Electric Tugger FAQS

Common and frequently asked questions about our electric tuggers, tows & pushers.


MasterMover SmartMover - SM100

General FAQs

What Is An Electric Tugger?

Electric tuggers are battery powered machines that allow a single pedestrian operator to move heavy loads on wheels without any physical effort.

They provide a very safe and highly efficient way to maneuver heavy loads in a controlled manner. MasterMover’s extensive range of tuggers caters for all loads from the very small to loads weighing up to 720,000 lbs.

What Types Of Electric Tugger Are Available?

MasterMover offer a range of 26 standard machines designed to deal with different loads levels, ensuring that you select the machine which meets your application and budgetary goals.

The SmartMover range is the perfect manual handling solution for moving loads weighing up to 2,600 lbs. The type of manual handling and time/cost associated with this type level of weight and task can be cut substantially by moving several items at once, not just one at a time.

If your application weighs more than 2,600 lbs you will be interested in our MasterTug or MasterTow range. There are 13 machines in the MasterTug range covering application weights up to 44,000 lbs. The MasterTow range consists of 6 machines capable of towing up to 26,500 lbs.

Both ranges can be used to transport larger loads, both on castors or on rails and is commonly found in manufacturing environments where something needs to be moved along a production process or if parts need delivering to the production line in a Just In Time (JIT) fashion.

The All Terrain range, ATT400, add further options to the requirement to move loads that are not on smooth surfaces or that need to move outside the factory environment.

Whichever electric tugger you select, the safety and efficiency of your application will be improved, increasing productivity and profitability.

What Industries Use Pedestrian Electric Tuggers?

MasterMover has supplied electric tuggers to many of the world’s largest companies to assist in the manufacturing of large vehicles including construction, mining and agricultural equipment, pharmaceutical manufacturing, oil and gas equipment and aerospace.

How Does A Pedestrian Electric Tugger Work?

A pedestrian electric tugger uses a coupling attached to your load which allows a transfer of weight to its drive wheel, delivering the grip required to easily pull or push with complete control.

Is A Pedestrian Electric Tugger Safe To Use?

An electric tugger from MasterMover is a very safe way to move heavy wheeled loads.

Our tuggers are designed with a number of safety features to ensure that the operator is always in control. Features include an emergency stop button, an anti-crush button that would be activated immediately if the user’s body came into contact with it and a sensor that automatically cuts off the power when the tiller arm returns to vertical.

The tuggers also have a warning horn and a self-adjusting castor guard that ensures it never becomes a foot trap risk, even once weight transfer has occurred.

Further safety options are available such as a two speed selector switch to suit your operating environment and a flashing safety light and motion bleeper.

Does The Load Stop When The Electric Tugger Stops?

Yes, your MasterMover electric tugger is physically connected to your load so when the tug stops, the load stops.

Each machine has a number of braking mechanisms that ensure it is safe to use in every eventuality. The operator can simply release the controls and the load will come to a halt.

There is an emergency cut out button situated on the tiller arm that can be manually pressed if needed; otherwise it is automatically activated when the tiller arm is returned to its vertical home position (i.e. you cannot use the machine with the tiller arm in a vertical position).

Do I Need A Licence To Operate A Pedestrian Electric Tugger?

No, you do not need a licence to use a MasterMover.

An electric tugger is the most appropriate method of moving wheeled loads, particularly in the forklift-free environments that are becoming commonplace in manufacturing sites. It does not lift the load clear of the ground and so does not come under the same regulations as a forklift truck. With a MasterMover electric tugger, you no longer need to wait for the availability of a fork lift truck or overhead crane to move a load.

Is Training Provided?

Yes, MasterMover provide training on how to use the machine safely and in the most productive way.

What Is Rolling Resistance?

Rolling resistance is the force required to keep an object moving.

What Is Starting Resistance?

Starting resistance is the energy required to get an object moving.

Are MasterMover Electric Tuggers Available In My Country?

Yes, MasterMover electric tuggers are available worldwide and are supported by our network of dealers on every continent.

What Is CE Marking?

Products manufactured and sold into Europe are required by law to comply with CE standards.

Outside of the EU, CE marking does not hold any authority although many countries will be aware of and respect the strict conditions a product must meet to be CE marked thus confirming the product is safe to use.

All MasterMover products are CE marked; they meet EU health, safety and environmental requirements.

Your company can incorporate a MasterMover tugger safe in the knowledge that it conforms to all appropriate legislation.

Product FAQs

How Long Does The Battery Last On An Electric Tugger?

This is dependent on your particular application. Relevant factors will be the load weight you are moving, the frequency of moving it, the condition of the floor surface and whether it is flat or has slopes.

Full details on maximising battery life and the best charging cycles for your application will be provided during the demonstration and commissioning of your new MasterMover electric tugger.

Each machine comes with a standard battery and most have the option for maintenance free or high power battery choices.

How Long Does The Battery Take To Charge?

We offer several types of battery and most are designed to charge within 8 hours.

To get the best performance from your battery, it is important to understand how charging it correctly will extend its working life. The first 10 – 15 charge cycles are critical in determining the longevity of your battery’s performance. The instructions that come with your machine will provide detailed advice.

We recommend that all machines are put on charge before the battery life falls below 30% (shown on the battery life indicator display on the machine) to ensure maximum lifetime.

Most machines are available with more than one charging option; a wall mounted charger (external) and, an on-board (internal) version. Each will have different charging performance. All figures are based on charging the machine from 30% of battery life back up to 100%.

Specifying the correct battery for your application will be part of the evaluation carried out and full guidance will be given on the appropriate charging routine.

Can Electric Tuggers Be Used Outside/In Wet Conditions?

All of our machines can be used outside and/or in wet conditions with some designed specifically to be used in those conditions. The All Terrain range of electric tuggers is particularly suitable for rough or coarse surfaces.

Operating outside normally means the machines have to work on tarmac, uneven concrete and deal with slopes, all of which inevitably affect the maximum load weight of a particular machine. When assessing which electric tugger best suits your application it is advisable to think of the worst case scenario it is likely to face. If the machine has enough power to move the load easily under these conditions then it is more than capable to do so during the more frequent of tasks.

We offer a range of stainless steel machines that are Ingress Protection (IP) rated and therefore ideal for use in food processing, pharmaceutical and chemical industry applications.

Which Floor Surfaces Are Suitable For A Pedestrian Electric Tugger?

Our electric tuggers will work on a range of floor surfaces.

Machines are currently being used on smooth concrete floors, tamped concrete, tarmac, laminate, tiles, steel chequer plate, block paving and many more.

Similar to inclines, the maximum load capacity of a machine is affected by the floor surface. For example, it requires a greater force to move a load on tarmac than it does on a smooth concrete floor.

How Do I Choose The Right Battery For My Electric Tugger?

The distance and frequency of laden and unladen journeys will then determine how much work the battery will be expected to do.

This will decide the battery type required for your application, the working time that you will achieve from a charge period and the appropriate wheel type.

What Difference Does Wheel Type Make?

There are several different materials for wheels and castors and all have an impact on the rolling resistance.

As the hardness of the material used increases the resistance between it and the floor surface decreases. Steel wheels sat on steel rails often provide the lowest resistance and is therefore the easiest to move.

Beyond that, hard polymers such as cast nylon, polypropylene and polyurethane are also very efficient, leading on into higher resistance materials such as pneumatic tires and solid rubber wheels.

If you need advice on the implications of your particular working environment, our engineers can help.

Will An Electric Tugger Work On Slopes?

Yes, all MasterMover machines will work on slopes. The maximum angle our tugs are capable of, on average, is 8°.

While this is usually more than enough for most applications, it is more important to remember that for every degree of slope involved, the maximum load capacity of the machine is reduced, just as pushing a car on the level requires less force than on a slope.

Therefore, if the weight of the load is already close to the maximum capacity of the machine a more powerful tugger may be needed to move the load on a slope.

How Should You Use A Tugger On A Slope?

To guarantee safety, traction and the control needed on an incline you should always PUSH the load UP a slope and PULL the load DOWN a slope when a MasterMover is concerned.

PUSH UP/ PULL DOWN, ensuring the user is always in front of the load.

Can Electric Tuggers Be Used In ATEX Rated Environments?

Yes, we can supply electric tuggers that have been specified for use in ATEX rated environments.

Can Tugs Operate With Any Trolley Wheel Configuration?

MasterMover machines can usually operate with any type of load trolley wheel configuration although the ideal is to have 2 fixed castors at the rear and 2 swivel castors at the front. This allows our machines to control and steer the load effectively.

The All Terrain Pusher (ATP400) does not steer loads and so is most suitable for applications on rails (where all wheels are fixed).

If the trolley has all swivel castors we suggest a number of options. Our MasterHandler is designed to control loads mounted on all swivel castors up to a maximum weight of 4,400 lbs.

Another option would be to change two of the castors to become fixed or at least lockable.

Lastly, there are applications when using 2 tuggers at once is the most appropriate way to move a load.

What Is MultiLink?

MultiLink is an option in which two (or more) PS3000+ machines are used simultaneously to move a single load.

Some loads are so large in size that it is not convenient to move with just one tugger. A modular building is one such load; by no means the heaviest of loads but one of the largest.

Having a tugger at each end ensures the building is easy to maneuver, that moving it is safe and that the operators have complete control at all times.

Service & Maintenance FAQs

How Long Is The Warranty?

MasterMover offer a 12 month warranty as standard.

How Do I Log A Warranty Claim?

Call MasterMover Service & Rentals team on 980-263-2210, please have your serial number, and site details available when calling.

How Do I Request An Engineer Visit?

Call MasterMover Service & Rentals team on 980-263-2210, please have your serial number, and site details available when calling.

How Often Are The Service Intervals?

Service intervals for electric tuggers depend largely on how often they are used. We offer three service packages that include 2 services per annum for low users, 3 for medium and 4 for high users.

High usage may be defined as using the machine as an integral part of your operations for 8 hours a day, every day.

Medium usage may be using the machine occasionally every day and low usage may be using it once a week.

To ensure your machine is always in good working order we suggest you pick the right frequency of service for your circumstance.

Who Can Service A MasterMover Electric Tugger?

In the US our machines are normally serviced by one of our own service engineers.

In territories where we have a dealer the machines are serviced by them backed up with our support.

In territories where we do not have a dealer the machines are often serviced by the customer’s existing material handling supplier or by the customer’s own maintenance engineers themselves.

All our customers are offered full support from MasterMover.

All of our machines have been designed with ease of service and maintenance in mind. They include easy access panels ensuring it is neither difficult nor time consuming to repair or replace parts.

Service and maintenance is carried out by MasterMover engineers or through our network of international dealers. There are different levels of service support, tailored to match your working practices.

How Do I Order Spare Parts?

Contact the MasterMover parts team on [email protected] or call 980-263-2210

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