Doosan Tugger BWT45S-7 Operation Manual

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Operation Manual

Tugger

DOOSAN and the DOOSAN logo are registered

trademarks of DOOSAN Corporation in the United

BWT45S-7 OM 514

States and various other countries around the

world.

July 2014

Original Instructions

Table of Contents

Summary of Contents for Doosan Tugger BWT45S-7

Page 1 Operation Manual Tugger DOOSAN and the DOOSAN logo are registered trademarks of DOOSAN Corporation in the United BWT45S-7 OM 514 States and various other countries around the world. July 2014 Copyright DOOSAN 2014 Original Instructions...
Page 3 If it is lost, order another one from your DOOSAN distributor. If there are any questions, contact your DOOSAN distributor. This manual may illustrate options and accessories not installed on your equipment.
Page 4 SAFETY MESSAGES Safety messages and safety decals included in this manual and on the machine provide instructions how to operate, service and maintain the machine. Safety messages and safety decals indicate potential hazards and describe safety precautions required to avoid hazards. Operator and maintenance personnel should read and understand these safety messages and decals before beginning operation or maintenance.
Page 5 Other Signal Words In addition to safety signal words, the following signal words are used to indicate proper and effective use of machine. IMPORTANT This signal word identifies procedures which must be followed to avoid damage to machine. NOTE: The word "NOTE" identifies information for effective use.
Page 6 Do not exceed machine capacity by modifying machine or using unapproved attachments. Exceeding machine capacity can adversely affect machine performance characteristics such stability, system certifications such as brakes and steering, and can result in death or serious injury. Contact your DOOSAN distributor for further information. Foreword BWT45S-7 OM 514...
Page 7 PRODUCT IDENTIFICATION With the aid of the product plates, shown below, it is possible to identify the machine and its components. The first two blocks indicate the model and the serial number of the machine. Make a note of the identification numbers. When ordering spare parts, and in all telephone inquiries or correspondence, the model and serial number of the machine, must always be referenced.
Page 8 Foreword BWT45S-7 OM 514...
Page 9: Table Of Contents
Table of Contents Safety ..................1-1 Safety Decals ..................1-2 General .................... 1-11 Operation ..................1-17 Maintenance ..................1-25 Transportation .................. 1-36 Environment and Circumstances ............. 1-38 Operating Controls ..............2-1 Component Locations ................ 2-2 Operator's Controls ................2-3 Operation..................3-1 To Operate The Tugger ..............3-1 Starting and Stopping Engine ............
Page 10 Table of Contents BWT45S-7 OM 514...
Page 11: Safety
BWT45S-7 OM 514 Safety Safety BWT45S-7 OM 514...
Page 12: Safety Decals
SAFETY DECALS Safety decals are attached to the machine to alert the operator maintenance person about potential hazards, consequences of potential injury, and instructions and/or actions required to avoid the hazard. The location of the safety decals and the description of the decals are reviewed in the following section.
Page 13 Safety Decals Without Text (No-Text) Vertical Configuration Safety decals without text consist of a safety sign and safety information panel. The safety sign panel is located at the top or left side and the safety information panel is located at the bottom or right side of the decal depending on its configuration.
Page 14 Information and Location for Safety Decals D1053 Operation of Machine 1. This electric vehicle should only be used on a smooth flat surface. 2. Read operator’s manual and be familiar with safe operation before use. 3. Do not operate outdoors in inclement weather. 4.
Page 15 Information and Location for Safety Decals (Continued) Operation of Machine 1. Only trained personnel should operate the vehicle. 2. Read and understand the operators manual completely before use. 3. Do not overload! Do not exceed the rated capacity of this vehicle.
Page 16 Read Manual Before Maintenance Warning D1105 Battery Level Caution The decal states: When indicator lights are flashing 1 or 2 it indicates that the battery is out of electricity. Stop using the truck and conduct charging immediately. Otherwise the truck may be damaged.
Page 17 Batteries (950205-01448, 950205-01677) DANGER To Avoid Death or Serious Injury: • Keep arcs, sparks, flames, and lighted tobacco away. • Do not store metal tools or flammable materials on or around batteries. • Wear safety goggles and rubber gloves when working with batteries.
Page 18 Warning Tag Used for Inspection and Maintenance (950205-01451, 950205-01760) To Avoid Death or Serious Injury: • Attach "DO NOT OPERATE" warning tag to the controls before servicing the machine. • Do not operate when performing inspection or maintenance. 950205-01451 FG018690 950205-01760 FG018596 Safety...
Page 19 Information and Location of Additional Decals There are other decals attached to the machine in addition to the safety decals. The location of these decals and their messages are reviewed in this section. Please become familiarized with these decals. Charging Plug Location D1096 D1080 Safety...
Page 20 2. Lifting Point Decal D1107 D1053 Safety BWT45S-7 OM 514 1-10...
Page 21: General
Proper Work Tools and Attachments Only use work tools and attachments that are recommended by DOOSAN for use on DOOSAN machines. When installing and using optional attachments, read instruction manual for attachment, and general information related to attachments in this manual.
Page 22 machine operation. Do not exceed maximum operating weight (machine weight plus load) that is listed the certification plate. Make sure that all guards and shields are in place on machine. While you are performing any maintenance, testing, or adjustments to the machine, stay clear of the pinch points and crushing surfaces.
Page 23 Correction of Machine Problems If any machine problems are found during operation and maintenance (noise, vibration, smell, incorrect gauges, smoke, oil leakage, etc.), stop the machine immediately and take the necessary corrective actions. Do not operate the machine until problem has been corrected. Crushing and Cutting Do not put your hand, arm or any other part of your body between movable parts.
Page 24 • Dust that is generated from repairing or grinding nonmetallic hoods or nonmetallic fenders can be toxic, flammable and explosive. Repair these components in a well ventilated area away from flames or sparks and wear a dust mask when grinding painted parts. Maintenance The machine has components that reach high temperatures under normal operating conditions.
Page 25 Welding and Grinding Always clean machine and attachment, disconnect battery switch, and disconnect wiring from electronic controllers before welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near machine when welding. Toxic dust or gas can be produced when grinding or welding painted parts.
Page 26 Fire Extinguisher and First-Aid Kit (Emergency Medical Kit) To be prepared in the event of a fire: • Be sure that fire extinguishers have been provided and read labels to ensure that you know how to use them. It is recommended that an appropriately sized (2.27 kg [5 lb] or larger) multipurpose A/B/C fire extinguisher be mounted on the machine.
Page 27: Operation
OPERATION Always make sure that the machine is properly maintained. Before Starting Machine Machine Condition Every day before starting engine for first time, perform the following checks and repair machine before operating, as necessary. If these checks are not properly done, death or serious injury could result.
Page 28 Mounting/Dismounting Before getting on or off machine, if there is any oil, grease, or mud on operator’s platform, wipe it off immediately. Always keep these parts clean. Never jump on or off machine. In particular, never get on or off a moving machine.
Page 29 Cleaning Remove all flammable debris accumulated in and around battery. Remove any dirt from mirrors and operator’s platform. Do not leave tools or spare parts in operator's station. Vibration of machine during operation can cause tools or spare parts to fall and create a hazard for the operator.
Page 30 Inspect equipment and repair immediately if there are problems with visual aids. If machine cannot be fixed immediately, DO NOT use the machine. Contact your DOOSAN distributor and arrange for repairs. Safety BWT45S-7 OM 514...
Page 31 Work Site Rules When operating or traveling during poor visibility conditions, follow the preceding work site rules. • If visibility cannot be sufficiently assured, use a flagman. The operator should pay careful attention to signals and follow instructions from flagman. •...
Page 32 Starting Machine Only operate the machine from the operator's station. Turn key switch to "O" (ON) position. Check for proper operation of all controls and all protective devices while you operate the machine slowly in an open area. Check operation of work equipment and travel system. Check for any problems with machine.
Page 33 • Sound horn to alert people in area. • Check that there is no one in area around machine. There are restricted visibility areas behind machine. • When operating in areas with poor visibility, designate a flagman to direct work site traffic. •...
Page 34 Operation on an Incline If it is not possible to avoid working on a incline, it is recommended that you reduce the size of the workload. On sloping surfaces, use caution when positioning the machine before starting. Stay alert for unstable situations and avoid getting into them.
Page 35: Maintenance
Untrained operators and failure to follow instructions can result in death or serious injury. • Never service DOOSAN equipment without instructions. • Use correct procedure to lift and support machine. • Cleaning and maintenance are required daily.
Page 36 950205-01451 FG018690 Figure 7 "DO NOT OPERATE" warning tags, are available from your DOOSAN distributor. • Always attach "DO NOT OPERATE" warning tag to machine control lever in the operator's station to alert others that service or maintenance is being performed on the machine.
Page 37 Attach a "DO NOT OPERATE" warning tag to starter switch or to controls before servicing or repairing equipment. Warning tags (Special Instruction, SEHS7332) are available from your DOOSAN distributor. Cleaning Clean machine before performing inspection and maintenance. If inspection and/or maintenance are done when machine is dirty, it...
Page 38 Disassembling Precautions When using a hammer to remove pins, pins can fly out or metal particles may break off. Always do the following: • Hitting hard metal pins, bucket teeth, cutting edges or bearings with a hammer, can cause metal pieces to break or fly off resulting in serious injury.
Page 39 Batteries give off flammable fumes that can explode and start a fire. Do not smoke while you are checking battery electrolyte level. Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact skin, eyes or other body parts. Always wear safety goggles and face protection when working with batteries.
Page 40 Rubber That Contains Fluorides Observe extra great care when it is suspected that you may have to handle rubber that contains fluorides. Certain seals which have to withstand high operating temperatures (e.g. in engines, transmissions, axles, hydraulic motors and pumps) may be made from rubber that contains fluorides, which, when exposed to high heat (fire), forms hydrogen fluoride and hydrofluoric acid.
Page 41 Rubber and Plastics Polymer materials when heated, can form compounds that create a health hazard and can harm the environment. Scrapped rubber and plastic must never be burned. Extra precautions must be taken when servicing machines that have been in a fire or exposed to extreme heat. If gas cutting or welding is to be done near such materials, the following safety instructions must be followed: •...
Page 42 Welding Repairs When performing welding repairs, perform welding in a properly equipped and well ventilated area. Repairs should only be performed by a qualified welder. Welding operations, can create potential hazards, including generation of gas, fire, or electric shock. Never let an unqualified welder do welding. A qualified welder must do the following: •...
Page 43 with blocks and stands strong enough to support weight of work equipment and machine. • Do not work under the machine if machine is lifted off ground and the machine is supported only with work equipment. If any control levers are moved, or there is damage to hydraulic system, work equipment or the machine will suddenly drop causing death or serious injury.
Page 44 • When charging battery in cold temperatures let battery electrolyte thaw and check that there is no leakage of battery electrolyte before starting operation. • Do not use or charge battery if battery electrolyte level is below LOW LEVEL line. This can cause an explosion. Periodically check battery electrolyte level and add distilled water to bring electrolyte level to FULL LEVEL line.
Page 45 Preservation/Storing Machine Perform the following if storing the machine for more than one month. Conditions Maintenance Required Cleaning Wash entire machine. Inspect for damage or loose or missing parts. Lubrication Perform all daily lubrication procedures. Battery Turn "OFF" the battery disconnect switch. CAUTION Do not use a pressure washer when cleaning machine.
Page 46: Transportation
Partial disassembly of the machine may be necessary to meet travel restrictions or particular conditions at work site. See Shop Manual for information on partial disassembly. The machine can be disassembled into parts for transporting. Contact your DOOSAN distributor assistance with disassembly. Loading and Unloading...
Page 47 Transporting Machine When transporting machine on a trailer or truck, do the following: • Always check the machine dimensions before transporting. • When passing over bridges or structures on private land, check that structure is strong enough to support weight of machine.
Page 48: Environment And Circumstances
Working in Contaminated Environment When working within area which is contaminated or where there is a health risk, check local laws and regulations and contact your DOOSAN distributor for assistance with identifying what additional safety precautions need to be taken. Safety...
Page 49 Operation In Hot Damp Climates IMPORTANT Do not store acid type storage batteries near stacks of tires. Acid fumes can damage rubber. Lubricate as specified. Do not park machine in sun for long periods of time. If possible, park machine under cover to protect it from sun, dirt and dust.
Page 50 Sound Sound Level Information: Hearing protection may be needed when machine is operated with an open operator station for extended periods or in a noisy environment. Sound pressure level (LpA) at operator position 73 dB(A) (Measurement according to ISO 6396) Sound power level (LwA) around the machine (Measurement according to 2001/14/EC with 107 dB(A)
Page 51: Operating Controls
BWT45S-7 OM 514 Operating Controls Operating Controls BWT45S-7 OM 514...
Page 52: Component Locations
COMPONENT LOCATIONS The following figure identifies the location of major machine components. D1053 Reference Description Number Control / Steering Handle Battery Compartment Hour Meter / Emergency Stop Dash Operator’s Platform Operating Controls BWT45S-7 OM 514...
Page 53: Operator's Controls
OPERATOR’S CONTROLS D1080 D1081 D1095 D1013 Control Steering Handle Reference Reference Description Description Number Number Key Switch Battery Level Indicator / Hour Meter Emergency Stop Operator Presence Switch Travel Switch Steering Handle Coast Control Switch Battery Connector Operator Safety Switch Horn Button Operating Controls BWT45S-7 OM 514...
Page 54 1. Key Switch D1081 The key switch (1) is mounted on the rear left side of the machine. The key has two positions, ON and OFF. When the key is in the OFF position the machine systems are disabled. The key switch can be used as an emergency shut-off.
Page 55 4. Steering Handle The operator controls the steering by moving the handle (4) assembly to the left or right. D1012 5. Coast Control Switch When activated the coast control switch (5) allows the machine to coast approximately 1 m (3 ft) to a stop when the travel switch is released.
Page 56 7. Operator Safety Switch A spring loaded momentary switch (7) that when pressed will reverse the direction of the machine. D1013 Horn Button A spring loaded momentary switch (8) to activate the horn. D1080 Battery Level Indicator / Hour Meter With the key switch ON the bar graph (1) displays the power level of the batteries.
Page 57: Operation
New Machine Break-in Procedures All DOOSAN machines are inspected before leaving the factory. However, it is required that operator follow these steps during the initial break-in period. Failure to follow these steps can result in damage to the equipment or reduced performance.
Page 58: Starting And Stopping Engine
Check machine for loose parts or for damage that may have occurred during shipping. Check for loose wiring or terminals, check gauge operation and battery electrolyte level. STARTING AND STOPPING MACHINE Inspection Before Starting Machine Walk-Around Checks WARNING AVOID DEATH OR SERIOUS INJURY Clean machine, remove all flammable materials from machine, and repair machine before operating.
Page 59 After starting machine • Check that all operational controls and components are in proper operating condition and are functioning correctly. Stop operation and correct any problems before continuing work. Operating The Machine Turn the key switch (1) to the ON position. D1081 Be sure the battery connector (2) is pushed down.
Page 60 To operate the machine in forward and reverse the operator must have both hands on the control handle and pull the handle down towards the operator. Use the thumb on either hand to operate the travel switch. Press the top of the switch (1) to move the machine FORWARD or the bottom of the switch (2) to move in REVERSE.
Page 61 Steering D1028 The operator must have both hands on the control handle (1) and pull the handle down towards the operator. The handle is moved to the RIGHT (2) to make a left turn and to the LEFT (3) to make a right turn. The handle is connected directly to the steering control wheel.
Page 62 When towing with a load follow these rules: • Always keep both hands on the control handle. • Clear the area of travel of all obstacles that could come in contact with the tugger on trailer during transport. • Clear the area of travel of all obstacles that could jar the tugger on trailer if it were to drive over them.
Page 63 Parking the Machine When not in use, park the machine on level ground. D1053 Turn the key switch (1) to the OFF position and remove the D1081 key from the switch. Pull up on the battery connector (1) to disable the machine. D1100 After use, charge the batteries.
Page 64 Charging The Machine Follow the procedures for parking the machine. Remove the battery connector (1) from the charger receptacle (2). WARNING AVOID DEATH OR SERIOUS INJURY Do not charge batteries if the electrolytic solution is below the battery plates. This could cause an explosion which could result in serious injuries or death.
Page 65: Maintenance Information
Check operational hour meter reading daily to see if necessary maintenance is scheduled to be performed. DOOSAN Genuine Replacement Parts Use DOOSAN genuine parts specified in Parts Book as replacement parts. DOOSAN Genuine Lubricants For lubrication of the machine, use DOOSAN genuine lubricants.
Page 66 Welding Instructions • Turn off power. Wait for approximately one (1) minute after turning off engine starter switch key, and then disconnect negative (-) terminal of battery. • Do not apply more than 200 V continuously. • Connect grounding cable within 1 m (3.3 ft) of area to be welded.
Page 67 Checks After Inspection and Maintenance Works Perform checks after inspection and maintenance to prevent operation problems. Always do the following: • Checks after operation (with machine stopped). – Have any inspection and maintenance points been forgotten? – Have all inspection and maintenance items been performed correctly? –...
Page 68: Machine Setup Position For Maintenance
MACHINE SETUP POSITION FOR MAINTENANCE WARNING AVOID DEATH OR SERIOUS INJURY If work has to be done on the machine before it has cooled down, be careful with hot liquids and hot parts of the machine to avoid burns. Before beginning any service work, park the machine using the following procedure (except for service work requiring the machine to be positioned differently).
Page 69: Maintenance Access
MAINTENANCE ACCESS Batteries Lift the battery box cover (1) for access to the cables and battery fill plugs. Clean the surface of the batteries with a solution of 240 mL (8 fl oz) of baking soda to 4 L (1 gal) water. Rinse the solution off the batteries and dry.
Page 70 Replacing Batteries Remove the retainer panel (1) from either side of the machine. D1082 Roll out the battery box (2) D1101 Disconnect the battery box connection (1). NOTE: The photo is from a different model but the connector is standard on all models. Connect the battery box connector.
Page 71 TROUBLESHOOTING Faults Cause Shooting The machine will not The fuse of the control circuit is burn out. Replace power up  The power switch contact is bad or damaged. Repair or (The contacts do not Replace work.) The fuse of the major circuit is broken. Replace The contact of the electric lock switch is bad Repair or...
Page 72 Faults Cause Shooting Difficult steering of the The gear or bearing is stuck because of for- Clean or drive wheel, noise and eign matters. replace the the motor is overloaded bearing There is clearance in the bearing or the fixing Reinstall the ring has come off.
Page 73: Specifications
BWT45S-7 OM 514 Specifications Specifications BWT45S-7 OM 514...
Page 74 SPECIFICATIONS Characteristics Model Driving model motor-driven Driving model stand driving (Manual, Walking, Stand driving, Seat driving, Order Picking) Load Capacity kg (lb) 4500 (9920.8) Rated drawbar pull (60 min) kg (lb) 110 (242.5) Draw chassis height mm (in) 128 ( Maximal drawbar pull (5 min) Tread Weight...
Page 75 Performance Data Traveling speed, laden/unladen Km/h 09% 14% Max. gradeability 04 20 Electromagnetic Traveling brake brake Motor Driving motor power Battery voltage / rated capacity V/Ah 24/560 Battery weight 780x335x625 Battery dimension (LXWXH) (30.7x13.2x24.6) Noise level at operator’s ear, according to dB(A) DIN12053 Specifications...
Page 76 Specifications BWT45S-7 OM 514...