Operation Manual: Mobile Belt Loader

MOBILE
BELT
LOADER
MODEL 660 & 663
OPERATION MANUAL
Volume 1 of 1
Originally Issued December 2015
CD397-Oper
Mobile Belt Loader Model 660 Introduction
Operation Manual
COPYRIGHT NOTICE
This manual is copyright © 2015 Tug Technologies Corporation (TUG). All rights reserved.
This manual contains confidential and proprietary information.
This document and any information contained herein, may not be reproduced or redistributed in
any form whatsoever without the express, written consent of TUG.
Any attempt to alter the contents of this manual in any way by anyone other than an authorized
agent of TUG shall be construed as copyright infringement and punishment will be pursued under
all applicable laws.
All vendor literature contained in this manual is the copyrighted property of the respective vendors,
protected by the same laws governing this manual.
Introduction - 1 - ii CD397-Oper
Introduction Mobile Belt Loader Model 660
Operation Manual
RECORD OF REVISIONS
Property of: _____________________________________________________________________

Company: _____________________________________________________________________
Address: _____________________________________________________________________
City: _______________________________ State/Province: _____________________
Country: _______________________________ Zip/Postal Code: _____________________
REVISION DATA
Check each revision received, and insert the revised and supplementary pages in your manual.Tug
Technologies Corporation assumes no liability for personal injury or equipment failure due to any oper-
ation performed without heed to manual revisions.
Date of original publication: December 2015
Table Introduction - 1 - 1: Revisions
Revision Number Date Brief Description
CD397-Oper Introduction - 1 - iii

Operation Manual
LIST OF EFFECTIVE PAGES

Only pages that have been revised are listed in Table Introduction - 1 - 2: List of Effective Pages.
Table Introduction - 1 - 2: List of Effective Pages
Page Revision Date Page Revision Date
Introduction - 1 - iv CD397-Oper
Operation Manual
TABLE OF CONTENTS
Copyright Notice ............................................................................................ Introduction - 1 - ii
Record of Revisions ...................................................................................... Introduction - 1 - iii
Revision Data........................................................................................... Introduction - 1 - iii
List of Effective Pages .................................................................................. Introduction - 1 - iv
Table of Contents ...............................................................................................Introduction-1-v
List of Figures ................................................................................................... Introduction-1-xi
List of Tables ................................................................................................... Introduction-1-xiii
Unit Identification ...........................................................................................Introduction - 1 - 1
Model Number ...............................................................................................Introduction - 1 - 2
Warranty Information .....................................................................................Introduction - 1 - 3
Introduction ...............................................................................................Introduction - 1 - 3
Pre-delivery Procedures ...........................................................................Introduction - 1 - 3
Authorization Requirements - Repairs Requiring Prior Approval ..............Introduction - 1 - 3
Warranty ........................................................................................................Introduction - 1 - 4
Warranty Statements ................................................................................Introduction - 1 - 4
Warranty Policy And Coverage.................................................................Introduction - 1 - 4
Service Recalls or Owner Notification Programs ................................Introduction - 1 - 4
Warranty Cancellation.........................................................................Introduction - 1 - 5
Warranty Exclusions .................................................................................Introduction - 1 - 5
Warranty Claim Process ...........................................................................Introduction - 1 - 6
Contact TUG Technologies.................................................................Introduction - 1 - 6
Parts....................................................................................................Introduction - 1 - 7
Return Parts ........................................................................................Introduction - 1 - 7
Labor ...................................................................................................Introduction - 1 - 7
Aircraft Ground Support Equipment ...............................................................Introduction - 1 - 8
Warranty Policy Statement .......................................................................Introduction - 1 - 8
General Warranty Terms & Conditions .....................................................Introduction - 1 - 8
Warranty Labor Flat Rate Guide ..................................................................Introduction - 1 - 10
Technical Assistance ...................................................................................Introduction - 1 - 17
How to Use This Manual ..............................................................................Introduction - 1 - 19
Safety ....................................................................................................... Safety - 1 - 1
Section 1: General Safety Guidelines ................................................................Safety - 1 - 1
1.1 Introduction ....................................................................................................... Safety - 1 - 1
1.2 Standard Safety Features ................................................................................. Safety - 1 - 1
1.3 Optional Safety Features .................................................................................. Safety - 1 - 3
1.4 Safety Responsibilities...................................................................................... Safety - 1 - 4
1.5 Operator Safety Responsibility ......................................................................... Safety - 1 - 5
1.6 Mechanic Safety Responsibility ........................................................................ Safety - 1 - 7
1.7 Emergency Procedures .................................................................................... Safety - 1 - 8
1.7.1 Disabled or Stalled Vehicle ...................................................................... Safety - 1 - 8
1.7.1.1 Operational Engine ......................................................................... Safety - 1 - 8
1.7.1.2 Operational Engine - Unable to Move ............................................. Safety - 1 - 9
1.7.1.3 Inoperable Engine With Electrical Power ...................................... Safety - 1 - 10
1.7.1.4 Inoperable Engine With Loss of Electrical Power ......................... Safety - 1 - 10
1.7.2 Recommended Fire Procedure.............................................................. Safety - 1 - 11
1.7.3 Collisions................................................................................................ Safety - 1 - 12
Section 2: IATA Flightline Safety Guidelines ..................................................Safety - 2 - 13
2.1 IGOM Chapter 4: Aircraft Handling Procedures.............................................. Safety - 2 - 13
CD397-Oper Introduction - 1 - v
Operation Manual
2.1.1 Ramp Safety in Aircraft Handling........................................................... Safety - 2 - 13

2.2 General Ramp Safety ..................................................................................... Safety - 2 - 13
2.2.1 Danger Areas......................................................................................... Safety - 2 - 13
2.2.2 Engine Intake Area ................................................................................ Safety - 2 - 14
2.2.3 Equipment Restraint Area & Equipment Restraint Line ......................... Safety - 2 - 17
2.2.3.1 FOD - Foreign Object Debris ........................................................ Safety - 2 - 17
2.2.3.2 FOD Checks.................................................................................. Safety - 2 - 18
2.3 Safety Instructions for Operating Motorized Vehicles on Ramp ..................... Safety - 2 - 19
2.3.1 General Safety Instructions for Ground Support Equipment (GSE)....... Safety - 2 - 19
2.3.2 Basic Operating Requirements for GSE ................................................ Safety - 2 - 19
2.3.3 Belt Loader Aircraft Loading Equipment ................................................ Safety - 2 - 20
2.3.4 Ground Support Equipment Safety Driving and Parking Inside ERA..... Safety - 2 - 21
2.4 Adverse Weather Conditions .......................................................................... Safety - 2 - 21
2.4.1 Winter or Slippery Apron Conditions ...................................................... Safety - 2 - 21
2.4.2 Thunderstorms....................................................................................... Safety - 2 - 22
2.4.3 High Wind Conditions ............................................................................ Safety - 2 - 22
2.5 ISO 7000 and 7010 Safety Guidelines............................................................ Safety - 2 - 22
2.5.1 International Decals and Symbols. ........................................................ Safety - 2 - 22
Material Data Safety Sheet Information ............................................................... Safety - 2 - 25
2.5.2 Links for products:.................................................................................. Safety - 2 - 26
Operation ...........................................................................................Operation - 1 - 1
Section 1: System Overview ........................................................................ Operation - 1 - 4
1.1 Safety Precautions.......................................................................................Operation - 1 - 4
1.2 Purpose of Equipment .................................................................................Operation - 1 - 4
1.3 General Description .....................................................................................Operation - 1 - 4
1.4 Major Components.......................................................................................Operation - 1 - 4
1.4.1 Power Package...................................................................................Operation - 1 - 4
1.4.2 Engine.................................................................................................Operation - 1 - 4
1.4.2.1 Gasoline and LPG - Ford 2.5L ...................................................Operation - 1 - 4
1.4.2.2 Diesel - Deutz 2.9L.....................................................................Operation - 1 - 5
1.4.3 Transmission.......................................................................................Operation - 1 - 5
1.4.4 Drive Shaft ..........................................................................................Operation - 1 - 5
1.4.5 Drive Axle............................................................................................Operation - 1 - 5
1.4.6 Steer Axle ...........................................................................................Operation - 1 - 5
1.4.7 Brakes.................................................................................................Operation - 1 - 5
1.4.7.1 Hydraulic ....................................................................................Operation - 1 - 5
1.4.7.2 Park Brake .................................................................................Operation - 1 - 5
1.4.8 Chassis ...............................................................................................Operation - 1 - 5
1.4.9 Body....................................................................................................Operation - 1 - 5
1.4.10 Conveyor...........................................................................................Operation - 1 - 6
1.4.11 Operator’s Compartment ..................................................................Operation - 1 - 6
1.4.12 Electrical System ..............................................................................Operation - 1 - 7
1.4.13 Hydraulic System ..............................................................................Operation - 1 - 7
1.4.13.1 General Hydraulics Operation..................................................Operation - 1 - 7
1.4.13.2 Steer and Braking ....................................................................Operation - 1 - 7
1.4.13.3 Lift Cylinders and Conveyor Motor...........................................Operation - 1 - 8
Section 2: Operational Procedures ........................................................... Operation - 2 - 11
2.1 Instrument Panel Controls and Indicators..................................................Operation - 2 - 11
2.1.1 Ford 2.5L...........................................................................................Operation - 2 - 11
2.1.2 Deutz 2.9L Tier 4F ............................................................................Operation - 2 - 11
Introduction - 1 - vi CD397-Oper
Operation Manual
2.1.3 Maneuvering Controls .......................................................................Operation - 2 - 15

2.1.4 Conveyor Controls ............................................................................Operation - 2 - 16
2.1.5 Electrical Supply ...............................................................................Operation - 2 - 17
2.1.6 Preliminary Checks ...........................................................................Operation - 2 - 17
2.1.7 Maneuvering Procedures..................................................................Operation - 2 - 18
2.1.7.1 Engine Start Procedure (Gas)..................................................Operation - 2 - 18
2.1.7.2 Engine Start (Diesel) ................................................................Operation - 2 - 19
2.1.7.3 Release parking brake. ............................................................Operation - 2 - 19
2.1.7.4 Transmission Drive (FWD/REV) Selection...............................Operation - 2 - 19
2.1.7.5 Depress foot throttle.................................................................Operation - 2 - 20
2.1.7.6 Maneuver vehicle with steering wheel. ....................................Operation - 2 - 20
2.1.7.7 Maneuvering the baggage loader around the aircraft ..............Operation - 2 - 21
2.1.8 Belt Loader Towing Instructions........................................................Operation - 2 - 21
2.1.8.1 Towing Requirements ..............................................................Operation - 2 - 21
2.1.9 Conveyor Safety Props .....................................................................Operation - 2 - 23
2.2 IATA ...........................................................................................................Operation - 2 - 24
2.3 SAE............................................................................................................Operation - 2 - 24
2.4 ISO EMC Evaluation ..................................................................................Operation - 2 - 24
2.5 ISO Product Safety Evaluation ..................................................................Operation - 2 - 25
2.6 Locations of Technical Construction Files .................................................Operation - 2 - 25
Section 3: Specifications ........................................................................... Operation - 3 - 27
3.1 General Specifications of the 660 ..............................................................Operation - 3 - 27
3.1.1 Dimensions .......................................................................................Operation - 3 - 27
3.2 Torque Values............................................................................................Operation - 3 - 28
3.2.1 Metric Fasteners ...............................................................................Operation - 3 - 28
3.2.2 Graded Bolts .....................................................................................Operation - 3 - 29
3.3 Performance ..............................................................................................Operation - 3 - 31
3.3.1 Specifications....................................................................................Operation - 3 - 31
3.3.2 Environmental Operating Limits........................................................Operation - 3 - 32
3.3.3 Environmental Vibration Information.................................................Operation - 3 - 32
3.3.4 Environmental Sound Information.....................................................Operation - 3 - 32
3.4 Engines ......................................................................................................Operation - 3 - 35
3.4.1 Gasoline............................................................................................Operation - 3 - 35
3.4.1.1 Ford MSG-425 2.5L .................................................................Operation - 3 - 35
3.4.2 Diesel ................................................................................................Operation - 3 - 35
3.4.2.1 Deutz D2.9L .............................................................................Operation - 3 - 35
3.5 Transmission..............................................................................................Operation - 3 - 36
3.5.1 Gear Ratios.......................................................................................Operation - 3 - 36
3.6 Standard Conveyor Heights and Angles....................................................Operation - 3 - 37
3.7 Compatible Aircraft ....................................................................................Operation - 3 - 38
3.8 Fluids .........................................................................................................Operation - 3 - 42
3.9 Coolant.......................................................................................................Operation - 3 - 43
3.10 Recommended Spare Parts.....................................................................Operation - 3 - 43
3.11 Safety Features........................................................................................Operation - 3 - 44
3.11.1 Shifter / Parking Brake Safety.........................................................Operation - 3 - 44
3.11.2 Shifter Guard...................................................................................Operation - 3 - 44
3.11.3 Neutral Safety Start Switch .............................................................Operation - 3 - 44
3.11.4 Anti-Restart Ignition Switch.............................................................Operation - 3 - 44
3.11.5 Engine Control Module (ECM) Starter Protection ...........................Operation - 3 - 45
3.11.5.1 Ford 2.5L................................................................................Operation - 3 - 45
CD397-Oper Introduction - 1 - vii

Operation Manual
3.11.5.2 Deutz 2.9L..............................................................................Operation - 3 - 45

3.11.6 Emergency Stop Switch..................................................................Operation - 3 - 45
3.11.7 Park Brake ......................................................................................Operation - 3 - 45
3.11.8 Pilot-Operated Hydraulic Check Valves ..........................................Operation - 3 - 45
3.11.9 Safety Props ...................................................................................Operation - 3 - 46
3.11.10 Side / Hand Rails ..........................................................................Operation - 3 - 46
3.11.11 Finger Guards ...............................................................................Operation - 3 - 46
3.11.12 Rubber Bumper Roll .....................................................................Operation - 3 - 46
3.11.13 Steel Hoop Guard (Optional) ........................................................Operation - 3 - 46
3.11.14 Grit Paper......................................................................................Operation - 3 - 46
Section 4: Shipping .................................................................................... Operation - 4 - 47
4.1 Shipping Preparation .................................................................................Operation - 4 - 47
4.1.1 Fuel Tank Preparation .....................................................................Operation - 4 - 47
4.1.2 Battery Preparation ..........................................................................Operation - 4 - 47
4.1.3 Pre-shipping Verification ..................................................................Operation - 4 - 47
4.2 Receiving ...................................................................................................Operation - 4 - 48
4.2.1 Preparing for Operation ....................................................................Operation - 4 - 48
4.2.1.1 Battery......................................................................................Operation - 4 - 48
4.2.1.2 Emergency Hydraulic Pump.....................................................Operation - 4 - 48
4.2.1.3 Radiator....................................................................................Operation - 4 - 48
4.2.1.4 Fuel Cell ...................................................................................Operation - 4 - 48
Section 5: Storage ...................................................................................... Operation - 5 - 49
5.1 Short Term Storage ...................................................................................Operation - 5 - 49
5.1.1 Gasoline Engine................................................................................Operation - 5 - 49
5.1.1.1 Ford 2.5 L Engine.....................................................................Operation - 5 - 49
5.1.1.2 Transmission............................................................................Operation - 5 - 49
5.1.1.3 Drive Axle.................................................................................Operation - 5 - 49
5.1.1.4 Tires .........................................................................................Operation - 5 - 50
5.1.1.5 Lubrication................................................................................Operation - 5 - 50
5.1.1.7 Fluid Levels ..............................................................................Operation - 5 - 50
5.1.2 Diesel Engine....................................................................................Operation - 5 - 50
5.1.2.1 Deutz 2.9L Engine....................................................................Operation - 5 - 50
5.1.2.2 Transmission............................................................................Operation - 5 - 50
5.1.2.4 Tires .........................................................................................Operation - 5 - 51
5.1.2.5 Lubrication................................................................................Operation - 5 - 51
5.1.2.7 Fluid Levels ..............................................................................Operation - 5 - 51
5.2 Returning the Vehicle to Operation After Short Term Storage...................Operation - 5 - 51
5.2.1 Tires ..................................................................................................Operation - 5 - 51
5.2.2 Battery...............................................................................................Operation - 5 - 51
5.2.3 Engine...............................................................................................Operation - 5 - 52
5.2.4 Transmission.....................................................................................Operation - 5 - 52
5.3 Long Term Storage ....................................................................................Operation - 5 - 52
5.3.1 Gasoline Engine................................................................................Operation - 5 - 52
5.3.1.1 Ford 2.5L Engine......................................................................Operation - 5 - 52
5.3.1.2 Engine Exterior.........................................................................Operation - 5 - 53
Introduction - 1 - viii CD397-Oper

Operation Manual
5.3.3 Tires ..................................................................................................Operation - 5 - 54

5.3.4 Lubrication ........................................................................................Operation - 5 - 54
5.3.5 Fluid Levels.......................................................................................Operation - 5 - 54
5.3.7 Diesel Engine....................................................................................Operation - 5 - 55
5.3.7.1 Deutz 2.9L Engine ...................................................................Operation - 5 - 55
5.3.9 Drive Axle..........................................................................................Operation - 5 - 56
5.3.10 Exhaust ...........................................................................................Operation - 5 - 57
5.3.11 Tires ................................................................................................Operation - 5 - 57
5.3.12 Lubrication ......................................................................................Operation - 5 - 57
5.3.13 Levels..............................................................................................Operation - 5 - 57
5.3.14 Wheel Bearings...............................................................................Operation - 5 - 57
5.3.15 Battery.............................................................................................Operation - 5 - 57
5.3.16 Fuel System ....................................................................................Operation - 5 - 58
5.3.17 Engine Exterior ...............................................................................Operation - 5 - 58
5.3.18 Tagging ...........................................................................................Operation - 5 - 59
5.4 Returning the Vehicle to Operation After Long-Term Storage ...................Operation - 5 - 59
5.4.1 Tires ..................................................................................................Operation - 5 - 59
5.4.3 Engine...............................................................................................Operation - 5 - 59
5.4.5 Drive Axle..........................................................................................Operation - 5 - 60
5.4.6 Pre-Operational Checks....................................................................Operation - 5 - 60
5.5 Cold Weather Storage ...............................................................................Operation - 5 - 60
5.6 Returning the Vehicle to Operation After Cold Weather Storage...............Operation - 5 - 61
5.6.1 Refill Fluids .......................................................................................Operation - 5 - 61
CD397-Oper Introduction - 1 - ix
Operation Manual
THIS PAGE INTENTIONALLY BLANK
Introduction - 1 - x CD397-Oper
Operation Manual
LIST OF FIGURES
Figure Introduction - 1 - 1 - TUG Identification Plate .........................................Introduction-1-1
Figure Introduction - 1 - 2 - Model Numbers ......................................................Introduction-1-2
Figure Safety - 2 - 1 - Idle Power - Engine Intake Area NO Zone............................. Safety-2-15
Figure Safety - 2 - 2 - Breakaway Power - Engine Blast Area NO Zone .................. Safety-2-16
Figure Safety - 2 - 3 - Equipment Restraint Area...................................................... Safety-2-17
Figure Safety - 2 - 4 - Fasten Seat Belts (White on Blue Background)..................... Safety-2-24
Figure Safety - 2 - 5 - Use Hearing Protection (White on Blue Background)............ Safety-2-24
Figure Safety - 2 - 6 - Hot Surface (Yellow Field with Black Border) ........................ Safety-2-25
Figure Operation - 2 - 1 - Instrument Panel - Ford 2.5L.......................................Operation-2-12
Figure Operation - 2 - 2 - Instrument Panel - Deutz 2.9L.....................................Operation-2-14
Figure Operation - 2 - 3 - Maneuvering and Conveyor Controls..........................Operation-2-16
Figure Operation - 2 - 4 - Conveyor Controls.......................................................Operation-2-17
Figure Operation - 2 - 5 - Belt Loader with Props Engaged.................................Operation-2-23
Figure Operation - 3 - 1 - Capscrew Examples....................................................Operation-3-28
Figure Operation - 3 - 2 - Sound - Engine Idle - Conveyor Down - Belt Stationary .....................
.............................................................................................................................Operation-3-33
Figure Operation - 3 - 3 - Sound - Engine Max - Conveyor Down - Belt Max Speed ..................
.............................................................................................................................Operation-3-33
Figure Operation - 3 - 4 - Sound - Engine Idle - Conveyor Up - Belt Stationary ..Operation-3-34
Figure Operation - 3 - 5 - Sound - Engine Max - Conveyor Up - Belt Max Speed .......................
.............................................................................................................................Operation-3-34
Figure Operation - 3 - 6 - Conveyor - Full Down Rear, Full Up Front ..................Operation-3-37
Figure Operation - 3 - 7 - Conveyor - Full Up Rear, Full Up Front.......................Operation-3-37
Figure Operation - 3 - 8 - Conveyor - Full Down Rear, Full Down Front..............Operation-3-38
Figure Operation - 3 - 9 - Conveyor - Full Up Rear, Full Down Front ..................Operation-3-38
CD397-Oper Introduction-1-xi
Operation Manual
Introduction-1-xii CD397-Oper
Operation Manual
LIST OF TABLES
Table Introduction - 1 - 1: Revisions ................................................................. Introduction-1-iii
Table Introduction - 1 - 2: List of Effective Pages ............................................. Introduction-1-iv
Table Introduction-1-1: Service Recalls/Notification ...........................................Introduction-1-4
Table Introduction-1-2: Flat Rate Labor Guide .................................................Introduction-1-10
Table Safety-1-1: Standard Safety Equipment ........................................................... Safety-1-1
Table Safety-1-2: Optional Safety Equipment............................................................. Safety-1-3
Table Safety-1-3: Operator Safety Responsibilities .................................................... Safety-1-5
Table Safety-1-4: Mechanic Safety............................................................................. Safety-1-7
Table Safety-2-1: Examples of FOD ......................................................................... Safety-2-18
Table Safety-2-2: FOD Checks................................................................................. Safety-2-18
Table Operation-2-1: Instrument Panel Description - Ford 2.5L ..........................Operation-2-12
Table Operation-2-2: Instrument Panel Description - Deutz 2.9L ........................Operation-2-14
Table Operation-3-1: Dimensions and Measurements ........................................Operation-3-27
Table Operation-3-2: Torque Values for Metric Fasteners ..................................Operation-3-28
Table Operation-3-3: Torque Values for Graded Bolts ........................................Operation-3-29
Table Operation-3-4: Performance Data..............................................................Operation-3-31
Table Operation-3-5: Specification Data.............................................................Operation-3-31
Table Operation-3-6: Environmental Limits .........................................................Operation-3-32
Table Operation-3-7: Ford MSG-425 (2.5 L).......................................................Operation-3-35
Table Operation-3-8: Deutz D2.9L.......................................................................Operation-3-35
Table Operation-3-9: Gear Ratios........................................................................Operation-3-36
Table Operation-3-10: Conveyor Positions..........................................................Operation-3-38
Table Operation-3-11: Aircraft Compatibility........................................................Operation-3-39
Table Operation-3-12: Hydraulic Fluid ................................................................Operation-3-42
Table Operation-3-13: Engine Oil .......................................................................Operation-3-42
Table Operation-3-14: Fluids ...............................................................................Operation-3-42
CD397-Oper Introduction-1-xiii
Operation Manual
Introduction-1-xiv CD397-Oper
Operation Manual
UNIT IDENTIFICATION
The information and instructions in this manual are intended to acquaint the operator with the
important operating features of the TUG Mobile Belt Loader Model 660. The various controls,
gauges, switches, and operating features are explained and illustrated throughout this manual.
Personnel responsible for operation of the vehicle should read this manual carefully.
To aid the technician in repair or service work on this unit, a TUG identification plate is located in
the operator's compartment.
TUG TECHNOLOGIES CORPORATION

1995 DUNCAN DRIVE
KENNESAW, GEORGIA 30144
SERIAL
MODEL # MFG DATE
NUMBER
UNLADEN WEIGHT w/OUT CAB 7,000 POUNDS 3,175 KILOGRAMS
WITH CAB 7,200 POUNDS 3,266 KILOGRAMS
MAXIMUM SPEED 25 MPH 40 KPH
PERMISSABLE TOTAL PAYLOAD EVENLY DISTRIBUTED ON THE BOOM AT MAXIMUM AND MINIMUM ANGLE IS:
2,000 POUNDS 907 KILOGRAMS
MAXIMUM SINGLE LOAD ON THE BOOM IS

500 POUNDS 227 KILOGRAMS
660−4−3728
Figure Introduction - 1 - 1: TUG Identification Plate
The serial number identification of each unit will appear on the nameplate along with the date of
manufacture. The mailing address of TUG is also located at the top of the data plate opposite
the TUG logo. This necessary information will ensure the customer a fast and accurate response
to any parts and/or service request.
Please verify the serial number on the identification nameplate of the unit and enter your unit
serial number here:______________________________________________________
If applicable, enter your company identification number here:
______________________________________________________________________
CD397-Oper Introduction - 1 - 1
Operation Manual
MODEL NUMBER
Tug numbers models according to the diagram in Figure Introduction - 1 - 2 Model Numbers.
Model Number Coding
Conveyor Engine
660 _ 44
Conveyor Variations Engine Variations

660 = 34 in Wide x 24 ft Long 28 = Ford MSG-425 (2.5 L) 4 Cylinder Gasoline/LP
663 = 31.5 in. Wide x 24 ft Long 44 = Deutz TCD 2.9 L Diesel Tier IV Final
Figure Introduction - 1 - 2: Model Numbers
Introduction - 1 - 2 CD397-Oper
Operation Manual
WARRANTY INFORMATION
INTRODUCTION
The primary goal of warranty adjustment is to satisfy our customers. Every satisfied customer
strengthens the components of our whole organization - all aspects of the products themselves
and the service that backs them up. This manual is directed to TUG Technologies’ distributors
and customers of TUG Equipment. It should be used to implement the Warranty Program at
every level.
This Warranty Policy and Procedures Manual includes the warranties of TUG Technologies’
products. It explains warranty policy and coverage, and describes the warranty claim process.
TUG Technologies is responsible for handling warranty and policy adjustments promptly and in
accordance with the provisions of the Sales and Service Agreement, TUG Technologies War-
ranty Statements and this manual. Customers who recognize the manual as the "heart" of the
warranty system and train their personnel in its use may expect service personnel qualified to
submit claims that are properly completed and fully-substantiated, resulting in prompt claims pay-
ment.
The guidelines and requirements in this manual apply to warranty claims sub-
NOTE:
mitted to TUG Technologies for reimbursement to the customer.
PRE-DELIVERY PROCEDURES
Establish pre-delivery procedures that ensure the appropriate inspections and adjustments are
made prior to equipment being placed in service.
AUTHORIZATION REQUIREMENTS - REPAIRS REQUIRING PRIOR APPROVAL

Certain repairs and claims require prior approval. Any repair which will take more then 2 hours
labor to complete must have prior approval.
Operation Manual
WARRANTY
A warranty is a specific document that guarantees the quality of goods to a purchaser within a
specified length of time and according to usage limitations. The TUG Technologies warranty
statement defines the conditions of the warranty. A warranty:
1. Remains in force for the specified period, provided that an occurrence has not taken
place to render the warranty inapplicable.
2. Assures the owner that if, under the conditions specified, a defect in factory workmanship
or material is encountered, it will be corrected at no charge or on a prorata basis.
3. Extension of coverage by any manufacturer does not change what is covered in the
basic, expressed limited warranty.
WARRANTY STATEMENTS
TUG Technologies Warranty Statements provide detailed information regarding coverage and
usage limitations for TUG products.
WARRANTY POLICY AND COVERAGE

Service Recalls or Owner Notification Programs
TUG TECHNOLOGIES may establish a program to resolve extensive customer concern about a
component beyond warranty coverage. Owners are notified to contact TUG Technologies for
replacement/repair. Customers will be notified by TUG TECHNOLOGIES with information that:
• Identifies the component and condition.
• Outlines the inspection and repair procedure required to correct the condition.
• Defines reimbursement.
Table Introduction-1-1: Service Recalls/Notification
Component Disposition
Shipment TUG will ship components for service recalls and / or approved warranty
claims free of charge.
Freight Charges Return of recalled components is covered when shipped via the prepaid
RGA tag or another approved, least-expensive method.
Labor for Service Reimbursed at the approved hourly warranty labor rate.
Non-TUG Parts Only covered with prior approval from TUG.
Operation Manual
Warranty Cancellation
Certain situations cause a warranty to be canceled. Examples of such situations include, but are
not limited to:
• Damaged due to accidents.
• Damage due to abuse, improper operation or poor maintenance practices.
Total or partial warranty cancellation is registered in TUG Technologies’ records.
WARRANTY EXCLUSIONS
The following items are examples of some of the non-reimbursable items under the Warranty and
Policy Program. Non-reimbursable repairs include:
• Any repair to a unit on which the mileage/hours or date of first use reported has been mis-
represented.
• Any repair to a unit on which the odometer / hour meter has been altered so that the true
mileage / hours cannot be determined.
This item applies only to cases in which mileage / hours are a condition of the
NOTE:
warranty.
• Any repair for which the date on the order has been misrepresented or altered to place an
out-of-warranty component within the warranty provisions.
• Any repair made to a product that has been misused or mistreated, or upon which a con-
version, modification, or installation of a non-TUG part has been made affecting the per-
formance, reliability or stability of a part.
Any failure to a TUG-supplied part resulting from such action is not covered by
NOTE:
the warranty.
• Parts handling charges.
• Parts damaged due to accident.
The warranty on parts damaged because of accident or an act of nature will be

canceled.
NOTE: Repairs on accident claims or conditions that could have contributed to per-
sonal injury or property damage must not begin until approval is obtained. Do
not scrap allegedly defective parts that may have contributed to injury or dam-
age until written approval is received.
Operation Manual
• Repairs required because of inadequate or incorrect protection in storage and / or prepa-

ration for storage.
• Repairs of damage or failure caused by poor outside workmanship.
• Any repair operation that changes the existing specifications of the equipment or compo-
nent.
• Repair techniques beyond the appropriate shop manual limits.
• Labor performed by anyone other than an authorized TUG technician without prior
approval, unless the situation is an emergency.
• Use of any other than genuine TUG parts, unless used in an emergency.
• A second or subsequent repair or adjustment necessitated by an incomplete or improper

original repair or adjustment.
• Adjustments made to improve appearance or performance beyond normal standards.
• Maintenance and normal replacement of service items. For example, replacement of fil-
ters and fluids, tightening of bolts, nuts, or fittings. Minor, labor-only repairs are reimburs-
able.
• Any repair to a part that is found not to be defective.
• Replacement of assembly rather than repair if replacement costs exceed repair costs,
and parts are available. Replacement requires prior approval.
• Labor operations such as additional diagnostic time, abnormal accessibility or diagnosis

time, hot testing and testing of new parts after repair. Standard labor allowances are
included in warranty labor time standards.
• Replacement parts damaged in shipment (carrier responsibility).
• Towing expense or transportation for moving equipment between the customer's location
and the repair location.
WARRANTY CLAIM PROCESS
No warranty invoice will be accepted unless TUG Technologies has been con-
NOTE:
tacted prior to the start of work being done to the unit.
Contact TUG Technologies

Phone: 1-800-989-8499 Ext. 1 or 770-422-8021
Email (preferred): [email protected]
Operation Manual
To expedite the claim process please provide the following information:
1. Unit S/N
2. Hours of operation
3. Description of problem or symptoms
4. List of parts required for repairs
5. Shipping address
6. Contact name
7. Contact phone number(s)
Parts
TUG Technologies will ship warranty parts at no charge once the claim has been received and
accepted.
Return Parts
Not all failed parts need to be returned to TUG Technologies. If parts are to be returned, an RGA
tag will be sent with the replacement warranty parts. The tag must be filled out completely and
attached to the return part(s).
NOTE: Parts not returned within 30 days of claim will be charged to your account.
TUG Technologies reserves the right to invoice for parts being returned for the reasons but not
limited to the reasons listed below.
• If deemed caused by an unwarrantable failure.
• If part is damaged due to inadequate packaging.
• Part was not supplied by TUG Technologies
• Proper documentation was not provided or sent back with faulty part.
Labor
TUG Technologies will reimburse labor based on the Standard Labor Rate Chart. Any work which
will exceed the times outlined in this chart requires prior approval. All warranty labor is subject to
TUG Technologies Warranty Approval Process.
Operation Manual
AIRCRAFT GROUND SUPPORT EQUIPMENT

WARRANTY POLICY STATEMENT
This Policy Statement sets forth the terms of the warranty provided by TUG Technologies Corp.
with respect to ground power units, air start units, tow tractors, cargo tractors and other equip-
ment sold for use in the commercial aviation industry (“Aircraft Ground Support Equipment”
“Industrial”).
The foregoing warranty gives Buyer specific legal rights that may vary from state to state. Some
states do not permit the limitation of incidental or consequential damages or limitation of reme-
dies under warranties. The above limitations apply only to the extent permitted by applicable law.
GENERAL WARRANTY TERMS & CONDITIONS

TUG Technologies warrants that each new item of equipment is of good workmanship and is free
of mechanical defects, provided that:
1. The equipment is installed and operated in accordance with the TUG Technologies Oper-
ation and Maintenance Manual.
2. The equipment is used under normal operating conditions, for which it was designed.
3. The equipment is not subject to misuse, negligence, or accident.
4. The equipment is properly maintained by qualified technicians in accordance with the

TUG Technologies Operation and Maintenance Manual.
This warranty expires, unless otherwise agreed by TUG Technologies in a special provision, 24
months after being shipped or after 2000 operating hours. TUG Technologies warranty does not
apply to fluids, oils, fuses, bulbs, accumulators, paint, seals, tires, bumpers, brakes, or wearable
parts, bulbs, batteries, etc.
All warranty claims must be sent to the warranty department for processing. All information per-
taining to specific claim must be provided for claim to be processed in a timely manner.
All the expenses related to a warranty claim will be invoiced to the buyer until TUG Technologies
has evaluated the claim. Whatever the circumstances, the buyer should not refuse or delay the
payment. If the evaluation concludes as TUG’s full responsibility, a credit will be issued in the
favor of the buyer.
This warranty is extended by TUG Technologies only to the buyer of new products from TUG
Technologies or its authorized distributors. The products purchased under this warranty are
intended for use exclusively by the buyer. There shall be no third party beneficiary of this war-
ranty.
Under no circumstances whatsoever shall TUG Technologies be liable for any special or conse-
quential damages, whether based on lost goodwill, lost resale profits, work stoppage, impairment
of other goods or otherwise, and whether arising out of breach of any express or implied war-
Operation Manual
ranty, breach of contract, negligence, or otherwise, except in the case of personal injury as may
be required by applicable law.
The warranty is automatically void by TUG Technologies in the following cases:
1. The product has received some modification not authorized or completed according to
TUG Technologies requirements.
2. Some original parts have been replaced by parts not provided by TUG Technologies.
Operation Manual
WARRANTY LABOR FLAT RATE GUIDE

Table Introduction-1-2, “Flat Rate Labor Guide,” lists the labor rates for various task.
Table Introduction-1-2: Flat Rate Labor Guide
Part Hours
R&R Cooling System

Fan 0.2
Radiator, Transfer Shroud 0.5
Top or Bottom Hose 0.5
Heater Hose 1.0
Water Pump 1.5
Thermostat 0.5
R&R Controls
Shifter 1.0
Shifter Cable & Adjust 1.0
Neutral Safety Switch 0.5
Adjust Neutral Safety Switch 0.5
Park Brake Link 1.0
Accelerator Cable & Adjust 1.0
Accelerator Pedal, Hookup, & Adjust 0.5
R&R Drive Axle & Mounting

Axle Assembly 4.0
Input Seal 0.5
Input Flange 0.5
Axle Shaft Seal 1.5
Shaft O-Ring Seal
Axle Shaft & Axle Bearing 1.0
R&R Drive Shaft

Drive Shaft 1.0
One U Joint 0.5
Operation Manual
Table Introduction-1-2: Flat Rate Labor Guide (Continued)
Part Hours
Body
Repaint 8.0
Repaint Cab 2.0
R&R Brakes
Master Cylinder & Bleed 1.5
Brake Booster 1.0
Adjust Brake Booster
Hard Brake Lines & Bleed 1.5
Master Cylinder Cover Gasket 0.2
Brake Pedal 0.5
Brake Return Spring 0.2
Hub Front 1.0
One Stud 1.0
Park Brake Cable to Rear Wheels / Linkage 1.0
Axle Shaft Leak 1.5
Brake Wheel Cylinder 2.0
R&R Brakes, Front Axle

Caliper & Bleed 1.0
Rotor 1.0
Wheel Bearings 1.0
Wheel Stud 1.0
Cab (Option - Call for Standard Rates)
R&R Electrical
Troubleshoot Short or No Power 2.0
Coolant Temp Sensor 0.5
Coolant Gauge 0.5
Operation Manual
Part Hours
Hour Meter 0.5
Ammeter 0.5
Electric Fuel Gauge 1.0
Electric Fuel Sender 1.0
Kysor Coolant Temp Sensor 0.5
Kysor Oil Pressure Sensor 0.5
Kysor Override Switch 0.5
Light Switch 0.5
Battery Cable 0.5
Wire Harness 5.0
Kysor Warning Light 0.5
Start Relay 0.5
Horn 0.3
Horn Relay 0.3
Battery 0.3
Turn Signal Light 0.3
Turn Signal Flasher 0.3
Tighten Battery Cable 0.3
Glow Plug Switch 0.3
Brake Switch 0.3
Adjust Brake Switch
R&R Engine
Starter Relay 0.3
Starter 1.0
Alternator 1.0
Fuel Pump or Lift Pump 1.0
Battery 0.5
Valve Cover Gasket 1.0
Operation Manual
Part Hours
Spark Plug Wires 0.5
Engine Assembly 7.0
Oil Pan 2.0
Front Crankshaft Seal 2.0
R&R Exhaust
Exhaust Pipe 0.5
Muffler 0.5
Tail Pipe 0.5
R&R Front Suspension & Steering

Front Spring 1.0
Front Axle and Transfer Springs 1.5
Tie Rod End & Adjust Toe In 0.5
King Pin 1.0
Drag Link 0.5
Pitman Arm - Gas 0.5
Pitman Arm - Diesel 0.5
Steer Cylinder 1.0
Steer Hose - Valve to Cylinder 0.5
Steer Pump 1.0
Steer Hose - Pump to Valve 0.5
Steer Sector 1.0
Steering Wheel 0.5
Horn Button Kit 0.5
Steer Valve 1.5
Upper Steering Bearing 0.5
Steering Wheel 0.3
Operation Manual
Part Hours
R&R Fuel System

Fuel Cell 2.5
Fuel Line Steel 0.5
LP Lock Off Valve 1.0
LP Regulator 1.0
Miscellaneous
Install Rubber Bumper 1.0
R&R Hood Latch 0.3
Install Decal 0.3
R&R Seating
Seat Frame 0.5
Bucket Seat 0.3
R&R Transmission
Transmission 3.0
Transmission Front Oil Seal - Gas 3.0
Transmission Rear Oil Seal 1.0
Modulator Valve 0.3
Modulator Cable 0.8
Pan Gasket & Refill1.0
Shifter Interlock Solenoid 0.5
Shifter Interlock Brake Switch 0.5
R&R Conveyor
Troubleshoot Conveyor Electrical 2.0
Switch-in Box 0.5
Control Relay 0.5
Relay Under Instrument Panel 0.5
Conveyor Kill Button 0.5
Operation Manual
Part Hours
Conveyor Kill Switch 0.5
Conveyor Kill Switch Wiring Harness 0.5
Electric Eyes 0.5
Glow Plug Relay 0.5
R&R Hydraulics
Hydraulic Pump 1.0
Hydraulic Pump Pulley 0.5
Main Manifold 1.0
Steering, Brakes Relief, & Adjustment Valve 0.5
2-Lever Valve Under Seat 1.0
Valve Lever 0.3
Relief Valve Under Seat 1.0
Main Hydraulic Pressure Relief Valve 0.5
Repair Hydraulic Leak 0.5
Electric Control Valve Assembly 1.0
Conveyor Hydraulic Motor 1.5
Conveyor Drive Roller Chain 0.5
Hoses Through Lift Arm to Conveyor 0.5
Hoses to Lift Cylinder
Front or Rear Lift Cylinder 2.0
Cylinder Holding Valve 1.0
Front Lift Arm 2.5
Rear Lift Arm 1.5
Small Manifold Valve Under Front of Conveyor 1.0
Adjust Conveyor Reverse Direction Holding Valve 1.0
Direction Valve Under Conveyor 1.0
Front or Manual Controls 1.0
Repair Direction Valve Spool Seal 1.0
Operation Manual
Part Hours
Hydraulic Tank 2.0
Drain and Refill Hydraulic Tank 1.0
R&R Conveyor
Conveyor Belt 2.5
Front Drive Roller (Includes Belt) 3.0
Front Drive Roller Bearing (Includes Belt) 3.0
Front Drive Roller Sprocket 3.0
Rear Idler Roller (Includes Belt) 3.0
Rear Idler Roller Bearing (Includes Belt) 3.0
Rear Idler Roller Bearing Adjusting Rod 3.0
Crowder Roller 3.0
Crowder Roller Bearings 3.0
Conveyor Roller 3.0
Conveyor Control Rod - Rear Part 3.0
Conveyor Control Rod - Front Part 3.0
Conveyor Control Detent 0.5
Conveyor Valve Control Arm 1.0
Adjust Belt Speed Control Link at Accelerator Pedal 0.5
Front Finger Guard 0.5
Front Roll Bumper 0.5
Operation Manual
TECHNICAL ASSISTANCE
Direct any questions concerning the operation of the 660 Mobile Belt Loader to:
TUG Technologies Corporation
1995 Duncan Dr.

Kennesaw, GA 30144
USA
Email: [email protected]
Direct any questions concerning parts for the 660 Mobile Belt Loader to:
Parts Department
USA: 1-800-989-8499
International: 00 + 1 + (770) 422-8021
Fax: 1-770-422-8730
Direct any questions concerning sales of the 660 Mobile Belt Loader to:
Equipment Sales
Phone: (770) 422-7230

Fax: (770) 428-7315
Direct any questions concerning warranty for the 660 Mobile Belt Loader to:
Warranty Department
Phone: (770) 422-8021

Toll Free: (800) 989-8499
Fax: 770-422-8730
All information in this manual is based on the latest production information available at the time of
publication.
Direct any questions concerning the contents or format of this manual to:
Technical Publications
Mobile Belt Loader Model 660
Operation Manual
Operation Manual
HOW TO USE THIS MANUAL
Important Notice: TUG recommends that the vehicle operator thoroughly study the
NOTE:
contents of this manual before attempting to operate the vehicle.
This manual contains an introduction, safety information, and one chapter. Refer to the Table of
Contents at the front of this manual and in the chapter for details of content.
The page numbering system in this manual is a three-part number. The first number represents
the chapter in which the page appears, the second number indicates the section within that chap-
ter, and the third number is the page number within that chapter.
The following symbols are examples of the Warnings, Cautions, and Notes used in this manual.
These Warnings, Cautions, and Notes will appear immediately prior to the procedure.
• The WARNING provides notice of potential safety issues that could, if ignored, result in
serious personal injury or, possibly, death.
• The Caution provides notice of potential safety issues that could, if ignored, result in
damage to equipment.
• Notes highlight issues or specific information that should be paid particular attention to
allow for an error-free procedure or provides important information concerning the proce-
dure.
WARNING: SAFETY NOTES THAT MUST BE FOLLOWED TO AVOID SERI-

OUS INJURY TO PERSONNEL OR EVEN DEATH.
CAUTION: Safety notes that need to be followed to prevent damage to equip-

ment.
NOTE: Important non-hazard information for the user.
Operation Manual
Safety Mobile Belt Loader Model 660
Operation Manual
Safety
Section 1: General Safety Guidelines
1.1 Introduction
Operator and mechanic safety is important at TUG. During the design and production of every
product, a thorough safety review of all components is standard operating procedure. As a result
of this review, safety warnings, cautions, and notes are provided throughout this manual. It is
important that operators and mechanics become familiar with all of these safety requirements.
To reinforce this action, this part of the manual has been devoted to safety.
CAUTION: Every operator and mechanic involved with this equipment must
read and abide by this safety section.
The safety part of this manual covers the following:
• Introduction
• Standard Safety Features
• Optional Safety Items
• Operator Safety Responsibility
• Mechanic Safety Responsibility
• IATA Flightline Safety Guidelines
It is strongly recommended that this chapter be reproduced and bound in the operator’s book,
along with your station safety rules.
1.2 Standard Safety Features

The following safety features are standard.
Table Safety-1-1: Standard Safety Equipment
No. Equipment
1 Recessed headlights
 Combination tail and stop lights
3 Back-up lights
CD397-Oper Safety - 1 - 1
Mobile Belt Loader Model 660 Safety
Operation Manual
Table Safety-1-1: Standard Safety Equipment (Continued)
No. Equipment
4 Turn signals with Hazard Warnings

5 Dual independent brake systems with brake warning light
6 Power-boosted front disc brakes and rear drum brakes
7 Adjustable over-center park brake hand lever
8 Lighted transmission shift control
9 Shift control with hand throttle interlock
10 Transmission shift lever guard
11 Neutral only start switch in shifter control
12 Angled right front corner
13 Ease of maneuverability
14 Center of steering wheel operated horn
15 Labeled controls
16 Left front driver position for excellent visibility
17 Conveyor lifting emergency pump
18 Conveyor safety props
19 Hydraulic steering
20 Pilot pressure operated cylinder holding valves
21 Pilot pressure operated reverse belt holding valve
22 Belt drive cushion valve
23 Hydraulic system pressure designed at 1500 psi (10.34 MPa or 102.07 atm) max.
All hydraulic hoses rated at 3250 psi (22.41 MPa or 221.15 atm). Always use OEM
24
hoses during replacement
25 Lagged belt driving roller
26 Hand and / or Guide Rails on either side of the conveyor
27 Non-slip fender surfaces
28 Boot cutouts in rear bumper for safe access to belt as walkway
29 Bolted down hydraulic tank and battery cover
30 Retracting Seat belts
Safety - 1 - 2 CD397-Oper
Operation Manual
Table Safety-1-1: Standard Safety Equipment (Continued)
No. Equipment
Independent expanding shoe and drum park brake on transmission output shaft or
31
in rear axle
32 Non slip covering on floor board
33 Non slip surface on brake and accelerator pedal
High coolant temperature/low oil pressure shutdown (Ford 2.5L only) (optional on
34
other engines)
1.3 Optional Safety Features

The following table contains a list of optional safety items.
Table Safety-1-2: Optional Safety Equipment
No. Items
1 Backup alarm
2 Amber flashing light
3 Amber strobe light
4 Mud and snow tires
5 Work lights
6 Reflective striping
7 Engine kill E-Stop buttons on conveyor and instrument panel
8 Conveyor up/down movement alarm
Transmission neutral only and park brake applied safety circuit for belt conveyor
9 movement interlock (Must be in neutral, park brake applied for conveyor to oper-
ate)
10 Gap filler strip between conveyor belt and front rubber bumper
11 Rubber bumper roll across the rear of the conveyor frame
12 Steel hoop guard across the rear of the conveyor frame
13 Cooling fan cover
14 Alternator belt
15 Manifold cover
Operation Manual
1.4 Safety Responsibilities

General rules cannot be written to cover every possible situation that may arise with each job
function, task, or procedure. Therefore, certain definite responsibilities rest with the individual.
These responsibilities include:
• Protection of yourself
• Protection of fellow employees
• Proper care of tools and equipment.
Report:
• unsafe conditions
• unsafe equipment
• unsafe operation
to the proper authorities. If unsure of an operating procedure, consult your supervisor for guid-
ance.
Operation Manual
1.5 Operator Safety Responsibility
WARNING: DO NOT DRIVE A BELT LOADER WITH DEFECTIVE BRAKES,

STEERING, TIRES, HORN, PARKING BRAKE, CONVEYOR BELT, OR
LIGHTS. COMMUNICATE THESE PROBLEMS TO YOUR SUPERVISOR.
Follow station safety rules. If you do not have a written list of safety rules, ask for one
NOTE:
prior to operating this belt loader.
Table Safety-1-3: Operator Safety Responsibilities
No. Operator Responsibility
1 Use proper hearing protection.

2 Follow training provided by your company.
Check before operating belt loader:
• Lights
• Brakes
• Parking Brake
3
• Steering
• Horn
• Tires
• Conveyor Belt for damaged or raised hooks
4 Keep hands and feet away from rotating parts and tires.
5 Wear secure clothing.
6 Bring belt loader to a complete halt and set parking brake before dismounting.
7 Use seat belts at all times when belt loader is in motion.
Do not shift transmission into gear with engine above idle speed. Keep foot off accel-
8
erator when shifting.
Bring belt loader to a complete stop before shifting from reverse to drive or from drive
9
to reverse.
Check the path is clear behind the belt loader prior to driving in reverse direction.
10 • Check local station rules and, if allowed, blow horn before reversing
• If not permitted, follow station rules for alerting other personnel prior to backing.
Use caution when in congested areas and around blind corners and rows of carts. Be
11
alert for other equipment and personnel.
Never operate at speeds inconsistent with operating conditions. Limit speed to allow
12
adequate time for braking in an emergency.
Operation Manual
Table Safety-1-3: Operator Safety Responsibilities (Continued)
No. Operator Responsibility
Do not allow the belt loader to be pushed by other equipment or use the belt loader to
13
push other equipment. Use proper towing equipment.
14 Do not tamper with engine.
Do not use the belt loader as a hoist for other personnel. Use proper equipment for
15
personnel.
16 Do not walk on fenders when icy or wet.
Walk ONLY on the conveyor and not on the painted frame. The painted frame is slip-
17
pery when wet.
18 Do not ride on the belt, conveyor, or fenders.
In event of a malfunction, stop operations and move the loader to a safe area, if possi-
19
ble, then notify a supervisor.
20 Do not stand on the belt when it is moving.
21 Use handrails when walking on the conveyor belt.
22 Keep hands, feet, and clothing away from the underside of the conveyor.
23 Do not put hands underneath the conveyor.
24 Do not wear rings on fingers when using the conveyor belt.
Check that the chain guards and finger guard at the rear roller are secured and the fin-
25
ger guard is adjusted as close to the roller as possible.
Know and understand the conveyor belt control stations operation, especially the “E”
26
Stops.
27 Do not insert the conveyor through the cargo door.
28 Do not approach the aircraft when personnel are present in the doorway.
29 Operate at creep speed when approaching aircraft or within 20 ft. of aircraft.
Always approach aircraft with the conveyor in the lowered position. Stop five feet from
30
the aircraft, raise the conveyor as required and creep into position.
31 Do not exceed 2000 pounds (907.2 kg) of weight on the conveyor belt.
32 Carry no passengers unless a seat with seatbelt is provided.
Work stations are at the right rear and left front of the conveyor (other locations
33
optional).
Operation Manual
1.6 Mechanic Safety Responsibility
WARNING: ALWAYS USE THE SAFETY PROPS WHEN WORKING UNDER

THE CONVEYOR.
Table Safety-1-4: Mechanic Safety
No. Mechanic Safety
1 Keep hands and clothing away from rotating parts

2 Wear secured clothing
3 Use the conveyor safety prop whenever working under conveyor
4 Allow engine to cool before adjusting the alternator belt or hydraulic pump belt
5 Keep hands. gloves, and clothing clear of cooling fan
6 Disconnect the battery positive cable when working on or under the conveyor
7 Do not substitute throttle return springs with lighter or other springs
8 Check brakes and fill master cylinder with DOT3 brake fluid.
If belt tracking, stop the belt while making adjustments on the left front corner, since the
9 drive chain is in that area. The other three corners can be adjusted with the belt running,
but keep hands out from under conveyor.
Inspect seat belts and attachment points regularly. Replace if damaged. Do not bleach or
10
red-dye seat belts, clean with soap and water.
11 Visually check for hydraulic leaks. Do not use hands or fingers to locate leaks
12 Verify all E Stops are functional
13 Check horns and lights
14 Check neutral start only switch for proper adjustment and operation.
15 Check tire and wheel condition, especially proper inflation pressures
16 Torque lug nuts to 125 ft-lbs (169.5 Nm).
17 Use proper lifting equipment when removing or replacing heavy components.
When working underneath belt loader, ensure it is properly supported on secure jack
18
stands that are rated. Do not rely on hydraulic jacks to support the belt loader.
If the belt loader is on a hydraulic or air-operated lift, make sure to place safety support
19
or jack stands in position prior to working under the belt loader.
20 Use a proper transmission jack when removing or replacing the transmission.
Operation Manual
Table Safety-1-4: Mechanic Safety (Continued)
No. Mechanic Safety
Jack the drive wheels off the floor and support the belt loader with rated jack stands
21
when troubleshooting the drive system.
22 Take nothing for granted when safety of the vehicle or operator is at stake.
23 Keep good maintenance records.
WARNING: DO NOT REMOVE THE RADIATOR CAP WHEN HOT! SERIOUS

BURNS MAY RESULT. ALLOW TIME TO COOL.
1.7 Emergency Procedures
read and understand emergency procedures prior to operation.
It is the operator’s responsibility to safeguard the unit and others when the unit or trailer is dis-
abled or in a collision. The following emergency procedures describe r e c o m m e n d e d steps to
follow, in t h e e v e n t of mechanical breakdown or equipment malfunction. Apply and/or adapt
these procedures to your company’s/station’s emergency procedures as necessary.
WARNING: IN CASE OF AN EMERGENCY - APPLY E-STOP TO DISABLE THE

VEHICLE. THE UNIT IS COMPLETELY INOPERABLE WHEN THE E-STOP
PUSH-BUTTON IS ENGAGED. FAILURE TO COMPLY MAY RESULT IN
DEATH, SERIOUS INJURY, OR PROPERTY DAMAGE.
1.7.1 Disabled or Stalled Vehicle

The Model 660 is equipped with an emergency hydraulic pump activated from the operator’s sta-
tion actuated b y a spring-loaded two-position switch. This e m e r g e n c y pump supplies
hydraulic pressure for the service brake and steering.
1.7.1.1 Operational Engine

When the engine is operational and the unit can be moved, perform the following steps:
1. Move the unit as far away from the traffic area as safely possible.
Operation Manual
2. Turn on the emergency hazard warning signals.
CAUTION: Turn on headlights when/if visibility is limited.
3. If unable to move the tow tractor out of the traffic area and when visibility is limited, set out
one type of emergency warning device (i.e. red cones, etc.) to the front and rear of the
unit.
1.7.1.2 Operational Engine - Unable to Move

When the engine is operable but the unit cannot be moved, perform the following steps:
1. Use a tow bar to attach the disabled unit to an operational tow tractor.
2. Release the park brake.
3. Ensure steering is operational in the disabled unit by turning the steering wheel.
NOTE: The disabled unit should be steered to follow the towing unit.
CAUTION: CAUTION: Towing speed must NOT exceed 6 mph (10 km/h). Do
NOT tow the disabled unit more than 6 mi. (10 km).
4. Tow unit.
5. Once towing destination is reached, place transmission of the towing vehicle in neutral,
apply the park brake, and turn the ignition key to the OFF position.
6. Chock wheels of the disabled unit.
7. Disconnect the vehicles by removing the tow bar.
Operation Manual
1.7.1.3 Inoperable Engine With Electrical Power

When the engine is inoperable it will experience loss of power.
CAUTION: Engaging the emergency hydraulic pump for more than one min-
ute will cause the electric motor to overheat. If emergency procedures can-
not be completed within one minute, disengage and allow the pump to cool
for at least 10 minutes before re-engaging. Failure to comply may result in
vehicle damage.
2. Engage the emergency hydro-steering pump by holding the toggle switch. Release the
toggle switch to disengage or shut off the hydro-steering pump.
3. Ensure steering is operational in the disabled unit by turning the steering wheel.
NOTE: Steer the disabled unit to follow the towing unit.
CAUTION: Towing speed must NOT exceed 3 mph (5 km/h). Do NOT tow the
disabled unit more than 6 mi. (10 km).
4. Tow unit.
apply the park brake and turn the ignition key to the OFF position.
1.7.1.4 Inoperable Engine With Loss of Electrical Power

An inoperable engine will experience loss of electrical power. When there is not enough electrical
power to engage the emergency steering pump, perform the following steps:
1. Use a tow bar to attach the disabled unit and an operational tow tractor.
CAUTION: Towing speed must NOT exceed 3 mph (5 km/h). Do NOT tow the
disabled unit more than 6 miles (10 km). The disabled unit will be difficult to
steer as there is no hydraulic pressure available.
Operation Manual
3. Tow unit.
apply the park brake and turn the ignition key to the OFF position.
1.7.2 Recommended Fire Procedure
WARNING: HAZARD EXISTS WHEN REFUELING AND DEFUELING THE

TRACTOR - NO SMOKING, NO OPEN FLAMES, NO ELECTRICAL DEVICE
OPERATIONS.
Operators should know how to prevent fires and have a basic understanding of fire-fighting tech-
niques. Some common causes of vehicle fires are as follows:
• Operating with low pressure tires.
• Overheated brakes.
• Leaking exhaust system.
• Leaking fuel system.
• Carelessly placed emergency flares or lamps.
• Short circuits in the electrical system
Following are recommended basic steps to perform when a fire occurs. Apply and/or adapt these
procedures in accordance with your company’s/station’s procedures as circumstances warrant.
1. Stop the unit in a safe position away from buildings and other vehicles.
2. Notify the appropriate emergency contacts (as outlined in your company’s/station’s emer-
gency policies and procedures) and inform them what type of fire is burning.
NOTE: Use all extinguishers according to the manufacturer’s instructions.
3. Based on type of fire, take all possible steps to extinguish the fire using the unit’s fire
extinguisher without endangering yourself or others.
4. If the fire is thought to be due to a short-circuit, engage the battery disconnect button.
Operation Manual
1.7.3 Collisions
WARNING: IN A COLLISION, INJURIES, POSSIBLE FUEL LEAKS, OR DAM-

AGE TO THE VEHICLE CAN OCCUR.
Every operator must take precautions to prevent collisions. If a collision occurs, remain calm and
perform the following steps:
1. Refer and adhere to your company’s/station’s emergency policies and procedures.
WARNING: IN CASE OF A FUEL LEAK - NO SMOKING, NO OPEN FLAMES,

NO ELECTRICAL DEVICE OPERATIONS.
2. All engines of units involved in the collision should be turned off.
3. Notify emergency personnel and supervisory personnel as outlined in your company’s/

station’s emergency policies and procedures.
Operation Manual
Section 2: IATA Flightline Safety Guidelines
2.1 IGOM Chapter 4: Aircraft Handling Procedures

This section of the TUG Operators Manual has been created from the IATA ground Operations
Manual (IGOM). This section provides general guidelines for GSE handling, including safety pro-
cedures. The ground support equipment operator must always follow the training and equipment
operating rules of their employer.
2.1.1 Ramp Safety in Aircraft Handling

Ramp safety rules and procedures promote safe ground handling. Therefore, the minimum
safety rules and procedures defined in this section shall always be applied and understood by all
personnel working on the ramp.
Aircraft damage can endanger passengers, employees, and aircraft. Disruptions may also nega-
tively impact safe airline operations.
Even a slight scratch or dent on an aircraft may result in a serious accident. If you observe or
cause any aircraft damage, you MUST report it. Refer to the operating airline’s policy regarding
reporting of aircraft damage.
2.2 General Ramp Safety

2.2.1 Danger Areas
Blast damage or injury from an aircraft engine’s exhaust or intake is very dangerous. The risk is
further increased when an aircraft comes to a stop and then re-applies the additional thrust
required to “break away” and continue taxiing.
Vehicles and personnel must remain clear of aircraft danger areas when aircraft engines are run-
ning and/or the anti-collision lights are on.
In order to prevent incidents and accidents caused by aircraft engines, you must never position
yourself or equipment in the following critical areas before or during aircraft departure and arrival:
• Engine Intake Area
• Engine Blast Area
• Propeller Rotation Area (where applicable)
The length of these areas vary for each aircraft type based on whether the engines
NOTE:
are IDLE or BREAKAWAY thrust.
Refer to each aircraft type specific manual for applicable distances and the Company’s instruc-
tions for guidance. Ground personnel and loose equipment must stay clear of the intake and
blast areas.
Operation Manual
2.2.2 Engine Intake Area

Make sure the engine intake area is clear:
• At arrival, until the engines have been switched off and are spooling down
• At departure or just before pushback
• At all times while engines are running.
• It is forbidden to pass through the blast area while engines are running.
Refer to the operating airline’s Ground Operation Manual (GOM) for distances applicable to the
specific aircraft type involved in the operation.
Sample Engine Danger Area for A330-300 and A330-200 aircraft are shown in Figure Safety - 2 -
1 and Figure Safety - 2 - 2.
Operation Manual
10 ft. (3m)
3.75 ft. (1m)
250 ft. (75m) 30°
Figure Safety - 2 - 1: Idle Power - Engine Intake Area NO Zone
Operation Manual
25 ft. (8m)
8 ft. (2.4m)
500 ft.
(150m) 30°
Figure Safety - 2 - 2: Breakaway Power - Engine Blast Area NO Zone
Operation Manual
2.2.3 Equipment Restraint Area & Equipment Restraint Line

The Equipment Restraint Area (ERA) is defined as the area of the apron bordered by a red line
known as the Equipment Restraint Line, or otherwise indicated, in which an aircraft is parked
during ground operations.
NOTE: If no markings exist, local procedures must establish safe parking areas.
The illustration below provides an example of the markings used in some locations.
Figure Safety - 2 - 3: Equipment Restraint Area
The ERA must be free of obstructions and Foreign Object Debris (FOD) before and during air-
craft arrival and departure.
2.2.3.1 FOD - Foreign Object Debris

Foreign Object Debris (FOD) is a general term which applies to all loose objects which are a dan-
ger to the safety and integrity of an aircraft and must not be left in any area where they would
constitute a hazard.
Operation Manual
Every individual has a responsibility to ensure that the risk of damage to aircraft from FOD is min-
imized. All FOD must be removed and properly disposed when found.
Table Safety-2-1: Examples of FOD
No. Example
1 Metal nuts and bolts

2 Plastic and paper bags
3 Rags
4 Empty oil and hydraulic cans
5 Tools and equipment
Natural objects:
• Rocks
6
• Pebbles
• Wood
Other debris:
7 • Burst ballast bags
• Luggage handles, wheels, and tags
CAUTION: Foreign object debris may be ingested into aircraft engines caus-
ing damage leading to engine failure. This is especially critical if FOD dam-
age occurs in flight, particularly during the take-off phase. In addition,
damage caused by FOD can occur to tires, the undercarriage, control sys-
tems and other parts of the airframe. All such damage could lead to inflight
failures.
2.2.3.2 FOD Checks

The following checks must be conducted prior to any aircraft movement or servicing operation:
Table Safety-2-2: FOD Checks
No. Checks
1 Check apron and stand areas

2 Check ground equipment staging and parking areas in the area of operation
3 Check ground equipment (Including floors of enclosed cabins)
4 Check garbage bin areas for cleanliness and secure covers fitted
5 Make sure anything carried in or on a vehicle is secure
6 Conduct a FOD walk of the aircraft parking stand removing all FOD found
Operation Manual
Table Safety-2-2: FOD Checks (Continued)
No. Checks
7 Pick up and dispose all FOD in designated garbage bins
2.3 Safety Instructions for Operating Motorized Vehicles on Ramp

2.3.1 General Safety Instructions for Ground Support Equipment (GSE)
Follow these procedures when operating GSE on ramp:
CAUTION: Only trained and authorized personnel are allowed to drive or

operate specific GSE.
CAUTION: When operating equipment, check the equipment contact zone

for possible aircraft damage and immediately report any damage found.
Use all safety devices fitted on GSE (e.g. bumpers, handrails, stabilizers, etc.) during aircraft
handling and servicing.
Ensure protective rubber bumpers ARE NOT compressed against the aircraft fuselage.
2.3.2 Basic Operating Requirements for GSE

• Check all GSE involved in aircraft handling at the start of a shift (at least once per day). In
particular the check the parking brake, rubber protective bumpers, 'E' Stops and other
safety systems and all other proximity sensors.
• Perform a vehicle/equipment walk around check prior to its use.
• Apply parking brakes and place the gear selector in the “PARK or “NEUTRAL” position on
all GSE when it is parked or positioned.
• When positioning GSE, maintain clearance between all GSE and the aircraft to allow for
vertical movement of the aircraft during the entire ground handling process to prevent
contact between the aircraft and equipment.
• Do not carry extra personnel during GSE movement without an approved seat - apply the
“no seat-no ride” principle.
• Do not operate vehicles or equipment while using hand-held portable electronic devices.
• After positioning equipment on the aircraft, raise all safety rails on conveyor belts, loaders
and other devices - except where restricted by aircraft type.
• If needed, walk only on the rubberized conveyor belt portion of the conveyor.
• Do not walk on the conveyor while the vehicle or belt are in motion
Operation Manual
• Do not leave any vehicle unattended with its engine running.
• Do not drive GSE with lifting devices in the raised position, except for final positioning of
the GSE onto the aircraft.
• Do not allow any GSE such as tractor, pallet transported, baggage/cargo carts and dollies
to move or be positioned under the aircraft fuselage.
• Do not move any GSE towards the aircraft unless all of the following criteria are met:
a. Aircraft has come to a complete stop;

b. Engines have been switched off and are spooling down;
c. Anti-collision lights are switched off;
d. Wheel chocks are positioned;
e. Ground/Flight Crew communication has been established, and clearance has
been given, if applicable.
NOTE: The above does not apply for ground power units (GPUs).
2.3.3 Belt Loader Aircraft Loading Equipment

The following precautions must be taken when operating a belt loader:
• The boom of the belt loader must never be positioned inside the cargo hold of any air-
craft.
• Position and remove a belt loader in a straight line with the cargo hold door at a 90
degree angle to the aircraft fuselage.
• Make sure the boom is clear of the aircraft or other obstacles before making a turn.
• The rubber bumpers on a conveyor belt loader must NEVER make contact with the air-
craft. The minimum distance to be maintained at all times is 1 in. (2.5 cm) from the fuse-
lage.
• Always raise side handrails as soon as belt loader is positioned. Make sure they do not
touch the aircraft fuselage.
• Specially designed belt loaders (e.g. Ramp Snake or Powerstow) require the equipment
to be positioned inside the cargo hold.
• Do not sit or stand on a conveyor belt while it is in operation (up or down).
Operation Manual
2.3.4 Ground Support Equipment Safety Driving and Parking Inside ERA
Apply the following precautions when driving or parking Ground Support Equipment (GSE) within
the ERA:
• Make a minimum of one complete stop with all motorized vehicles/equipment prior to
entering the ERA.
- Conduct a “Brake Check” or “Safety Stop” by coming to a full and complete stop to
confirm the serviceability of the brake system on the vehicle and to test the apron
surface.
CAUTION: This action MUST be carried out even if there is no Equipment

Restraint Line marked on the apron. This stop must be conducted at a dis-
tance of no less than 15 ft (5 m) from the aircraft.
• Do not drive GSE faster than walking speed.
• Maneuver GSE carefully in order to prevent personnel injury and/or aircraft damage.
CAUTION: When reversing vehicles or equipment with limited rear-view vis-

ibility inside the ERA, make sure you are guided by an agent using standard
IATA signals and/or assisted by means of a rear-view video or mirror.
• Any moving vehicle that is not positioning at the aircraft must stay outside the operational
safety buffer zone.
• Do not drive or park under the aircraft fuselage and/or wing.
• Safety cones are a caution sign for drivers to maintain required safety clearances. Cones
protect parts of the aircraft against collision by GSE.
2.4 Adverse Weather Conditions

Adverse or poor weather conditions may have a negative impact on aircraft handling activities
and ground safety.
2.4.1 Winter or Slippery Apron Conditions

Winter weather brings extra hazards which require awareness and more care on the part of per-
sonnel working on the aprons to prevent accidents.
Plan additional time for all ramp activities and take extra care when walking across
NOTE:
apron surfaces which can be slippery.
Operation Manual
CAUTION: Take extra care when driving, especially approaching the aircraft.
Remember that vehicles require greater distance to stop safely.
CAUTION: Reduce speeds in slippery apron conditions. Adjust all activities

and operations on the ramp to suit conditions.
2.4.2 Thunderstorms
Refer to local airport or operating airline policy. Thunderstorm communication may be imple-
mented in alert phases and the following represents a minimum standard.
WARNING: DO NOT WEAR A HEADSET CONNECTED TO THE AIRCRAFT

DURING A THUNDERSTORM OR IF A WARNING HAS BEEN ISSUED.
WARNING: WHEN LIGHTNING IS PRESENT: DO NOT COMMUNICATE

WITH THE FLIGHT DECK USING A CONNECTED COMMUNICATION HEAD-
SET. IF NECESSARY, COMMUNICATE USING STANDARD HAND SIGNALS
AS SHOWN IN IGOM.
WARNING: DO NOT STAY IN OPEN AREAS, UNDER THE AIRCRAFT

LOADING BRIDGE OR NEAR ANY POLE.
WARNING: STOP ALL GROUND HANDLING OPERATIONS.
2.4.3 High Wind Conditions

High winds pose a great risk of damage and the following minimum precautions should be taken:
• Make sure parking brakes are set on all parked GSE.
2.5 ISO 7000 and 7010 Safety Guidelines

2.5.1 International Decals and Symbols.
TUG Technologies produces Aerospace Ground Support Equipment used all over the world.
Operator safety makes it imperative to avoid language barriers caused by decals written in West-
ern-style English. International Standards ISO 7000 and ISO 7010 (Registered Safety Signs) are
becoming accepted for universal, non-verbal communication.
These guidelines define:
• Safety Signs,
• Mandatory Action Signs,
• Prohibition Signs, and
• Warning Signs using only symbols and colors and no words.
Operation Manual
- Safety Signs are green and square
- Mandatory Action Signs are blue and circular
- Prohibition Signs are a red circle with a red diagonal
- Warning Signs are safety yellow color and triangular
This page is being added to all TUG Service Manuals to aid interpretation of the graphic symbols
being used on TUG Technologies equipment. TUG Technologies strongly suggests using this
information as training material for operators of TUG equipment.
Since ISO 7000 and 7010 are under constant revision, TUG Technologies will maintain this page,
keeping TUG Technologies manuals current as ISO 7000 and ISO 7010 evolve.
As decals become worn or damaged, new decals can easily be ordered by referring
NOTE: to the TUG Part Number written on the damaged decal. The Decal Part Number is
also listed in the Decal Location Guide in the 660 Maintenance Manual.
Operation Manual
T-B7
Figure Safety - 2 - 4: Fasten Seat Belts (White on Blue Background)
T-B8
Figure Safety - 2 - 5: Use Hearing Protection (White on Blue Background)
Operation Manual
TY-64
Figure Safety - 2 - 6: Hot Surface (Yellow Field with Black Border)
MATERIAL DATA SAFETY SHEET INFORMATION

A Material Safety Data Sheet (MSDS) is a written document that outlines information and proce-
dures for handling and working with chemicals
MSDS documents contain
• physical and chemical property information,
• potential hazard information,
• emergency procedures, and
• manufacturer contact information.
MSDS documents are legal documents containing information on the potential effects on your
health from exposure to chemicals. Each MSDS is a nine-section document, dealing with
• toxicity,
• use,
• storage,
• handling, and
• emergency procedures.
It describes the
• possible hazards involved with the product,
• how to use it safely, and
Operation Manual
• what to expect when the safety recommendations are not followed.
• In addition, it explains what to do when accidents occur and how to recognize symptoms
of overexposure.
The MSDS listed within this Service manual apply to all models of the belt loader, it is recom-
mended they be communicated to your company’s Health & Safety Organization for reference in
an emergency
TUG has listed MSDS that are from American Sources. Because MSDS vary from country to
country, it is strongly advised to access the manufacturers web site to obtain the specific MSDS /
SDS / PDS for your country.
Below are hyperlinks that you will find useful.
2.5.2 Links for products:

MSDS for Castrol Heavy Duty Multipurpose ATF:
http://msdspds.castrol.com/msdspds/msdspds.nsf/CastrolResults?Open-
Form&c=USA%20(US)&l=English%20(US)&p=&n=465389&b=All&t=MSDS&autosearch=N
o&autoload=No&siteland=EN&output=Full&spu=Lubricants&unrestrictedmb=No&cols=0
MSDS for Dexron VI ATF
https://mobiloil.com/en/automatic-transmission-fluid/dexron-vi-atf
MSDS for Castrol Universal Tractor Fluid
o&autoload=No&sitelang=EN&output=Full&spu=Lubricants&unrestrictedmb=No&cols=0
MSDS for Castrol Tection Extra 15W-40(CJ-4)
MSDS for Lead Acid Battery Wet, Filled With Acid
http://www.dekabatteries.com/assets/base/a.pdf
MSDS for Windshield Washer Amtifreeze (+32)
http://southwinltd.com/msds-request/
MSDS for Castrol Limited Slip 80W-90
Operation Manual
MSDS for NAPA DOT 3 Brake Fluid
http://s7d9.scene7.com/is/content/GenuinePartsCompany/715873pdf?$PDF$
MSDS for CHEVRON Supreme Prediluted 550/50 Antifreeze Coolant (Contains Bitterant)
https://cglapps.chevron.com/msdspds/MSDSDetailPage.aspx?docDataId=34258&docFor-
mat=PDF
MSDS for Castrol Pyroplex Red EP 2
Link for CASTROL MSDS in different languages
http://msdspds.castrol.com/msdspds/msdspds.nsf/CastrolSearch?Open-
Form&sitelang=EN
Link for CHEVRON MSDS in different languages
https://cglapps.chevron.com/msdspds/MSDSPage.aspx?language=en&coun-
try=&region=EAME
Operation Manual
Operation Mobile Belt Loader Model 660
Operation Manual
Operation
Section 1: System Overview ............................................................................ Operation-1-4
1.1 Safety Precautions.......................................................................................... Operation-1-4
1.2 Purpose of Equipment .................................................................................... Operation-1-4
1.3 General Description ........................................................................................ Operation-1-4
1.4 Major Components.......................................................................................... Operation-1-4
1.4.1 Power Package...................................................................................... Operation-1-4
1.4.2 Engine.................................................................................................... Operation-1-4
1.4.3 Transmission.......................................................................................... Operation-1-5
1.4.4 Drive Shaft ............................................................................................. Operation-1-5
1.4.5 Drive Axle............................................................................................... Operation-1-5
1.4.6 Steer Axle .............................................................................................. Operation-1-5
1.4.7 Brakes.................................................................................................... Operation-1-5
1.4.8 Chassis .................................................................................................. Operation-1-5
1.4.9 Body....................................................................................................... Operation-1-5
1.4.10 Conveyor.............................................................................................. Operation-1-6
1.4.11 Operator’s Compartment ..................................................................... Operation-1-6
1.4.12 Electrical System ................................................................................. Operation-1-7
1.4.13 Hydraulic System ................................................................................. Operation-1-7
Section 2: Operational Procedures ............................................................... Operation-2-11
2.1 Instrument Panel Controls and Indicators..................................................... Operation-2-11
2.1.1 Ford 2.5L.............................................................................................. Operation-2-11
2.1.2 Deutz 2.9L Tier 4F ............................................................................... Operation-2-11
2.1.3 Maneuvering Controls .......................................................................... Operation-2-15
2.1.4 Conveyor Controls ............................................................................... Operation-2-16
2.1.5 Electrical Supply .................................................................................. Operation-2-17
2.1.6 Preliminary Checks .............................................................................. Operation-2-17
2.1.7 Maneuvering Procedures..................................................................... Operation-2-18
2.1.8 Belt Loader Towing Instructions........................................................... Operation-2-21
2.1.9 Conveyor Safety Props ........................................................................ Operation-2-23
2.2 IATA .............................................................................................................. Operation-2-24
2.3 SAE............................................................................................................... Operation-2-24
2.4 ISO EMC Evaluation ..................................................................................... Operation-2-24
2.5 ISO Product Safety Evaluation ..................................................................... Operation-2-25
2.6 Locations of Technical Construction Files .................................................... Operation-2-25
Section 3: Specifications ............................................................................... Operation-3-27
3.1 General Specifications of the 660 ................................................................. Operation-3-28
3.1.1 Dimensions .......................................................................................... Operation-3-28
3.2 Torque Values............................................................................................... Operation-3-28
3.2.1 Metric Fasteners .................................................................................. Operation-3-29
3.2.2 Graded Bolts ........................................................................................ Operation-3-30
3.3 Performance ................................................................................................. Operation-3-31
3.3.1 Specifications....................................................................................... Operation-3-31
3.3.2 Environmental Operating Limits........................................................... Operation-3-32
3.3.3 Environmental Vibration Information.................................................... Operation-3-32
3.3.4 Environmental Sound Information........................................................ Operation-3-32
3.4 Engines ......................................................................................................... Operation-3-36
3.4.1 Gasoline............................................................................................... Operation-3-36
CD397-Oper Operation - 1 - 1
Mobile Belt Loader Model 660 Operation
Operation Manual
3.4.2 Diesel ................................................................................................... Operation-3-36

3.5 Transmission................................................................................................. Operation-3-37
3.5.1 Gear Ratios.......................................................................................... Operation-3-37
3.6 Standard Conveyor Heights and Angles....................................................... Operation-3-38
3.7 Compatible Aircraft ....................................................................................... Operation-3-39
3.8 Fluids ............................................................................................................ Operation-3-43
3.9 Coolant.......................................................................................................... Operation-3-44
3.10 Recommended Spare Parts........................................................................ Operation-3-44
3.11 Safety Features........................................................................................... Operation-3-45
3.11.1 Shifter / Parking Brake Safety............................................................ Operation-3-45
3.11.2 Shifter Guard...................................................................................... Operation-3-45
3.11.3 Neutral Safety Start Switch ................................................................ Operation-3-45
3.11.4 Anti-Restart Ignition Switch................................................................ Operation-3-45
3.11.5 Engine Control Module (ECM) Starter Protection .............................. Operation-3-46
3.11.6 Emergency Stop Switch..................................................................... Operation-3-46
3.11.7 Park Brake ......................................................................................... Operation-3-46
3.11.8 Pilot-Operated Hydraulic Check Valves ............................................. Operation-3-46
3.11.9 Safety Props ...................................................................................... Operation-3-47
3.11.10 Side / Hand Rails ............................................................................. Operation-3-47
3.11.11 Finger Guards .................................................................................. Operation-3-47
3.11.12 Rubber Bumper Roll ........................................................................ Operation-3-47
3.11.13 Steel Hoop Guard (Optional) ........................................................... Operation-3-47
3.11.14 Grit Paper......................................................................................... Operation-3-47
Section 4: Shipping ........................................................................................ Operation-4-47
4.1 Shipping Preparation .................................................................................... Operation-4-47
4.1.1 Fuel Tank Preparation ......................................................................... Operation-4-47
4.1.2 Battery Preparation .............................................................................. Operation-4-47
4.1.3 Pre-shipping Verification ...................................................................... Operation-4-47
4.2 Receiving ...................................................................................................... Operation-4-48
4.2.1 Preparing for Operation ....................................................................... Operation-4-48
Section 5: Storage .......................................................................................... Operation-5-49
5.1 Short Term Storage ...................................................................................... Operation-5-49
5.1.1 Gasoline Engine................................................................................... Operation-5-49
5.1.2 Diesel Engine....................................................................................... Operation-5-51
5.2 Returning the Vehicle to Operation After Short Term Storage...................... Operation-5-52
5.2.1 Tires ..................................................................................................... Operation-5-52
5.2.2 Battery.................................................................................................. Operation-5-52
5.2.3 Engine.................................................................................................. Operation-5-53
5.2.4 Transmission........................................................................................ Operation-5-53
5.3 Long Term Storage ....................................................................................... Operation-5-53
5.3.1 Gasoline Engine................................................................................... Operation-5-53
5.3.3 Tires ..................................................................................................... Operation-5-55
5.3.4 Lubrication ........................................................................................... Operation-5-55
5.3.5 Fluid Levels.......................................................................................... Operation-5-55
5.3.7 Diesel Engine....................................................................................... Operation-5-56
5.3.9 Drive Axle............................................................................................. Operation-5-57
Operation - 1 - 2 CD397-Oper
Operation Manual
5.3.10 Exhaust .............................................................................................. Operation-5-58

5.3.11 Tires ................................................................................................... Operation-5-58
5.3.12 Lubrication ......................................................................................... Operation-5-58
5.3.13 Levels................................................................................................. Operation-5-58
5.3.14 Wheel Bearings.................................................................................. Operation-5-58
5.3.15 Battery................................................................................................ Operation-5-58
5.3.16 Fuel System ....................................................................................... Operation-5-59
5.3.17 Engine Exterior .................................................................................. Operation-5-59
5.3.18 Tagging .............................................................................................. Operation-5-60
5.4 Returning the Vehicle to Operation After Long-Term Storage ...................... Operation-5-60
5.4.1 Tires ..................................................................................................... Operation-5-60
5.4.3 Engine.................................................................................................. Operation-5-60
5.4.5 Drive Axle............................................................................................. Operation-5-61
5.4.6 Pre-Operational Checks....................................................................... Operation-5-61
5.5 Cold Weather Storage .................................................................................. Operation-5-61
5.6 Returning the Vehicle to Operation After Cold Weather Storage.................. Operation-5-61
5.6.1 Refill Fluids .......................................................................................... Operation-5-61
Operation Manual
Section 1: System Overview

This section provides an introduction to the Mobile Belt Loader Model 660. Summary descrip-
tions of the unit are provided including descriptions of the major systems.
1.1 Safety Precautions

All operators and mechanics should refer to the information located in the Safety section, and to
the Warnings, Cautions, and Notes throughout this manual.
1.2 Purpose of Equipment
read and abide by the Safety section.
The TUG Mobile Belt Loader Model 660 is a self-propelled vehicle designed to load and unload
baggage, light freight, and mail into and out of the lower hold of aircraft. The conveyor may also
be used to transfer freight from trucks or between any two points at the same or differing eleva-
tions.
1.3 General Description

Following topics describe the components that make up the Mobile Belt Loader Model 660.
• The power package (engine and drive train),
• The brakes,
• The belt loader portion of this vehicle,
• The operator’s compartment and controls, and
• The hydraulic system.
1.4 Major Components

1.4.1 Power Package
The tractor is equipped with an industrial type engine [4-cylinder Diesel, Gasoline (EFI), Lique-
fied Petroleum Gas (LPG, HD5 grade only), or Compressed Natural Gas (CNG)] with an auto-
matic transmission. The engine is certified by the manufacturer to meet the emissions standards
required by USA law applicable as of the date of manufacture. The gasoline engine is designed
to operate satisfactorily using 87 Octane no-lead fuel, and the diesel engine operates satisfacto-
rily using Ultra Low Sulfur Diesel (ULSD).
1.4.2 Engine
1.4.2.1 Gasoline and LPG - Ford 2.5L
The gasoline engine is a heavy duty, industrial type with a short stroke and exhaust valve rota-
tors.
Operation Manual
1.4.2.2 Diesel - Deutz 2.9L

The diesel engine is a heavy duty, industrial type four cycle with Common Rail Direct Injection
(CRDI).
1.4.3 Transmission
The transmission is a GM 4L70 automatic with abuse protection valve body and torque converter.
1.4.4 Drive Shaft

The tractor’s drive shaft is an automotive type with double universal joints and slip yokes.
1.4.5 Drive Axle

The rear (drive) axle is a Dana Model 60 with full floating axles and drum brakes.
1.4.6 Steer Axle

The front (steer) axle is a Brierton with disc brakes.
1.4.7 Brakes
1.4.7.1 Hydraulic
Hydraulic service brakes are provided on all four wheels. The master cylinder is mounted on the
rear side of the front bumper. Pressure is transmitted to all four brake assemblies by depressing
the brake pedal.
1.4.7.2 Park Brake

A cable-actuated parking brake is provided, and is engaged by the brake lever mounted to the
right of the seat in the operator’s compartment.
1.4.8 Chassis
The 660 Mobile Belt Loader is built on a heavy duty chassis which includes the power package
and running gear. The chassis has a 110 in. (279.4 cm) wheel base, formed steel channel frame
supported by the front and rear axles.
1.4.9 Body
The vehicle's body panels are formed from 3/16in. (0.476 cm) steel and bolted to the chassis.
The front and rear fenders are installed with standard mounting hardware and are independently
replaceable from the center section.
The 3/16 in. (0.476 cm) formed steel body panels are fabricated in 6 sections (3 sections on right
and 3 sections on the left side of vehicle). The front and rear fenders are mounted separately
from the center section and may be replaced independently.
A body panel support structure is integrated in chassis which incorporates the pivot and attaching
points for the front and rear lift frames and the lift cylinders.
Protective rub strips can be attached to the full length of both sides of the vehicle to provide fur-
ther protection for the body panels.
Operation Manual
1.4.10 Conveyor
The conveyor is fabricated from structural shapes and formed steel, and is attached to the chas-
sis through front and rear lifting frames.
The front cylinder, supporting the front lifting frame, raises the conveyor to 170 in. (431.8 cm) on
the Model 660.
The conveyor frame is 34 in. (86.36 cm) wide on 660 and 31.5 in. (80.009 cm) on 663. The con-
veyor belt is 24 in. (60.96 cm) wide on all models and is supported by 2 in. (5.08 cm) diameter
rollers and is hydraulic motor-driven through a roller chain reduction. The front roller is mounted
in a flange block with a screw-adjustable take-up that allows 6 in. (15.24 cm) of adjustment.
Crowder rollers under the support rollers direct the return side of the belt into areas where
required clearances around fixed components is maintained. An inverted angle iron track on the
lower forward section of the conveyor maintains lateral stability through V-shaped rollers
mounted to the front lift frame.
Operator stations for controlling the conveyor belt are located on the left side at each end of the
conveyor. Alternative positions are available as options.
1.4.11 Operator’s Compartment

The operator's compartment contains all the required controls to drive the vehicle and to control
the lifting and lowering of the conveyor.
! . . . . .. .
Steering
ALWAYS
BRING T HE
UNIT TO
PLACE A COMPLETE
THE DIRECTIONAL STOP,
AND APPLY CONTROL
T HE PARK
DISMOUNTING! IN NEUTRAL,
BR AKE
ALW AYS BEFORE
BRAKE!
STOP TRACTOR
NEVER W ITH SERVICE
STOP TRACTOR (FOOT)
BRAKE! WITH PARKING
(HAND)
Wheel Shifter
T Y-59
CAUTION
ALL OPERATORS CAUTIO
EQUIPMENT USING THIS PUT T RAN
N
SHALL: SMISSION
1. BE PROPERLY IN N EUTR
AL AND
TRAINED. PARKIN SET
2. COMPLY G BRAKE
BEFOR E
3. ADHERE WITH OPERATION . OPER ATING
C ONVEYOR
TO ALL SAFETY S MANUAL.
REQUIREM OR SERVICING
ENTS. AIRCRAFT
T-
Y
T-430
BELTLO
ADER OP
DAILY ERATOR'S
CHECKLIST
Bumper
Belt
Conveyer
Emergency Electric Control
3 Horn Stop (E-Stop) Box
4 Driver compartment button (s)
- pedals, components:
- dash panel,
- seat belt.
Parking brake
Anti-slip coating
Headlights
Fuel/State
of charge
Chocks (as applicable)
Battery ( as applicable)
housing
Safety rail
Spot light
Tires (if applicable)
AV U nder the
vehicle for
leaks
When any
becom es piece of ground
inoperable: equipm ent
1. Remove
not use untilthe equipm ent
the repairs from service
have been and
made. do
Turn
2. Notify a
ram p supervisor.
T-W40
LFUR
L OW-SUONLY A56 D
T-
ULTRA FUEL
DIESEL AR
Signal Parking
Brake
Instrument . . . . . ..
. . .. .
. . . .. .
. . . . .. . . . . . . . . .. . ..
.
. . . . . . . . .. . .. .
. . . ... . .
. .. . .
. . .. .
Panel
. . . .. . . .. . . . . .. ..
. .. . .. . ... . . . .. .
. . .. .. . . .. . . .
.. . .
. .. . . . . . .
. .. . .. . . .
. . .. . . .
T-B8 . .. . . .
. . . .. . . .. . . . .. . . .
. .. . . . . . . .. . . .
. . . . .. . .
. . . . . .. . .. . . . .. . . . .
. . . .. .
. . . . . .. .
. . . . . .. .. . .
. . .. . . . ..
. . . .. . . .. . .. .
. .. .. . . . .. . . . . . . . . .. . . . ..
. .. . . . . .. .
.. . .. . . . . . .. . .
.. . . . ... . .. . . ... .. . .. .. .. .
.. . . .. . . .
. . . ... .
. .. . .. .
. . . .. . . .
.. . .
. .
. . . .. .. . ..
T-B7
Code
Switch MAL
T6- 4700-
NOR 076
READ 2
CODE CH66 0-1- 298
SWIT
Foot
Throttle
. .
. . ..
... .
.. .. . .. .
. .. . .
. .. .. . .. .
. .. .. . . ..
.. . . . .. . .. . . .. ..
.. . .. . . .. .. .
.. . . .. . .. . .
.. . .. . . .. . . . ..
.
. . .
. .... .. . .. .
.. . . . . .. .. . . .
.. .
. .. .. . . . ..
.. . . . .
. .. . .. . . .. . . .
. .... . .. . .. .
. .. .. .. . . .
... . . . . .. ...
.. . . . . .. .. .
... . .. . ..
. . ... . .. . .. .
. .. ..
. .. . . .. FRON
.. .
.. . . .
T REA
.. . .
.. .
. ..
. .. ..
. . ..
.. ..
... ..
.
. . ..
. . ..
. ..
C ON VEYORR
CONTROL
UP
WARNING
. . . .. . . .
... . Hydraulic
. . . . . . . .. .
.. .
... fluids under
.. . can cause
. .. .
. .. ..
. . ..
... injury. Keeppressure
. .. . . .. away from hands
.. . . . ... .. leaks.
.
.. .
.. . . .. .
..
. .. . under pressure Hydraulic fluid
. . ... . .. can penetrate
... .. . . . skin through
.. . . ..
. . . .. . . Do not gloves or
. .. .. . attempt to clothing.
.. . . . .. ..
.. . . . .. with hands. look for
.. . . .. . ... DOW leaks
... . .
. ...
. .. . . 85 N T-
.. . . . . .. 11 -4
. .. T6 -90 A1
MJ-1E
.. . NO.:
. . . PART
5
Brake T-S2
Pedal
Front
Cylinder
Control
Rear
Cylinder
Control
Figure Operation - 1 - 1: Operator’s Compartment
Operation Manual
Engine controls are mounted in the operator’s compartment instrument panel and include hour
meter, ignition switch, and light switches.
1.4.12 Electrical System

Electrical power is supplied by an alternator, belt-driven, mounted on the side of the engine. The
system is a 12-volt, direct current system with negative ground.
All operating circuits are wired through the ignition switch and are protected by circuit breakers.
1.4.13 Hydraulic System

1.4.13.1 General Hydraulics Operation
The hydraulic schematic (see the Maintenance Manual) represents an open center system that
supplies power to raise and lower the conveyor and to drive the conveyor belt.
Hydraulic power is supplied by a hydraulic pump, belt- or gear-driven, mounted on the engine.
The pump supplies 9 gpm (34.08 lpm) at 1500 rpm to raise and lower the conveyor and to drive
the conveyor belt.
Both lift cylinders are locked in any position by holding valves.The orbital motor has incorporated
a counterbalance and cushion valve in the circuit.
All hydraulic hose connections are Gates brand Mega Crimp. Mega Crimp connectors join the
reinforcing wire inside the hose. This is more reliable than the grip on the rubber of the hose.
Mega Crimp connections are plated to resist damage from corrosion. The Mega Crimp connec-
tions are rated at 3000 psi (US) (20.68 MPa or 204.14 atm) working pressure. All hydraulic hoses
are Gates brand Mega 3000 rated for 3250 psi (22.41 MPa or 221.15 atm) working pressure. All
pipes are constructed from Benteler hydraulic piping rated for 3000 PSI (20.68 MPa 204.14 atm)
working pressure.
Hydraulic fluid is drawn from the hydraulic oil reservoir to the hydraulic pump at a rate of six gals
(22.71 l) to ten gals (37.85 l) per minute into a pipe manifold. From the pump, fluid is directed to a
pressure-compensated flow divider valve in the valve manifold, located under the driver’s seat.
The pressure-compensated flow divider valve separates the hydraulic system into a steering and
braking section and a lift cylinder and conveyor motor section.
1.4.13.2 Steer and Braking

The pressure-compensated flow divider valve provides a constant 2 gpm (7.57 lpm) of oil flow to
the Steering / Braking portion of the hydraulic system. Hydraulic fluid pressure for the steering
and braking section is limited by a pressure relief valve, set at 1000 psi (6.9 MPa or 68.05 atm),
in the hydraulic manifold. Hydraulic oil then flows to the hydraulic brake system assist valve via
port, then to the hydraulic steering motor.
Fluid from the hydraulic brake system assist valve and the hydraulic steering motor return to the
manifold. This fluid then exits the manifold. Fluid passes through the return line hydraulic filter
before returning to the hydraulic oil reservoir.
When the brake pedal is depressed, pressurized hydraulic fluid enters the hydraulic brake sys-
tem assist valve and exerts pressure on a spring loaded check valve, closing the hydraulic fluid
Operation Manual
line that returns oil to the hydraulic oil reservoir through ports on the valve manifold assembly.
When the brake pedal is released, pressure is reduced and the spring loaded check valve opens,
allowing hydraulic fluid to return to the hydraulic oil reservoir through ports on the valve manifold
assembly and the return line hydraulic filter.
Hydraulic fluid also flows to the hydraulic steering motor which controls the hydraulic steer cylin-
der.
When the steering wheel position is altered, pressurized hydraulic fluid enters the steering valve
through port. Depending on the direction of steering input, flow is diverted through ports to the
appropriate side of the steer cylinder through hydraulic lines. Flow out of the steering cylinder
and excess flow coming in through port returns to the manifold via ports. This fluid then exits the
manifold via port. Fluid passes through the return line hydraulic filter before returning to the
hydraulic oil reservoir.
1.4.13.3 Lift Cylinders and Conveyor Motor

Pressurized hydraulic oil not being used by the steering/braking systems bypasses the flow
divider valve and then flows into an adjustable relief valve that allows hydraulic fluid to return to
the hydraulic oil reservoir through port on the valve manifold assembly and the return line
hydraulic filter.
When the two manual levers for the front and back lift cylinders or the motor driven directional
valve are activated, the upstream adjustable relief valve closes at the set pressure of 1500 psi
(10.34 MPa or 102.07 atm).
The adjustable relief valve, located downstream of the front lift cylinder, closes at the set pres-
sure of 900 psi (6.2 MPa or 62.24 atm), keeping the front cylinder from applying excessive down-
wards force.
The two manual levers control the front and rear lift cylinders and the motor driven directional
valve controls the conveyor hydraulic motor / CBV assembly.
When a manual lever is actuated, the lever mechanically shifts the spool valve position, porting
fluid to that side of the lift cylinder to be pressurized. Spool Valve movement also opens a chan-
nel for the non-pressurized portion of the lift cylinder piston to allow unpressurized oil to return to
the hydraulic oil reservoir through port on the valve manifold assembly and the return line
hydraulic filter.
Likewise, when the conveyor motor control valve is actuated in either direction, its electric sole-
noid shifts the spool valve position, porting fluid to the forward or reverse side of the conveyor
motor/CBV assembly. Spool valve movement also opens a channel for the non-pressurized por-
tion of the conveyor motor/CBV assembly to allow unpressurized oil to return to the hydraulic oil
reservoir through port on the valve manifold assembly and the return line hydraulic filter.
With the manual control levers in their neutral state, the front and rear cylinders are locked in the
current position by load holding valves, located on their respective cylinders.
Operation Manual
DC Emergency Pump
In the case of Main Hydraulic Pump failure, the DC-operated Emergency Pump is available for
the temporary activation of the Hydraulic Lift Cylinders and the Conveyor Motor. The emergency
pump cannot operate the steering and braking system.
The 660 belt loader is equipped with an electrically operated emergency hydraulic pump to allow
short term operation of the hydraulic system for raising or lowering the conveyor, in the event of
an engine failure. The hydraulic pump relies on the 12 volt starter battery for energy.
CAUTION: The emergency hydraulic pump should only be operated when

the regular propulsion engine is OFF or NOT operating.
The purpose of the emergency hydraulic pump is to enable lowering of the conveyor into its nor-
mal down position, or to retrieve luggage that may be on the belt at the time of engine failure. It
may also be used to gain access to the engine compartment if the conveyor is in the down posi-
tion.
CAUTION: Use the safety props to support the conveyor at all times when
performing maintenance under the conveyor.
The emergency hydraulic pump is not to be used to load or unload luggage to or from the hold of
the plane at any time.
The emergency hydraulic pump is activated by a button on the instrument panel that is labeled
“Emergency Hydraulic Pump”. Pressing the button down activates the pump, releasing the button
stops the operation of the pump, thus all the time hydraulic power is required during emergency
conditions the button should be depressed.
There is an electrical safety circuit for the emergency pump, located next to the
hydraulic tank, it will trip if the current drawn from the battery to operate the emer-
NOTE:
gency pump exceeds preset limits. It may be reset by pressing down the red but-
ton marked 105.
The Emergency Hydraulic Pump should be tested daily before equipment use, any concerns
about its operation should be reported to the crew supervisor.
Operation Manual
Operation Manual
Section 2: Operational Procedures
2.1 Instrument Panel Controls and Indicators

2.1.1 Ford 2.5L
Table Operation-2-1, “Instrument Panel Description - Ford 2.5L,” lists the controls, indicators,
and equipment found on the instrument panel for the 660 belt loader with the Ford 2.5L gasoline
engine, and explains the specific function of each. Reference Table Operation - 2 - 1, “Instrument
Panel - Ford 2.5L,” for the location of the items listed.
2.1.2 Deutz 2.9L Tier 4F

“Figure Operation - 2 - 2” lists the controls, indicators, and equipment found on the instrument
panel for the 660 Belt loader with the Deutz Tier 4F engine, and explains the specific function of
each. Reference Table Operation-2-2, “Instrument Panel Description - Deutz 2.9L,” for a descrip-
tion of the items shown.
Operation Manual
6
5
4
3
9
2
1
10 13
11 14
12
Figure Operation - 2 - 1 Instrument Panel - Ford 2.5L
Table Operation-2-1 Instrument Panel Description - Ford 2.5L
No. Name Description

1 Ignition Switch Turn this switch to start or turn off the engine.
2 Warning Light (Green) This light will not illuminate if an e-stop on the vehi-
cle is activated.
3 Spot Light Switch (Optional) This switch turns the spotlight on. Press down for
off, or up for on.
4 Warning Code Light (Red) This light illuminates briefly during engine start and
when an engine fault occurs.
5 Hour Meter This gauge displays the number of operation hours
on the tractor.
6 Fuel Select Toggle Switch This switch controls the dual fuel operation. Select
(Optional) LP or gasoline as the engine fuel source.
Operation Manual
Table Operation-2-1 Instrument Panel Description - Ford 2.5L (Continued)

7 Conveyor Hand Throttle This knob controls the engine speed only while the
unit is in neutral and the parking brake is applied.
Turn the knob counterclockwise and the engine will
speed up. Depress the hand throttle knob and the
engine will return to idle.
8 Morse Shifter This is the main drive control for forward or reverse
direction. The shifter is labeled: F=Forward,
R=Reverse, and N=Neutral.
9 Code Toggle Switch Press this switch to read fault codes via the diagnos-
tic lamp.
10 Brake Warning Light (Red) This light illuminates if the brake system pressure
falls below a preset level.
11 Emergency Steering Switch This switch activates the emergency steering pump.
Press and hold the switch to start the pump, or
release the switch to stop the pump. The emergency
steering pump activates only if hydraulic pressure is
low.
12 Head Light Switch This switch turns the tractor’s headlights on or off.
Pressing down turns lights off and pressing up turns
lights on.
13 Ignition Switch (Optional This switch starts or turns off the tractor's engine.
Location)
14 Left Front Headlight Cover This cover is installed below the dash and conceals
the tractor's wiring harnesses.
Operation Manual
8 9 10 11 12 13
6
1
4 3
2
Figure Operation - 2 - 2 Instrument Panel - Deutz 2.9L
Table Operation-2-2 Instrument Panel Description - Deutz 2.9L

1 Shifter This is the main drive control for forward or
reverse direction. The shifter is labeled:
F=Foward, R=Reverse, and N=Neutral.
2 Converter Speed Control These buttons control the engine speed only
while the belt loader is in neutral and the parking
brake is applied. Press the button closest to the
UP arrow: engine RPMs and belt speed
increases. Press the DOWN arrow: engine
RPMs and belt speed decreases.
3 Hearing Protection Decal Always wear hearing protection.
4 Ignition Switch Turn this switch to start or turn off the engine.
5 Headlight Switch This switch turns the headlights on or off. Flip
switch up to turn lights ON and down to turn
lights OFF.
6 Warning Light This warning light illuminates when headlights
are on.
Operation Manual
Table Operation-2-2 Instrument Panel Description - Deutz 2.9L (Continued)

7 Deutz Cold Start Wait Light When the ignition switch is turned on, this light
illuminates. When the light goes out, it shows
that the glow plugs are heated and the vehicle
can be started.
8 Emergency Stop Switch Press the switch down to shut the engine off.
The switch must be rotated clockwise and pulled
out to allow the engine to restart.
9 Warning Light Optional warning light.
10 Emergency Lift Pump Switch Press this button for emergency hydraulic pres-
sure to the conveyor.
11 Warning Light Optional warning light.
12 Murphy CAN Display Information displayed is provided by the ECM
and may include:
• Engine Speed
• Engine Torque
• Coolant Temperature
• Intake Air Temperature
• Exhaust Gas Temperature
• Oil Pressure
• Coolant Pressure
• Fuel Level
• Battery Voltage
• Total Operating Hours
• Error Messages
13 Fasten Seat Belt Decal Always fasten seat belt before operating the
Mobile Belt Loader Model 660.
2.1.3 Maneuvering Controls

1. Steering Wheel
2. Brake Pedal
3. Foot Throttle
4. Turn Signal
5. Shifter
Operation Manual
Steering
ALWAYS
BRING THE
PLACE UNIT TO
A COMPLETE
THE DIRECTION
AND APPLY AL CON STOP,
DISMOUNT THE PARK BR TROL IN NEUT
AKE BEFORE RAL,
ALWAYS ING!
BRAKE!
STOP TRACTOR
N EVER WITH SERVICE
(FOOT)
STOP TRACTOR
BRAKE! WITH PARKING
( HAN D)
Wheel Shifter
T Y-59
CAUTION
ALL OPERATO CAUT ION
EQUIPME RS USING
NT SHALL: THIS PUT TRAN
SMISSION
1. BE PROPER IN N EUTR
AL AN D SET
2. COMPLY LY TRAINED. PAR KING
BRAKE BEFORE
WITH OPERAT . OPER ATING
3. ADHERE I ONS MANUAL. C ONVEYOR
TO ALL SAFETY OR SER
REQUIRE VIC ING AIR
MENTS. CRAFT T-
Y
T-430
BELTLO
ADER OPERAT
DAILY O R'S
CHECK
Bumper
LIST
Belt
Conveyer
Emer gencyElectric Control
3 Horn Stop (E-Stop) Box
4 button
Driver compartmen (s)
- pedals, t components
- dash panel, :
- seat belt.
Parki ng brake
Anti-slip
coating
Headlights
Fuel/State
Chocks of char ge
(as applicab
Battery ( as applicable) le)
housing
Safet y rail
Spot light
Tires (if applicable)
AV Under the
vehicle for
lea ks
When any
becomes piece of ground
inoperable: equipm ent
1. Remove
not u se untilthe equipment
the repairs from service
have been and
made. do
Turn
2. Notify
a ramp supervisor
.
T-W40
R
-S ULFU
A LOW ONLY D
T-A56
ULTR L FUEL
DIESE AR
Signal Parking
Brake
T-B
8
T-B7
00-
MAL
T6-47
NOR 076
D
E REA
COD ITCH660-1-2982
SW
Foot
Throttle
FRON
T REA
C ONVEYORR
CONTROL
UP
WARN ING
Hydrauli c
fluids under
can cause
injury. Keeppressur e
away from hands
leaks.
under pressure Hydraulic fluid
skin through can penetra
gloves or te
Do not clothing
attempt to
DOW with hands. look for leaks.
5 N T-
11-48 A1
T6-90 MJ-1E
NO.: 5
PART
Brake T-S2
Pedal
Front
Cylinder
Control
Rear
Cylinder
Control
Figure Operation - 2 - 3 Maneuvering and Conveyor Controls
2.1.4 Conveyor Controls

Conveyor height controls in the operator’s compartment (located below driver’s seat) are limited
to:
1. Front Cylinder: Raises / lowers front of conveyor. See Figure Operation - 2 - 3
2. Rear cylinder: Raises / lowers back of conveyor. See Figure Operation - 2 - 3
Operation Manual
Electrical belt drive controls may be located at any combination of the conveyor's four corners.
On the Ford 2.5L, the conveyor hand throttle controls engine speed while in neutral. Turn the
knob counterclockwise and the engine will speed up. Depress the hand throttle knob and the
engine will return to idle.
On the Duetz, the conveyor speed control is located on the instrument panel. Push buttons con-
trol the conveyor speed (see callout #2 on Figure Operation - 2 - 2), while in neutral. Push the
button with the arrow pointing up to increase engine speed or push the button with the arrow
pointing down to return to idle.
Conveyor
Belt Drive
Controls
Figure Operation - 2 - 4 Conveyor Controls
Control relays for the electrical conveyor belt drive solenoid control valves are located on the
conveyor frame.
2.1.5 Electrical Supply

The main electrical supply panel is located
• Ford: below the instrument panel

• Deutz: in the battery compartment.
See the electrical schematics in the Maintenance Manual for description of electri-
NOTE:
cal components.
2.1.6 Preliminary Checks

Procedures for preliminary checks before maneuvering the vehicle to an aircraft shall include (but
may not be limited to) the following items:
Operation Manual
1. Fuel Level
2. Tire Inflation
3. Engine Oil Level
4. Transmission Oil Level
5. Seatbelt Serviceability
6. Service Brake Effectiveness
7. Parking Brake Effectiveness
8. Vehicle Drive Forward
9. Vehicle Drive Reverse
10. Check the hydraulic fluid level with the conveyor down
11. Conveyor Belt Drives in Forward direction
12. Conveyor Belt Drives in Reverse direction
13. Front Cylinder Extension: Raises front of conveyor
14. Front Cylinder Retraction: Lowers front of conveyor
15. Rear Cylinder Extension: Raises back of conveyor
16. Rear Cylinder Retraction: Lowers back of conveyor
17. Verify all "E" Stops function correctly
2.1.7 Maneuvering Procedures

Procedures for maneuvering the vehicle to an aircraft are outlined below:
WARNING: OBSERVE ALL SAFETY PRECAUTIONS DISCUSSED IN THE

SAFETY SECTION OF THIS MANUAL.
2.1.7.1 Engine Start Procedure (Gas)

1. Apply parking brake.
2. Move transmission selector to Neutral. (Starter motor will not activate unless selector is in
Neutral).
Operation Manual
3. Move ignition switch to “Start”.
4. Allow ignition switch to return to “On” upon engine start.
NOTE: Switch must be returned to “Off” (reset) before it can be moved to start again.
2.1.7.2 Engine Start (Diesel)

2. Move transmission selector to Neutral. (Starter motor will not activate unless selector is in
Neutral).
3. Move ignition switch to “Start”.
4. Wait for “Wait-to-Start” light to go out.
5. Allow ignition switch to return to “On” upon engine start.
NOTE: Switch must be returned to “Off” (reset) before it can be moved to start again.
2.1.7.3 Release parking brake.

The parking brake is a cable-actuated type attached to the brake shoes in the rear axle.
The parking brake is located to the right of the driver’s seat in the driver’s compart-
NOTE:
ment. See Figure Operation - 2 - 3.
1. To apply parking brake, pull up.
2. To release parking brake, push down.
2.1.7.4 Transmission Drive (FWD/REV) Selection.

A Morse control is connected to the transmission shift lever through a flexible push/pull cable.
To select a vehicle drive direction in a USA configured belt loader:
1. Move transmission drive selector lever up (toward instrument panel) to select reverse
drive direction.
2. Move transmission drive selector lever down (toward driver’s seat) to select forward drive
direction.
3. Neutral is located midway between forward and reverse and is indicated by a positive
stop notch into which the spring loaded lever will fall when shifting.
Operation Manual
4. Select transmission drive (FWD/REV)
To select a vehicle drive direction in a CE configured belt loader:
1. Move transmission drive selector lever up (toward instrument panel) to select forward
drive direction.
2. Move transmission drive selector lever down (toward driver’s seat) to select reverse drive
direction.
3. Neutral is located midway between forward and reverse and is indicated by a positive
stop notch into which the spring loaded lever will fall when shifting.
4. Select transmission drive (FWD/REV)..
This transmission is equipped with Abuse Protection Valve Body. To shift into
Reverse (R) or Drive (D), all three of the following conditions must be met:
1. Throttle position must be less than 25%.
2. Engine RPM must be less than 1500 RPM.

NOTE:
3. Vehicle speed must be 0 MPH.
If any of the above conditions are not met, the transmission will be placed into a
neutral state until all three conditions are met. This neutral state may slightly drag
the forward or reverse clutch, moving the vehicle very slowly and give the impres-
sion that the transmission is slipping. To fully engage the desired gear, simply come
to a complete stop with the engine at idle.
2.1.7.5 Depress foot throttle.

The foot throttle is a conventional automobile accelerator connected to the ECM by electrical
connection.
• To increase speed, depress foot throttle.
• To decrease speed, release foot throttle.
2.1.7.6 Maneuver vehicle with steering wheel.

The steering system is a hydrostatic type powered from the belt-driven hydraulic pump.
• To turn left, rotate the steering wheel counterclockwise.
• To turn right, rotate the steering wheel clockwise.
Operation Manual
2.1.7.7 Maneuvering the baggage loader around the aircraft

1. Approach the aircraft to a distance of two or three feet.
2. Move transmission selector to Neutral.
4. Raise the front and rear of the conveyor to the correct heights for the aircraft.
5. Release the parking brake
6. Move transmission selector to FWD and slowly approach the cargo door opening
7. When in the correct position, move the transmission selector to Neutral.
8. Apply the parking brake.
9. Make final height adjustments.
10. When baggage loading is complete, reverse the above steps.
2.1.8 Belt Loader Towing Instructions

Occasionally, due to a mechanical failure, a TUG Belt Loader may require towing for some dis-
tance. If at all possible, the Belt Loader should be moved with a suitable tow truck or on a flat bed
tow truck. If this is not practical, the Belt Loader can be towed with all four wheels on the ground.
In this situation, extreme diligence is required.
CAUTION: Do not tow the Belt Loader if it has experienced a hydraulic fail-
ure as the unit may not be steerable! The maximum tow distance with the
driveshaft installed is 1 mile at a speed of no more than 5 mph. If the
required towing distance is more than 1 mile, the driveshaft must be
removed from the Belt Loader to avoid transmission damage. The maxi-
mum towing speed without the driveshaft is 5 mph.
2.1.8.1 Towing Requirements
WARNING: FAILURE TO USE PROPER TOWING GEAR CAN CAUSE SERI-

OUS INJURY OR DEATH.
Operation Manual
CAUTION: Do not tow the Belt Loader unless absolutely necessary.
CAUTION: Do not allow the Belt Loader to be pushed by other equipment.
CAUTION: Verify the steering system operates properly. The steering

wheel should turn the front wheels of the vehicle. Steering effort will be
greater than normal, but should be possible. If the Belt Loader cannot be
steered, do not tow the Belt Loader.
CAUTION: Use a properly sized tow vehicle for the vehicle being towed
and the conditions present. Connect the other end of the tow straps to an
appropriate location on the towing vehicle.
CAUTION: Tow only with suitably sized tow straps rated for the weight of
the Belt Loader (7,200 lbs or 3265.9 kg).
1. Connect the tow straps to the D-rings located under the front bumper. The D-rings should
be marked with decals labeled TOW.
2. Put the transmission in Neutral.
3. While applying the foot brake, release the parking brake using the parking brake handle.
4. Tow only as fast as the conditions allow, but no faster than 5 mph (8.05 kph).
5. Tow only the minimum distance required to get the belt loader to a safe location for
repairs.
6. Once the tow is complete, reapply the parking brake and chock the wheels of the belt
loader.
7. Disconnect the tow straps and make repairs prior to returning the belt loader to service.
Operation Manual
2.1.9 Conveyor Safety Props
WARNING: ALWAYS USE THE SAFETY PROPS WHEN WORKING UNDER

THE CONVEYOR.
Rear Safety
Props
Front Safety
Props
Figure Operation - 2 - 5 Belt Loader with Props Engaged
1. The safety props are provided to support the front and rear of the conveyor for mainte-
nance, checking oil, etc.
2. To engage the safety props:
• raise the front or rear of the conveyor to a height that permits the safety prop to be
rotated to the “UP” position.
• Raise the safety prop to the “UP” position.
Operation Manual
• Slowly let the conveyor down until the safety prop aligns with sockets on bottom of the lift
arm.
CAUTION: Make sure the safety prop is fully engaged inside sockets
before working under the conveyor.
CAUTION: Lower the conveyor GENTLY onto yellow safety props or struc-
tural failure may result.
2.2 IATA
The following are IATA standards that TUG follows when designing GSE.
• AHM 913: Basic Requirements for Aircraft Ground Support Equipment

• AHM 914: Compatibility of Ground Support Equipment for Aircraft Types
• AHM 915: Standard Controls
• AHM 925: Functional Specification for Self-Propelled Conveyor-Belt Loader
• IATA: Ground Operations Manual (Effective April 2013)
2.3 SAE
The following are SAE standards that TUG follows when designing GSE.
• AIR 1336A: Vehicle Electrical Systems

• AIR 1375C: Minimum Safety Requirements for Special Purpose Airline Ground Support
Equipment
• AIR 4286: Maintenance of Ground Support Equipment
• AIR 4905: Wheel Chocks
• ARP1247D: Aircraft Ground Support equipment - General Requirements
• ARP1287A: SAE Standards for Use in the Design of Aerospace, Vehicular Ground
Equipment
• AS4828A: Technical Manual requirements for Ground Support Equipment
2.4 ISO EMC Evaluation

The following are ISO EMC Evaluation standards that TUG follows when designing GSE.
• EN 12895: Industrial Trucks Electromagnetic Compatibility

• EN 55011: Radiated Emission
• EN 61000-4-3: Radiated Immunity
• EN 61000 -4-2: ESD Immunity
• EN 12100: Safety of machinery General principles for design
• EN 4413: Hydraulic fluid power General rules and safety requirements
• EN 4413: Hydraulic fluid power General rules and safety requirements
• EN 13849-1: Safety of machinery Safety related parts of control systems
• EN 60204-1: Safety of machinery Electrical equipment of machines
• EN 62061-1: Safety of machines Functional safety of safety related electrical, electronic,
and programmable electronic control systems
• EN 60259: Degrees of protection provided by enclosures
Operation Manual
• EN 12312-3: Aircraft ground support equipment Part 3 Conveyor Belt Vehicle

• EN 1915-1: Aircraft ground support equipment - Part 1 Basic safety requirements
• EN 1915-2: Aircraft ground support equipment - Part 2 Stability and strength requirements
• EN 1915-3: Aircraft ground support equipment - Part 3 Vibration measurement
• EN 1915-4: Aircraft ground support equipment - Part 4 Noise measurement
• EN 1915-4: Safety of machinery Sound level test
2.5 ISO Product Safety Evaluation

The following are ISO Product Safety standards that TUG follows when designing GSE.
• EN 12100: Safety of machinery: general principles for design. Risk assessment and risk
reduction
• EN 4413: Hydraulic fluid power: General rules and safety requirements for systems and
their components
• EN 13849-1: Safety of machinery: Safety related parts of control systems Part 1 General
principles of design
• EN 60204-1: Safety of machinery: Electrical equipment of machines
• EN 62061: Safety of machinery: Functional safety of safety related electrical, electronic
and programmable electronic control systems
• EN 60259: Degrees of protection provided by enclosures EN 12312-3 -Aircraft ground
support equipment - specific requirements - Part 3: conveyor belt vehicle
2.6 Locations of Technical Construction Files

The Technical Construction Files are in two places:
1. F2 Labs, Ohio, USA (CE Certifying Body)
2. TUG Technologies Corporation, Kennesaw, GA, USA
The Technical File at TUG will be made available at our premises if requested.
Operation Manual
Operation Manual
Section 3: Specifications
This section contains information about the specifications for the Mobile Belt Loader Model 660.
3.1 General Specifications of the 660

3.1.1 Dimensions
Table Operation-3-1: Dimensions and Measurements
Dimension Measurement
Length 300 in (762 cm)
Width (excluding side bumpers) 78 in (198.1 cm)
Height 59 in (149.9 cm)
Ground Clearance 7.5 in. (19.05 cm)
Wheel Base 110 in (279.4 cm)
Conveyor Length (less front bumper) 294 in (746.7 cm)
Conveyor Width (less side rails) - Standard Width 34 in (86.4 cm)
Conveyor Width (less side rails) - Narrow Width 31.5 in (80 cm)
Belt Width 24 in (61 cm)
Gross Vehicle Weight with Cab 7,200 lb (3266 kg)
Gross Vehicle Weight without Cab 7,000 lb (3175 kg)
Operation Manual
3.2 Torque Values

Metric capscrews and nuts are identified by the grade number stamped on the head of the cap-
screw or surface of a nut; while Standard capscrews are identified by a series of lines:
• Grade 5: three (3) lines
• Grade 8: six (6) lines

Metric Capscrew Standard Capscrew
8.8
Figure Operation - 3 - 1: Capscrew Examples

The following torque tables apply to graded metric and standard fasteners used on the Model
660. The listed values apply to bolts threaded into either nuts or tapped holes in iron or steel.
These torque values are not a replacement for torque values specified elsewhere in this manual.
3.2.1 Metric Fasteners

Table Operation-3-2: Torque Values for Metric Fasteners
Nominal
Pitch Class 8.8 Class 10.9 Class 12.9
Diameter
(mm) (Nm) (Nm) (Nm)
(mm)
4 0.7 2.576 3.661 4.339
5 0.8 5.288 7.457 8.813
6 1 8.948 12.745 14.914
7 1 14.914 21.422 24.947
8 1.25 21.693 31.048 36.200
10 1.5 42.844 61.283 71.723
12 1.75 74.706 106.974 125.006
14 2 119.448 170.969 199.848
16 2 185.747 265.740 310.482
18 2.5 256.250 366.070 428.438
20 2.5 362.003 517.922 604.695
22 2.5 493.518 706.381 825.693
24 3 625.032 894.840 1045.336
Operation Manual
Table Operation-3-2: Torque Values for Metric Fasteners (Continued)
Nominal
Pitch Class 8.8 Class 10.9 Class 12.9
Diameter
(mm) (Nm) (Nm) (Nm)
(mm)
27 3 916.533 1312.432 1533.430
30 3.5 1243.285 1778.833 2079.825
33 3.5 1692.060 2421.491 2829.592
36 4 2173.376 3110.246 3634.948
NOTE: The listed torque values are based on the use of zinc plated, dry threads (or as
received for the 12.9).
3.2.2 Graded Bolts

Table Operation-3-3: Torque Values for Graded Bolts
Nominal Threads SAE J429 Grade 5 SAE J429 Grade 8

Diameter (in.) per Inch (ft-lbs) (ft-lbs)
Unified Coarse Thread Series
1/4 20 7.2 10
5/16 18 15 21
3/8 16 26 37
7/16 14 42 59
1/2 13 64 90
9/16 12 92 130
5/8 11 128 180
3/4 10 227 320
7/8 9 365 515
1 8 547 772
1 1/4 7 952 1545
1 1/2 6 1657 2688
Fine Thread Series
1/4 28 8.3 12
5/16 24 16 23
Operation Manual
Table Operation-3-3: Torque Values for Graded Bolts (Continued)
Nominal Threads SAE J429 Grade 5 SAE J429 Grade 8

Diameter (in.) per Inch (ft-lbs) (ft-lbs)
3/8 24 30 42
7/16 20 47 66
1/2 20 72 102
9/16 18 103 146
5/8 18 144 204
3/4 16 253 357
7/8 14 403 568
1 14 614 867
1 1/4 12 1055 1710
1 1/2 12 1865 3024
NOTE: The listed torque values are based on the use of zinc plated, dry threads.
Operation Manual
3.3 Performance
Table Operation-3-4: Performance Data
Unit Performance
660 Top Speed 25 mph (43 kph)
Conveyor Capacity (to 15° angle) 2000 lb (907 kg)
Maximum Conveyor Load 2000 lb (907 kg)
Maximum Conveyor Load 200 lb per ft2
(976.4 kg per m2)
Belt Control Electric
Conveyor Belts Speeds 45 to 90 ft/min (14 to 27 m/min)
Turning Radius 27 ft, measured to the outside front wheel (8.2 m)
Aircraft Capability Will service aircraft with door sills height from 40 to
170 in (101 to 431 cm)
3.3.1 Specifications
Table Operation-3-5: Specification Data
Item Specification
Battery 12 Volt
Ground Negative
Fuel Tank Capacity 15 gal (US) (56.78 l)
Hydraulic Reserve Capacity 10 gal (US) (37.81 l)
Hydraulic Hose Rating 3000 psi (US) (22.407 MPa)
Service Brakes - Rear Hydraulic, internal-expanding, drum-type, self-adjusting
Service Brakes - Front Hydraulic Disc
Rear Axle Dana, single-speed, limited slip differential, full-floating
Tire and Rims 8.00 x 16.5, 6-ply tubeless on 16.5 x 6.0 G rims
Operation Manual
3.3.2 Environmental Operating Limits

Table Operation-3-6: Environmental Limits
Condition Minimum Maximum

Operating Temperature -25° F (-31° C) 125° F (52° C)
Storage Temperature -25° F (-31° C) 125° F (52° C)
Operating Humidity 0% 100%
Recommended Operating Altitude Sea Level 10,000 Ft (3048 m)
Please contact Tug Technologies for operating procedures in colder environments.
3.3.3 Environmental Vibration Information

The following information covers vibrations transmitted by the machinery to the hand-arm system
or to the whole body:
• The hand-arm vibration does not exceed 8.202 ft/s2 (2.5 m/s2).
• The highest root mean square value of weighted acceleration to which the whole body is
subjected is less than 1.64 ft/s2 (0.5 m/s2).
• The measured vibration at the driver's position with the vehicle idling and the belt running
at full speed is: 9.843 ft/s2 (3.0 m/sec2) pk 5.249 ft/s2 rms (1.6 m/sec2 rms).
• The measured vibration at the driver's position without the belt running is: 4.265 ft/s2
(1.3m/s2) pk 1.312 ft/s2 rms (0.4 m/sec2 rms).
3.3.4 Environmental Sound Information

The following diagrams indicate the Sound Pressure Levels (SPL) that were measured in accor-
dance with:
• BS EN ISO 1915-4 Aircraft ground support equipment, General requirements Part 4

Noise measurement methods
• BS EN ISO 11201 Determination of emission sound pressure levels at a work station in

an essentially free field over a reflecting plane with negligible environmental corrections.
Operation Manual
All measurements were taken in an acoustic free field over a concrete surface using an Extech
brand SPL meter in the “A” Weighted Mode.
BS EN 1915 - 4 Noise measurement methods 1 M from contour and 1.6 M above ground level
660-28 All measurements are "A" Weighted dB
Belt Loader Stationary
Conveyor Down
Engine Idle
Belt Stationary 67 69 70 70 71 69 71.5
Operator
71
67 69
Driver
Operator
70
72 72 71 70 69 68.5 68.5
Figure Operation - 3 - 2: Sound - Engine Idle - Conveyor Down - Belt Stationary

1 M from contour and 1.6 M above ground level
BS EN 1915 - 4 Noise measurement methods 660-28 All measurements are "A" Weighted dB
Belt Loader
Stationary
78.5 82.5 83.5 82.5 82 81 81
Conveyor Down
Engine Max RPM
Belt Max Speed Operator
81
78 78.5
Driver
Operator
80
77 81 81 81 81 82 78.5
Figure Operation - 3 - 3: Sound - Engine Max - Conveyor Down - Belt Max Speed
Operation Manual

Conveyor Up
Engine Idle
Belt Stationary 39.5 73 72.5 73 73 73 72.5
Operator
72
72 69
Driver
Operator
N/A
69 73 72.5 72.5 72.5 72 72
Figure Operation - 3 - 4: Sound - Engine Idle - Conveyor Up - Belt Stationary


Conveyor Up
Engine Max RPM 81.5 83 82.5 82 82 82 81
Belt Max Speed
Operator
80
83.5 79.5
Driver
Operator
N/A
79.5 81 82.5 82 82 82 84
Figure Operation - 3 - 5: Sound - Engine Max - Conveyor Up - Belt Max Speed
Operation Manual
3.4 Engines
3.4.1 Gasoline
3.4.1.1 Ford MSG-425 2.5L
Table Operation-3-7: Ford MSG-425 (2.5 L)
Item Specification
Type In-Line 4-Cylinder
Bore and Stroke 3.50 in x 3.94 in (89 x 100 mm)
Total Displacement 152.5 CID (2.5 L)
Compression Ratio 9.7:1
Firing Order 1-3-4-2
Fuel Unleaded Gasoline or LPG*
Oil Capacity 7.0 qt (6.6 L) with Oil Filter
Alternator Size 95 Amps
*LPG requires optional fuel system
NOTE: See Ford Operator's Manual for detailed engine data.
3.4.2 Diesel
3.4.2.1 Deutz D2.9L
Table Operation-3-8: Deutz D2.9L
Item Specification
Type In-Line 4-Cylinder
Bore and Stroke 3.6 in x 4.3 in (92 mm x 110mm)
Total Displacement 176.9 CID (2.9 L)
Compression Ratio 18.4:1
Firing Order 1-3-4-2
Fuel Diesel
Oil Capacity 2 gal (7.57 L)
Alternator Size 95 Amps
Operation Manual
NOTE: Deutz Operator's Manual for more detailed engine data.
3.5 Transmission
The 4-speed automatic transmission is equipped with a torque converter.
3.5.1 Gear Ratios

The following table lists the gear ratios for the transmission.
Table Operation-3-9: Gear Ratios
Gear Ratios
First 3.059
Second 1.625
Third 1.000
Fourth 2.294
Reverse 2.294
Operation Manual
3.6 Standard Conveyor Heights and Angles
170"
(431.8 cm)
13"(33cm)
Figure Operation - 3 - 6: Conveyor - Full Down Rear, Full Up Front
168"
(426.7 cm)
37"
(94 cm)
Figure Operation - 3 - 7: Conveyor - Full Up Rear, Full Up Front
Operation Manual
40"
36" (101.6 cm)
(91.4 cm)
Figure Operation - 3 - 8: Conveyor - Full Down Rear, Full Down Front
61"
(154.9 cm)
31"
(78.7 cm)
Figure Operation - 3 - 9: Conveyor - Full Up Rear, Full Down Front
Table Operation-3-10: Conveyor Positions
Conveyor Attitude Front Rear Angle

Front Up, Rear Down 170 in. (431.8 cm) 13 in. (33.02 cm) 35°
Front Up, Rear Up 168 in. (426.72 cm) 37 in. (93.98 cm) 27°
Front Down, Rear Down 40 in. (101.6 cm) 36 in. (91.44 cm) 1°
Front Down, Rear Up 31 in. (78.74 cm) 61 in. (154.94 cm) -6°
3.7 Compatible Aircraft

Table Operation-3-11, “Aircraft Compatibility,” provides a list by aircraft manufacturers and mod-
els showing the front and rear cargo door heights with an additional 30 in. (76.2 cm) conveyor
height above the door sill to allow for ease of loading and unloading of cargo. The rear of the con-
veyor is set at 30 in. (76.2 cm) above ground level.
The listed aircraft are compatible with the Mobile Belt Loader Model 660. The height measure-
ments are from the IATA Airport Handling Manual (AHM) 904 “Aircraft Doors, Servicing Points
and System Requirements for the Use of Ground Support Equipment.”
Operation Manual
Table Operation-3-11: Aircraft Compatibility
Aircraft Type Front Door Rear Door

Airbus A300 B2 320-B2/C4 137.5 in.(349.25 cm) 152.04 in. (386.18 cm)
Airbus A300 F4-600 134.52 in. (341.68 cm) 155.16 in. (394.11 cm)
Airbus A310-200/200C 133.32 in. (338.63 cm) 136.32 in. (346.25 cm)
Airbus A318 111.6 in. (283.46 cm) 121.2 in. (307.85 cm)
Airbus A330-200F 152.4 in. (387.096cm) 168.6 in. (428.24 cm)
Airbus A300-300 136.2 in. (345.95 cm) 165 in. (419.1 cm)
Airbus A340-200/300 137.4 in. (348.97 cm) 165.72 in. (420.93 cm)
Airbus A340-500/600 143.28 in.(363.93 cm) 169.08 in. (429.46 cm)
Airbus A380-800/800F 121.1 in. (307.6 cm) 152.4 in. (387.1 cm)
AN24 81.2 in. (206.25 cm) 85.1 in. (216.15 cm)
AN26 N/A 87.9 in. (2233.27 cm)
AN30 81.2 in. (206.25 cm) 85.1 in. (216.15 cm)
AN32 87.1 in. (221.23 cm) 89.8 in. (228.09 cm)
ATR42 100/200 73 in. (185.42 cm) N/A
AVRO RJ70 63 in. (160.02 cm) 63 in. (160.02 cm)
AVRO RJ85 62 in. (157.48 cm) 61 in. (154.94 cm)
AVRO RJ100 62 in. (157.48 cm) 61 in. (154.94 cm)
Boeing B707-320B/320C 84 in. (213.36 cm) 88 in. (223.52 cm)
Boeing B727-100/100C 81 in. (205.74 cm) 81 in. (205.74 cm)
Boeing B727-200 80 in. (203.2 cm) 76 in. (193.04 cm)
Boeing B737-100/200/200C 81 in. (205.74 cm) 91 in. (231.14 cm)
Boeing B737-300/40/500 85 in. (215.9 cm) 84 in. (213.36 cm)
Boeing B737-600/700/700C 87 in. (220.98 cm) 100 in. (254 cm)
Boeing B737-800/900/900ER 87 in. (220.98 cm) 101 in. (256.54 cm)
Operation Manual
Table Operation-3-11: Aircraft Compatibility (Continued)

Boeing B747-100/200/300 134 in. (340.36 cm) 136 in. (345.44 cm)
Boeing B747-400/400C 136 in. (345.44 cm) 141 in. (358.14 cm)
Boeing B747 SP 138 in. (350.52 cm) 144 in. (365.76 cm)
Boeing B767-200/200 ER 119 in. (302.26 cm) 119 in. (302.26 cm)
Boeing B767-300/300 ER/300 Freighter 120 in. (304.8 cm) 116 in. (294.64 cm)
Boeing B767-400 ER 124 in. (314.96 cm) 146 in. (370.84 cm)
Boeing B777-200/200 LR 141 in. (358.14 cm) 157 in. (398.78 cm)
Boeing B777-300/300 ER/300 Freighter 141 in. (358.14 cm) 157 in. (398.78 cm)
BAC 1-11-400 69 in. (175.26 cm) 77 in. (195.58 cm)
BAC 1-11-500 69 in. (175.26 cm) 76 in. (193.04 cm)
BAe ATP (J61) 107 in. (271.78 cm) 100 in. (254 cm)
BAe (H.S.) - 748 N/A 102 in. (259.08 cm)
C-212 N/A 62 in. (157.48 cm)
CL-44 N/A 144 in. (365.76 cm)
CL-65 (CRJ 100/200) 90 in. (228.6 cm) 92 in. (233.68 cm)
CN-235 N/A 77 in. (195.58 cm)
Caravelle 78 in. (198.12 cm) 71 in. (180.34 cm)
DC8-40/50 F Series 99 in. (251.46 cm) 118 in. (299.72 cm)
DC8-61/61 F & 62/62 F & 63/63 F 105 in. (266.7 cm) 112 in. (284.48 cm)
DC9-15/21, 32, 41, & 51 65 in. (165.1 cm) 69 in. (175.26 cm)
DC10-10/10 CF 138 in. (350.52 cm) 134 in. (340.36 cm)
DC10-30/40 & 30/40 CF 139 in. (353.06 cm) 135 in. (342.9 cm)
DHC-7 N/A 88 in. (223.52 cm)
DHC DASH 8 73 in. (185.42 cm) N/A
Dornier 328 Jet N/A 73.7 in. (187.199 cm)
Embraer EMB-120-Brasilia N/A 94 in. (238.76 cm)
Operation Manual

Embraer EMB-135 88.82 in. (225.6 cm) 95.75 in. (243.0 cm)
Embraer 170 & 175 128 in. (325.12 cm) 120 in. (304.8 cm)
Embraer 190 & 195 129 in. (327.66 cm) 146 in. (370.84 cm)
F-27 MK-200 & MK-400/600 & MK-400 M N/A 78 in. (198.12 cm)
F-27 MK-500 C & MK-500 F N/A 81 in. (205.74 cm)
F-28 MK 1000/1000C/3000/3000C 82 in. (208.28 cm) 88 in. (223.52 cm)
F-28 MK 2000/4000 82 in. (208.28 cm) 86 in. (218.44 cm)
Fokker 50 (F27 MK 050) & (F27 MK 0502) 72 in. (182.88 cm) 71 in. (180.34 cm)
Fokker 70 (F28 MK 0070) 77 in. (195.58 cm) 89 in. (226.06 cm)
Fokker 100 (F28 MK 0100) 84 in. (213.36 cm) 87 in. (220.98 cm)
IL-18 108.3 in. (275.08 cm) 107.2 in. (272.29 cm)
IL-62 107 in. (271.78 cm) 107 in. (271.78 cm)
IL-62M 107 in. (271.78 cm) 103 in. (261.62 cm)
IL-76T 79 in. (200.66 cm) 75 in. (190.5 cm)
IL-86 113 in. (287.02 cm) 111 in. (281.94 cm)
IL-96 124 in. (314.96 cm) 132 in. (335.28 cm)
IL-114 103 in. (261.62 cm) 115 in. (292.1 cm)
L-100/20-30 Series N/A 79.2 in. (201.17 cm)
L1011-1/100/200/250/500 137 in. (347.98 cm) 135 in. (342.9 cm)
Lockheed L188 Electra 91.5 in. (232.41 cm) 97 in. (246.38 cm)
MD-11 140 in. (355.6 cm) 134 in. (340.36 cm)
MD-80 73 in. (185.42 cm) 85 in. (215.9 cm)
Saab SF-340 N/A 94 in. (238.76 cm)
Shorts 330/200 & 360 N/A 77 in. (195.58 cm)
TU-134 124 in. (314.96 cm) 131.2 in. (333.25 cm)
TU-134A 124 in. (314.96 cm) 126 in. (320.04 cm)
Operation Manual

TU-154B 94 in. (238.76 cm) 95 in. (241.3 cm)
TU-204 111.4 in. (282.96 cm) 104.3 in. (264.92 cm)
YAK-40 102.8 in. (261.11 cm) N/A
YAK-42 99.7 in. (253.24 cm) 94.4 in. (239.78 cm)
3.8 Fluids
The following tables contain information about fluids used in the Mobile Belt Loader Model 660.
These fluids must be checked daily.
Table Operation-3-12: Hydraulic Fluid
Item Ambient Temperature Hydraulic Fluid Type
1 -60° F (-51° C) to +50° F (+10° C) Mobil DTE II
2 -15° F (-26° C) to +140° F (+60°C) Mobil DTE I3
Table Operation-3-13: Engine Oil
Oil (Must meet API Service

Item Ambient Temperature
SE/CC)
-10° F (-23° C) to +90° F (+32° C) Gasoline Engine: 10W-40 SJ
1
Diesel Engine: 15W-40 CJ-4
Table Operation-3-14: Fluids
Item Component Interval Lubricant
1 Transmission Check level weekly Dexron VI ATF
2 Brake Cylinder Check level weekly DOT3 Heavy Duty Brake Fluid
3 Conveyor Drive Chain Lube weekly Same as engine oil
4 Rear Axle Check at 6 months 85W-90 Limited Slip
5 Zerk Fittings Lube at 6 months Chassis Grease
6 Wheel Bearings Repack at 24 months Wheel Bearing Grease
Operation Manual
3.9 Coolant
Tug recommends Delco® Extended Life Coolants for the Mobile Belt Loader Model 660.Recom-
mended service life is 12,000 hours or 8 years.
CAUTION: Do NOT add conventional Coolants or SCAs. Top off with Delco
ELC Prediluted 50/50 only (CPS 227811). Adjust freeze point with Delco ELC
concentrate (CPS 227808).
Delco Extended Life Coolants meet or exceed:
• ASTM D 6210
• ASTM D 3306
3.10 Recommended Spare Parts

1. Oil Filters
2. Hydraulic Filters
3. Fuel Filters
4. Air Filters
5. Hydraulic Oil
6. Engine Oil
7. Transmission Fluid
8. Transmission Filters and Gaskets
9. Spark Plugs (Gasoline only)
10. Lubrication Grease
11. Axle Oil
12. Tires
13. Brake Shoes and Brake Caliper Pads
14. Engine Belt
Operation Manual
3.11 Safety Features

3.11.1 Shifter / Parking Brake Safety
The following safety features are provided:
• The foot throttle will only function when the parking brake is in the OFF/DOWN position.
• The hand throttle (knob or push button) will only function when the parking brake is in the
ON/UP position AND the shifter is in neutral.
• The conveyor belt will only function when the parking brake is in the ON/UP position AND
the shifter is in neutral.
• The engine is automatically returned to idle speed when either the parking brake is
placed in the OFF/DOWN position OR if the shifter is placed into FWD or REV.
• OPTIONAL: Conveyor will not raise or lower unless the shifter is in neutral AND the
parking brake is in the ON/UP position.
3.11.2 Shifter Guard

Integral with the right-hand side of the Instrument Panel, the Shifter Guard prevents cargo falling
off the conveyor belt, knocking the belt loader unintentionally into gear.
3.11.3 Neutral Safety Start Switch

The Neutral Safety Start Switch is located in the shifter / throttle assembly and is wired between
the ignition and the starter. The Neutral Safety Start Switch closes when the shifter is in the NEU-
TRAL position, allowing the starter to engage. If the shifter is in the FORWARD or REVERSE
position, the Neutral Safety Start Switch is open and the starter will not engage.
3.11.4 Anti-Restart Ignition Switch

The Anti-Restart Ignition Switch prevents starter engagement while the engine is running. To
engage the starter, the Anti-Restart Ignition Switch must be turned to the OFF position and then
turned to the START position. The starter cannot be engaged from the START position without
first cycling through the OFF position.
Operation Manual
3.11.5 Engine Control Module (ECM) Starter Protection

The following starter protections are provided by the engine ECMs.
3.11.5.1 Ford 2.5L

Over Crank Protection
The starter cannot be engaged for more that 8 consecutive seconds. Then it must rest for 20 sec-
onds. Once 24 total seconds of cranking is reached, the key switch (ignition voltage to the GCP)
must be recycled.
Starter
The starter cannot be re-engaged once the engine is running.
Engine Shutdown
During engine shutdown, the GCP monitors the engine speed and is timed to prevent the starter
re-engaging until the engine has come to a complete stop.
3.11.5.2 Deutz 2.9L

Over Crank Protection
The starter cannot be engaged for more than 8 consecutive seconds. Then it must cool down
for 24 seconds.
Starter
The ECM checks engine speed. If the engine displays any RPMs the starter will not engage.
Engine Shutdown
The ECM checks engine speed during shutdown and prevents the starter re-engaging until the
engine has come to a complete stop.
3.11.6 Emergency Stop Switch

The Emergency Stop Switch is a push-button switch located on the dash and all control points on
the conveyor belt assembly and the belt loader. The Emergency Stop Switch stops the conveyor
and engine immediately in an emergency situation. The Emergency Stop Switch must be reset
before the unit can be restarted
3.11.7 Park Brake

The Park Brake is located on the drive shaft and is activated by an Orchelin over-center lever.
With the Park Brake engaged, the loader will not move even when shifted into gear.
3.11.8 Pilot-Operated Hydraulic Check Valves

The Pilot-Operated Hydraulic Check Valves are located on both lift cylinders and the reverse
travel direction of the conveyor belt motor. The Conveyor Belt Motor Counter-balance Valve pre-
vents the free wheeling of the conveyor belt if the belt is stopped with the conveyor at an incline.
The check valves prevent the cylinders from lowering unless pressurized.
Operation Manual
3.11.9 Safety Props

Safety Props are located at the front and rear of the vehicle under the conveyor. Painted yellow,
these manually-engaged safety devices prevent the conveyor from possibly drifting down during
maintenance work. The Safety Props should be engaged any time the conveyor is in the raised
position during maintenance or daily equipment checks.
3.11.10 Side / Hand Rails

The Side Rails are mounted on the side of the conveyor to prevent cargo from falling off the con-
veyor belt. The operator holds the Hand Rails when climbing the conveyor to rearrange the load.
When not needed, these rails hinge down to conveyor belt level.
3.11.11 Finger Guards

Finger guards painted yellow and are located on the front, rear, and bottom of the conveyor.
When used correctly, the adjustable guards prevent the operator from getting fingers caught
between the conveyor belt and the conveyor frame. The guards are adjustable as the belt
stretches.
3.11.12 Rubber Bumper Roll

A Rubber Bumper Roll across the front of the conveyor frame protects the frame from damage.
3.11.13 Steel Hoop Guard (Optional)

A Steel hoop guard across the rear of the conveyor frame protects the belt from damage.
3.11.14 Grit Paper

Grit paper is positioned on the working platforms and the floor of the cab for better walking trac-
tion and safer operation. The grit paper on working platforms should be inspected monthly and
replaced when found to be torn or worn off.
Operation Manual
Section 4: Shipping
4.1 Shipping Preparation
WARNING: HAZARD EXISTS WHEN REFUELING AND DEFUELING THE

TRACTOR - NO SMOKING, NO OPEN FLAMES, NO ELECTRICAL DEVICE
OPERATIONS.
4.1.1 Fuel Tank Preparation

1. Drain fuel from fuel tank into appropriate container.
NOTE: Drain is located under unit immediately below tank.
2. Disconnect fuel line at lowest accessible connection and drain fuel from fuel line.
3. Reconnect fuel lines.
4. Leave fuel cap on tank, but loosened.
4.1.2 Battery Preparation

1. Use emergency hydraulic pump to lower conveyor, if required.
2. Disconnect battery terminals from battery posts.
3. Leave battery in battery box.
4.1.3 Pre-shipping Verification
NOTE: On tractors so equipped, make certain in-line fuel shut-off valve is open.
1. Make certain fuel line is connected.
2. Make certain shut-off valve on radiator is closed.
3. Make certain fuel cell drain valve is closed.
Operation Manual
4.2 Receiving
4.2.1 Preparing for Operation
WARNING: MAKE CERTAIN ALL FUEL LINES ARE PROPERLY CONNECTED

FROM TANK TO FUEL PUMP TO FUEL RAIL (GASOLINE) OR INJECTOR
PUMP (DIESEL).
4.2.1.1 Battery
• Connect battery terminals to battery posts.
4.2.1.2 Emergency Hydraulic Pump

1. Use emergency hydraulic pump to raise conveyor, if required.
2. Insert safety props.
4.2.1.3 Radiator
1. Make certain that radiator drain valve is closed.
2. Add required amount of coolant / water mixture to radiator.
4.2.1.4 Fuel Cell

1. Add fuel to fuel tank.
2. Check all fuel lines for leaks.
WARNING: WHEN SHIPPED TO THE EUROPEAN UNION, THE BELT

LOADER WILL NOT BE FITTED WITH LP TANKS.
For the LP engine option, the vehicle is built in the United States with non-EU com-
NOTE: ponents and tested to US standards. These components are removed prior to ship-
ment to EU destinations.
Operation Manual
Section 5: Storage
5.1 Short Term Storage
Short term storage applies to equipment that is to be stored for a period of 30 to 120
NOTE:
days.
5.1.1 Gasoline Engine

5.1.1.1 Ford 2.5 L Engine
1. Add fuel stabilizer.
CAUTION: Ford part number E8AZ-19C544-A, or an equivalent additive can

be used, for any length of storage. It is imperative in any application where
the fuel will not be consumed within thirty days. Without additives, fuel in
the fuel tank will cause varnish and contaminants to form. This causes prob-
lems in fuel delivery by clogging fuel injectors.
Ford fuel stabilizer comes in an 8 fl. oz. (236.6 cc) bottle available through all EDI
NOTE: Distributors. The correct ratio is 2 fl. oz.(59.15 cc) stabilizer to 5 gals. (18.9 L) of
gasoline.
2. While the engine is running, treat upper cylinders by spraying engine fogging agent (from
your local aftermarket supplier) into the air intake for about two minutes.
3. Open throttle for short burst of speed.
4. Shut off engine
5. Allow engine to come to a stop while continuing to spray into the air intake.
6. Leave spark plugs in holes or seal spark plug holes with suitable threaded metal plugs
7. Cover all openings into engine with dust-proof caps or shields (suitable non-hygroscopic
material).
8. Check coolant fluid levels.
5.1.1.2 Transmission
No special attention needed unless the engine is without transmission. Then, spray flywheel and
ring gear with one part recommended engine oil and one part Stoddard Solvent, or equivalent.
5.1.1.3 Drive Axle

No special requirements.
Operation Manual
5.1.1.4 Tires
1. Raise the vehicle
2. Chock the axles to prevent tire contact with the ground.
WARNING: TO AVOID INJURY TO PERSONNEL OR DAMAGE TO EQUIP-

MENT, ALWAYS USE LIFTING EQUIPMENT, SAFETY JACKS, AND CHAINS
WITH A SAFE MINIMUM CAPACITY OF ONE AND A HALF TIMES THE
WEIGHT OF THE VEHICLE BEING LIFTED.
3. Reduce tire air pressure to 15 psi (103.42 Kpa or 1.02 atm).
5.1.1.5 Lubrication
Lubricate all points with specified grease, oil, etc. See Lubrication schematic in the maintenance
manual (Ch.1, Sect. 1).
5.1.1.6 Battery
Disconnect battery terminals. Keep the battery fully charged during storage.
5.1.1.7 Fluid Levels

All fluid levels should be checked and topped off as necessary.
5.1.2 Diesel Engine

5.1.2.1 Deutz 2.9L Engine.
Check coolant protection.
5.1.2.2 Transmission
No special attention needed unless the engine is without transmission. If so, then spray the fly-
wheel and ring gear with a mix of one part recommended engine oil and one part Stoddard Sol-
vent, or equivalent.
5.1.2.3 Drive Axle

No special attention needed.
Operation Manual
5.1.2.4 Tires
1. Using a forklift or a crane, raise the vehicle
2. Chock the axles to remove tire contact with the ground.

MENT, ALWAYS USE LIFTING EQUIPMENT, JACK STANDS, AND CHAINS
3. Reduce tire pressure to 15 psi (103.42 Kpa or 1.02 atm).
5.1.2.5 Lubrication
Ensure that all points are lubricated with specified grease, oil, etc.
5.1.2.6 Battery
Disconnect battery terminals. Keep the battery fully charged during storage.
5.1.2.7 Fluid Levels

All fluid levels should be checked and topped off as necessary.
5.2 Returning the Vehicle to Operation After Short Term Storage

5.2.1 Tires
1. Check the tire pressure.
NOTE: If required, inflate tires to 45 psi (310 kPa) - Standard.
2. Use a forklift or a crane to lift the vehicle off the chocks.

3. Remove the blocks from beneath the vehicle.
4. Lower the vehicle to the ground.
5.2.2 Battery
1. Clean the battery posts and cable clamps.
Operation Manual
2. Check the electrolyte levels and service the battery, if required.
TUG installs maintenance-free batteries on the belt loader. This step is only
NOTE:
required if the battery has been replaced with a non-maintenance-free type.
3. Charge the battery, if required.
4. Lightly coat the battery clamps and posts with petroleum jelly.
5. Connect the battery cables.
5.2.3 Engine
• Visually inspect the engine systems to ensure integrity.
• Check the fluid levels and service as required.
5.2.4 Transmission
Service as required. (See Maintenance Manual).
5.3 Long Term Storage
NOTE: Long term storage is defined as a period of time exceeding 120 days.
5.3.1 Gasoline Engine

5.3.1.1 Ford 2.5L Engine
1. Add fuel stabilizer, Ford part number E8AZ-19C544-A, or equivalent.
CAUTION: Fuel stabilizer is critical where fuel will not be consumed over
thirty days. Without additives, fuel will cause varnish and contaminants to
form and cause problems in fuel delivery with clogged fuel injectors.
2. While the engine is running, treat upper cylinders by spraying engine fogging agent into
the air intake for about two minutes.
3. Open throttle for short bursts, shut off engine and continuing spraying into air intake until
engine stops.
4. Run engine until completely out of fuel.
5. Gasoline only: Restart and run on unleaded gasoline mixed with stabilizer for at least 10
minutes.
6. While engine is still running, treat upper cylinders by spraying fogging agent into the air
intake for two minutes.
Operation Manual
7. Open throttle for short burst of speed, shut off engine and continue spraying into air intake
until engine stops.
8. Completely enclose the air cleaner with dark plastic bag and seal with tape.
9. Drain crankcase completely and renew the oil filter.
10. Drain antifreeze from radiator and engine block.
11. Attach a tag on steering wheel stating:
CAUTION: Oil and antifreeze have been removed from engine.
12. Clean exterior surface of engine and loosen belt tension.
13. Leave spark plugs in holes or seal holes with suitable threaded metal plugs.
14. Seal all openings in engine and accessories with non-hygroscopic material. Mask off
(seal) all areas with electrical contacts. Place and seal the plastic cover over the dipstick.
15. Ensure all surfaces are dry, then spray all taped openings, all engine accessories includ-
ing ignition wiring, and all exterior surfaces of engine with Insulation Compound.
5.3.1.2 Engine Exterior

1. Apply multipurpose grease on moving parts such as rod threads, linkage, and joints.
2. Check all openings of the engine to ensure that plastic covers are in place and sealed.
3. Secure a waterproof cover over the engine.
Remove the waterproof cover every 2 to 3 months and check for corrosion and
NOTE: integrity of sealed areas. If any sealed system appears open, refer to the appropri-
ate system and repeat the application.
5.3.2 Transmission
See manufacturer's recommendation in the transmission service manual.
NOTE: Prolonged storage may be detrimental to transmission seals.
If the engine is less transmission, then spray flywheel and ring gear with one part recommended
engine oil, and one part Stoddard Solvent, or equivalent.
Operation Manual
5.3.2.1 Drive Axle

1. Drain drive axle by removing drain plug located on the underside of the differential carrier
housing.
2. Reinstall plug after draining.
CAUTION: Oil has been removed from the drive axle.
5.3.3 Tires
1. Raise the vehicle and chock the axles to prevent tire contact with ground.
2. Reduce air pressure to 15 psi (103.42 Kpa or 1.02 atm).
3. Spray tires with a rubber preservative.
5.3.4 Lubrication
Ensure that all points are lubricated with specified grease, oil, etc.
1. Repack wheel bearings.
2. Drain crankcase completely and renew the oil filter.
3. Drain antifreeze from radiator and engine block.
5.3.5 Fluid Levels

All fluid levels should be serviced, as necessary.
5.3.6 Battery
Remove the battery and store separately. Store in a cool dry place not in direct sunlight. Maintain
storeroom temperature from 32° F (0° C) to 90° F (32° C). If stored outside, cover the battery for
protection against dirt and moisture. Slow charge the battery every one to two months.
Operation Manual
5.3.7 Diesel Engine

5.3.7.1 Deutz 2.9L Engine
Crankcase and Filter Elements.
Oil filter elements do not need to be changed if the engine oil has been used 50
hours or less, leave it in the sump and add 3 to 4% by volume of VCI.
NOTE:
If the oil has more than 50 hours of use, change the oil.
1. Run engine until reaching normal operating temperature.
2. Turn the engine off.
3. Drain oil from crankcase.
4. Replace the oil filter.
5. Re-fill the engine with new oil.
6. Add 3 to 4% of VCI.
CAUTION: Oil will be hot.
7. Place and seal the plastic cover over the dipstick and the crankcase breather.
8. Use tape to seal any openings.
9. Drain antifreeze from radiator and engine block (excluding Deutz diesel units).
10. Attach a tag on steering wheel stating,
CAUTION: Oil and antifreeze have been removed from engine.
Operation Manual
11. Clean exterior surface of engine.
Use volatile corrosion inhibitors (VCI) (NOX-RUST VCI#10 oil), black or dark col-
ored plastic bags, and sealing tape (Kendall No. 231) to prevent internal engine
damage from moisture. Use an air compressor with a sprayer attachment to apply
oil. After application, completely seal the engine to prevent the vapors from escap-
ing. For information on VCI, contact:
Customer Service
NOTE: Daubert Chemical Co.
4700 S. Central Avenue
Chicago, Illinois 60638
Telephone: (800) 688-0459
Fax: 708-496-7367
Outside U.S.: 708-496-7350
http://www.daubertchemical.com
12. Seal all openings in engine and accessories with non-hygroscopic material.
13. Mask off (seal) all areas with electrical contacts.
14. Ensure all surfaces are dry
15. Spray all taped openings, all engine accessories, including ignition wiring, and all exterior
surfaces of engine with Insulation Compound.
16. Loosen belt tension.
19. Secure a waterproof cover over the engine
Remove the waterproof cover every 2 to 3 months and check the engine for corro-
NOTE: sion and integrity of its sealed areas. If any sealed system appears open, refer to
the appropriate system and repeat the application.
5.3.8 Transmission
Refer to the manufacturer's recommendation contained in the transmission service manual in the
maintenance manual.
5.3.9 Drive Axle

1. Drain drive axle by removing drain plug located on the underside of the differential carrier
housing.
Operation Manual
2. Reinstall plug after draining.
CAUTION: Oil has been removed from drive shaft.
5.3.10 Exhaust
1. Disconnect the exhaust system at the engine exhaust manifolds.
2. Use a sprayer to apply a mixture of 50% VCI oil and 50% engine oil into the exhaust man-
ifold openings.
NOTE: A minimum application is 2 oz (60 ml).
3. Connect the exhaust system.
4. Seal the exhaust pipe with tape and plastic.
5.3.11 Tires
1. Raise the vehicle and chock the axles to prevent tire contact with ground.
2. Reduce air pressure to 15 psi (103.42 Kpa or 1.02 atm).
3. Spray tires with a rubber preservative.

5.3.12 Lubrication
Ensure all points are lubricated with specified grease, oil, etc. (See Ch.2, Sect. 1 in Maintenance
Manual)
5.3.13 Levels
Service all fluid levels.
5.3.14 Wheel Bearings

Repack wheel bearings.
5.3.15 Battery
1. Disconnect the battery cables.
Operation Manual
2. Remove the battery and store separately.
Store the battery in a cool dry well ventilated area not exposed to direct sunlight.
NOTE: A recommended storeroom temperature of 32° F (0° C) to 90° F (32° C) should be

maintained. If stored outside, cover the battery for protection against dirt and mois-
ture.
3. Slow charge the battery every one to two months.
5.3.16 Fuel System

1. Drain the fuel tank.
2. Use a sprayer to apply 1 oz (30 ml) of VCI oil for each 7.50 gal (30 L) of tank capacity.
3. Seal the tank opening.
4. Remove the fuel filter, drain, and reinstall.
5. Clean the primary fuel filter (if equipped).
6. Remove the fuel injectors, check them, and recondition them, if necessary.
7. Spray 1 oz (30 ml) of 50% VCI oil and 50% engine oil in each cylinder.
8. Install the fuel injectors and tighten them to 30 ft/lb (40 Nm).
9. Using a bar or turning tool, turn the engine over slowly to lubricate the cylinder walls.
5.3.17 Engine Exterior

3. Secure a waterproof cover over the engine.
Remove the waterproof cover every 2 to 3 months and check the engine for corro-
NOTE: sion and integrity of its sealed areas. If any sealed system appears open, refer to
the appropriate system (listed above) and repeat the application.
Operation Manual
5.3.18 Tagging
Fasten a tag to the starting switch on the control panel stating:
WARNING: DO NOT START THE ENGINE! UNIT IN STORAGE! ALL SYS-

TEMS DRAINED OR PRESERVED!
5.4 Returning the Vehicle to Operation After Long-Term Storage

5.4.1 Tires
1. Inflate the tires to 45 psi (310 kPa or 1.06 atm) - Standard.

2. Using a forklift or a crane, lift the unit.
3. Remove the blocks from beneath the tractor.
4. Lower the tractor to the ground.
5.4.2 Battery
1. Check the battery levels and service them, if required.
2. Install the batteries in the vehicle.
3. Clean the battery cables and posts.
4. Lightly coat the clamps and the battery posts with petroleum jelly.
5. Connect the battery cables to the posts.
6. Charge the batteries.
5.4.3 Engine
1. Remove the plastic covers and tape from all engine and fuel tank openings.
2. Drain the oil sump, if needed.
3. Replace the filters, if needed.
4. Refill the oil sump.
5. Tighten the alternator and water pump belt.
Operation Manual
6. Replace the fuel filter and the water separator.
7. Fill the fuel tank and prime the system.
8. Check the coolant system and service the system, if required.
9. Using a bar or turning tool, turn the engine in its normal direction of rotation
10. Ensure there are no hydraulic locks or resistance.
5.4.4 Transmission
Refer to the manufacturer's recommendation contained in the transmission service manual.
5.4.5 Drive Axle

Refill the drive axle, if needed.
5.4.6 Pre-Operational Checks

1. Perform pre-operational checks.
2. Remove the warning tag from the operator compartment or cab, if equipped.
3. Start the unit.
The unit may run rough and smoke for a few minutes until it has cleared all the pre-
NOTE:
servatives from the system.
4. Operate the system at no load conditions to ensure that all the systems are operating cor-
rectly before returning the unit to service.
5.5 Cold Weather Storage

The Belt Loader can be stored at temperatures down to -40° F (-40° C) in the standard configura-
tion. It can be stored down to -65° F (-54° C) if the following steps are taken:
1. Perform all steps for the long term storage in previous section.
2. Ensure the following components are removed from the vehicle and stored in a safe,
warm location:
a. Batteries
b. Serpentine belt
c. Drain
• The radiator and engine block of coolant.
• Drain the windshield washer fluid (If equipped).
Operation Manual
5.6 Returning the Vehicle to Operation After Cold Weather Storage

The following components, which were removed from the tractor and stored in a safe, warm loca-
tion need to be installed back on the tractor:
• Batteries
• Serpentine belt
5.6.1 Refill Fluids

Follow this procedure to ready the tractor for operation.
1. Refill radiator and engine block of coolant
2. Refill windshield washer tank
3. Perform all steps for returning the tractor to operation after long term storage.
Operation Manual

Operation Manual: Mobile Belt Loader

Uploaded by

Copyright:

Available Formats

Operation Manual: Mobile Belt Loader

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Operation Manual: Mobile Belt Loader

Uploaded by

Copyright:

Available Formats

MOBILE

Property of: _____________________________________________________________________

Date of original publication: December 2015

Table Introduction - 1 - 1: Revisions

Revision Number Date Brief Description

CD397-Oper Introduction - 1 - iii

LIST OF EFFECTIVE PAGES

Table Introduction - 1 - 2: List of Effective Pages

Page Revision Date Page Revision Date

2.1.1 Ramp Safety in Aircraft Handling........................................................... Safety - 2 - 13

2.1.3 Maneuvering Controls .......................................................................Operation - 2 - 15

CD397-Oper Introduction - 1 - vii

3.11.5.2 Deutz 2.9L..............................................................................Operation - 3 - 45

Introduction - 1 - viii CD397-Oper

5.3.3 Tires ..................................................................................................Operation - 5 - 54

THIS PAGE INTENTIONALLY BLANK

THIS PAGE INTENTIONALLY BLANK

THIS PAGE INTENTIONALLY BLANK

TUG TECHNOLOGIES CORPORATION

UNLADEN WEIGHT w/OUT CAB 7,000 POUNDS 3,175 KILOGRAMS

WITH CAB 7,200 POUNDS 3,266 KILOGRAMS

MAXIMUM SPEED 25 MPH 40 KPH

2,000 POUNDS 907 KILOGRAMS

MAXIMUM SINGLE LOAD ON THE BOOM IS

Figure Introduction - 1 - 1: TUG Identification Plate

If applicable, enter your company identification number here:

Model Number Coding

Conveyor Variations Engine Variations

Figure Introduction - 1 - 2: Model Numbers

AUTHORIZATION REQUIREMENTS - REPAIRS REQUIRING PRIOR APPROVAL

WARRANTY POLICY AND COVERAGE

• Identifies the component and condition.

Table Introduction-1-1: Service Recalls/Notification

• Damaged due to accidents.

• Damage due to abuse, improper operation or poor maintenance practices.

Total or partial warranty cancellation is registered in TUG Technologies’ records.

• Parts handling charges.

• Parts damaged due to accident.

The warranty on parts damaged because of accident or an act of nature will be

• Repairs required because of inadequate or incorrect protection in storage and / or prepa-

• Repairs of damage or failure caused by poor outside workmanship.

• Repair techniques beyond the appropriate shop manual limits.

• A second or subsequent repair or adjustment necessitated by an incomplete or improper

• Adjustments made to improve appearance or performance beyond normal standards.

• Any repair to a part that is found not to be defective.

• Labor operations such as additional diagnostic time, abnormal accessibility or diagnosis

• Replacement parts damaged in shipment (carrier responsibility).

WARRANTY CLAIM PROCESS

Contact TUG Technologies

To expedite the claim process please provide the following information:

3. Description of problem or symptoms

4. List of parts required for repairs

7. Contact phone number(s)

• If deemed caused by an unwarrantable failure.

• If part is damaged due to inadequate packaging.

• Part was not supplied by TUG Technologies

AIRCRAFT GROUND SUPPORT EQUIPMENT

GENERAL WARRANTY TERMS & CONDITIONS

3. The equipment is not subject to misuse, negligence, or accident.