How to Pick a Tugger Battery for Runtime, Charging and Multi-Shift Use
Pick a tugger battery by your shift pattern. For one shift a day, an AGM tugger like the Pony Express 1061-HD runs up to 8 hours and recharges in about 4 hours overnight. For two or three shifts, a lithium electric tugger like the 1061-HD Lithium swaps packs in seconds, so a charged pack goes on and the tugger keeps working.
Both tow the same 2,000 lb. The battery does not change how much a tugger pulls. It changes how long the tugger can keep working.
Three questions
- How long does the tugger run on a charge?
- How long does it take to recharge?
- Can one tugger cover back to back shifts?
Answer them in order and the battery choice follows.
Run time on one charge
The AGM Pony Express models from the 1061 to the 1065-XHD run up to 8 hours on a charge. That covers one full shift.
Our CartCaddy tugs run on 24 or 36 volt battery systems. The CartCaddyShorty and the RiderCaddy run up to 16 hours on a charge, and the CartCaddyLite about 6 hours.
Real run time depends on the work. A shift mixes towing, waiting at a dock and sitting parked while carts are loaded. Heavy loads and ramps all day use more charge than light carts on a flat floor. Tell us your loads and route and we tell you what to expect.
Ask us for the run time of a lithium model on your route.
Recharge time
| Model | Battery | Charger | Recharge |
|---|---|---|---|
| Pony Express 1061-HD | 35 Ah AGM | Onboard | About 4 hours |
| Pony Express 1062 | 35 Ah AGM, 70 Ah AGM option | Onboard | About 4 hours |
| Pony Express 1065 | 70 Ah AGM | Onboard | About 4 hours |
| Pony Express 1061 Lithium | 40 Ah lithium iron phosphate | External | About 2 hours |
| Pony Express 1061-HD Lithium | 40 Ah lithium iron phosphate | External | About 2 hours |
| Pony Express 1065 Lithium | 24 VDC, 40 Ah lithium iron phosphate | External | About 90 minutes |
| Pony Express AC Tugger 25K+ | 48 VDC, 100 Ah AGM or 120 Ah lithium iron phosphate | External | About 90 minutes |
The onboard charger on the AGM models plugs into a standard 120 or 240 volt outlet. You plug the whole tugger in at the end of the shift, and the 4 hour recharge finishes well before the next morning.
AGM or lithium
Buy AGM when one shift a day is the real demand. Buy lithium when the day has no long window for charging.
AGM suits single shift work. The battery and charger ride on the tugger, so there is nothing else to manage. Run the shift, plug it in overnight and repeat.
Lithium suits back to back shifts. The pack swaps in seconds, so a charged spare goes on while the empty pack charges off the machine. The tugger never waits on the charger. The lithium models also have a battery management system that warns with sound and light before the pack needs a charge, and a Bluetooth app that shows the charge on a phone.
There is a middle path. If you want a longer single shift on AGM, the 1062 takes an optional 70 Ah AGM package in place of its standard 35 Ah battery.
Same tugger, two batteries
The 1061-HD and the 1061-HD Lithium show the choice clearly, because the rest of the machine is the same.
| Spec | 1061-HD | 1061-HD Lithium |
|---|---|---|
| Tows on casters | 2,000 lb | 2,000 lb |
| Width | 22 in | 22 in |
| Top speed | 3 mph | 3 mph |
| Battery | 35 Ah AGM deep cycle | 40 Ah lithium iron phosphate, hot swappable |
| Charger | Internal, 120 or 240 VAC | External, 85 to 270 VAC |
| Recharge | About 4 hours | About 2 hours |
| Run time | Up to 8 hours | Ask us |
The battery rows are where the two differ, and they should drive the choice. The spare pack routine matters more than the faster recharge. One pack works on the tugger while the other charges.
Charging in short breaks
An AGM model needs about 4 hours on the charger, which does not fit a lunch break or a shift change. If your floor has no long charging window, plan on a lithium model with a spare pack. Swap the pack at the break and charge the empty one off the machine.
On the 1065 Lithium, the battery management system tells the operator to swap at the 80 percent discharge point. A pack recharges in about 90 minutes.
Sizing the battery to the job
- Count your shifts. One shift points to AGM. Two or three point to lithium with a spare pack.
- Check the charging window you really have. An overnight gap of 4 hours or more fits AGM.
- Confirm the towing capacity covers your heaviest loaded train.
Battery size grows with capacity in the AGM line. The 1061-HD tows 2,000 lb on a 35 Ah pack. The 1065 tows 5,000 lb on a 70 Ah pack. The 1065-XHD tows 7,500 lb on a 70 Ah pack. The AC Tugger 25K+ tows 25,000 lb on casters with a 48 volt pack, AGM or lithium, chosen at order time.
On the 1065 Lithium, extra packs and the charging station are sold separately, so you can build the rotation your shifts need. Send us your shift pattern and loads and we put the packs on the quote.
Questions
How long does a battery powered tugger last on one charge?
The AGM Pony Express models from the 1061 to the 1065-XHD run up to 8 hours on a charge, one full shift. Real run time depends on load weight, ramps and how much of the shift the tugger sits parked.
How long does a tugger battery take to recharge?
About 4 hours on the AGM models. About 2 hours on the 1061 Lithium and 1061-HD Lithium, and about 90 minutes on the 1065 Lithium and AC Tugger 25K+.
Which battery do I need for two or three shifts?
A swappable lithium pack. Keep a charged spare on the charger and swap it in when the pack runs low. The tugger stays in service across back to back shifts.
Does a lithium battery make the tugger pull more?
No. The 1061-HD and 1061-HD Lithium both tow 2,000 lb. The battery changes run time and recharge, not capacity.