An ITA Class VI vehicle that pulls cart trains, common in JIT manufacturing and airport baggage operations.
Detailed Definition
A tow tractor, often called a tugger, pulls a train of carts, dollies or trailers instead of lifting loads itself. Industry classification places tractors in Class VI, which covers electric and internal combustion tractors. In plants, tuggers run set routes delivering parts and collecting empty containers along assembly lines, and at airports they move baggage carts. Pallets usually ride on carts in the train and are placed or removed with a forklift or pallet jack at each end.
How tugger trains move pallets
A tugger train replaces many separate forklift trips with one scheduled route. Carts built for pallets may have roller decks, lift tops or side-loading frames so a pallet can be transferred at the line without a forklift. The route, stops and timing are often set to match production demand, which is why tuggers are associated with lean and just-in-time material delivery.
Sizing and safety points
Tow tractors are rated by drawbar pull and towing capacity rather than lift capacity. Check:
- Total train weight on the steepest ramp in the route, with all carts loaded.
- Cart tracking, so the train follows the tractor around corners without cutting into racks or walkways.
- Hitch type and the number of carts the manufacturer allows.
- Floor condition and dock plates, since small cart wheels are sensitive to gaps and debris.
Tow tractors are powered industrial trucks, so OSHA operator training under 29 CFR 1910.178 applies.
Tow tractor or forklift for long horizontal moves
A forklift is flexible but carries one or two pallets per trip and often drives back empty. A tugger train carries several loads per trip on a fixed loop. Many plants use both: forklifts load carts at a staging area and tuggers handle the long runs.
Related Glossary Terms
Frequently Asked Questions
Does a tugger driver need forklift certification?
OSHA's powered industrial truck standard covers tractors as well as forklifts, so tow tractor operators need training and a performance evaluation on the type of truck they drive, and the employer must certify it. Training on a counterbalanced forklift does not automatically qualify someone for a tugger, because towing, cart behavior on turns and stopping distances with a loaded train are different.
What is the difference between a tow tractor and a burden carrier?
A tow tractor pulls loads behind it on carts or trailers. A burden carrier carries a load on its own deck or bed and may also tow light loads. Both are horizontal transport vehicles rather than lifting trucks. The choice depends on whether material moves in trains of carts on a regular route or is carried individually from point to point.