GT35 4F - CD406-Oper - Operation - Nov2015

PUSHBACK
MODEL GT-35
OPERATION MANUAL
Volume 1 of 1
Originally Issued November 2015
CD406-Oper
Pushback Model GT-35 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 CD406-Oper
Introduction Pushback Model GT-35
Operation Manual
RECORD OF REVISIONS
Property of:_________________________________________________________________
Company:__________________________________________________________________
Address:___________________________________________________________________
City:_________________________________ State:_______ Zip/Postal Code:____________
Revision Data:
Check each revision received, and insert the revised and supplementary pages in your manual.Tug Tech-
nologies Corporation assumes no liability for personal injury or equipment failure due to any operation
performed without heed to manual revisions.
Date of original publication: November 2015

Table Introduction-1-1: Revisions
Revision Number Date Brief Description
Only pages that have been revised are listed in Table Introduction-1-2, “List of Effective Pages,” .
CD406-Oper Introduction - 1 - iii

Operation Manual
LIST OF EFFECTIVE PAGES
Table Introduction-1-2: List of Effective Pages
Page Revision Date Page Revision Date
Introduction- 1 - iv CD406-Oper
Operation Manual Manual
TABLE OF CONTENTS
Copyright Notice - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Introduction-1-ii
Record of Revisions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-iii
List of Effective Pages- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-iv
Unit Identification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-xiii
Model number - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-xiv
Technical Assistance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Introduction-1-xv
Warranty Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-xvii
How to Use This Manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-xix
Safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-1
Section 1: General Safety Guidelines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-1
1.1 Safety Features/Equipment- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-1
1.1.1 Standard Safety Features/Equipment - - - - - - - - - - - - - - - - - - - - - - - Safety-1-1
1.1.2 Optional Safety Features/Equipment - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-2
1.2 Safety Responsibilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-3
1.2.1 Operator Safety Responsibility - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-4
1.2.2 Mechanic Safety Responsibility - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-7
1.3 Emergency Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-10
1.3.1 Disabled or Stalled Vehicle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-10
1.3.1.1 Operational Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-10
1.3.1.2 Inoperable Engine With Electrical Power - - - - - - - - - - - - - - - - Safety-1-11
1.3.1.3 Inoperable Engine With Loss of Electrical Power - - - - - - - - - - Safety-1-12
1.3.2 Recommended Fire Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-13
1.3.3 Collisions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-14
Section 2: IATA Flightline Safety Guidelines - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-1
2.1 Aircraft Handling Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-1
2.2 General Ramp Safety- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-1
2.2.1 Ramp Safety In Aircraft Handling - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-1
2.2.2 Danger Areas - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-1
2.2.3 Engine Intake Area - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-2
2.2.4 Equipment Restraint Area & Equipment Restraint Line - - - - - - - - - - - Safety-2-5
2.2.4.1 FOD - Foreign Object Debris - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-5
2.2.4.2 FOD Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-6
2.3 Safety Instructions for Operating Motorized Vehicles on Ramp- - - - - - - - - - Safety-2-7
2.3.1 General Safety Instructions for Ground Support Equipment (GSE) - - - Safety-2-7
2.3.2 Basic Operating Requirements for GSE - - - - - - - - - - - - - - - - - - - - - - Safety-2-7
2.3.3 Ground Support Equipment Safety Driving and Parking Inside ERA - - Safety-2-8
2.4 Adverse Weather Conditions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-9
2.4.1 Winter or Slippery Apron Conditions - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-9
2.4.2 Thunderstorms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-10
2.4.3 High Wind Conditions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-10
2.5 Safety Cones- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-10
2.6 International Decals and Symbols - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-10
2.7 Material Safety Data Sheet Information - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-13
2.7.1 Links for Products - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-13
MSDS for Castrol Heavy Duty Multipurpose ATF - - - - - - - - - - - - - - - - Safety-2-13
MSDS for Chevron Drive Train Fluid HD SAE 10W, 30, 50, 60 (USA) - Safety-2-13
MSDS for Castrol Tection Extra 15W40(CJ-4) - - - - - - - - - - - - - - - - - - Safety-2-14
CD406-Oper Introduction - 1 - v
Operation Manual
MSDS for Lead Acid Battery Wet, Filled With Acid - - - - - - - - - - - - - - - Safety-2-14
MSDS for Windshield Washer Antifreeze (+32) - - - - - - - - - - - - - - - - - Safety-2-14
MSDS for Castrol Limited Slip 80W-90 - - - - - - - - - - - - - - - - - - - - - - - Safety-2-14
MSDS for CHEVRON Supreme Prediluted 550/50 Antifreeze Coolant
(Contains Bitterant)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-14
MSDS for Castrol Pyroplex Red EP 2 - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-14
MSDS for Castrol in Different Languages - - - - - - - - - - - - - - - - - - - - - Safety-2-14
MSDS Chevron in Different Languages - - - - - - - - - - - - - - - - - - - - - - Safety-2-14
MSDS John Deere in Different Languages - - - - - - - - - - - - - - - - - - - - Safety-2-14
SDS Badger Fire Protection in Different Languages- - - - - - - - - - - - - - Safety-2-14
Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-1
Section 1: Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-1
1.1 Safety Precautions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-1
1.2 Purpose of Equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-1
1.3 General Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-1
1.4 Major Components- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-2
1.4.1 Power Package - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-2
1.4.2 Hydraulic System- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-3
Two-wheel Steering System (Standard) - - - - - - - - - - - - - - - - - - - - - Operation-1-3
Four-wheel Steering System (Optional) - - - - - - - - - - - - - - - - - - - - - Operation-1-3
1.4.3 Driveline Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-4
1.4.4 Fuel System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-4
1.4.5 Cooling System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-4
1.4.6 Air Intake System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-4
1.4.7 Lubrication System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-4
1.4.8 Electrical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-4
1.5 Minor Components- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-5
1.5.1 Frame- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-5
1.5.2 Battery Disconnect Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-5
1.5.3 Fasteners - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-5
1.5.4 Tow Brackets/Hitches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-5
1.5.5 Cab (Optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-5
1.5.6 Arctic Package (Optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-6
1.6 Standard and Optional Equipment/Features - - - - - - - - - - - - - - - - - - - - - Operation-1-6
1.6.1 Standard Equipment/Features: - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-6
1.6.2 Optional Equipment/Features:- - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-6
1.7 Ballast - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-7
1.8 Towing Capability - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-7
1.9 Turning Radius - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-8
Section 2: Operational Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-1
2.1 Principles of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-1
2.2 Operator’s Compartment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-1
2.2.1 Front Upper Control Panel (Optional)- - - - - - - - - - - - - - - - - - - - - - Operation-2-2
2.2.2 Rear Upper Control Panel (Optional) - - - - - - - - - - - - - - - - - - - - - - Operation-2-3
2.2.3 Instrument and Control Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-4
2.2.4 Transmission Shifter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-6
2.2.5 Steering Mode Panel (Optional) - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-7
2.2.6 Engine LCD Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-8
Engine LCD Display: Home Menu Screen- - - - - - - - - - - - - - - - - - - Operation-2-11
Introduction - 1 - vi CD406-Oper
Engine LCD Display: Utilities Menu Screen - - - - - - - - - - - - - - - - - - Operation-2-12

Engine LCD Display: Utilities - System Settings Screen - - - - - - - - - Operation-2-13
Engine LCD Display: Utilities - Date and Time Screen - - - - - - - - - - Operation-2-14
Active Diagnostic Code (Warning Message) - - - - - - - - - - - - - - - - - Operation-2-17
2.2.7 Battery Disconnect- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-18
2.3 Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-19
2.3.1 Pre-Operation Checklist - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-19
2.3.2 Starting Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-20
2.3.3 Transmission Range Selection - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-21
2.3.4 Steering Mode Selection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-22
2.3.5 Driving Instructions. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-24
2.3.6 Moving an Aircraft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-24
2.3.7 Park Brake Operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-25
2.3.8 Shutdown Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-26
2.4 Preventive Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-26
Section 3: Specifications and Capabilities - - - - - - - - - - - - - - - - - - - - - - - - Operation-3-1
3.1 General Specifications of the GT-35 - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-1
3.1.1 Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-1
3.1.2 Ramp Angles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-1
3.1.3 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-2
3.1.4 Weight and Drawbar Pull - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-2
3.1.5 Speed- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-3
3.2 Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-3
3.3 Transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-4
3.4 Axles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-4
3.5 Hydraulic System- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-5
3.6 Steering System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-5
3.7 Hitch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-5
3.8 Fluids and Lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-6
3.9 Arctic Package (Optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-6
3.9.1 120 VAC / 24 VDC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-6
3.9.2 240 VAC / 24 VDC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-7
Section 4: Shipping - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-4-1
4.1 Shipping Preparation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-1
4.1.1 Tie-Down Points (Truck Shipping) - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-1
4.1.2 Lifting (Truck Shipping) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-2
4.1.3 Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-2
4.1.4 Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-2
4.1.5 Fuel Tank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-3
4.1.6 Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-3
4.2 Preparation for Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-4
4.2.1 Tie-Down Points (Truck Shipping) - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-4
4.2.2 Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-4
4.2.3 Radiator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-4
4.2.4 Fuel Tank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-4
4.2.5 Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-4
4.2.6 Additional Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-4
CD406-Oper Introduction - 1 - vii

Operation Manual
Section 5: Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-1

5.1 Short Term Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-1
5.1.1 Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-1
5.1.2 Transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-1
5.1.3 Battery Pack - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-1
5.1.4 Lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-1
5.1.5 Fluid Levels- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-1
5.1.6 Axles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-1
5.1.7 Tires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-1
5.1.8 Cold Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-2
5.2 Returning the Tractor to Operation After Short-Term Storage- - - - - - - - - Operation-5-3
5.2.1 Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-3
5.2.4 Tires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-3
5.3 Long-Term Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-4
5.3.1 Engine and Engine Components - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-4
5.3.1.3 Cooling System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-5
5.3.3 Lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-7
5.3.4 Fluid Levels- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-7
5.3.6 Tires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-8
5.3.7 Windows (Cab Option only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-8
5.3.8 Cold Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-8
5.4 Returning the Tractor to Operation After Long-Term Storage - - - - - - - - - Operation-5-9
5.4.1 Tires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-9
5.4.2 Axles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-9
5.4.3 Windows (Cab Option only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-9
5.4.4 Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-9
5.4.5 Engine and Engine Components - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-9
5.4.5.1 Fuel System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-9
5.4.5.2 Lubrication Oil System - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-9
5.4.5.3 Coolant System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-9
5.4.5.4 Additional Engine Components - - - - - - - - - - - - - - - - - - - - - Operation-5-10
5.4.6 Transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-10
5.4.7 Pre-Operation Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-11
5.4.8 DEUTZ Recommended Corrosion Protection Agent/Cleaning
Agent - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-11
Introduction - 1 - viii CD406-Oper

LIST OF FIGURES
Safety-2-1: Idle Power - Engine Intake Area No Zone - - - - - - - - - - - - - - - - - - - - - Safety-2-3
Safety-2-2: Breakaway Power - Engine Blast Area NO Zone - - - - - - - - - - - - - - - - Safety-2-4
Safety-2-3: Example ERA - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-5
Safety-2-4: Fasten Seat Belts (White on Blue Background) - - - - - - - - - - - - - - - - Safety-2-11
Safety-2-5: Use Hearing Protection (White on Blue Background) - - - - - - - - - - - - Safety-2-12
Safety-2-6: Hot Surface (Yellow Field with Black Border) - - - - - - - - - - - - - - - - - - Safety-2-12
Operation-1-1: Pushback GT-35 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-1
Operation-1-2: Turning Radius Two-Wheel Steer- - - - - - - - - - - - - - - - - - - - - - - Operation-1-8
Operation-1-3: Turning Radius Four-Wheel Steer - - - - - - - - - - - - - - - - - - - - - - Operation-1-9
Operation-2-1: Upper Controls Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-2
Operation-2-2: Rear Upper Controls Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-3
Operation-2-3: Controls and Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-4
Operation-2-4: Transmission Shifter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-6
Operation-2-5: Steering Mode Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-7
Operation-2-6: Engine LCD Display Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-8
Operation-2-7: Engine LCD Display Screen - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-9
Operation-2-8: Home Menu Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-11
Operation-2-9: Home Menu Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-12
Operation-2-10: Home Menu Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-13
Operation-2-11: Date & Time Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-14
Operation-2-12: Engine Diagnostics Screen - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-15
Operation-2-13: No Fault Codes Example- - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-16
Operation-2-14: Multiple Fault Codes Example - - - - - - - - - - - - - - - - - - - - - - - Operation-2-16
Operation-2-15: Active Diagnostic Code Example - - - - - - - - - - - - - - - - - - - - - Operation-2-17
Operation-2-16: Battery Disconnect - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-18
Operation-4-1: GT-35 Tie Down Points - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-4-1
Operation-4-2: Hydraulic Lift Example - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-4-2
CD406-Oper Introduction - 1 - ix
Operation Manual
THIS PAGE INTENTIONALLY BLANK
Introduction - 1 - x CD406-Oper
LIST OF TABLES
Introduction-1-1: Revisions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-iii
Introduction-1-2: List of Effective Pages - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-iv
Introduction-1-3: Service Recalls/Notification- - - - - - - - - - - - - - - - - - - - - - -Introduction-1-xviii
Introduction-1-4: Flat Rate Labor Guide - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-xxiv
Safety-1-1: Standard Safety Features/Equipment - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-1
Safety-1-2: Optional Safety Items - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-2
Safety-1-3: Operator Safety Responsibilities - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-4
Safety-1-4: Mechanic Safety Responsibilities - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-7
Safety-2-1: Example of FOD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-5
Safety-2-2: FOD Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-6
Operation-1-1: Ballast - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-7
Operation-1-2: GT-35 Towing Capacities - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-7
Operation-2-1: Upper Controls Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-2
Operation-2-2: Rear Upper Controls Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-3
Operation-2-3: Controls and Indicators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-4
Operation-2-4: Transmission Shifter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-6
Operation-2-5: Steering Mode Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-7
Operation-2-6: Engine LCD Display Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-8
Operation-2-7: Engine LCD Display Screen - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-9
Operation-2-8: Home Menu Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-11
Operation-2-9: Home Menu Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-12
Operation-2-10: Home Menu Display - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-13
Operation-2-11: Date & Time Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-14
Operation-2-12: Engine Diagnostics Screen - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-15
Operation-2-13: Active Diagnostic Code Example - - - - - - - - - - - - - - - - - - - - - Operation-2-17
Operation-2-14: Battery Disconnect Compartment - - - - - - - - - - - - - - - - - - - - - Operation-2-18
Operation-3-1: Dimensions and Measurements - - - - - - - - - - - - - - - - - - - - - - - - Operation-3-1
Operation-3-2: Ramp Angles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-1
Operation-3-3: Specification Data - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-2
Operation-3-4: Dimensions and Measurements - - - - - - - - - - - - - - - - - - - - - - - - Operation-3-2
Operation-3-5: Dimensions and Measurements - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-3
Operation-3-6: Engine Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-3
Operation-3-7: Transmission Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-3-4
Operation-3-8: Front Axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-4
Operation-3-9: Rear Axle- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-4
Operation-3-10: Inter-Axle Differential- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-4
Operation-3-11: Hydraulic System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-5
Operation-3-12: Instrumentation Specifications - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-5
Operation-3-13: Hitch Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-5
Operation-3-14: Fluids and Lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-6
Operation-3-15: 220 VAC / 24VDC- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-6
Operation-3-16: 120 VAC / 24VDC- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-7
Operation-5-1: DEUTZ Recommended Corrosion Protection Agent/Cleaning
Agent - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-11
CD406-Oper Introduction - 1 - xi
Operation Manual
Introduction - 1 - xii CD406-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 Pushback GT-35. The various controls, gauges,
switches, and operating features are explained and illustrated throughout this manual. Person-
nel 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.
/1&'.
07/$'4
5'4+#.
07/$'4
914- &#6'
14&'4 1(
07/$'4 /(4
)89
4'('4615'4+#.019*'04'37'56+0)5'48+%'
Figure Introduction-1-1: 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 below:
Serial Number
If applicable, enter your company identification number in the appropriate box below.
Model Number
CD406-Oper Introduction - 1 - xiii

Operation Manual
MODEL NUMBER
Tug numbers models according to the diagram in Figure Introduction-1-2 Model Number.
GT35 D4F GT35AXXXX
Engine:
Serial
*D4F=Deutz TD/TCD 3.6 L4 Tier 4F Diesel Engine Number
Figure Introduction-1-2: Model Number
*This engine can be optionally down-rated to the Tier III emission standards for use
NOTE:
in unregulated emission locations.
Introduction - 1 - xiv CD406-Oper

Operation Manual
TECHNICAL ASSISTANCE
Direct any questions concerning the operation of the Pushback Model GT-35 to:
TUG Technologies Corporation

1995 Duncan Dr.
Kennesaw, GA 30144
USA
Email: [email protected]
Direct any questions concerning parts for the Pushback Model GT-35 to:
Parts Department
Phone USA: 1-800-989-8499

Phone International: 00-1-770-422-8021
Fax: 1-770-422-8730
Direct any questions concerning sales of the Pushback Model GT-35 to:
Equipment Sales
Phone USA: 770-422-7230

Fax: 770-428-7315
Direct any questions concerning warranty for the Pushback Model GT-35 to:
Warranty Department
Phone USA: 1-800-989-8499

Fax: 770-422-8730
All information in this manual is based on the latest production information available at the time of
publication.
CD406-Oper Introduction - 1 - xv
Operation Manual
Introduction - 1 - xvi CD406-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
payment.
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
Established 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.
CD406-Oper Introduction - 1 - xvii

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:
• Remains in force for the specified period, provided that an occurrence has not
taken place to render the warranty inapplicable.
• Assures the owner that if, under the conditions specified, a defect in factory work-
manship or material is encountered, it will be corrected at no charge or on a pro-
rata basis.
• 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-1-3: Service Recalls/Notification
Component Disposition
Shipment TUG will ship components for service recalls and/or approved war-
ranty 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.
Introduction - 1 - xviii CD406-Oper

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 misrepresented.
• 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 conversion, modification, or installation of a non-TUG part has been made
affecting the performance, 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.
CD406-Oper Introduction - 1 - xix

Operation Manual
• Repairs required because of inadequate or incorrect protection in storage and /

or preparation for storage.
• Repairs of damage or failure caused by poor outside workmanship.
• Any repair operation that changes the existing specifications of the equipment or
component.
• 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 stan-

dards.
• Maintenance and normal replacement of service items. For example, replace-

ment of filters and fluids, tightening of bolts, nuts, or fittings. Minor, labor-only
repairs are reimbursable.
• 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
TUG Technologies’ approval is required prior to the start of warranty work on the
NOTE:
unit and is required to ensure warranty invoice acceptance.
Contact TUG Technologies:
Phone: 1-800-989-8499 Ext. 1 or 00-1-770-422-8021 (International)

Email (preferred): [email protected]
Introduction - 1 - xx CD406-Oper
Operation Manual
To expedite the claim process please provide the following information:
• Unit S/N
• Hours of operation
• Description of problem or symptoms
• List of parts required for repairs
• Shipping address
• Contact name
• 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 following reasons:
• 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 returned with faulty part.
NOTE: TUG Technologies is not limited to the reasons as listed above.
Labor:
TUG Technologies will reimburse labor based on the Standard Labor Rate Chart (see
Table Introduction-1-4, “Flat Rate Labor Guide,” ). 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.
CD406-Oper Introduction - 1 - xxi

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 Technolo-
gies Operation and/or Maintenance Manuals.
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/or Maintenance Manuals.
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 determines TUG’s full responsibility, a credit will be issued in 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
consequential damages, whether based on lost goodwill, lost resale profits, work stoppage,
Introduction - 1 - xxii CD406-Oper

Operation Manual
impairment of other goods or otherwise, and whether arising out of breach of any express or
implied warranty, 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:
• The product has received some modification not authorized or completed accord-
ing to TUG Technologies’ requirements.
• Some original parts have been replaced by parts not provided by TUG
Technologies.
CD406-Oper Introduction - 1 - xxiii

Operation Manual
WARRANTY LABOR FLAT RATE GUIDE

Table Introduction-1-4, “Flat Rate Labor Guide,” lists the labor rates for various task.
Table Introduction-1-4: Flat Rate Labor Guide
PUSHBACK MODEL GT35-D4F LABOR

(Hrs)
Body
R&R Hood 0.5
R&R Radiator Shroud 0.5
Repaint 10.0
Repaint Cab 4.0
Brakes
R&R Brake Pedal 0.5
R&R Hub Front 3.0
R&R One Stud 1.0
R&R Axle Shaft Leak 2.0
Brakes, Front Axle

R&R Wheel Stud 1.0
Cab
R&R Heater 1.0
R&R Heater Core 1.0
R&R Heater Fan Motor 1.0
R&R Heater Switch 0.3
R&R Wiper Motor 0.5
R&R Wiper Arm 0.2
R&R Wiper Switch 0.3
R&R Outside Door Handle 0.3
R&R Door Operator 0.3
R&R Door Latch Assembly 0.3
R&R Door Retainer Strap 0.3
R&R Dome Light 0.3
Introduction - 1 - xxiv CD406-Oper

Operation Manual

(Hrs)
R&R Vinyl Door 1.0
Adjust Door 0.5
Cooling System
R&R Fan 1.0
R&R Radiator, Transfer Shroud 2.5
R&R Top or Bottom Hose 0.5
R&R Heater Hose 1.0
R&R Water Pump 1.5
R&R Thermostat 0.5
Controls
R&R Shifter 0.3
Drive Axle & Mounting

R&R Axle Assembly 6.0
R&R Input Seal 0.5
R&R Axle Shaft Seal 3.0
R&R Axle Shaft and Axle Bearing 1.0
Drive Shaft
R&R Drive Shaft 1.0
R&R One "U" Joint 0.5
Electrical
Troubleshoot Short or No Power 2.0
R&R Coolant Temp Sensor 0.5
R&R Electric Fuel Sender 1.0
R&R Light Switch 0.5
R&R Battery Cable 0.5
R&R Wire Harness 6.0
CD406-Oper Introduction - 1 - xxv

Operation Manual

(Hrs)
R&R Horn 0.3
R&R Horn Relay 0.3
R&R Battery 0.3
R&R Turn Signal Light 0.3
R&R Turn Signal Flasher 0.3
Tighten Battery Cable 0.3
R&R Brake Switch 0.3
Engine
R&R Starter Relay 0.3
R&R Starter 1.0
R&R Alternator 1.0
R&R Fuel Pump or Lift Pump 1.0
R&R Battery 0.5
R&R Valve Cover Gasket 1.0
R&R Engine Assembly 7.0
R&R Oil Pan 2.0
R&R Front Crankshaft Seal 2.0
Exhaust
R&R Exhaust Pipe 1.0
R&R Muffler 1.0
R&R Tail Pipe 1.0
Front Suspension and Steering

R&R Front Axle 4.0
R&R Tie Rod End and Adjust Toe In 1.0
R&R Steer Cylinder 3.0
R&R Steer Hose - Valve to Cylinder 0.5
R&R Steering Wheel 0.5
Introduction - 1 - xxvi CD406-Oper

Operation Manual

(Hrs)
R&R Horn Button Kit 0.5
R&R Steer Valve 1.5
Fuel System
R&R Fuel Cell 1.0
Miscellaneous
R&R Hood Latch 0.3
Install Decal 0.3
Seating
R&R Seat Frame 0.5
R&R Bucket Seat 0.3
Transmission
R&R Transmission 5.0
R&R Transmission Front Oil Seal 5.0
R&R Transmission Rear Oil Seal 1.0
CD406-Oper Introduction - 1 - xxvii

Operation Manual
Introduction - 1 - xxviii CD406-Oper

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 Introduction, Safety and Operation segments. Refer to the Table of
Contents at the front of this manual for details regarding manual content.
The page numbering system in this manual is a three-part number. The first variable represents
the segment in which the page appears, the second number indicates the section within that
segment, and the third number is the page number within that section.
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 any applicable procedure.
• The WARNING provides notice of potential safety issues that could, if ignored, result in seri-
ous 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 procedure.
WARNING: SAFETY NOTES THAT MUST BE FOLLOWED TO AVOID

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

equipment.
NOTE: Important non-hazard information for the user.
CD406-Oper Introduction - 1 - xix

Operation Manual
Introduction - 1 - xx CD406-Oper
Safety Pushback Model GT-35
Section 1 Operation Manual
Safety
Section 1: General Safety Guidelines
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 section of the manual has been devoted to safety. It is strongly
recommended that this chapter be reproduced and bound in the operator’s book, along with your
station safety rules.
Every operator and mechanic involved with this equipment must read and
abide by this safety section.
1.1 Safety Features/Equipment

1.1.1 Standard Safety Features/Equipment
The following are standard safety features/equipment:
Table Safety-1-1: Standard Safety Features/Equipment
No. Features/Equipment
1 Reflectors
2 Recessed headlights and taillights
3 Combination tail and stop lights
4 Reverse lights and back up alarm
5 Front and rear turn signals with Hazard Warnings
6 Dual independent brake systems with brake warning light
7 Accumulator pressure-assisted back-up brake system
8 Spring-applied/hydraulic-release parking brake
9 Engine speed governor set for a maximum speed of 15 mph
10 Emergency Stop (E-stop), locking style
11 Power-shift transmission with down-shift inhibitor
12 Neutral only start switch in shifter control
CD406-Oper Safety - 1 -1
Pushback Model GT-35 Safety
Operation Manual Section 1
Table Safety-1-1: Standard Safety Features/Equipment
No. Features/Equipment
13 Passenger seats with retractable seat belts
14 Center of steering wheel horn button
15 ISO 7000 and 7010 compliant dash interface
16 Power steering
17 Non slip covering on running boards and floor boards
18 Non slip surface on brake and accelerator pedal
19 Front hitch visibility from operator seat
20 Low center of gravity
1.1.2 Optional Safety Features/Equipment

The following table contains a list of optional safety features/equipment:
Table Safety-1-2: Optional Safety Items
No. Items
1 Multi-functional amber beacon (cab)
2 Marker,/Clearance Lights
3 Overhead guard
4 Operator enclosure (cab with tempered glass, front and rear defroster and wipers
5 High Visibility Reflector Package (ECE Reflective stripping and decals)
6 Front & Rear hitch/work lights
7 Alternating tail/reverse lights while in reverse
8 Low Profile Rear Hitch Mirror
9 Fire Extinguishers
Safety - 1 - 2 CD406-Oper
1.2 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, fellow employees, along with proper care of
tools and equipment. Report unsafe conditions, equipment, or operation to the proper authori-
ties. If unsure of an operating procedure, consult your supervisor for guidance.
1.2.1 Operator Safety Responsibility
WARNING: DO NOT DRIVE A TOW TRACTOR WITH DEFECTIVE BRAKES,

STEERING, TIRES, HORN, PARKING BRAKE 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
NOTE: one prior to operating this tow tractor. Communicate any concerns about the
equipment or any of its features to your supervisor.
Table Safety-1-3: Operator Safety Responsibilities
No. Operator Responsibilities
1 Use proper eye and hearing protection.
2 Follow training provided by your company.
Check before operating tow tractor:

• Lights
• Hood Latches
• Brakes
3
• Parking Brake
• Steering
• Horn
• Tires
4 Keep hands and feet away from rotating parts and tires.
5 Wear secure clothing, as loose fitting clothing may get caught in moving parts.
6 Bring tow tractor to a complete stop and set parking brake before dismounting.
7 Use seat belts at all times when tow tractor is in motion.
8 Do not shift transmission into gear with engine above idle speed.
Bring tow tractor to a complete stop before shifting from reverse to drive or from drive
9
to reverse.
10 Secure load prior to moving the unit.
Check the path is clear behind the tow tractor prior to driving in reverse direction.
• Check local station rules and, if allowed, blow horn before reversing
11
• 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
12
alert for other equipment and personnel.

Never operate at speeds inconsistent with operating conditions. Limit speed to allow
13
adequate time for braking in an emergency.
Do not use the tractor for pushing operations except those for which it was designed.
14
Use the proper towing equipment.
Do not allow the tow tractor to be pushed by other equipment or use the tow tractor to
15
push other equipment. Use proper towing equipment.
In event of a malfunction, stop operations and move the tow tractor to a safe area, if
16
possible, then notify a supervisor.
17 Operate at idle speed when approaching aircraft or within 20 ft. (6.1 m) of aircraft.
WARNING: DO NOT TOW OBJECTS FROM ANY POINT OTHER THAN THE
HITCH PROVIDED. TOWING FROM A POINT ABOVE THE REAR AXLE
CENTER LINE COULD CAUSE THE TRACTOR TO ROLL OVER BACKWARDS.
18 Do not disconnect or otherwise disable the Ryder safety seat system if so equipped.
19 Never refuel the unit while the engine is running.
20 Never enter wheel wells while engine is running.
21 Do not fill the fuel tank above the bottom of the filler screen.
22 Clean the unit of any spilled oil or fuel.
23 Do not smoke while refueling.
24 Do not store, spill or use fuel near an open flame.
25 Do not check the engine oil while the engine is running.
26 Do not use the battery in this unit to start other vehicles.
WARNING: DO NOT REMOVE THE RADIATOR CAP WHEN HOT! SERIOUS

BURNS MAY RESULT. ALLOW TIME TO COOL BEFORE REMOVING THE
CAP.
Do not drive up or down hills with slopes greater than 15 degrees or drive across any
27
slope.
28 Leave room when stopping and starting on hills to allow for slight roll back downhill.
29 Never engage in “horseplay” with the tractor.

WARNING: NOT PLACE FINGERS OR HANDS NEAR ELECTRIC FAN AS IT
MAY TURN ON WITHOUT WARNING.
Exercise good common sense, stay alert and be aware of what is happening around
30
the tractor at all times.
1.2.2 Mechanic Safety Responsibility
WARNING: WHEN WORKING UNDERNEATH THE TRACTOR, ENSURE THE

TRACTOR IS SUPPORTED PROPERLY ON SECURE JACK STANDS. DO NOT
RELY ON HYDRAULIC JACKS TO SUPPORT THE TRACTOR.
Table Safety-1-4: Mechanic Safety Responsibilities
No. Mechanic Safety Responsibilities

Review the “Operator Responsibilities” section of this chapter prior to operating this
1
equipment.
2 Disconnect the battery positive cable when working on or under the vehicle.
3 If electrolyte is spilled, always wash hands or clothing immediately.
WARNING: DO NOT SMOKE NEAR THE BATTERY. FUMES FROM

CHARGING ELECTROLYTE ARE EXPLOSIVE. ALWAYS KEEP THE
BATTERY AWAY FRO SPARKS, FLAME AND SMOKING MATERIALS.
Remove metal bracelets, watches, etc. prior to installing, removing or servicing the
4
battery.
5 Do not short the battery terminals.
When connecting battery, the positive terminal must always be connected first to
6
prevent sparks from accidental grounding.
When working underneath tow tractor, ensure it is properly supported on secure jack
7
stands that are rated. Do not rely on hydraulic jacks to support the tow tractor.
If the tow tractor is on a hydraulic or air-operated lift, make sure to place safety
8
support or jack stands in position prior to working under the tow tractor.
9 Use proper lifting equipment when removing or replacing heavy components.
10 Keep hands and clothing away from rotating parts.
11 Wear secure clothing, as loose fitting clothing may get caught in moving parts.
12 Keep hands, gloves, and clothing clear of cooling fan.

WARNING: DO NOT TOUCH HOT ENGINE, EXHAUST OR HYDRAULIC
COMPONENTS AS SERIOUS BURNS MAY RESULT.
13 Always stop the engine when adjusting fan and alternator belts.
Always discharge the accumulators prior to performing any work on the hydraulic
14
system.
15 Allow engine to cool before adjusting the alternator belt.

WARNING: DO NOT REMOVE THE RADIATOR CAP WHEN HOT! SERIOUS
BURNS MAY RESULT. ALLOW TIME TO COOL BEFORE REMOVING THE
CAP.
16 Do not check engine oil while the engine is running.
17 Visually check for hydraulic leaks. Do not use hands or fingers to locate leaks.
18 Never refuel the unit while the engine is running.
19 Do not smoke while refueling.
Do not fill the fuel cell above the bottom of filler screen. Do not overfill. Clean off any
20
spilled oil or fuel.
21 Do not store, spill or use fuel near an open flame.
22 Do not use the battery in this unit to start other vehicles.
Jack the drive wheels off the floor and support the tow tractor with rated jack stands
23
when troubleshooting the drive system.
24 Check tire and wheel condition, especially proper inflation pressures.
25 Torque lug nuts to 325 ft-lb (440.4 N-m).
Always deflate a tire and wheel assembly prior to removing it for servicing or
26
dismounting.
Always use a safety cage or other restraining device and a clip-on air chuck with a
27
remote valve and pressure gauge when inflating a tire.
Ensure the tire and wheel assembly is properly assembled prior to inflating it. Visually
28 inspect it for proper seating of beads and side or lock rings prior to removing it from
the cage.
Do not attempt to seat a tire bead, side, or lock ring by using inflation pressure or any
29 flammable or explosive substance such as starting fluid or ether. Never inflate a tire
beyond the rated pressure.
Do not add air to a tire that has been in service with less than 80% recommended
30 pressure without first fully deflating, removing, disassembling and inspecting the tire
assembly for damage.
Always install lock ring wheels such that the lock ring faces the inside of the wheel
31
well so that it will be contained by the wheel well and axle in case of failure
Do not work in the vicinity of the wheel wells when tires are being inflated on the
32
tractor.
33 Never enter wheel wells while engine is running.
Do not hammer, pry or weld on or near an inflated or partially inflated wheel and tire
34
assembly.
35 Do not rework, weld, heat or braze any wheel parts for any reason.
Do not use wheels or wheel components that are cracked, bent, pitted or corroded.
36 Insure all wheel components are of the same type and size and that wheel size and
tire size match. Inspect all components carefully prior to use.
Check the condition and tightness of all fasteners. Always use Grade 8 heat-treated
37 bolts throughout the unit. Grade 8 heat treated bolts can be identified by six lines on
the bolt head.
38 Check steering for excessive backlash and adjust as required.
39 Check neutral start only switch for proper adjustment and operation.
40 Verify all E-Stops are functional.
41 Check horns and lights.
42 Check brakes and fill master cylinder with DOT3 brake fluid.
Inspect seat belts and attachment points regularly. Replace if damaged. Do not
43
bleach or red-dye seat belts, clean with soap and water.
44 Immediately replace any parts that show wear or deterioration.
WARNING: MODIFICATIONS TO THIS UNIT ARE TO BE MADE ONLY BY THE

ORIGINAL MANUFACTURER OR A CERTIFIED TESTING LABORATORY.
45 Never engage in “horseplay” with the tractor.
46 Take nothing for granted when safety of the vehicle or operator is at stake.
Always exercise good common sense, stay alert and be aware of what is happening
47
around the tractor at all times.
48 Keep good maintenance records.
1.3 Emergency Procedures
Every operator and mechanic involved with this equipment must read and
understand emergency procedures prior to operation.
It is the operator’s responsibility to perform the appropriate actions to safeguard the unit and
others when the unit or trailer is disabled or in a collision. The following emergency procedures
describe the r e c o m m e n d e d steps to follow, in case of mechanical breakdown or equipment
malfunction. Apply and/or adapt these procedures in adherence to your company’s/station’s
emergency procedures as circumstances warrant.
WARNING: IN CASE OF AN EMERGENCY - ONLY 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 SERIOUS INJURY, DEATH, OR PROPERTY DAMAGE.
1.3.1 Disabled or Stalled Vehicle

The GT-35 is equipped with an optional emergency hydraulic pump activated from the operator’s
station actuated b y a spring-loaded two-position switch. This pump allows for supplying hydraulic
pressure for the service brake and steering.
1.3.1.1 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.
2. Turn on the emergency hazard warning signals.
NOTE: It is recommended to turn on the headlights when visibility is limited.
3. If unable to move the tow tractor out of the traffic area and when visibility is
limited, it is recommended to set out one type of emergency warning device (i.e.
red cones, etc.) to the front and rear of the unit.
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 as outlined in 2.3.7 Park Brake Operation.
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.
Towing speed must NOT exceed 6mph (10 km/h). Do NOT tow the disabled
unit more than 3 miles (5 km).
4. Proceed with towing.
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.
1.3.1.2 Inoperable Engine With Electrical Power

When the engine is inoperable but there is enough electrical power to engage the emergency
steering pump (if so equipped) or the unit is not equipped with an electrical steering pump,
perform the following steps:
1. Release the park brake by using the manual park brake override process 2.3.7
Park Brake Operation.
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 can 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.

Towing speed must NOT exceed 5 mph (10 km/h). Do NOT tow the disabled
unit more than 3 miles (5 km).

neutral, apply the park brake by rotating manual override knob direction, and turn
the ignition key to the OFF position.
1.3.1.3 Inoperable Engine With Loss of Electrical Power

An inoperable engine may experience loss of electrical power. When there is not enough
electrical power to engage the emergency steering pump or the unit is not equipped with an
electrical steering pump, perform the following steps:
1. Use a tow bar to attach the disabled unit and an operational tow tractor.
2. Release the park brake by using the manual park brake override process 2.3.7
Park Brake Operation.
NOTE: The disabled unit will be difficult to steer as there is no hydraulic pressure available.
Towing speed must NOT exceed 5 km/h (3 mph). Do NOT tow the disabled
unit more than 5 km (3 miles).

neutral, apply the park brake by rotating manual override knob direction, and turn
the ignition key to the OFF position.
1.3.2 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
The GT-35 can be equipped with a multi-purpose ABC dry chemical fire extinguisher. The fire
extinguisher may be used to extinguish the following fire types:
• Class A: fires include burning wood, paper, textiles, tires, etc.
• Class B: fires include grease, oil, gasoline, solvents, paints, etc.
• Class C: fires occurring in live electrical equipment
Following are recommended basic steps to perform when a fire occurs. Apply and/or adapt these
procedures in adherence to 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/sta-

tion’s emergency 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.

1.3.3 Collisions
WARNING: IN A COLLISION, INJURIES, POSSIBLE FUEL LEAKS OR

DAMAGE TO THE VERHICLE CAN OCCUR.
Every operator must take the necessary precautions to prevent collisions. If a collision occurs,
remain calm and perform the following recommended steps:
1. Refer and adhere to your company’s/station’s emergency policies and proce-

dures.
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 com-

pany’s/station’s emergency policies and procedures.
Section 2: IATA Flightline Safety Guidelines

This section of the TUG Operation Manual has been created from the IATA Ground Operations
Manual (IGOM). This section provides general guidelines for aircraft handling, including safety
procedures. The Ground Support Equipment Operator must always follow the training and
equipment operating rules of their employer.
2.1 Aircraft Handling Procedures

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 see or cause
any aircraft damage, you MUST report it. Refer to your employer regarding reporting of aircraft
damage.
2.2 General Ramp Safety

2.2.1 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 must always be applied and understood by
all personnel working on the ramp.
2.2.2 Danger Areas

There is a particular risk of blast damage or injury from an aircraft engine’s exhaust or intake.
The risk is further increased if for any reason an aircraft stops and then applies the additional
thrust required to “break away’ and continue the maneuver.
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 lntake 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 at IDLE or BREAKAWAY thrust.
Refer to your employer’s instructions for guidance. Ground personnel and loose equipment must
stay clear of the intake and blast areas.
CD406-Oper Safety - 2 - 1
2.2.3 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 push back;
• at all times while engines are running.
It is forbidden to pass through the blast area while the engines are running.
Refer to the operating airline’s Ground Operations Manual for distances applicable to the spe-
cific aircraft type involved in the operation. Sample Engine Danger Area A330-300 and A330-
200 aircraft are shown in Figure Safety-2-1 Idle Power - Engine Intake Area No Zone and
Figure Safety-2-2 Breakaway Power - Engine Blast Area NO Zone.
Figure Safety-2-1: Idle Power - Engine Intake Area No Zone
Figure Safety-2-2: Breakaway Power - Engine Blast Area NO Zone
2.2.4 Equipment Restraint Area & Equipment Restraint Line

The Equipment Restraint Area (ERA) is defined as the area of the apron bordered by a weighted
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, etc.
The illustration below provides an example of the markings used at some locations.
Figure Safety-2-3: Example ERA

The ERA must be free of obstructions and Foreign Object Debris (FOD) before and during air-
craft arrival and departure.
2.2.4.1 FOD - Foreign Object Debris

Foreign Object Debris (FOD) is a general term which applies to all loose objects which are a
danger to the safety and integrity of an aircraft and which, therefore, must not be left in any area
where they would constitute a hazard.
Every individual has a responsibility to ensure that the risk of damage to aircraft from FOD is
minimized. All FOD must be removed and properly disposed of as soon as it is discovered.
Table Safety-2-1: Example of FOD
No. Example
1 Metal nuts and bolts
2 Plastic and paper bags
Table Safety-2-1: Example of FOD (Cont.)
No. Example
3 Rags
4 Empty oil and hydraulic cans
5 Tools and equipment
Natural objects:
6 • Rocks/Pebbles
• Wood
Other debris:
7 • burst ballast bags
• Luggage handles, wheels, and tags
WARNING: FOREIGN OBJECT DEBRIS MAY BE INGESTED INTO AIRCRAFT

ENGINES CAUSING DAMAGE LEADING TO ENGINE FAILURE. THIS IS
ESPECIALLY CRITICAL IF FOD DAMAGE OCCURS IN FLIGHT, PARTICU-
LARLY 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 IN FLIGHT FAILURES!
2.2.4.2 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.
Check ground equipment staging and parking areas in the area of
2
operation.
3 Check ground equipment (including floors of enclosed cabins).
4 Check garbage bin areas for cleanliness and secure fitted covers.
5 Ensure that anything carried in or on a vehicle is secured.
6 Conduct a FOD walk of the aircraft parking stand removing all FOD found.
7 Pick-up and safely 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)
CAUTION: Only trained and authorized personnel are allowed to drive or

operate specific GSE. When operating equipment, check the equipment
contact zone for possible aircraft damage and immediately report any
damage found.
Apply these procedures when operating GSE on ramp:
1. GSE must not be moved or driven across the path of:
• Taxing aircraft
• Embarking and disembarking passengers on the ramp.
2. Use all safety devices fitted on GSE during aircraft handling and servicing.
3. Ensure protective rubber bumpers ARE NOT compressed against aircraft

fuselage.
2.3.2 Basic Operating Requirements for GSE

Check these items at the start of a shift (at least once per day). In particular, check the parking
brake, rubber protective bumpers, E-Stops and other safety systems.
• 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.
• 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.
• Turn off engine once positioned unless required for equipment operation.
• Do not leave any vehicle unattended with its engine running.
GPUs and PCA/Cabin heater units may be left running unattended when connected
NOTE:
to the aircraft.
• If equipped with stabilizers, ensure they are deployed before operation.
• Do not allow any GSE such as tractor, pallet transported, baggage/cargo carts
and dollies to move or be positioned under the aircraft fuselage.
• GSE must be parked in designated airside equipment parking areas when not in
use. Do not obstruct access to firefighting equipment or to the fuel hydrant emer-
gency stop switch.
• Do not move any GSE towards the aircraft unless all of the following criteria are
met:
1. Aircraft has come to a complete stop;
2. Engines have been switched off and are spooling down;
3. Anti-collision lights are switched off;
4. Wheel chocks are positioned;
5. Ground/Flight Crew communication has been established, and clearance has

been given, if applicable.
2.3.3 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.
This action MUST be carried out even if there is no Equipment Restraint Line
NOTE: marked on the apron. Do not conduct this stop no less than 15 ft (5 m) from the air-
craft.
• Do not drive GSE faster than walking speed.
• Maneuver GSE carefully in order to prevent personnel injury and/or aircraft dam-
age.
• Avoid performing any sharp turns near the aircraft, particularly when towing
equipment.
When reversing vehicles or equipment with limited rear-view visibility inside the
NOTE: ERA, ensure you are guided by an agent using standard IATA signals and/or
assisted by means of a rear-view video or mirror.
• When GSE is being moved in close proximity to the aircraft, and when the vision
of the GSE operator is or might be restricted, the GSE operator must:
1. guided by a guide person using standard IATA signals, and/or
2. assisted by means of a suitable camera system or mirror.
3. if visual contact with the guide person(s) is lost, the GSE operator must stop
movement of the GSE immediately
• 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.
Exceptions:
1. GSE and vehicles needed for aircraft servicing (e.g. aircraft refueling truck, water
servicing truck, toilet servicing truck).
2. On stations or with aircraft types where the aircraft/stand configuration makes it

necessary to tow dollies under the wing during (off)loading of the aft cargo hold of
a wide body aircraft. In such situations: Tow only empty dollies under the rear-
most part of the right wing only.
• When parking equipment within the ERA, do not:
1. obstruct the evacuation of persons from the aircraft in an emergency;
2. prevent or obstruct the movement of a fueling vehicle away from the aircraft;
3. unnecessarily impede other aircraft handling operations.
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. The following precautions to reduce accident
risk must be taken:
• Plan additional time for all ramp activities and take extra care when walking
across apron surfaces which can be slippery.
• Take extra care when driving, especially approaching the aircraft. Remember that
vehicles require greater distance to stop safely.
• Reduce speeds in slippery apron conditions. Adjust all activities and operations
on the ramp to suit the conditions at the time.
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.
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 this
chapter.
• do not stay in open areas, under the aircraft loading bridge or near any pole.
• 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:
• Ensure the safety of the aircraft by installing additional chocks and removing all
equipment from around the aircraft.
• Make sure parking brakes are set on all parked GSE.
2.5 Safety Cones

Safety cones are a caution sign for drivers to maintain required safety clearances. Cones protect
parts of the aircraft against collision by GSE.
• GSE must not approach the aircraft until all safety cones have been placed.
2.6 International Decals and Symbols

TUG Technologies produces Ground Support Equipment used all over the world. Operator
safety makes it imperative to avoid language barriers caused by decals written in Western-style
English. International Standards ISO 7000 and ISO 7010 (Registered Safety Signs & Symbols)
are becoming accepted for universal, non-verbal communication.
These guidelines define the following signs using only symbols and colors without words:
• Safety Signs: are green and square,
• Mandatory Action Signs: are blue and circular,
• Prohibition Signs: are a red circle with a red diagonal, and
• Warning Signs: are safety yellow color and triangular.
This page has been added to all TUG Service Manuals to aid interpretation of the graphic sym-
bols being used on TUG Technologies equipment. TUG Technologies strongly suggested 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
to the TUG Part Number written on the damaged decal. The Decal Part Number is
NOTE:
also listed in the Decal Location Guide in the Low Profile Tow Tractor GT-35
Maintenance 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)
TY-64
Figure Safety-2-6: Hot Surface (Yellow Field with Black Border)
2.7 Material Safety Data 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 informa-
tion, emergency procedures, and manufacturer contact information.
A MSDS is a legal document containing information on the potential effects on your health from
exposure to chemicals. Each MSDS is a nine-sectioned 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 what to
expect when the safety recommendations are not followed. In addition, it tells you what to do
when accidents occur and how to recognize symptoms of overexposure.
The MSDS listed within this manual apply to all models of the GT-35 tow tractor, it is recom-
mended the MSDS listed be communicated to your company’s Health & Safety Organization for
reference in an emergency.
TUG has listed MSDS that are from United States sources. As they vary from country to country,
you are strongly advised to access the manufacturers web site to obtain the specific MSDS /
SDS / PDS for your country. Below are hyper links that you may find useful:
2.7.1 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=No&a
utoload=No&siteland=EN&output=Full&spu=Lubricants&unrestrictedmb=No&cols=0
MSDS for Chevron Drive Train Fluid HD SAE 10W, 30, 50, 60 (USA):
https://cglapps.chevron.com/msdspds/MSDSDetailPage.aspx?docDataId=332196&docFor-
mat=PDF
John Deere Low Viscosity Hy-Gard Transmission & Hydraulic Fluid:
https://www.3eonline.com/ImageServer/NewPdf/7ca6d871b8c3477189687e8db3532436.pdf
MSDS for Castrol Tection Extra 15W40(CJ-4):
utoload=No&sitelang=EN&output=Full&spu=Lubricants&unrestrictedmb=No&cols=0
MSDS for Lead Acid Battery Wet, Filled With Acid:
http://www.dekabatteries.com/assets/base/a.pdf
MSDS for Windshield Washer Antifreeze (+32):
http://southwinltd.com/msds-request/
MSDS for Castrol Limited Slip 80W-90:
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:
MSDS for Castrol in Different Languages:
http://msdspds.castrol.com/msdspds/msdspds.nsf/CastrolSearch?OpenForm&sitelang=EN
MSDS Chevron in Different Languages:
https://cglapps.chevron.com/msdspds/MSDSPage.aspx?language=en&coun-
try=&region=EAME
MSDS John Deere in Different Languages:
https://www.3eonline.com/EeeOnlinePortal/DesktopDefault.aspx
SDS Badger Fire Protection in Different Languages:
http://www.badgerfire.com/Pages/SDS-Sheets.aspx
Operation Pushback Model GT-35
Operation
Section 1: Description
1.1 Safety Precautions
CAUTION: Every operator and mechanic involved with this equipment must
read and abide by the Safety section.
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

The TUG Pushback GT-35 is designed to push and tow aircraft from point to point on airport
grounds.
1.3 General Description

The GT-35 Tow Tractor is available in various weights (see “Ballast” on page 7). At a gross
weight of 35,000 lbs. (15875.7 kg) and 40,000 lbs. (18143.7 kg), the unit will generate approxi-
mately 28,000 pounds (12,701 kg) of drawbar pull. In addition to transporting aircraft, this unit is
also equipped to carry one (1) operator and two (2) passengers.
Figure Operation-1-1: Pushback GT-35
CD406-Oper Operation - 1 -1
Pushback Model GT-35 Operation
1.4 Major Components

The GT-35 consists of the following major components:
• diesel engine,
• four-speed power shift transmission,
• hydraulic system,
• driveline assembly,
• fuel system,
• air intake system,
• lubrication system,
• cooling system,
• and electrical system.
1.4.1 Power Package

The unit is equipped with a Deutz D 3.6 L4 (Tier IV) Engine and ZF 4WG190 transmission.
1.4.1.1 Engine
The GT-35 is powered by a four stroke, four cylinder, electronically-controlled, turbo-charged
diesel engine. The engine is certified by the manufacturer to meet the emission standards
required by Federal Law applicable as of the date of manufacture. Alternatively, this engine can
be optionally down-rated to the Tier III emission standards for use in unregulated emission
locations. The engine also includes the following protections:
• Overheat Derate/shutdown
• Low coolant shutdown
• Low fuel pressure shutdown
• Low oil shutdown
The engine is designed to operate satisfactorily using ultra low sulfur Diesel (ULSD) fuel or
Diesel No. 2 (Tier III only).
1.4.1.2 Transmission
The unit is equipped with the ZF 4WG190 transmission. This transmission features an inter-axle
differential and an electronic shifter controls its four forward and two reverse speeds. The
transmission also includes the following protections:
Operation - 1 -2 CD406-Oper
• Start and transmission shift protection
• Transmission temperature derator.
1.4.2 Hydraulic System

The GT-35 hydraulic system provides for steering and braking. Hydraulic pressure for the
steering and braking systems is provided by a single, variable displacement, axial piston, gear
driven hydraulic pump mounted on the transmission.
1.4.2.1 Steering System

The GT-35 is equipped with one of two steering systems, the two-wheel steer or the four-wheel
steer.
Two-wheel Steering System (Standard).
The two-wheel steering system engages a turning movement from the steering wheel is trans-
mitted to the front axle via a hydrostatic steering system with Char-lynn steering valve and
hydraulic cylinders on the front axle.
Four-wheel Steering System (Optional).
Alternatively, the GT-35 can be equipped with the optional four-wheel steering sub-system. The
four-wheel steering system is includes the standard two-wheel steering system in addition to the
following components:
• Proportional Steer Valve: controls the rear axle using input from the Steering
Logic Controller (SLC). The proportional valve will only supply fluid to the rear
axle steer cylinders if one of these actions occurs:
- The operator turns the steering wheel.
- The operator allows the tractor to travel forward or reverse.
- The operator presses and holds one of the three steer mode selection buttons on
the steering terminal located on the dash.
1.4.2.2 Brake System

There are two brake systems, park and service, incorporated into the GT-35.
• Park brake: spring-applied, hydraulically released disc brake; hydraulic pressure

is released to the brake.
• Service brake: hydraulic brake that utilizes a foot operated hydraulic valve to
apply hydraulic pressure to the axle brakes.
1.4.3 Driveline Assembly

The front and rear drive shafts transmit torque to the front and rear differentials which transmit
the torque to the axles, the planetary wheel assemblies, and the wheels.
1.4.4 Fuel System

An electric fuel pump pulls fuel from the fuel tank to a remotely mounted water-separator and
then delivers it to an engine-mounted fuel filter.
• The tractor fuel tank is constructed of steel and is mounted beneath the rear
access hatch.
• Fuel capacity of approximately 26 U.S. gal (98.4 L).
1.4.5 Cooling System

The tractor's cooling system consists of the engine cooling system, the transmission cooling
system, and the hydraulic cooling system.
1.4.5.1 Engine Cooling System

The Deutz 3.6L Tier4 engine cooling system consists of a radiator, a charge air cooler, a
thermostat, a coolant pump, a lube oil cooler, and a radiator expansion tank system.
1.4.5.2 Transmission Cooling System

The transmission cooling system consists of a transmission oil cooler integrated into the engine
radiator and features a thermostat bypass valve to allow the transmission to reach an operating
temperature faster.
1.4.5.3 Hydraulic Cooling System

The hydraulic system features a separate oil/air cooler.
1.4.6 Air Intake System

The TUG GT-35 is equipped with an air intake system that utilizes an air filter and intake hoses
to route incoming air to the engine.
1.4.7 Lubrication System

The engine lubrication system consists of an oil pump, oil cooler, a bypass and full-flow filter, a
pressure regulator valve, and a pressure relief valve.
1.4.8 Electrical System

The tractor utilizes a 24-Volt, automotive type, negative ground, electrical system. This system
includes the following components:
• Alternator (minimum 55 ampere)
• Starter 24V, 3.5 kW
• (2) 12 VDC batteries
• Fuse and relay control box
1.5 Minor Components

1.5.1 Frame
The chassis frame is a heavy gauge welded steel construction. The frame consists essentially of
inner and outer frame rails, front and rear bumpers, and cross members.
1.5.2 Battery Disconnect Switch

The battery disconnect switch disconnects positive power from the battery and is located inside
the rear access panel of the unit adjacent to the battery pack.(See Figure Operation-2-16 Battery
Disconnect).
1.5.3 Fasteners
All major structural fasteners are Grade 8, heat treated and use high strength lock nuts, or lock
washers depending on the joint design.
1.5.4 Tow Brackets/Hitches

The tractor has two pin-coupler hitches, one hitch at the center of each bumper. Each pin is
pulled upward for removal and attached to the hitch by a short chain, keeping the pin off the
ground. Each hitch has a locking device.
1.5.5 Cab (Optional)

The GT-35 features an optional front cab with provisions for the operator and two passengers.
The cab fully encloses the driving compartment and is equipped with front and rear windshields
and two side doors. Both doors have an inside and outside release, sliding windows, and are
removable from the main cab assembly.The cab assembly also includes:
• Enclosed cab frame
• Side view mirrors located on each of the cab doors
• Front and rear windshield wipers and washer system
• Front and rear window defrost system
• Rear and side window ventilation
• Cab dome light
• Heater
1.5.6 Arctic Package (Optional)

For units that operate in temperatures below -20 °F (-28.9 °C) down to -40 °F (-40 °C), an arctic
package can be included as an option to allow for better engine starting. The unit can be
equipped with a 120 VAC or 240 VAC. The components for the package include a(n):
• battery heater,
• engine block heater,
• fuel heater,
• transmission heater,
• and a hydraulic tank heater.
1.6 Standard and Optional Equipment/Features

The TUG GT-35 Pushback is manufactured with standard equipment/features, as well as a
variety of optional equipment/features:
1.6.1 Standard Equipment/Features:

• Front and Rear Turn signals
• Brake Warning Light and Back-up Alarm
• Front and Rear Brakes
• Front bumper mounted, Emergency Stop (locking style)
• Transmission Cooler
• Hydraulic Cooler
• High Water Temperature/Low Oil Pressure Shut-Off
• Power Steering
• Glow Plug Starting Aids
1.6.2 Optional Equipment/Features:

• Front and Rear Hitch Mirrors
• Front, Rear and in-Cab Communication Jacks
• Four-wheel Steering
• Arctic Package (Cold Weather Starting Aids)
1.7 Ballast
The standard unballasted GT-35 weighs 20,000 lb (9,070 kg) gross vehicle weight (GVW).
Optional ballast kits are available to bring the GVW to 22,000 pounds (9,979 kg), 30,000 pounds
(13,636 kg), 35,000 pounds (15,910 kg), or 40,000 pounds (18,144 kg). Table Table Operation-
1-1, “Ballast,” lists the GVW and the location of the ballasts.
Table Operation-1-1: Ballast
Gross Vehicle Weight Location of Ballast

20,000 lb (9,072 kg) Built into the standard frame construction
One 1,000 (454 kg) removable ballast weight in each of the side
22,000 lb (9,979 kg) ballast compartments, located on the top of the standard frame
between the front and rear wheels.
One 5,000 lb (2,268 kg) removable ballast weight in each of the
30,000 lb (13,620 kg) side ballast compartments, located on the top of the standard
frame between the front and rear wheels.
Two 7,500 lb (3,401.9 kg) removable ballasts in the side ballast
35,000 lb (15,910 kg)
compartments.
Two 7,500 lb. (3,401.9 kg) removable ballasts in each of the side
40, 000 lb (18,160 kg) ballast compartments, located on a heavy duty frame that is 5,000
lbs. (2,273 kg) heavier than the standard version.
Each ballast weight is designed with lifting eyes in the center of the ballast to allow installation
and removal with a fork lift or an overhead crane.
1.8 Towing Capability

The TUG Model GT-35 has five options for gross weight and drawbar pull capacity.
Table Operation-1-2: GT-35 Towing Capacities
Gross Vehicle Weight Maximum Drawbar Pull*

20,000 lb (9,072 kg) 16,000 lb (7,257 kg)
22,000 lb (9,979 kg) 17,600 lb (7,983 kg)
30,000 lb (13,620 kg) 24,000 lb (10,910 kg)
35,000 lb (15,910 kg) 28,000 lb (12,727 kg)
40, 000 lb (18,160 kg) 28,000 lb (12,727 kg)
* At 0.8 traction coefficient. 3% variation on published drawbar pull and weight,

NOTE:
owing to manufacturing tolerances.
1.9 Turning Radius

The turning radius of the GT-35 Pushback with standard front-wheel steering is 22.0 ft (6,70 m);
while the optional four-wheel steering unit has a turning radius of 16.0 ft (4,88 m). The turning
radii are measured at the outer most edge of the frame.
Figure Operation-1-2: Turning Radius Two-Wheel Steer
Figure Operation-1-3: Turning Radius Four-Wheel Steer
Operation - 1 - 10 CD406-Oper
Section 2: Operational Procedures
2.1 Principles of Operation
WARNING: ONLY PROPERLY TRAINED, AUTHORIZED DRIVERS SHOULD

BE ALLOWED TO OPERATE THE TRACTOR.
The TUG Model GT-35 is powered by an internal combustion 4-cylinder, water cooled diesel
engine and has an operating temperature range from -20°F (-29°C) to 125°F (51°C).
• Steering system utilizes orbital-operated hydraulic cylinders (hydrostatic

steering).
• The vehicle employs two (2) 12 VDC, 925 CCA maintenance free batteries tied in
series to supply 24 V of power.
• An adjustable driver’s seat is located on the left side of the vehicle with the provi-
sion of additional seating to carry two passengers.
• The vehicle is designed to travel at maximum speed of 15 mph (24 km/h) forward
and 7 mph (11.3 km/h) in reverse with no towing load.
2.2 Operator’s Compartment

The control layout is designed to combine maximum driving comfort with maximum efficiency.
It is essential that the operator becomes accustomed to both the location and the operation of
the instruments/controls before attempting to operate the vehicle.
CD406-Oper Operation - 2 - 1
2.2.1 Front Upper Control Panel (Optional)

The upper control panel controls may be present when the unit is equipped a cab (optional). The
upper panel controls are located inside the on the driver, above the windshield.
3
2
1
Figure Operation-2-1: Upper Controls Panel
Table Operation-2-1: Upper Controls Panel
No. Name Description

This knob operates the front windshield washer fluid
1 Front Windshield Wiper by pushing the button inward and the front
windshield wipers by turning clockwise.
This knob operates the rear windshield wiper by
2 Rear Windshield Wiper
turning clockwise.
This knob operates the front windshield defroster
Cab Heater/Defroster and cab heater by turning clockwise to the LOW or
3
(Optional) HIGH position. Turn the knob counter-clockwise to
turn the defroster/heater OFF.
2.2.2 Rear Upper Control Panel (Optional)
The upper control panel controls may be present when the unit is equipped a cab (optional). The
upper panel controls are located inside the on the driver, above the windshield.
1 2
Figure Operation-2-2: Rear Upper Controls Panel
Table Operation-2-2: Rear Upper Controls Panel

1 Cab Fan Switch This switch operates the cab fan. Toggle ON/OFF.
This switch operates the cab dome light. Toggle
2 Cab Dome Light Switch
ON/OFF.
2.2.3 Instrument and Control Panel

Figure Operation-2-3 Controls and Indicators shows the location of controls, while the following
table gives a brief summary of their operation.
12
10 11
13
8 9
7
6
5
4
3 14
15
2
18
16
17
19
20
Figure Operation-2-3: Controls and Indicators
Table Operation-2-3: Controls and Indicators

The STOP, RUN, START switch starts and
1 Ignition Switch stops the engine and connects and discon-
nects the electrical controls.
This panel shows the engine operating
2 Dash, PV450 LCD
parameters on an LCD screen.
Table Operation-2-3: Controls and Indicators

Steering Logic Controller Indicates wheel position and allows user to
3
(Optional) switch steering modes.
This lever controls the tractor’s direction of
4 VTS 3 Shifter
motion and the speed range.
Displays gear selection, fault codes, and other
5 Transmission Display
information from the transmission.
This switch operates the front hitch light.
6 Front Hitch Light Switch (Optional)
Toggle ON/OFF.
This switch operates the rear hitch light.
7 Rear Hitch Light Switch (Optional)
Toggle ON/OFF.
8 Beacon Switch (Optional) This light controls the warning beacon
This light illuminates the operator’s instrument
9 Dash Light
panel.
This light illuminates when the engine has a
10 Check Engine Light
malfunction.
This light illuminates when the brake system
11 Brake Warning Light
pressure falls to 800 psi (5515.8 kPa).
12 Transmission Light This light indicates a transmission fault.
This button shuts the engine down. To reset,
13 E-Stop Button (Optional)
gently twist clockwise.
This light illuminates while the glow plugs are
warming up and goes out when they reach
14 Yellow Glow Plug Light
their proper temperature. The engine is then
ready to start.
15 Battery Light This light indicates a charging system fault.
This light illuminates when the Park Brake is
16 Park Brake Warning Light
set.
This switch operates the headlight switch.
17 Head Light Switch
Toggle ON/OFF.
18 Low Fuel Warning Light Illuminates when fuel is level is low.
This switch operates the Emergency Steer
19 Emergency Steering Pump Switch
Pump. Toggle ON/OFF.
This switch operates the parking brake. Toggle
20 Park Brake Switch
ON/OFF.
2.2.4 Transmission Shifter
Figure Operation-2-4: Transmission Shifter
Table Operation-2-4: Transmission Shifter

This lever controls the direction of the tractor’s
VTS 3 Shifter (Directional motion (F-Forward, R-Reverse) and places the
1
Control) transmission in neutral (N-Neutral), disengaging
the gear sets.
2.2.5 Steering Mode Panel (Optional)
3
1
Figure Operation-2-5: Steering Mode Panel
Table Operation-2-5: Steering Mode Panel

TRACK Mode (Front-Wheel Press the TRACK mode button to select two wheel
1
Steering) steering (TRACK) mode.
2 LCD Screen Displays steering information.
COORD Mode (Four-Wheel Press the COORD mode button to select four wheel
3
Steering) coordinated steering (COORD) mode.
Press the CRAB mode button to select four wheel
4 CRAB Mode
steering (CRAB) mode.
2.2.6 Engine LCD Display

The GT35 uses a Murphy pV450 LCD display to communicate engine and transmission informa-
tion to the operator.
2.2.6.1 Engine LCD Display Buttons

There are four buttons on either side of the display that are used to navigate from the gauge
display screen to menu settings. The button icons can be displayed by pushing any button.
1 2
3 4
5 6
7 8
Figure Operation-2-6: Engine LCD Display Buttons
Table Operation-2-6: Engine LCD Display Buttons

This button initiated the Home Menu Screen to
1 Home Screen
appear int he LCD screen.
This button toggles the background illumination
2 Day/Night Settings between the Day and Night contrast and color set-
tings.
3 (Unassigned) This button is not assigned to any function.
This button enables or disables the button icons to
8 Clear Icons
be displayed/not displayed by the LCD.
2.2.6.2 Engine LCD Display Screen

The Engine LCD Display screen displays the Gauge Display as the default.
1 2 3
8 6 4
7 5
Figure Operation-2-7: Engine LCD Display Screen
Table Operation-2-7: Engine LCD Display Screen

*This gauge indicates the engine oil pressure in
1 Oil Pressure Gauge
pounds per square inch (PSI).
*This gauge displays the engine’s revolutions per
2 RPM Gauge
minute (RPM).
*This gauge indicates the engine coolant tempera-
3 Temperature Gauge
ture in degrees Fahrenheit.
This gauge indicates the 24 volt system voltage in
4 Battery Gauge
volts.
This gauge indicates the level of diesel fuel in the
5 Fuel Gauge
fuel tank.
**This indicates the transmission gear selected and
6 Gear Gauge
in use (N, 1F, 2F, 3F, 4F, 1R and 2R).
Transmission Oil Temperature *This indicates the transmission oil temperature in
7
Gauge degrees Fahrenheit.
Table Operation-2-7: Engine LCD Display Screen

This indicates the number of hours the engine has
8 Engine Hours Gauge
been operating.
This gauge displays speeds in miles per hour (MPH)
9 Speedometer Gauge
and total miles traveled.
*Under normal operating conditions, the measurement values displayed should be within the
following parameters:
• Oil Pressure: 30 psi - 90 psi (206 kPa - 620.5 kPa)
• RPM range: 800 rpm - 2400 rpm
• Engine Temperature: 185 °F - 200 °F (85 °C - 93.3 °C)
• Battery Voltage: 24 V - 28 V
• Transmission Oil Temperature: 160 °F - 210 °F (71.0°C - 98.9 °C)
**When the unit is placed into either 1R or 2R gears, the LCD display automatically
NOTE:
switches from the Gauge Display Screen to displaying the Rear View Camera.

Engine LCD Display: Home Menu Screen.
After the operator has selected to enter the Home Menu area, the LCD leaves the Gauge display
screen and shows the screen below:
1
2
Figure Operation-2-8: Home Menu Screen
Table Operation-2-8: Home Menu Screen

Button will navigate back to the Gauge Display
1 Gauge Display
screen.
2 Utilities button will navigate to the Utilities Menu Screen.
button will navigate to the Engine Diagnostics
3 Engine Diagnostics
Screen.
NOTE: All other buttons from this home screen are disabled.
Engine LCD Display: Utilities Menu Screen.
After the operator has selected to enter Utilities, the LCD leaves the Home Menu display screen
and shows the Utilities screen. The Utilities Menu is an area where the operator can view LCD
system configuration information as well as have the option to set the system’s date and time.
1
2
Figure Operation-2-9: Home Menu Display
Table Operation-2-9: Home Menu Display

1 System Settings Button navigates to the System Settings screen.
2 Date & Time Button navigates to the Date & Time screen.
3 Main Menu Button navigates to the Main Menu screen.

Engine LCD Display: Utilities - System Settings Screen.
The System Settings displays detailed information about the Murphy configuration software, as
seen in the example illustration .
Figure Operation-2-10: Home Menu Display
Table Operation-2-10: Home Menu Display

1 Back Arrow Button navigates to the Utilities Menu.
Engine LCD Display: Utilities - Date and Time Screen.
This screen allows the operator to set the LCD real time clock.
1 5
2 6
Figure Operation-2-11: Date & Time Screen
Table Operation-2-11: Date & Time Screen

*Button navigates to move the input field up
1 Yellow Up Arrow
between Year, Date and Time fields.
*Button navigates to move the input field down.
2 Yellow Down Arrow
between Year, Date and Time fields.
3 Back Arrow Button navigates to the Utilities Menu.
4 Save Icon Information is saved by pressing this button.
5 Grey Up Arrow Changes the values (increase) in the selected field.
6 Grey Down Arrow Changes the values (decrease) in the selected field.
NOTE: *The field to be changed is outlined in yellow.

Engine LCD Display: Engine Diagnostics
After the operator has selected to enter the Engine Diagnostics section, the LCD leaves the
Home Menu display screen and shows the Engine Diagnostics screen. Engine Diagnostics is
where the operator can view inactive fault codes that have been stored in the engine or trans-
mission electronic controller modules. Upon entering this screen, wait while the LCD system
pulls up the requested information (stored inactive fault codes).
1 4
2 5
Figure Operation-2-12: Engine Diagnostics Screen
Table Operation-2-12: Engine Diagnostics Screen

Button navigates to a screen for service and TUG
1 Clear Faults personnel only. See GT35 Maintenance manual for
specifics.
2 Delete Button navigates to the Home Menu screen.
Button toggles up multiple stored fault codes (when
3 Yellow Up Arrow
applicable).
Button navigates down multiple stored fault codes
4 Yellow Down Arrow
(when applicable).
Button will initiate the request to pull up stored fault
5 Get Faults
codes again.
When there are no stored inactive faults codes in either of the engine or transmission electronic
controller modules, the below screen is shown displaying the message, “NO STORED FAULT
CODES”.
Figure Operation-2-13: No Fault Codes Example
When there are multiple stored fault codes, one message will appear at a time. The yellow up/
down arrows can be used to view each message.
Figure Operation-2-14: Multiple Fault Codes Example
The “Clear Faults” button is for service and TUG personnel ONLY. See the GT-35
NOTE:
Maintenance Manual details for clearing fault codes.

Active Diagnostic Code (Warning Message).
When a fault code is active from the engine or transmission, an overlay will appear on the
current display screen. The dialogue box displayed at the bottom center of the LCD screen gives
the operator the SPN number of the active fault code and gives the operator a description of the
fault code.
Figure Operation-2-15: Active Diagnostic Code Example
Table Operation-2-13: Active Diagnostic Code Example

*Button hides the dialogue box so that the covered gauges
1 Hide
are visible and operation of the tractor can continue.
The symbol at the top with the exclamation point will remain on the screen until
NOTE: either the engine or transmission electronic controller modules (ecms) do not see a
fault condition and cancel the fault code.
NOTE: *All other buttons from this home screen are disabled.
2.2.7 Battery Disconnect

The battery disconnect is to be used whenever it is desirable to prevent accidental starting of
engine. For safety reasons, the switch maybe locked in the OFF position by using a safety
padlock (Lock out - Tag Out functionality).
1
2
Figure Operation-2-16: Battery Disconnect
Table Operation-2-14: Battery Disconnect Compartment

1 Battery Pack Two (2) 12 VDC batteries.
Switch disconnects positive power from the battery
2 Battery Disconnect Switch
by turning clockwise to the OFF position.
Holds the safety padlock to LOCK the battery dis-
3 Battery Disconnect Padlock
connect switch in the off position.

2.3 Procedures
2.3.1 Pre-Operation Checklist

The following items must be checked before putting the tractor into service:
1. Unit exterior for cleanliness and/or damage.
2. Air pressure tires. When applicable, inflate tires to 125 psi (861.8 kPa).
3. Condition of tires:
• cuts,
• breaks, or
• excessive wear.
4. Torque on wheel lug nuts. Ensure torque is 325 ft-lb (440.4 N-m).
5. Under unit for signs of leaking of the following:
• hydraulic fluid,
• transmission fluid,
• lubricating oil,
• planetary wheel end housings,
• coolant (hoses, and cleanliness of the radiator’s exterior),
• air intake system (soot marks around coupling hardware indicates leakage),
• fuel system (hoses, lines, fittings and linkage).
If significant leaks are found, repair them as soon as possible. Do NOT use the
equipment until repaired.
6. Fluid levels. When applicable, top off when necessary:
• engine oil level,
• transmission fluid level,
• hydraulic fluid level,
• radiator coolant level,
• brake fluid level, and
• fuel level.
7. That all controls are in good working order.
8. Operator seat settings: all three (3) seats are identical and adjustable. To adjust:
• pull out and hold the “L” shaped handle under the left side of the seat,
• slide the seat in the desired direction,

• when the desired position is reached, release the handle,
• push on the seat in both directions to check that it is locked,
• fasten seat belt(s):
As an optional safety feature, the tractor is inoperable until the Ryder-Safe seat is
NOTE:
activated. The Ryder-Safe seat is activated when the operator is securely seated.
2.3.2 Starting Instructions
WARNING: DO NOT ATTEMPT TO ADJUST THE SEAT WHILE THE TRAC-

TOR IS IN MOTION. LOSS OF TRACTOR CONTROL MAY RESULT.
1. Adjust the operator's seat so that all controls may be comfortably reached. Fasten
your seat belts.
2. Verify that the parking brake is set ON and shift selector is in NEUTRAL (N).
3. Check that all other switches are OFF.
4. Turn the STOP, RUN, START switch clockwise to RUN.
5. WAIT for the glow plug light to extinguish/turn off.
6. Turn the STOP, RUN, START switch to START.
7. Start the engine and check the engine oil pressure gauges and the voltmeter.
Observe that they are within limits.
8. Allow the engine to idle for approximately 5 minutes (warm up).
9. Turn on all necessary system switches (lights, etc.) for the operation.
10. Turn the steering wheel until the wheels are in straight-ahead position.
11. Set the steering mode select switch to the desired steering mode (optional).

2.3.2.1 Arctic Package (Optional)

The arctic package requires a 120 VAC l20A or 240 VAC I20A external supply (except the fuel
heater is 24VDC powered onboard).
1. Plug in the 120 VAC/240 VAC heating system at least 2 hours prior to engine start
in temperatures below -20 "F (-28.9 "C).
In temperatures below -20 "F (-28.9 "C), the ignition key should be on for 10
NOTE:
minutes before engine start to allow the fuel heater to warm up sufficiently.
2. Low ambient oil is to be installed at this point if necessary.
3. Following the remaining steps as outlined in Section 2.3.2 Starting Instructions.
2.3.3 Transmission Range Selection

The transmission shifter is an electronic unit and is located to the right of the steering wheel.
Use neutral with the parking brake set in the ON position, if leaving the tractor unat-
NOTE:
tended with engine running.
1. Select NEUTRAL when starting the engine, when checking the tractor's accesso-
ries, and when idling the engine for extended periods.
2. Choose the direction of travel by depressing the button on the shifter head and
moving the shifter handle either forward (drive) or back (reverse).
• Shifting into FORWARD (F) selects the forward gears.
• Shifting into REVERSE (R) selects the gears that drive the tractor back-
wards.
• To shift up, move the shifter to the right allowing the shifter head to return
to its position.
NOTE: When equipped with optional reverse shifter, to shift up move the shifter to the right.
• To shift down, move the shifter to the left allowing the shifter head to return
to its position.
NOTE: When equipped with optional reverse shifter, to shift up move the shifter to the left.
3. Start the operation in the gear most appropriate for the tow conditions.
Up-shifting and down-shifting is best accomplished by shifting through the normal

NOTE:
sequence of speeds. Down-shifting will generally produce a braking effect.
4. Stop the tractor before changing direction.
CAUTION: Do not coast the vehicle with the transmission in NEUTRAL.

Severe damage to the transmission may result.
CAUTION: Never shift from any forward gear to Reverse or from Reverse to
any Forward gear while the unit is in motion. The unit can be damaged or
stop suddenly.
Occasionally, certain conditions make it necessary to restrict shifting to a lower

range. In addition to more pulling power at lower speeds, these selections provide
NOTE:
progressively greater engine braking for going down medium grades (the lower the
gear range, the greater the braking effect).
2.3.4 Steering Mode Selection
WARNING: BEFORE ATTEMPTING TO USE THE GT-35, THE OPERATOR

AND ASSOCIATED GROUND SUPPORT EQUIPMENT EMPLOYEES MUST
BE TRAINED ON THE OPERATION OF THE UNIT AND ITS STEERING
MODES. ALL PERSONNEL SHOULD REMAIN AWARE OF POSSIBLE DAN-
GEROUS SITUATIONS TO AVOID SERIOUS INJURY OR DEATH.
WARNING: WHEN THE GT35 UNIT IS IN OPERATION, ALL PERSONNEL

EXTERNAL TO THE VEHICLE NEED TO MAINTAIN A SAFE DISTANCE
FROM FRONT AND REAR WHEEL WELLS TO AVOID CONTACT WITH THE
WHEELS OR BECOME TRAPPED BETWEEN THE VEHICLE FRAME AND
THE WHEEL. MAINTAINING A SAFE DISTANCE TO AVOID CONTACT IS
CRITICAL:
• AS GT35 CAN CHANGE DIRECTION / MOVE SIDEWAYS MUCH FASTER

THAN A CONVENTIONAL ROAD VEHICLE;
• WHEN STEERING, THE WHEELS WILL PROTRUDE OUTSIDE THE WHEEL

WELL;
• IN CERTAIN CIRCUMSTANCES, THE WHEELS MAY ALIGN FOR STRAIGHT

AHEAD OR TURN LEFT / RIGHT EVEN WHEN THE VEHICLE IS STATION-
ARY.
The steering modes are operated through a Steering Logic Controller (SLC). The SLC contains
an LCD display and eight white buttons, with blue back lighting. On the GT-35 unit, only the three
left white buttons on the top row are utilized (see Figure).
• When the START/RUN/STOP switch is moved from STOP to RUN, the LCD dis-
play back-lighting will illuminate and “TUG Technologies Corporation” will appear
in the display for a period of about 3-5 seconds.

• Simultaneously, the (8) blue lights will illuminate for about 5 seconds. The
company name will extinguish and two audio beeps will be heard and all (8) lights
will flash in synchronization.
• After the two audio beeps, (7) of the (8) lights will extinguish and one will remain
brightly illuminated: the TRACK (front wheels turn / rear wheels straight) mode
button. This is the default steering mode.
The system will automatically be placed in TRACK mode every time the tractor is
NOTE:
started.
• If the rear wheels are not centered at this point, the light will be flashing. There
are three ways to bring rear axle into center position:
1. Press and hold the TRACK mode button.
2. Turn the steering wheel back (counter clockwise) and forth (clockwise).
3. Turn off the park brake, place the unit in Forward or Reverse gear, and start
moving. The rear axle will slowly swing into the center position as the vehicle
moves.
With all these methods, the blue light will become solid (and cease flashing) when the rear axle
is centered. The screen will display the image indicating a centered rear axle.
1. With the GT-35 park brake ON, and the unit running, ensure that no one is near
the tractor as the axles will be turning.
2. Press the key pad button for the desired steering mode.
Steering modes can be changed in neutral, first, or second gear as long as the
NOTE:
steering angle of the front axle is less than 10° left or right
3. Select the desired mode by depressing one of the three buttons on the steering
terminal.
If the front and rear axle are not in alignment with the selected mode, then the red
NOTE: light will flash until they are aligned by one of the three methods described above
(see Proportional Steer Valve).
• Any of the three steering modes can be used while the transmission is in NEU-
TRAL, 1ST gear, or 2ND gear.
• When the transmission is shifted to 3RD or 4TH gear, the LCD display will sound
a warning beep and the SLC will automatically revert to TRACK mode (indicated
by the red light illuminating in the TRACK position).
• If the tractor is moving, the rear axle will lock into place the next time the operator
bring it to the center position.
• If the unit is not moving, use one of the three methods described in to Section ??
to bring the rear axle into the center position.
2.3.5 Driving Instructions
WARNING: MATCH DRIVING SPEEDS TO LOADS BEING TOWED AND

WEATHER CONDITIONS. SLOW DOWN WHEN TOWING HEAVY LOADS AND
WHEN ROAD SURFACE IS WET OR ICY. USE EXTREME CAUTION WHEN
THESE CONDITIONS ARE PRESENT ON GRADES.
NOTE: The unit cannot be started unless the transmission is in the Neutral position.
1. Apply service brake.
2. Release the parking brake by setting the parking brake switch to OFF.
The parking brake must be released (set to OFF) before any forward or reverse
NOTE:
gear is selected with the transmission shift selector. If not, the horn will sound.
3. Select the desired direction of travel and speed range by placing the shifter in the
gear most appropriate for the speed and weight of the tow (i.e. Forward, Reverse,
etc.).
4. Gently release the service brake pedal and press the accelerator pedal, gradually
increasing pressure until the required speed is obtained.
To slow the tractor, release the accelerator pedal and gradually apply pressure to the service
brake.
2.3.6 Moving an Aircraft

SAFE and EFFICIENT operation depends entirely on YOU, the operator. If you are an experi-
enced driver, the following ‘rules’ will serve to refresh your memory. If you are a trainee, they will
assist you to become an expert driver.
Each individual airline has established procedures for attaching the tractor to an aircraft, detach-
ing the tractor from an aircraft, and for towing or pushing back an aircraft. All operators must be
familiar with these procedures prior to operating the tractor during any aircraft-related opera-
tions..
CAUTION: Maximum tow speed of this unit is 15 mph (24.1 km/h)

NOTE: Heavy loads or aircraft should only be towed in first or second gear.
1. Ensure the aircraft is secure and is within the rated drawbar pull of the unit.
2. Ensure the towing coupling is secure.
3. Start as slowly as possible to allow any ‘slack’ in towing arrangements to be taken

up.
4. Travel at a speed consistent with road and load conditions.
5. Slow down and sound the horn when approaching corners and junctions.
6. Take all corners wide.
7. Always be alert. Watch out for pedestrians and never drive too close behind other
vehicles.
8. Do not carry unauthorized passengers.
9. If your trip involves crossing road bridge plates, ensure they are secure and are
strong enough to withstand the combined weight of the unit and driver, or aircraft.
10. When approaching the destination, reduce speed sufficiently to ensure a slow,
rolling halt. A sudden halt could cause a load displacement.
2.3.7 Park Brake Operation
WARNING: ALWAYS SET THE PARKING BRAKE ON PRIOR TO SHUTTING

OFF THE ENGINE OR EXITING THE CAB. OTHERWISE, THE TRACTOR CAN
ROLL AWAY, CAUSING DEATH, SEVERE PERSONAL INJURY, AND/OR
PROPERTY DAMAGE.
CAUTION: Release the parking brake before moving the unit. Except in an
emergency, do not apply the parking brake while the unit is in motion.
Parking brake damage will occur.
Each time you park,
1. bring the tractor to a complete stop,
2. return the transmission shift lever to neutral,
3. apply the park brake, and
4. turn the STOP, RUN, START switch counter clockwise to STOP.
2.3.8 Shutdown Procedure

1. Shutdown Procedure
2. Bring the tractor to a full stop.
3. Place the transmission in NEUTRAL (N).
4. Set the parking brake switch to ON.
5. Turn off all system and accessory switches.
CAUTION: The turbocharger may fail if the engine is not allowed to idle for a
minimum of 3 minutes prior to engine shutdown.
6. Allow the engine to run at idle for approximately 3 minutes, then shut it down by
turning the STOP, RUN, START switch to STOP.
2.4 Preventive Maintenance
CAUTION: Only qualified personnel should service this tractor. Do not

attempt to carry out repairs unless you are a qualified maintenance
mechanic. Report a faulty tractor and do not use until repaired.
Maintaining the unit may, or may not be your responsibility, depending on company policy. In
either case, maintenance participation, by you (the operator) is advantageous. It will enable you
to identify the tractor’s components and understand their function so well that you will be able to
report immediately on any mechanical irregularities.
It is recommended that in addition to mechanical irregularities one should check for the presence
and quality of exterior reflector markings. To ensure continued safe operation, any noted
deficiencies should be corrected immediately.
Routine maintenance is essential if your tractor is to be an efficient materials handling unit. Lack
of maintenance will result in costly repairs - loss through downtime - and interruptions in plant
operation.
Refer to GT-35 Maintenance manual “Preventive Maintenance” section.

Section 3: Specifications and Capabilities
3.1 General Specifications of the GT-35

3.1.1 Dimensions
Table Operation-3-1: Dimensions and Measurements
Dimension Measurement
Length (without hitches) 185.75 in. (471 cm)
Length (with standard hitches) 211.25 in. (537 cm)
Width 89 in. (226 cm)
Height (without cab) 65.6 in. (166 cm)
Height (with cab) 80 in. (203 cm)
Wheelbase 88 in. (223 cm mm)
Minimum Ground Clearance 8 in. (20 cm)
Turning Radius (standard front-wheel steer) 22.0 ft. (6,71 m)
Turning Radius (optional four-wheel steer) 16.0 ft. (4,87 m)
3.1.2 Ramp Angles

Table Operation-3-2: Ramp Angles
Item Specification
Approach Angle 12.0
Breakover Angle 14.0
Departure Angle 21.0
3.1.3 Specifications
Table Operation-3-3: Specification Data
Item Specification
Battery 24 VDC, 925 CCA @ 0°F(-32°C)
Ground Negative
Alternator 55 amp
Fuel Tank Capacity 26 UG gal (98 L)
Hydraulic Reserve Capacity 9 qt (8.5 L)
Hydraulic Hose Rating 3,000 psi (20684 kPa)
Service Brakes Wet disc, internal
Parking Brake Spring applied hydraulic release
Tires 315/80R22.5 radial, tubeless
Standard Operating Temperature -20 °F (-28.9 °C).
3.1.4 Weight and Drawbar Pull

Gross Vehicle Weight Maximum Drawbar Pull*

Without ballast 20,000 lb (9072 kg) 16,000 lb (7257 kg)
With ballast 22,000 lb (9979 kg) 17,600 lb (7983 kg)
With ballast 40, 000 lb (18160 kg) 28,000 lb (12727 kg)
* At 0.8 traction coefficient. 3% variation on published drawbar pull and weight,

NOTE:
owing to manufacturing tolerances.
3.1.5 Speed
Directional Gear Speed

Forward 1st 2.5 mph (4.0 km/h)
Forward 2nd 5.75 mph (9.3 km/h)
Forward 3rd 13.25 mph (21.3 km/h)
Forward 4th 15 mph (24.1 km/h)
Reverse 1 2.5 mph (4.0 km/h)
Reverse 2 6.0 mph (9.7 km/h)
3.2 Engine
NOTE: See Deutz Operation Manual for detailed engine data.
Table Operation-3-6: Engine Specifications
Item Specification
Manufacturer Deutz TCD 3.6L (Tier 4F)
Number of Cylinders 4
Cylinder Arrangement Vertical In-line
Bore 4.0 in. (9.8 cm)
Stroke 5.0 in. (12.0 cm)
Compression Ratio 17.2:1
Governed Speed 2300 rpm @ 74 hp
Total Displacement 3.621 L (US)
Fuel System Type Diesel
Aspiration Turbo-charged
Firing Order 1-3-4-2
Emission Level Tier 4 Final
Combustion System Direct Injection
Direction of Rotation On left looking at flywheel
3.3 Transmission
Table Operation-3-7: Transmission Specifications
Item Specification
Manufacturer ZF
Model 4WG190
Speeds 4 Forward, 3 Reverse
Controls Electronic with Downshift Inhibitor
Type Torque Converter/Powershit
3.4 Axles
Table Operation-3-8: Front Axle
Item Specification
Manufacturer DANA
Type Steer Planetary Drive Axle Type 223
Differential 45% Limited Slip
Planetary Ratio 1:5.25 (Overall axle ratio 1:23.25)
Integrated Steer System, max steer angle 30 (factory pre-set)
Table Operation-3-9: Rear Axle
Item Specification
Manufacturer DANA
Type Steer Planetary Drive Axle Type 123
Differential 45% Limited Slip
Planetary Ratio 1:5.25 (Overall axle ratio 1:23.25)
Table Operation-3-10: Inter-Axle Differential
Item Specification
Type Integral with transmission, optional locking differential
3.5 Hydraulic System

Table Operation-3-11: Hydraulic System
Item Specification
Type Axial-piston, variable displacement, PTO driven
Displacement 1.80 cubic in. (0.0295 L)
Hydraulic Oil Tank Capacity 9 qt. (8.52 L)
System Pressure 2250 psi (15513.2 kPa)
3.6 Steering System

Table Operation-3-12: Instrumentation Specifications
Item Specification
Type Char-Lynn, closed-center
Emergency Steering Pump 24 VDC Hydraulic pump and motor (optional)
Four Wheel Steering (Optional) PLC controlled
3.7 Hitch
Table Operation-3-13: Hitch Specifications
Dimension Specification
Type Pin coupler, cam-locked
Height from ground 16 in. (40.6 cm)
Pin diameter 2.5 in. (6.35 cm)
3.8 Fluids and Lubricants

Table Operation-3-14: Fluids and Lubricants
Item Specification
Refer to the Deutz Engine Manual (GT-35 Maintenance manual
Engine Oil*
Chapter 4)
Transmission Fluid Chevron Drive Train Fluid HD SAE 10W
Hydraulic Dexron III
Brake Fluid Dexron III
Tier 4 Engine: Ultra Low Diesel (ULSD) fuel only
Fuel
Tier III Engine: Number 2 Diesel
*Standard oil (15W-40) will be installed at the factory. For units operating in low
NOTE: ambient temperatures, oil must be changed to low ambient oil at the 50 hour initial
interval.
3.9 Arctic Package (Optional)

3.9.1 120 VAC / 24 VDC
Table Operation-3-15: 120 VAC / 24 VDC
Item Specification
Battery Heater Blankets
(2X) 120 VAC, 80W
(284-4001)
Coolant Heater 120 VAC [ON @ 100 °F (37.8 °C) /OFF @ 120 °F (48.9 °C)]
Fuel Heater Pad 24V, includes a toggle switch to turn off the fuel heater in
(G1-30198) warmer weather.
Transmission Heater
120 VAC, 250W
Pad (EH-2802)
Hydraulic Tank Heater
120 VAC, 250W
Pad (ELE-10021)
3.9.2 240 VAC / 24 VDC

Table Operation-3-16: 240 VAC / 24 VDC
Item Specification
Battery Heater
(2X) 240 VAC, 200W
(G35-10034)
Coolant Heater 240 VAC [ON @ 100 °F (37.8 °C) /OFF @ 120 °F (48.9 °C)]
Fuel Heater Pad 24V, includes a toggle switch to turn off the fuel heater in
(G1-30198) warmer weather.
Transmission Heater
220 VAC, 250W
Pad (EH-3202)
Hydraulic Tank Heater
240 VAC, 125W
Pad (ELE-10019)
Operation - 3 - 8 CD406-Oper
Section 4: Shipping
This section contains instructions for the preparation of shipping the tow tractor from one location
to another. Normally, the shipping of the unit does not involve storage time. If the unit is to be
stored before or after shipment, refer to Figure 5 Storage of this chapter for details of
preparation.
The tractor is normally shipped in a fully operational status and can be driven to on-load or off-
load from the trailer bed of the transporting truck. Any systems that are not operational shall be
appropriately tagged on the unit and indicated on the shipping document that accompanies the
tractor.
Refer to your load master regarding your method of shipment. If the fully operational
NOTE:
method of shipment is not preferable, refer to Sections through.
4.1 Shipping Preparation

4.1.1 Tie-Down Points (Truck Shipping)
The tow tractor is secured through the front and rear hitch pins and through the designed chain
holes in the four wheel wells and an additional four points of the tractor (See Figure Operation-4-
1 GT-35 Tie Down Points). No other tie-down points are authorized.
Tie Down
Point
Tie Down
Point
Tie Down Tie Down

Tie Down Point
Point
Point
Tie Down
Point Tie Down
Point
Tie Down
Point
Figure Operation-4-1: GT-35 Tie Down Points
4.1.2 Lifting (Truck Shipping)
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 (1.5)TIMES THE
WEIGHT OF THE VEHICLE BEING LIFTED.
The tow tractor may be lifted by a hydraulic lift (forklift) with capacity of 1.5 times greater than the
unit being lifted (See Figure Operation-4-2 Hydraulic Lift Example). No other lifting points are
authorized.
Fork Lift
Line
Fork Lift
Line
Figure Operation-4-2: Hydraulic Lift Example
4.1.3 Engine
No special requirements.
4.1.4 Battery
1. Disconnect battery terminals from battery posts.
2. Leave battery in battery box.
4.1.5 Fuel Tank
WARNING: HAZARD EXISTS WHEN REFUELING AND DEFUELING THE

TRACTOR - NO SMOKING, NO OPEN FLAMES, NO ELECTRICAL DEVICE
OPERATIONS.
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.
4.1.6 Checks
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 fuel cell drain valve is closed.
3. Review the transportation data plate (if equipped) for additional shipping
information.
4.2 Preparation for Operation
WARNING: MAKE CERTAIN ALL FUEL LINES ARE PROPERLY CONNECTED

FROM TANK TO FUEL PUMP TO INJECTOR PUMP.
4.2.1 Tie-Down Points (Truck Shipping)

Remove tie-downs from the forward and rear hitch pins of the tractor
4.2.2 Engine
4.2.3 Radiator
Make certain that radiator drain valve is closed.
4.2.4 Fuel Tank

1. Add fuel to fuel tank.
2. Check all fuel lines for leaks.
4.2.5 Battery
Connect battery terminals to battery posts.
4.2.6 Additional Components

1. Perform Pre-operational checks (See 2.3.1 Pre-Operation Checklist), and start
the unit.
2. Operate the unit under NO LOAD conditions until it is clear that all of the systems
are operating correctly before returning it to service.
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 Engine
5.1.2 Transmission
5.1.3 Battery Pack

Disconnect battery terminals for each battery.
NOTE: Keep the battery pack fully charged during storage.
5.1.4 Lubricants
Ensure all major components are lubricated with specified lubricant.
5.1.5 Fluid Levels

Check all fluid levels and top off as necessary.
5.1.6 Axles
5.1.7 Tires

1. Using a forklift, lift the unit.
2. Remove the tractor’s weight from its tires by supporting it with blocks placed
beneath the axle or the body.
A floor jack may also be used to lift the unit as long as the proper jacking proce-
NOTE:
dures are followed. (Refer to GT-35 Maintenance manual for jacking instructions).
3. Reduce tire air pressure to 414 kPa (60 psi).
5.1.8 Cold Storage

For units that operate in temperatures below -20°F (-28.9 °C) down to -40°F (-40 °C) perform the
following additional steps:
1. Remove serpentine belt and store in a safe location
2. Drain coolant from engine block and radiator
3. Drain windshield washer fluid
4. Remove LCD dash display and store in a safe location
5.2 Returning the Tractor to Operation After Short-Term Storage

5.2.1 Engine
1. Visually inspect the engine systems to ensure integrity.
2. Check engine fluid levels and service as required.
5.2.2 Transmission
Service transmission in accordance with the manufacturer’s recommendations contained in
Chapter 4 of the GT-35 Maintenance manual.
5.2.3 Battery Pack

1. Clean the battery posts and cable clamps.
2. Check the electrolyte levels and service the batteries, if required.
3. Lightly coat the battery clamps and posts with petroleum jelly.
4. Connect the battery cables.
5. Charge the batteries if required.
5.2.4 Tires

1. Using forklift, lift the unit.
2. Remove blocks from beneath the tractor.
A floor jack may also be used to lift the unit as long as the proper jacking
NOTE: procedures are followed. (Refer to the GT-35 Maintenance manual for jacking
instructions).
3. Lower the tractor to the ground.
4. Check tire pressure. If required, inflate them to 125 psi (861.6 kPa).
5.3 Long-Term Storage
NOTE: Long-term storage is storage time that exceeds 120 days.
5.3.1 Engine and Engine Components

This section of the TUG Operation Manual has been created from the Deutz Operator Manual
and Technical Bulletin 0199-99-1170/2 EN. This section provides general guidelines for
preparing the engine and engine components for long term storage.
The requirements for a 12-month protection are met by the following measures for corrosion
protection after shutting down the engine from operation.
CAUTION: A shorter corrosion protection duration is to be expected in

case of deviation from the measures by exposure of the corrosion
protected engines or parts to unfavorable conditions (installation
outdoors of storage in damp, unventilated places) or damage to the
corrosion protection coating.
CAUTION: The engine corrosion protection should be checked about

every 3 months by opening the covers. If corrosion is detected, the corro-
sion protection should be renewed.
The internal corrosion protection is always effected by wetting the walls with the
NOTE: corrosion protection agent by running the engine. The corrosion protection run can
be carried out once to protect the different systems.
5.3.1.1 Fuel System
These include the injection pump, the fuel injectors, fuel filter, fuel pump, overflow
NOTE:
valve, fuel pipes and fuel tank.
1. Close the fuel/tank/supply line to the engine so that the system is protected
against dirt and dust.
2. Drain the fuel tank.
3. Fill the fuel tank with a mixture of 90% distilled fuel and 10% corrosion protection
oil.
Biodiesel-free fuel according to EN 590 or ASTM D975 Grade 1-D S15 can also be
NOTE:
used alternatively.
4. Seal the tank opening.
5. Remove the fuel filter, drain, and reinstall.
6. Clean the primary fuel filter (if equipped).
7. Remove the fuel injectors, check them, and recondition them, if necessary.
8. Install the fuel injectors and tighten them to 30ft/lb (40 Nm).
9. Using a bar or turning tool, turn the engine over slowly to lubricate the cylinder
walls.
10. Perform a corrosion protection run with no load for at least 5 minutes.
5.3.1.2 Lubrication System
NOTE: Oil filter elements do not need to be changed.
1. Darin lubricating oil from warm engine.
2. Thoroughly clean following lubricating components with cleaning agent:
• lube oil tray,
• cylinder head with rocker arms,
• valves, and
• valve springs.
3. Fill the engine with corrosion protection oil (TITAN EM 2020 Deutz SAE 20W-20)
up to the MAX mark.
4. Perform a corrosion protection run (together with corrosion protection run for fuel
system), warm up the engine to approximately 140 °F (60 °C), for at least 5
minutes so that all the components of the lubricating system are whetted.
5. Place and seal the plastic cover over the dipstick and the crankcase breather.
6. Use tape to seal any openings.
5.3.1.3 Cooling System

When a coolant with corrosion protection properties is poured into liquid-cooled engines, no
further action is necessary after draining. If not, the following steps must be performed:
1. Drain existing coolant.
2. Clean cooling system according to manufacturer’s requirements.
3. Fill with 95% treated water and 5% CORACON Liquid BL 2 corrosion protection
agent OR 82% treated water and 18% COROACON Liquid BF2 with conserving
property and light antifreeze up to 5 °F,(-15 °C).
CAUTION: When turning the engine over with the starting circuit
disabled, DO NOT operate the starter for more than 30 seconds; doing so
can overheat and damage the started motor.
4. Start unit and allow its temperature to rise sufficiently to circulate the coolant. The
duration of the corrosion run and concentration of the corrosion protection agent
are specified by the manufacturer of the corrosion protection agent.
WARNING: DO NOT LEAVE UNIT RUNNING MORE THAN 10 MIN TO

PREVENT COOLANT FROM BECOMING HOT. DO NOT REMOVE
RADIATOR CAP WHEN ENGINE IS HOT AS SERIOUS BURNS MAY
RESULT. ALLOW RADIATOR TO COOL BEFORE REMOVING CAP.
5. Stop the unit and allow it to cool.
6. Drain the coolant and install the radiator cap.
5.3.1.4 Air Intake System

1. Remove the air intake filter element.
2. Disable the starting circuit by pulling fuse F5.
3. Spray ANTICORIT VCI UNI O 40 corrosion protection or TITAN EM 2020 DEUTZ

(SAE 20W-20) preservation oil into the air intake pipe..
NOTE: Minimum application rate is 2 ounces (60 ml).
4. Install the air filter element.
5. Enclose the air cleaner completely with dark plastic bag and seal it with tape.
5.3.1.5 Additional Engine Components

1. Coat or spray all bare exterior parts and surfaces (e.g. flywheel) with corrosion
protection agent.
2. Rub down unpainted rubber parts (e.g. muffs) with talcum powder.
3. Remove V-belts and V-rib belts and store packed.
4. Spray V-belt pulleys and tension rollers with corrosion protection agent.
5. Loosen tension on all other belts.
6. Fit all engine openings with air-tight, water-tight covers to delay the vaporization
process of the corrosion protection agents
NOTE: A completely sealed engine prevents the VCI vapors from escaping.
7. Fasten a tag to the starting switch on the control panel reading as follows:
“WARNING: DO NOT START THE ENGINE
UNIT IN STORAGE! ALL SYSTEMS HAVE
BEEN DRAINED OR PRESERVED.”
5.3.2 Transmission
1. Drain transmission fluid.
2. Refill transmission.
3. Refer to the manufacturer’s recommendations contained in Chapter 4 of the GT-

35 Maintenance manual for any additional transmission requirements.
5.3.3 Lubricants
Ensure all major components are lubricated with specified lubricant.
5.3.4 Fluid Levels

Check all fluid levels and top off as necessary.
5.3.5 Battery Pack
CAUTION: DO NOT store the battery directly on the floor or ground. The
battery must be stored in a cool, dry place and must not be exposed to
direct sunlight.
1. Disconnect the battery cables and remove the batteries from the unit.
2. Lightly coat the cable clamps and hold-down hardware with petroleum jelly.
3. Place the battery in a dry, well ventilated area. Recommended storeroom

temperature of 0 °C (32 °F) to 32 °C (90 °F).
4. Charge the battery, if required, to obtain a specific gravity of 1.225.
5.3.6 Tires

WITH A SAFE MINIMUM CAPACITY OF ONE AND A HALF (1½)TIMES THE
1. Remove the weight from the tractor’s tires by supporting the tractor with blocks
beneath the axles and the body.
2. Reduce the air pressure in the tires to 60 psi (414 kPa).
5.3.7 Windows (Cab Option only)

Using bands to hold it, place heavy cardboard over the windows.
5.3.8 Cold Storage

For units that operate in temperatures below -20 °F (-28.9 °C) down to -40 °F (-40 °C) perform
the following additional steps:
1. Remove belts (i.e. serpentine, alternator, etc.) and store in a safe location
2. Drain windshield washer fluid
3. Remove LCD dash display and store in a safe location
5.4 Returning the Tractor to Operation After Long-Term Storage

5.4.1 Tires
1. Inflate the tires to 125 psi (861.8 kPa).
2. Remove the tractor from blocks as outlined in segment 5.1.7 Tires of this section.
5.4.2 Axles
Axles have no special requirements.
5.4.3 Windows (Cab Option only)

Remove cardboard and strapping for the windows.
5.4.4 Battery
1. Check the battery levels and service if required.
2. Install battery in the tractor.
3. Clean the battery cables and posts.
4. Lightly coat the clamps and battery posts with dielectric grease.
5. Connect the battery cables to the posts.
5.4.5 Engine and Engine Components

Remove the plastic covers and tape from all engine and fuel tank openings.
5.4.5.1 Fuel System

1. Drain the diesel fuel still in the fuel tank.
2. Replace the fuel filter and water separator.
3. Fill the fuel tank and fuel system with the intended fuel.
5.4.5.2 Lubrication Oil System

1. Drain the oil sump.
2. Replace the filters
3. Refill the oil sump.
5.4.5.3 Coolant System

If the implemented corrosion protection agent is compatible with the intended cooling system
protection agent, this can be filled directly into the coolant system as specified.
If it is uncertain whether the implemented corrosion protection agent is compatible with the
cooling system protection agent, the cooling system should be purged with fresh water for about
15 minutes before filling.
5.4.5.4 Additional Engine Components

All areas and components coated with corrosion protection agent much be washed off with dis-
tilled fuel or a suitable cleaning agent.
1. Wash out grooves of V-belt pulleys if necessary.
2. Mount V-belts or V-rib belts as specified.
3. Tighten the alternator and water pump belts.
4. Using a bar or turning tool, turn the engine in it normal direction of rotation and
ensure it doesn’t hydraulically lock or offer other resistance.
5.4.6 Transmission
Refer to the manufacturer’s recommendations contained in the Vendor section of Chapter 4 of
GT-35 Maintenance manual.

5.4.7 Pre-Operation Checks

1. Perform Pre-operational checks (2.3.1 Pre-Operation Checklist).
2. Remove the warning tag from the cab, and start the unit.
The unit will run rough and emit smoke vapor for the first few minutes until
NOTE:
all preservatives have cleared from the systems.
3. Operate the unit under no load conditions until it is clear that all the systems are
operating correctly.
5.4.8 DEUTZ Recommended Corrosion Protection Agent/Cleaning Agent

We list the corrosion protection agents and cleaning agents with which you can achieve the best
results below.
NOTE: The supplier's safety instructions and safety data sheets must be observed.
Table Operation-5-1: DEUTZ Recommended Corrosion Protection Agent/Cleaning Agent
Product Designation/
Name Application
Supplier
DEUTZ diesel fuel
Obtainable through the entire
additive
Protecting the fuel system authorized DEUTZ dealer
"DEUTZ Clean Diesel
network
InSyPro"
Filling up the fuel system with Diesel fuel without fatty acid
Diesel fuel
diesel fuel methylester (FAME) additive
TITAN EM 2020 DEUTZ (SAE
20W-20)
Protecting the lubricating oil
Preservation oil
system Obtainable through the entire
authorized DEUTZ dealer net-
work
CORACON Liquid BL 2
or
CARACON Liquid BF 2-66
Corrosion protection
Protecting the coolant system
agent
Fa. Aqua-Conzept GmbH
82166 Gräfeling
www.coracon.net
ANTICORIT OHK (spray can)
Corrosion protection
Protecting the air compressor Fa. Fuchs Europe GmbH
agent
68169 Mannheim
Product Designation/
Name Application
Supplier
ANTICORIT BW 10
Corrosion protection air guide chamber in air-cooled
Fa. Fuchs Europe GmbH
agent V-engines
68169 Mannheim
ANTICORIT DFW 430
Corrosion protection Bare external surfaces and
agent parts
68169 Mannheim
Bare external surfaces and
parts
ANTICORIT BW366
Corrosion protection AND
agent
68169 Mannheim
For extreme conditions, (e.g.
sea transport or military specifi-
cations
FUCHS RENOCLEAN KU
(containing solvent)
Corrosion protection removal
Cleaning agent OR
agent
FUCHS RENOCLEAN VR 1021
(watery-alkaline) *
Talcum fine, white
Talcum Rubber parts Fa. Silbermann GmbH
86456 Gablingen
*Cleaning with the watery RENOCLEAN VR 1021 spray must be doen with a high-
NOTE:
pressure cleaning system at 60 - 70 °C

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City:_________________________________ State:_______ Zip/Postal Code:____________

Date of original publication: November 2015

Revision Number Date Brief Description

CD406-Oper Introduction - 1 - iii

LIST OF EFFECTIVE PAGES

Table Introduction-1-2: List of Effective Pages

Page Revision Date Page Revision Date

Engine LCD Display: Utilities Menu Screen - - - - - - - - - - - - - - - - - - Operation-2-12

CD406-Oper Introduction - 1 - vii

Section 5: Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-5-1

Introduction - 1 - viii CD406-Oper

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THIS PAGE INTENTIONALLY BLANK

Introduction - 1 - xii CD406-Oper

Figure Introduction-1-1: Identification Plate

CD406-Oper Introduction - 1 - xiii

GT35 D4F GT35AXXXX

Figure Introduction-1-2: Model Number

Introduction - 1 - xiv CD406-Oper

TUG Technologies Corporation

Phone USA: 1-800-989-8499

Phone USA: 770-422-7230

Phone USA: 1-800-989-8499

THIS PAGE INTENTIONALLY BLANK

Introduction - 1 - xvi CD406-Oper

AUTHORIZATION REQUIREMENTS - REPAIRS REQUIRING PRIOR APPROVAL

CD406-Oper Introduction - 1 - xvii

• Extension of coverage by any manufacturer does not change what is covered in

WARRANTY POLICY AND COVERAGE

Service Recalls or Owner Notification Programs

• Identifies the component and condition.

Table Introduction-1-3: Service Recalls/Notification

Introduction - 1 - xviii CD406-Oper

• 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.

Non-reimbursable repairs include:

• Parts handling charges.

• Parts damaged due to accident.

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

CD406-Oper Introduction - 1 - xix

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

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

• Repair techniques beyond the appropriate shop manual limits.

• Labor performed by anyone other than an authorized TUG technician without

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

• Adjustments made to improve appearance or performance beyond normal stan-

• Maintenance and normal replacement of service items. For example, replace-

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

• Replacement of assembly rather than repair if replacement costs exceed repair

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

• Replacement parts damaged in shipment (carrier responsibility).

• Towing expense or transportation for moving equipment between the customer's

WARRANTY CLAIM PROCESS

Contact TUG Technologies:

Phone: 1-800-989-8499 Ext. 1 or 00-1-770-422-8021 (International)

To expedite the claim process please provide the following information:

• Description of problem or symptoms

City:_____________________________ State:_ Zip/Postal Code:__________