Lakeside Ergo-One Plus 8162 Owner's manual

Ergo-One®
Plus Power
Tug
by
Model 8162
Owners/Operator’s
Manual
Lakeside Manufacturing, Inc. 4900 W. Electric Avenue West Milwaukee, WI 53219
Lakeside products are protected by patents, patents pending and other rights reserved.
Toll free: 800-558-8565 Fax: [phone] Visit us on line at eLakeside.com
040909
TABLE OF CONTENTS

1
INTRODUCTION 2
SAFETY FIRST 3
OPERATING THE Ergo-One®Plus Power Tug 4
CONTROLS 4
ON-OFF KEY SWITCH 4
SPEED RANGE SWITCH 4
DIRECTION OF MOTION 4
RECEIVER CONTROL SWITCH 4
BRAKING SYSTEMS
EMERGENCY REVERSING PAD 4 4
HORN
BATTERY DISCHARGE INDICATOR
DRIVING THE CART
5
5
5
CHARGING
OPTIONAL EXCHANGEABLE BATTERY PACKAGE 5 6
TOWING WITH THE Ergo-One®Plus Power Tug 7
BATTERIES 8
BATTERY LIFE 8
BATTERY LOAD TESTING 8
CIRCUIT BREAKER & FUSES 9
MAINTENANCE 9
MAINTENANCE SCHEDULE 9
MAINTENANCE PROCEDURES 9
TROUBLE SHOOTING CHECKLIST 10
PUSHING MANUALLY
MODIFYING EXISTING CARTS FOR TOWING
WARRANTY
10
11
15
Ergo-One®Plus Power Tug PRODUCT SERVICE INFORMATION
(please fill out and keep this manual on hand for service records)
Company Name
Address
City State Zip
Representative Telephone
Purchase Date
Serial Number
Purchased From
Telephone
101008

2
INTRODUCTION
Welcome to the Ergo-One®Plus Power Tug...a member of Lakeside Manufacturing’s family of
quality material handling products. We know you'll be depending on the TUG, so we have taken great
care to make it completely reliable. This Owner's Manual is designed to help you get the most out of
your Ergo-One®Plus Power Tug and includes very important safety and care information. Please read
it thoroughly and keep it handy for reference. Thank you for choosing the Ergo-One®Plus Power Tug.
Information in this manual is based upon specifications in effect at the time of publication. Lakeside
reserves the right to make changes at any time without notice. Lakeside products are covered by patents,
patents pending, and other rights reserved.
Be sure to complete the Owner's Information box on the front cover. This will be your record of
important information which will help you if your Ergo-One®Plus Power Tug ever requires service.
When seeking repair parts while your Ergo-One®Plus Power Tug is under warranty, a copy of your bill
of sale may be requested to verify warranty status.
FAILURE TO READ THIS OWNER'S MANUAL WILL VOID THE WARRANTY.
If there is anything in this manual that you do not understand or that you are unsure of, DO NOT
OPERATE your Ergo-One®Plus Power Tug. Call our Customer Service Hotline at:
800-558-8565.

3
SAFETY FIRST
To prevent accidents which can cause injury to you, damage the Ergo-One®Plus Power Tug or
damage your cargo, observe the following rules:
1. Read and understand this Owner's/ Operator's
Manual before operating the Ergo-One®Plus
Power Tug.
2. Read and understand all safety instructions
provided with the cart or piece of equipment
which is to be towed by the Ergo-One®Plus
Power Tug.
3. Only trained personnel should be allowed to
use the Ergo-One®Plus Power Tug. All
persons using the Ergo-One®Plus Power
Tug must read this owner's/operator's manual.
4. The Ergo-One®Plus Power Tug has a
maximum towing capacity of 1,500 pounds
on a level surface. Do not exceed the rated
1,500 pound towing capacity.
5. Do not tow carts or multiple carts in excess of
20’ in length.
6. Do not travel up or down inclines greater than
9°. Towing capacity is reduced on inclines.
7. Do not travel sideways on inclines.
8. Always place the Tug in Turtle Speed Range
before traveling down an incline.
9. Do not stop the Ergo-One®Plus Power Tug
on an incline. Always park, load and unload
on a flat, level surface.
10. Do not go up or down curbs. Only operate
the Ergo-One®Plus Power Tug on smooth,
flat surfaces.
11. Do not carry on or tow passengers with the
Ergo-One®Plus Power Tug.
12. Always detach the Ergo-One®Plus Power
Tug before connecting towed carts or loading
or unloading carts.
13. Always load the towed carts evenly,
distributing the load to prevent tipping.
14. Always take corners slowly and with caution
to prevent the load from shifting.
15. Do not use the Ergo-One®Plus Power Tug
to push or pull stationary objects.
16. Always unplug the batteries before making
any adjustments or repairs to the Ergo-One®
Plus Power Tug.
17. Sound Horn when approaching or operating
in areas with limited visibility.
18. Do not expose the Ergo-One®Plus Power
Tug to high temperatures. The Ergo-One®
Plus Power Tug is battery operated.
Batteries may explode if exposed to high
temperatures.
19. Do not operate the Ergo-One®Plus Power
Tug with a flat tire, broken wheel or broken
or bent cart frame.
20. Use extreme caution when operating the
Ergo-One®Plus Power Tug near doorways,
in hallways and near stair wells. Reduce
speeds in these areas.
21. Do not manually release the electro-
mechanical brake on or near an incline. If
you must release this brake, release the brake
only when on a level surface and with the
TUG is detached from the towed carts.
20. Always make sure the tow pin is fully
inserted into the tug’s hitch receiver prior to
moving the cart. Failure to do so may result
in an unsafe condition where the towed cart
would release from the tug causing harm or
damage to surrounding people or objects.

4
OPERATING THE Ergo-One®Plus Power Tug
We would like you to be satisfied using your
Ergo-One®Plus Power Tug. When you use the
Ergo-One®Plus Power Tug for the first time,
you must know how to properly operate and care
for it to avoid unsafe situations. Please read this
manual thoroughly and become familiar with all
of the safety information provided.
Be aware of your surroundings, drive slowly and
cautiously. Avoid collisions and/or changing
directions quickly which could cause damage to
the Ergo-One®Plus Power Tug, or shift the
load, damaging the goods or injuring you or any
surrounding people.
Anticipate and avoid unsafe situations. Be
courteous of others and let your presence be
known.
Perform first time operation in an open area on a
flat surface - free of obstacles. Have someone
familiar with the operation of the Ergo-One®
Plus Power Tug available to assist you.
CONTROLS
Read and understand all instructions and control
functions before attempting to operate the Ergo-
One®Plus Power Tug.
On-Off Key Switch:
The on-off key switch is located on the under-
side of the Ergo-One®Plus Power Tug’s control
handle.
Drive Position:
To turn the power on, fully insert the key into
the key switch, and then turn the key
clockwise. When the power is on, the battery
discharge indicator, located on the shroud
under the handle, will illuminate.
Speed Range Switch:
The Speed Range Switch is located on the top,
left side of the handle control. Depressing the
turtle side of the switch will reduce the maximum
speed of the Ergo-One®Plus Power Tug.
Always reduce speeds during training, in close
quarters or in circumstances in which you risk
damage or injury if the maximum speed is not
limited.
Direction of Motion:
Direction of motion is controlled by the finger
control lever located to the right and left sides of
the center section of the hand control unit.
Rotating the top of the lever away from you
accelerates the cart away from you. Rotating the
bottom of the lever accelerates the cart towards
you. To STOP, release the control lever. Let the
cart come to a complete stop before changing
directions.
Receiver Control Switch:
The receiver control switch is located on the right
side top of the control handle. Pushing on the
switch arrow pointing at you extends the actuator,
rotating the receiver away from you, allowing
some of the towed carts weight to be transferred
to the tug’s drive system. Pushing on the switch
arrow pointing away from you will retract the
actuator, lowering the towed cart to a release
position.
Braking Systems:
The Ergo-One®Plus Power Tug has two types
of braking systems. It has dynamic regenerative
braking while moving and electromechanical
braking for parking.
Dynamic Regenerative Braking
Dynamic regenerative braking automatically
brings the Ergo-One®Plus Power Tug to a
smooth stop when you release the control lever.
However, it does not lock the wheels in place.
Electromechanical Braking
After the dynamic braking has brought the Ergo-
One®Plus Power Tug to a stop, or near stop, the
electro-mechanical brake will lock the wheels in
place. The drive wheels, must be contacting the
floor surface for the brake to hold.
Emergency Reversing Pad (Belly Button):
The Emergency Reversing Pad is located on the
back side of the hand control unit and is designed
to rapidly accelerate the TUG away from you
immediately upon being depressed providing that
the key switch is in the on position. The cart will
continue to move as long as the pad is pushed
upon.
Horn

5
The horn switch is located on the top side of the
Ergo-One®Plus Power Tug’s control handle and
is marked with a horn symbol. Push on the
button to sound the horn.
The horn will sound automatically when the tug
is traveling towards the operator.
The Horn is located under the shroud and above
the actuator push tube.
Battery Discharge Indicator (BDI) Description:
The BDI has four ranges of indicating battery
condition:
1. Bar #1 indicates the batteries are fully (or
nearly fully) charged.
2. Middle bars 2-9 indicate the batteries are
being drawn down. Fully charge the
batteries at the earliest convenience.
3. Bar #10, on left side indicates the batteries
need charging. Fully charge as soon as
possible.
4. Flashing Red bars #9 & 10- Charge The
Batteries at Once! Drive the Ergo-One®
Plus Power Tug to the closest 115 Volt 60
Hz AC outlet to charge.
The BDI may fluctuate between the different
ranges depending on the driving conditions at the
time. Quick acceleration or moving between
floor surfaces - concrete to carpeting - may cause
the BDI to drop momentarily to the next level.
DRIVING THE CART
The Ergo-One®Plus Power Tug is equipped
with electronically proportional speed control.
Driving speed is proportional to the force of the
push or pull of your fingers on the control lever.
The harder you push or pull, the faster it will go.
To Drive the Ergo-One®Plus Power Tug:
1. Turn the key switch clockwise to the Drive
Position.
2. Select the speed range by depressing either
the rabbit or turtle side of the speed range
switch.
3. For the cart to travel away from you, gently
rotate the top of the control lever away from
you. The cart will start to move and
accelerate away from you to the desired
speed proportional to the pressure on the
control lever.
4. To stop, release the control lever. The cart
will gently slow down with the aid of
dynamic regenerative braking. Stopping
distance increases as the load increases.
Allow for extra stopping distance when
towing heavy loads or multiple carts.
5. To go in opposite direction, toward you,
gently rotate the bottom of the control lever
away from you. The cart will accelerate
toward you to the desired speed proportional
to your finger pressure on the control lever.
6. To stop, release the control lever. The cart
will gently slow down with the aid of
dynamic regenerative braking. Stopping
distance increases as the load increases.
Allow for extra stopping distance when
towing heavy loads or multiple carts.
CHARGING
The Ergo-One®Plus Power Tug is equipped
with two absorbed glass mat or gel-cell batteries
which require charging on a regular basis. An on
board charging system is integrated into the
electronics of the Ergo-One®Plus Power Tug to
make charging easy. When the cart is plugged in,
the Ergo-One®Plus Power Tug is charging.
To Charge the Ergo-One®Plus Power Tug:

6
1. Position the cart close to a 115 Volt 60 Hz
AC power outlet.
2. Turn the unit off and remove the key.
3. The cart's main charging cord is wrapped on
the cord holder below the hand controls.
4. Plug the cord end into the outlet. If needed,
connect only an industrial grade grounded
extension cord to the charging cord and then
to the 115 Volt AC power supply outlet.
Make sure the plug is fully engaged into the
supply outlet.
5. Allow the unit to charge four to eight hours,
for a full charge if the unit was completely
discharged.
6. Unplug the cord (and extension cord from
the unit) from the power supply outlet before
attempting to turn the unit on. The unit will
not operate while in the charging mode.
OPTIONAL Exchangeable Battery
Package:
The Ergo-One®Plus Power Tug was designed to
exchange batteries as an optional way to charge
the batteries. This kit contains two batteries with
quick disconnect style wiring and a 24 volt
charger.
To exchange the batteries:
1. Drive the tug to the desired exchange
location.
2. Turn the unit off and remove the key.
3. Unwrap the charging cord from the cord
holder below the hand controls.
4. Locate and remove the four finger turn
screws that secure the plastic shroud to
the frame.
5. Gently lift the shroud up and forward,
carefully feeding the charging cord
through the shroud. The shroud is still
attached to the wiring harness.
6. Locate the Battery Indicator wiring
harness located below the Battery
Discharge Indicator on the shroud.
7. Disconnect the wiring harness at its
connecter.
8. Place the shroud off to the side.
9. Locate the large red and black connecters
on the wiring harnesses attached to each
battery.
10. Disconnect the connectors by grasping the
red and black connectors and pulling
straight apart.
11. Unscrew the battery hold down and
remove the hold down strap.
12. Carefully remove the battery from the
cart.
13. Place the exchange batteries in place on
the cart and reverse instructions to
reassemble the tug.
14. Connect the spent batteries to the charger
that came in the kit by attaching like color
connectors.
15. Plug the charger cord end into a 115 Volt
60 Hz AC power outlet. If needed,
connect only an industrial grade grounded
extension cord to the charging cord and
then to the 115 Volt AC power supply
outlet. Make sure the plug is fully
engaged into the supply outlet.
NOTE: Both of the batteries must be
charged at the same time in order for the
charger to work.
Towing with the Ergo-One®Plus
Power Tug:

7
The Ergo-One®Plus Power Tug was designed to
tow wheeled carts fitted with a Lakeside Docking
Assembly.
To Tow with the Ergo-One®Plus Power Tug:
1. Drive the Tug up to the desired cart to be
towed and align the lip of the Tug’s receiver
with the cart’s tow pin.
2. Slowly drive the Tug forward to bump the
lip of the Tug’s receiver with the cart’s tow
pin.
3. Gently pull back on the Tug’s handle to
engage the pin into the receiver. The
receiver angle may need to be adjusted
slightly to engage the pin fully. Push on the
receiver control switch arrows to change the
angle of the receiver. Make sure the pin is
fully engaged before proceeding.
4. With the cart’s pin fully engaged in the
receiver, push the receiver control switch’s
arrow pointing at you to extend the actuator.
Stop when the receiver is firmly on the pin
so the tug can not disengage when the handle
is pushed forward. The more weight
transferred on to the tug, the harder it is to
steer.
Note: The Tug’s tiller will slowly come
towards the operator as the receiver grips the
pin.
STOP pushing on the Up Arrow when
the cart’s wheels lift slightly off the
ground or when the actuator stalls.
5. With the cart attached to the Tug, careful
driving operation can resume. Remember
that stopping distance increases as the load
increases. Allow for extra stopping distance
when towing heavy loads or multiple carts.
6. Detach the Tug from the towed cart by first
bringing the Tug to a complete stop on a
level surface. Then push the down arrow
side of the Receiver Control Switch on the
hand control unit until the cart’s wheels are
back on the ground and tension is relived
from the tow pin in the receiver.
7. Gently push the handle of the Tug towards
the towed cart to disengage the tow pin from
the receiver.
BATTERIES
FOR BEST RESULTS: USE ABSORBED GLASS MAT OR GEL-CELL BATTERIES WITH
YOUR Ergo-One®Plus Power Tug.

8
1. The batteries supplied with the Ergo-
One®Plus Power Tug are maintenance free,
sealed, absorbed glass mat or gel-cell batteries.
DO NOT remove the battery caps.
DO NOT attempt to add water. This will ruin
your batteries and void your warranty. Liquid-
electrolyte batteries are not recommended for use
with your Ergo-One®Plus Power Tug.
2. If a crusty or powdery white substance
appears on or around the battery terminals, clean
them: use a solution of baking soda and water
with a toothbrush. DO NOT allow this solution
to enter the battery vents.
If you do not clean the batteries when this
substance appears, or if it is left for prolonged
periods, it will reduce the quality of battery
connection and affect performance.
3. When replacing the batteries, clean the
terminals and battery posts using a wire brush.
When re-attaching the terminals, be sure all
connections are tight. Failure to connect with
proper polarity will damage the control module.
BATTERY LIFE
Battery life depends upon use and proper care. If
you use the Ergo-One®Plus Power Tug a lot,
your batteries will need replacement sooner than
if you only use your Ergo-One®Plus Power Tug
a little.
If the distance you travel on a charge becomes
noticeably shorter, and ramps once easily climbed
become difficult to go up, you may need to
replace the batteries. Heating or swelling of the
batteries (sometimes accompanied by an acrid
odor) is another sign that the batteries may
require replacement.
Other factors which can reduce battery life are:
irregular or inefficient charging, leaving the
batteries in a discharged state for a prolonged
period of time, extreme temperatures and cargo
weight.
If you notice any of these conditions, have your
batteries load tested.
BATTERY LOAD TESTING:
A "load test" is a sure test of battery condition,
and can be performed by your local Authorized
Service Center.
Load testing measures battery voltage under a
heavy load. Before the load test, your batteries
should be fully charged. The service center will
measure the open circuit voltage, or voltage
across the batteries, prior to a load test. This
open circuit voltage must measure at least 12.6
volts on each battery in order to receive an
accurate assessment during a load test. The
service center will set the load tester to 100
amperes and hold the setting for 10 seconds.
At the end of 10 seconds, the service center will
read the results while the batteries are still under
load. If the load test voltage is below 10.0 volts
each, the batteries should be replaced.
CIRCUIT BREAKER
A manually reset circuit breaker is located
between the positive wire from the main
controller and one battery wire attached to the
positive (+) terminal of one of the batteries. The
circuit breaker protects the controller wiring and

9
batteries against damage in the event of a short
circuit.
If a breaker opens, try to determine the cause or
reason why it opened. Reset the breaker by
pushing in on the tab. If it opens again in a short
time - there is a short circuit which must be found
and corrected. DO NOT TAPE THE TAB DOWN!
DO NOT DEFEAT THE BREAKER! DO NOT
REMOVE OR BYPASS THE CIRCUIT BREAKER!
If any additional wiring is added to the Ergo-
One®Plus Power Tug, it must not bypass the
breaker.
FUSES
Two automotive style fuses are installed in the
wiring harness of the Ergo-One®Plus Power
Tug. One fuse protects the actuator circuit. The
other fuse protects the hand control unit. These
in-line fuses are located on the main wiring
harness and are attached to wires coming from
the main control box. See picture on page 8.
Replace fuses with same amperage size only.
MAINTENANCE
MAINTENANCE SCHEDULE
Your Ergo-One®Plus Power Tug will give you
years of safe and dependable service in return for
regular maintenance and early attention to any
developing problems. We recommend the
following maintenance program.
If you use your Ergo-One®Plus Power Tug
often, you will find it to your advantage to
perform this maintenance more frequently.
CAUTION: Turn the cart off before
performing any maintenance.
Every Day or As Needed:
1. Maintain the batteries' charge.
2. Clean debris from the wheels and drive unit
assembly.
3. Inspect tow hitch assemblies installed on
towed carts.
Once Each Month:
1. Check for loose connectors and any signs of
unusual wear.
Once Every Three Months:
1. Check the exposed wires for wear, fraying
or cracking.
2. Check the connectors for wear or cracking.
3. Examine the tires or wheel assemblies for
wear or damage.
Once Each Year:
1. Check the motor brushes for wear.
NOTE: This maintenance is best performed
by your local Authorized Service Center.
MAINTENANCE PROCEDURES
Cleaning Your Ergo-One®Plus Power Tug:
Turn the power OFF before cleaning your cart.
DO NOT hose off your Ergo-One®Plus Power
Tug. Excessive water may damage electronic
components. Wipe the hand controls with a damp
cloth and dry immediately.
Do not use harsh or abrasive cleansers on the
Ergo-One®Plus Power Tug or its tires. These
types of cleansers will damage the finish of your
Ergo-One®Plus Power Tug, and may cause
premature tire wear. Clean your tires with a rag
or a soft bristle brush dipped in warm water.
TROUBLE SHOOTING CHECKLIST