Big Joe T15 User manual

OPERATOR’S MANUAL
Big Lift LLC
www.bigjoeforklifts.com Manual Part No. 901639 08/16/2018
T15
PEDESTRIAN
TUGGER

BL-T15-OP - 08-16-2018 iii

BL-T15-OP - 08-16-2018 iv
FOREWORD
The present original operating instructions are designed to provide sufficient
instruction for the safe operation and maintenance of the T15. Please be sure to
read this operator manual carefully if you are an operator or are in charge of the
tugger, before you operate and service the tugger.
If you have any questions, please reach out to the manufacturer or your autho-
rized servicing dealer.
TABLE OF CONTENTS
Section Page
1 TUGGER DESCRIPTION....................................................................................... 1
1-1 APPLICATION............................................................................................. 1
1-2 TUGGER ASSEMBLIES.............................................................................. 2
1-2.1 CONTROL HANDLE.................................................................................... 3
1-2.2 KEY SWITCH .............................................................................................. 3
1-2.3 BATTERY DISCHARGE INDICATOR......................................................... 4
1-2.4 POWER UP TEST....................................................................................... 4
1-3 IDENTIFICATION POINTS AND DATA PLATES........................................ 5
1-4 TUGGER DATA PLATE .............................................................................. 6
2 COMMISSIONING.................................................................................................. 7
2-1 USING THE TUGGER FOR THE FIRST TIME........................................... 7
2-2 INITIAL USE ................................................................................................ 7
3 OPERATION .......................................................................................................... 8
3-1 SAFETY REGULATIONS FOR OPERATION OF TUGGERS .................... 8
3-2 OPERATING THE TUGGER
3-2.1 PREPARATION........................................................................................... 8
3-2.2 SAFETY REGULATIONS FOR TUGGER OPERATION............................. 9
3-2.3 TRAVEL, STEERING, BRAKING .............................................................. 10
3-2.4 TRAVELING WITH TRAILERS.................................................................. 11
3-3 PARKING THE TUGGER SECURELY...................................................... 12
4 BATTERY MAINTENANCE & CHARGING .......................................................... 13
4-1 SAFETY REGULATIONS FOR HANDLING ACID BATTERIES ............... 13
4-2 BATTERY TYPE & DIMENSIONS............................................................. 13
4-3 CHARGING THE BATTERY...................................................................... 14
4-4 BATTERY REMOVAL AND INSTALLATION ............................................ 15
4-5 BATTERY MAINTENANCE....................................................................... 16
4-6 BATTERY DISPOSAL ............................................................................... 17

BL-T15-OP - 08-16-2018 v
TABLE OF CONTENTS - Continued
Section Page
5 TUGGER MAINTENANCE....................................................................................18
5-1 OPERATIONAL SAFETY...........................................................................18
5-2 MAINTENANCE SAFETY REGULATIONS................................................18
5-3 SERVICING AND INSPECTION ................................................................19
5-3.1 MAINTENANCE CHECKLIST ....................................................................20
5-3.2 MAINTENANCE INSTRUCTIONS..............................................................21
5-4 DECOMMISSIONING THE INDUSTRIAL TUGGER..................................22
5-4.1 PRIOR TO DECOMMISSIONING ..............................................................22
5-4.2 RESTORING TUGGER TO OPERATE AFTER DECOMMISSIONING.....22
5-5 SAFETY CHECKS TO BE PERFORMED AT REGULAR
INTERVAL AND FOLLOWING ANY UNUSUAL INCIDENTS....................23
5-6 FINAL DECOMMISSIONING, DISPOSAL .................................................23
6 TROUBLESHOOTING...........................................................................................24
CORRECT USE AND APPLICATION
The operator’s manual is available at bigjoesupport.com.The guidelines are an important
component of these operating instructions and must be observed. The tugger described in
the operator’s manual is an industrial tugger designed for transporting loads.
It must be used, operated and serviced in accordance with the present instructions. Any
other type of use is beyond the scope of application and can result in injury to personnel,
damage to the tugger or property. In particular, avoid overloading the tugger with loads
which are too heavy or placed on one side. The towing capacity decal attached to the tug-
ger is binding for the maximum load capacity. The industrial tugger must not be used in fire
or explosion endangered areas, or areas threatened by corrosion or excessive dust.
Owners responsibilities
For the purposes of the present operator manual the “Owner” is defined as any natural or
legal person who either uses the industrial tugger himself, or on whose behalf it is used. In
special cases (e.g. leasing or renting) the proprietor is considered the person who, in accor-
dance with existing contractual agreements between the owner and user of the industrial
tugger, is charged with operational duties.
The proprietor must ensure that the tugger is used only for the purpose it is intended for
and that danger to life and limb of the user and third parties are excluded.
Furthermore, accident prevention regulations, safety regulations and operating, servicing
and repair guidelines must be followed. The owner must ensure that all tugger operators
have read and understood the operatorsmanual.
Failure to comply with the operator’s manual shall Void the warranty. The same applies if
improper work is carried out on the tugger by the customer or third parties without the per-
mission of the manufacturer’s customer service department.
Adding accessories
The mounting or installation of additional equipment which affects or enhances the perfor-
mance of the industrial tugger requires the written permission of the manufacturer.

NOTES

1
SECTION 1 TUGGER DESCRIPTION
1-1. APPLICATION
The T15 is an electric pedestrian tugger. It is designed for transporting goods on
level surfaces in buildings. The maximum towing capacity is indicated on the decal
on the top cover.
Figure 1-1 Tugger

2
1-2. TUGGER ASSEMBLIES
Figure 1-2 Tugger Overview
Table 2 Tugger Overview
Item Component Item Component
1 Drive Unit 8 Battery Discharge Indicator
2 Trailer Coupling 9 Handle Tilt Adjustment
3 Battery 10 Control Handle
4 Cover 11 Charger Cord
5 Key Switch 12 Caster(s)
6 Emergency Power Disconnect 13 Drive Wheel(s)
7 Led Charger Lamp

3
1-2.1. CONTROL HANDLE
Figure 1-3 Control Handle
1-2.2. KEY SWITCH
Key switch to power tugger on or off.
Truck power supply is off when the
key turned to "OFF" position.
Truck power supply is on when the
key turned to "ON" position.
Removing the key prevents the tugger
from being powered on by unautho-
rized personnel.
Item Component Function
14 Travel switch Controls the driving speed and direction
15 Horn button Triggers a warning signal.
16 Safety reversing
switch. Safety function which, when activated, forces the
truck to reverse until the switch restored to neutral.

4
1-2.3. BATTERY DISCHARGE INDICATOR
The LEDs (1) represent battery residual capacity,
Battery Discharge Indicator(1)
When the key switch is turned to the “ON” position the battery charge status is dis-
played.
1-2.4.POWER UP TEST
When tugger powered on the display
shows:
The charge status
NOTE:
Low Voltage Protection
This vehicle has a low-voltage protection function. When the battery voltage is too
low, the tugger will go in to creep speed and the battery needs to be charged.

5
1-3 IDENTIFICATION POINTS AND DATA PLATES
Figure 1-4 Tugger Decal
Item Description
1 Truck Name Plate
2 Direction Decal On Control Handle
3 Key Switch Decal
4 Towing Capacity Decal

6
1-4 TUGGER DATA PLATE
Figure 1-5 Tugger Data Plate
For questions regarding the tugger or ordering spare parts please quote the tug-
gers serial number(10).
Item Description
1 Model
2 Serial No.
3 Weight of T15 unit (lbs./kg)

NOTES

7
SECTION 2 COMMISSIONING
2-1 USING THE TUGGER FOR THE FIRST TIME.
Procedure for preparing the tugger for operation after delivery or transport:
Check the equipment for any damages.
Install the batteries if necessary (where required), (see 4-4 “Battery removal and
installation” section in this manual) make sure to not damage the battery cables.
Charge the battery (see 4-3 “Charging the battery” section in this manual).
When the tugger is parked the surface of the tires will flatten. The flattening will
disappear after a short period of operation.
2-2 INITIAL USE
We recommend operating the tugger under light load conditions for the first stage
of operation and make sure to follow the points below:
• Prevent the new battery from over discharging. Charge the battery when
remaining power is less than 20%.
• Perform specified planned maintenance services regularly.
• Avoid sudden stop, starts or turns.
• Oil changes and lubrication are recommended the first 100 hours of use ear-
lier than specified.
• Limit load to 70-80% of the rated load.

8
NOTES

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SECTION 3 OPERATION
3-1 SAFETY REGULATIONS FOR THE OPERATION OF TUGGERS.
Driver authorization: The tugger may only be used by suitably trained personnel,
who have demonstrated that they can drive and handle loads and have been
authorized to operate the tugger by the proprietor or his/her representative.
Driver’s obligations and responsibilities: The driver must be informed of his
duties and responsibilities and be instructed in the operation of the tugger and
shall be familiar with the operator manual. Safety shoes must be worn with pedes-
trian operated tuggers.
Unauthorized Use of tugger: The driver is responsible for the tugger during the
time it is in use. He/she shall prevent unauthorized persons from driving or operat-
ing the tugger. It is forbidden to carry passengers or lift personnel.
Damage and Faults: The supervisor must be immediately informed of any dam-
age or faults to the tugger. Tuggers not safe for operation (e.g. wheel or brake
problems etc.) must not be used until they have been rectified.
Repairs: The driver must not carry out any repairs or alterations to the tugger
without the necessary training and authorization to do so. The driver must never
disable or adjust safety mechanisms or switches.
Hazardous area: A hazardous area is defined as the area in which a person is at
risk due to tugger movement, lifting operations, the load handler (e.g. forks or
attachments) or the load itself. This also includes areas which can be reached by
falling loads or lowering operating equipment.
Unauthorized persons must be kept away from the hazardous area.
When there is danger to personnel, a warning must be sounded with sufficient
notice.
If unauthorized personnel are still within the hazardous area the tugger shall be
brought to a halt immediately.
Safety Devices and Warning Signs: Safety devices, warning signs and warning
instructions shall be strictly observed.
3-2 OPERATING THE TUGGER
3-2.1.PREPARATION
Before the tugger can be commissioned, operated or a load unit lifted, the driver
must ensure that there is nobody within the hazardous area.
Checks and operations to be performed before starting daily work
• Visually inspect the entire tugger (in particular wheels and trailer coupling/
load handler) for obvious damage.
• Visually inspect the battery attachment and cable connections.

9
3-2.2.SAFETY REGULATIONS FOR TUGGER OPERATION
Travel conduct:
The driver must adapt the travel speed to local conditions. The tugger must be
driven at slow speed when negotiating bends or narrow passageways, when
passing through swing doors and at blind spots. The driver must always observe
an adequate braking distance between the tugger and the vehicle in front and
must be in control of the tugger at all times.
Travel visibility:
The driver must look in the direction of travel and must always have a clear view
of the route ahead. The tugger must travel with the load at the rear. If the driver
does not have a clear view, a second person must act as a lookout for the area.
Negotiating slopes and inclines:
Negotiating slopes or inclines is only permitted if such roads are clean and have a
non-slip surface and providing such journeys are safely undertaken in accordance
with the technical specifications for the tugger in question. The industrial tugger
must not be turned, operated at an angle or parked on inclines or slopes. Inclines
must only be negotiated at slow speed, with the driver ready to brake at any
moment.
Towing trailers:
Do not exceed the maximum trailer load specified for the tow tugger for trailers
with or without brakes. The trailer load must be secured in accordance with regu-
lations and must not exceed the dimensions permitted for that roadway. After cou-
pling and before starting, the driver shall ensure that the trailer coupling cannot
become detached. Tuggers pulling a load must be driven such that the trailing
vehicle is driven safely and can be stopped under any conditions.
Warning: Observe the trailer manufacturer's speed restrictions.

10
3-2.3.TRAVEL, STEERING, BRAKING
Do not drive the tugger unless the covers are closed and properly locked.
Figure 3-1 Travel, Steering and Brake
1Driving: Set the travel switch (1) to control the driving speed and direction.
NOTE: Change the position of Control handle by the tilt adjustment knob.
2 Steering: Apply the control handle to the left or right.

11
3 Braking:
The brake pattern of the tugger depends largely on the ground conditions. The
driver must take this into account when operating the tugger.
The driver must be looking ahead when traveling. If there is no hazard, brake
moderately to avoid moving the load and to prevent the trailer from veering out.
The tugger can brake in four different ways: Emergency stop, Regenerative
braking, Inversion braking, Parking brake.
•Emergency stop: Engaging the emergency power disconnect. All electrical
functions are deactivated.
• Regenerative braking: If the travel switch(1) is set to "0", the tugger auto-
matically brakes regeneratively. When the speed is below 0.62 mph, the brake
applies.
• Inversion braking: You can set the travel switch (1) to the opposite direction
when traveling. The tugger brakes regeneratively until it starts to move in the
opposite direction.
Warning: In hazardous situations set the travel switch (1) to the opposite
direction to engage maximum braking force.
• Parking brake: Electronically applied when speed below 0.62 mph.
3-2.4.TRAVELING WITH TRAILERS
• In difficult application conditions (inclines, smooth or slippery travel routes)
the tow load must be reduced to ensure braking without risk of accidents. The
maximum, permissible load indicated applies only when towing on level surfaces
on a good bearing, non-slip surface. In no case should the rated capacity of the
unit be exceeded.
• Always pull, never push a trailer.
• Familiarize yourself with the brake and steering systems of the trailer when
you start to travel.
• On cornering with long trailers and trailer trains, notice how the angle is
reduced. . Start the tugger slowly until the trailer coupling has become taut.
Then gradually increase the travel speed. . To stop, reduce the speed so that
both tugger and trailer gradually slow down. Brake with care!
• Make sure the angle is correct when cornering.

12
3-3 PARKING THE TUGGER SECURELY
When you leave the tugger it must be securely parked even if you only intend to
leave it for a short time.
Do not park the tugger on a slope.
• Press Emergency Power Disconnect (2).
• Turn off the key (1) switch and remove the key.
Figure 3-2 Parking Tugger Securely

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NOTES