ELECTRODRIVE Tug Compact User manual

Tug Compact
Operating Manual

Tug Compact Operating Manual—OM0012E/2
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: [e-mail]
Made in Australia by:
Electrodrive Pty Ltd
2A Ayton Street, Sunshine North VIC Australia 3020
p: 1300 934 471 (within Australia)
p: [phone] (International)
e: [email protected]
w: www.electrodrive.com.au
© Electrodrive

Tug Compact—Operating Manual
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Contents
Introduction..................................................................................................................... 5
Features ....................................................................................................................... 5
Controls ........................................................................................................................ 6
Operating instructions ................................................................................................... 6
Controls ........................................................................................................................ 7
Driving instructions ........................................................................................................ 9
Safety check ................................................................................................................. 9
Hitching to a trolley....................................................................................................... 9
Steering......................................................................................................................... 9
Unhitching..................................................................................................................... 9
Charging ..................................................................................................................... 10
Maintenance ................................................................................................................. 11
Batteries...................................................................................................................... 11
Tyres............................................................................................................................ 11
Motor and transmission.............................................................................................. 11
Brakes......................................................................................................................... 11
Motor controller .......................................................................................................... 11
Throttle lever ............................................................................................................... 11
Fuses .......................................................................................................................... 11
Self-resetting circuit breaker....................................................................................... 12
Warranty ........................................................................................................................ 13
Modications and misuse will void your warranty...................................................... 13
General wear items not covered under warranty........................................................ 13
Appendix 1: Machine rating conditions...................................................................... 14
Appendix 2: Fault codes .............................................................................................. 15
Appendix 3: Wiring diagram ........................................................................................ 16
Appendix 4: Charging procedures for SLA batteries ................................................ 17

4
Charging setup ........................................................................................................... 17
During charging .......................................................................................................... 17
Charger manual .......................................................................................................... 17
Appendix 5: Spare parts list......................................................................................... 18
Service log .................................................................................................................... 20

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Introduction
Move your existing manual trolleys with the battery powered Tug Compact.
The Tug Compact simply hooks on to your existing trolley with a simple 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.
The Tug Compact allows an operator to eortlessly move heavy trolleys:
§Through long corridors, factory aisles, round tight corners.
§Up and down ramps,
§On and o lifts.
Features
§24 Volt DC power.
§Variable speed drive unit.
§Electro-magnetic park brake.
§Travel speed—up to 5 kph.
§Robust steel chassis.
§Tiller handle steering that folds up to reduce space when not in use.
§Programmable motor controller.
§Automatic charger.

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Operating instructions
Controls
Controls
Hitch
Emergency stop Battery level indicator
Tiller arm
Speed selector
Key switch
Throttle lever
Emergency back-o
button
Direction selector
Tiller post

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Controls
Key switch
The key switch must be turned clockwise to switch the unit on. When ON, the LED
status indicator will be illuminated. If a fault occurs with the electronics, this LED light
will ash an error code (refer to Appendix 2). It is important to note that the unit should
be switched o 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.
Emergency stop and back-o button
The controls have two emergency buttons.
1. Emergency stop button—in an emergency, push this button to stop the unit. To
release, slightly twist the button and it will pop back up.
2. Emergency back-o 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.
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 governed speed.
Releasing the lever stops the unit.
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 conned area.
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.
Horn (where tted)
Push to sound the horn, release to turn o.

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Charger socket
The charger socket is located on the body panel of the unit, next to the tiller post.
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.
Capacity
Refer to the serial plate for the unit’s safe working load, located on the body adjacent to
the tiller post.

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Driving instructions
Safety check
Before using the Tug 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.
Hitching to a trolley
The Tug can be tted with a variety of hitches.
In all cases, 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.
Towing a trolley with castors in poor condition can overload the Tug,
and cause damage not covered under warranty.
Steering
The tiller arm provides easy steering. The Tug with an attached trolley can be
manoeuvred through tight areas.
It is STRONGLY RECOMMENDED that the operator lead the Tug and
trolley, rather than using the Tug to “push” the trolley. This will ensure
that the operator has a safe unobstructed view ahead. This will also make
the Tug and trolley easy to manoeuvre.
Unhitching
Always make sure the trolley is on a at level surface. Apply the castor brakes (if tted)
or chock the wheels of the trolley before releasing it from the Tug.

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Charging
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 4.
Only use the battery charger supplied with this Tug.
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.

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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 should be maintained at a pressure of 40 psi. For replacement tyres, please
contact an authorised Electrodrive technician.
Motor and transmission
The transaxle is a sealed unit and does not require regular maintenance.
Brakes
The dynamic braking system does not require regular maintenance.
Motor controller
This unit is not serviceable. Any diculties 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 suer
damage they should be replaced. If the handle loosens with wear, the hinge nut can
be gently tightened. However, rst conrm that the lever is in the correct position as it
may need to be reset. (Test by squeezing the lever slightly. The Tug should slowly move,
release and the Tug should completely stop).
Fuses
The control circuit is protected against inadvertent current over-loads. This fuse is
located adjacent to the controller under the top cover.

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Self-resetting circuit breaker
This Tug is tted with a self resetting circuit breaker in case of momentary over-
load. This circuit breaker can be found beneath the top cover on the main electrical
control panel. If the unit repeatedly over-loads, test the machine, as the motor may be
damaged, and continued use could damage the unit further.

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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.
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
modied in any way.
Modications and misuse will void your warranty
The following activities (including, but not limited to) are examples:
Modications
§The machine is re-wired by an unauthorized service agent.
§The motor controller is re-programmed by an unauthorized service agent.
§There are modications to the body or frame of the machine.
§Use of non-specied parts.
§The machine is serviced by an unauthorized service agent.
Misuse
§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-o system to change direction regularly.
§Exposed to a corrosive environment.
§Driven o road—potholes, gravel, etc.
§Driven on slopes with a steeper gradient than 1:12.
§Not being charged adequately.
§Using the emergency stop button as an ON/OFF button.
General wear items not covered under warranty
§Castors.
§Drive wheels and motor brushes.
§Hand grips.

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Appendix 1: Machine rating conditions
Model Safe Working Load Max Load
TUGCOM500NH 500 kg 500 kg
The Tug Compact 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 Compact IS NOT to be operated outside of
the recommended conditions.
1100
891
609

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Appendix 2: Fault codes
LED codes Explanation
LED o No power or defective controller.
Solid on Controller operational; No faults.
1, 1 R R Thermal cutback fault.
1, 2 R RR Throttle fault.
1, 3 R RRR Speed limit pot fault.
1, 4 R RRRR Undervoltage fault.
1, 5 R RRRRR Overvoltage fault.
2, 1 RR R Main contactor drive ‘o’ fault.
2, 3 RR RRR Main contactor fault.
2, 4 RR RRRR Main contactor drive ‘on’ fault.
]3, 1 RRR R HPD fault present for > 10 seconds.
3, 2 RRR RR Brake ‘on’ fault.
3, 3 RRR RRR Precharge fault.
3, 4 RRR RRRR Brake ‘o’ fault.
3, 5 RRR RRRRR HPD (high pedal disable) fault.
]4, 1 RRRR R Current sense fault.
]4, 2 RRRR RR Motor voltage fault (hardware failsafe).
]†4, 3 RRRR RRR EEPROM fault.
]4, 4 RRRR RRRR Power section fault.
] = Must cycle keyswitch to clear.
† = Must use programmer to clear, as follows: Select ‘parameters menu’;
alter data vaule of any parameter; cycle keyswitch.
Note: Only one fault is indicated at a time, and faults are not queued up.

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Appendix 3: Wiring diagram

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Appendix 4: 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 conrm 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 airow to help keep the batteries as cool as possible.
§If the batteries are swollen turn o immediately and call your service technician.
§Always leave batteries on charge until the charge is COMPLETE. This is indicated
when charger LED turns o.
Charger manual
Please read BA1105—Battery Charger Operating Manual for more information.

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Appendix 5: Spare parts list
Part Description
EDBATGEL33AH Battery—12V 33 Ah
EDBA1010 Battery—12V 40 Ah (upgrade option)
EDBA1105 Charger—24V 7 Amp
EDCL1052 Tiller handle membrane loom
EDCL1130 Loom—charger with socket
EDCL1141 Loom—controller suit tiller
EDEL1041 Battery leads blue/white
EDEL1100 Blanking plug—13mm
EDEL1910 Circuit breaker—40Amp
EDEL2080 Motor controller—Curtis 1228
EDEL2338 Emergency reverse button
EDEL2380 Emergency stop button
EDEL2450 Fuse 1 Amp (charger) (3AG)
EDEL2470 Fuse 10 Amp (control) (3AG)
EDEL2500 Fuse holder panel mount
EDEL2620 Horn button (optional)
EDEL2720 Key switch with key
EDEL2775 Membrane key pad
EDEL2805 Hour meter 12-48V (optional)
EDEL3010 Potentiometer — 5k(internal)
EDGM1810 Handgrip 7/8" x 5"—tiller
EDGM2040 Spring—tiller handle position
EDGM2051 Tiller pot spring
EDGM2150 Throttle cable
EDGM2170 Throttle lever for tiller handle
EDGM2210 Tiller pin—zinc plated
EDTX1010 Transaxle—V24 250W 85 RPM

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Part Description
EDWH1200 Rim 6" white 5 bolt
EDWH1260 Tube (for 410 x 350-6 tyre)
EDWH1420 Tyre 410x350-6 grey
EDWP1049 Tiller handle—complete
EDWP1875 Tiller post

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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