Doosan Tugger BWT45S-7 User manual

Original InstructionsCopyright DOOSAN 2014
Operation Manual
Tugger
BWT45S-7 OM 514
July 2014
DOOSAN and the DOOSAN logo are registered
trademarks of DOOSAN Corporation in the United
States and various other countries around the
world.

BWT45S-7 OM 514
I
Foreword
1Foreword
This Operation & Maintenance Manual was written to give owner
or operator instructions on safe operation and maintenance of
DOOSAN equipment. READ AND UNDERSTAND THIS
OPERATION AND MAINTENANCE MANUAL BEFORE
OPERATING YOUR DOOSAN EQUIPMENT. Keep this manual
with the machine so it is always available. 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.
Any modification made without written authorization or approval
from DOOSAN can create a safety hazard.
Always replace parts with genuine DOOSAN parts or DOOSAN
authorized replacement parts.

BWT45S-7 OM 514Foreword
II
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.
Signal Words
The signal words "DANGER", "WARNING", "CAUTION" are
used throughout safety messages and safety decals in this
manual or on the machine. They indicate an existence of, and
the relative seriousness of, a hazard. All three indicate that a
safety risk is involved. Observe the precautions indicated
whenever a Safety Alert Symbol is present, no matter which
signal word appears next to it.
SAFETY ALERT SYMBOL
Be Prepared - Get to Know All Operating and Safety
Instructions.
This is a Safety Alert Symbol. Wherever it appears in this
manual or on safety decals on the machine, you must be
alert to the potential for personal injury or accidents.
Always observe safety precautions and follow
recommended procedures.
DANGER
DANGER -This signal word is used on safety messages and
safety labels and indicates an imminently hazardous situation
which, if not avoided, will result in death or serious injury.
WARNING
WARNING -This signal word is used on safety messages and
safety labels and indicates a potentially hazardous situation
which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION -This signal word is used on safety messages
and safety labels and indicates a potentially hazardous
situation which, if not avoided, could result in minor or
moderate injury.

BWT45S-7 OM 514
III
Foreword
Other Signal Words
In addition to safety signal words, the following signal words are
used to indicate proper and effective use of machine.
NOTE: The word "NOTE" identifies information for effective
use.
AEM SAFETY MANUAL 
(NORTH AMERICA ONLY)
The AEM Safety Manual delivered with the machine gives
general safety information.
The AEM Safety Manual must be read and understood before
beginning operation or maintenance and is not intended to
replace the Operation & Maintenance Manual delivered with the
machine.
IMPORTANT
This signal word identifies procedures which must be
followed to avoid damage to machine.

BWT45S-7 OM 514Foreword
IV
PRODUCT INFORMATION
Intended Use
The machine is intended to be used under normal conditions for
applications described in this manual. If it is used for other
purposes, or in potentially hazardous environments, special
precautions must be followed and the machine must be
equipped for such use. Examples include, but are not limited:
falling object guards, work lights, etc. Do not engage in
prohibited uses as described in this manual. Contact your
DOOSAN distributor for further information.
Machine Capacity
Do not exceed machine capacity by modifying machine or using
unapproved attachments.
Exceeding machine capacity can adversely affect machine
performance characteristics such as: stability, system
certifications such as brakes and steering, and can result in
death or serious injury. Contact your DOOSAN distributor for
further information.

BWT45S-7 OM 514
V
Foreword
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.
The product plate provides the operator with the model number
and serial number for ordering parts. It also provides information
on lift height, battery capacity, service weight, rated capacity,
weight without batteries, allowed battery weight and voltage.
D1064

BWT45S-7 OM 514Foreword
VI

BWT45S-7 OM 514
I
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............................................................3-2
Inspection, Maintenance and Adjustment...............................4-1
Maintenance Information ...................................................................4-1
Machine Setup Position for Maintenance...........................................4-4
Maintenance Access..........................................................................4-5
Specifications ............................................................................5-1
Specifications.....................................................................................5-2

BWT45S-7 OM 514Table of Contents
II

BWT45S-7 OM 514
1-1
Safety
BWT45S-7 OM 514
1Safety

BWT45S-7 OM 514Safety
1-2
SAFETY DECALS
Safety decals are attached to the machine to alert the operator
or maintenance person about potential hazards, the
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. Please become familiarized with all safety decals and
their messages.
Make sure that all the safety decals are in their correct location
and legible. Clean or replace the safety decals if they are
damaged, missing, or the texts and pictorials are not legible.
When you clean the safety decals, use a soft cloth, water, and
soap. Do not use solvent, gasoline, or other harsh chemicals to
clean the safety decals because this could loosen the adhesive
that secures the decals to the machine. Remember, if a safety
decal is attached to a part that is replaced, install a new safety
decal on the replacement part.
This machine uses safety decals with and without text. The type
and number of safety decals can vary depending upon
geographical regions and machine models.
Safety Decals With Text
Safety decals with text consist of a signal word, pictorial and a
text message panel. In some cases, a pictorial panel may not be
part of the safety decal.

BWT45S-7 OM 514
1-3
Safety
Safety Decals Without Text (No-Text)
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. The
safety sign panel uses a black triangular band and a pictorial to
identify the hazard and the potential consequences of the failure
to follow instructions. The safety information panel uses
pictorials and/or prohibition signs to identify the actions
necessary to avoid the hazard.
Horizontal Configuration
Vertical Configuration
Hazard
Panel
Avoidance
Panel
Hazard
Panel Avoidance Panel
FG018723
Figure 1

BWT45S-7 OM 514Safety
1-4
Information and Location for Safety Decals
1. 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. When parking, set parking brake and remove key to
prevent unauthorized use.
5. Push e-stop switch to shut off power when charging.
D1053
1
2
3
4
56

BWT45S-7 OM 514
1-5
Safety
Information and Location for Safety Decals
(Continued)
2. 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.
4. Slow down in turns or congested areas.
5. Do not stand on the load surface.
6. Operate the truck only from the operators compartment.
7. Secure loads before traveling. Take extra care when
loads extend outside the profile of the truck.
8. Press the e-stop button to shut off power in an
emergency.
9. Use extra care on ramps or uneven surfaces.
10. Battery maintenance should be performed away from
heat or flame.
11. Make wide turns when towing.
12. Always be aware of other vehicles or pedestrians in the
area.
3. Read Manual Warning
D1006

BWT45S-7 OM 514Safety
1-6
4. Read Manual Before Maintenance Warning
5. 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.
D1105

BWT45S-7 OM 514
1-7
Safety
6. Batteries (950205-01448, 950205-01677)
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.
• If battery acid contact occurs:
1) Flush your skin with water immediately and
apply baking soda or lime to neutralize the acid.
2) Flush your eyes with water for 10 -15 minutes.
3) Get medical attention immediately.
DANGER
BATTERY EXPLOSION OR CONTACT
WITH BATTERY ACID WILL CAUSE
SERIOUS INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco
away.
DO NOT store metal tools or flammable
materials on or around batteries.
Wear safety glasses and rubber gloves when
working with batteries.
If battery acid contact occurs:
1. Flush your skin with water immediately and
apply baking soda or lime to neutralize the
acid.
2. Flush your eyes with water for 10-15 minutes.
3. Get medical attention immediately.
950205-01448
FG018650
950205-01677
FG018651

BWT45S-7 OM 514Safety
1-8
7. 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.
DO NOT OPERATE
when performing inspection
WARNING
950205-01451
or maintenance
FG018690
FG018596
950205-01760

BWT45S-7 OM 514
1-9
Safety
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.
1. Charging Plug Location
D1096
D1080
3

BWT45S-7 OM 514Safety
1-10
2. Lifting Point Decal
D1107
D1053
2