Service agent
Machine serial number
Summary of works
Next service due
18
36 month service
Date of service Service agent
Machine serial number
Summary of works
Next service due
42 month service
Tug Smart—Operating Manual
Date of service Service agent
Machine serial number
Summary of works
Next service due
19
48 month service
Date of service Service agent
Machine serial number
Summary of works
Next service due
54 month service
Date of service Service agent
Machine serial number
Summary of works
Next service due
20
Tug Smart—Operating Manual
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Tug Smart—Operating Manual
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Mobility solutions to help you push, pull & lift with ease.
www.electrodrive.com.au
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