TUG Technologies 660 Manuel utilisateur

OPERATIONMANUAL

Volume1of1

OriginallyIssuedDecember2015

CD397-Oper

MOBILEBELT

LOADER

MODEL660&663

Introduction - 1 - ii CD397-Oper

Mobile Belt Loader Model 660

Operation Manual

Introduction

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 - iii

CD397-Oper

Introduction Mobile Belt Loader Model 660

Operation Manual

RECORDOFREVISIONS

REVISIONDATA

Check each revision received, and insert the revised and supplementary pages in your manual.Tug

Technologies Corporation assumes no liability for personal injury or equipment failure due to any oper-

ation performed without heed to manual revisions.

Date of original publication: December 2015

Property of: _____________________________________________________________________

Company: _____________________________________________________________________

Address: _____________________________________________________________________

City: _______________________________ State/Province: _____________________

Country: _______________________________ Zip/Postal Code: _____________________

TableIntroduction-1-1:Revisions

RevisionNumber Date BriefDescription

Introduction - 1 - iv CD397-Oper

Mobile Belt Loader Model 660

Operation Manual

Introduction

LISTOFEFFECTIVEPAGES

Only pages that have been revised are listed in Table Introduction - 1 - 2: List of Effective Pages.

TableIntroduction-1-2:ListofEffectivePages

Page Revision Date Page Revision Date

CD397-Oper Introduction - 1 - v

Mobile Belt Loader Model 660

Operation Manual

Introduction

TABLEOFCONTENTS

Copyright Notice ............................................................................................ Introduction - 1 - ii

Record of Revisions ...................................................................................... Introduction - 1 - iii

Revision Data........................................................................................... Introduction - 1 - iii

List of Effective Pages .................................................................................. Introduction - 1 - iv

Table of Contents ...............................................................................................Introduction-1-v

List of Figures ................................................................................................... Introduction-1-xi

List of Tables ................................................................................................... Introduction-1-xiii

Unit Identification ...........................................................................................Introduction - 1 - 1

Model Number ...............................................................................................Introduction - 1 - 2

Warranty Information .....................................................................................Introduction - 1 - 3

Introduction ...............................................................................................Introduction - 1 - 3

Pre-delivery Procedures ...........................................................................Introduction - 1 - 3

Authorization Requirements - Repairs Requiring Prior Approval..............Introduction - 1 - 3

Warranty ........................................................................................................Introduction - 1 - 4

Warranty Statements ................................................................................Introduction - 1 - 4

Warranty Policy And Coverage.................................................................Introduction - 1 - 4

Service Recalls or Owner Notification Programs ................................Introduction - 1 - 4

Warranty Cancellation.........................................................................Introduction - 1 - 5

Warranty Exclusions .................................................................................Introduction - 1 - 5

Warranty Claim Process ...........................................................................Introduction - 1 - 6

Contact TUG Technologies.................................................................Introduction - 1 - 6

Parts....................................................................................................Introduction - 1 - 7

Return Parts........................................................................................Introduction - 1 - 7

Labor ...................................................................................................Introduction - 1 - 7

Aircraft Ground Support Equipment ...............................................................Introduction - 1 - 8

Warranty Policy Statement .......................................................................Introduction - 1 - 8

General Warranty Terms & Conditions .....................................................Introduction - 1 - 8

Warranty Labor Flat Rate Guide ..................................................................Introduction - 1 - 10

Technical Assistance ...................................................................................Introduction - 1 - 17

How to Use This Manual ..............................................................................Introduction - 1 - 19

Safety ....................................................................................................... Safety - 1 - 1

Section 1: General Safety Guidelines ................................................................Safety - 1 - 1

1.1 Introduction ....................................................................................................... Safety - 1 - 1

1.2 Standard Safety Features................................................................................. Safety - 1 - 1

1.3 Optional Safety Features .................................................................................. Safety - 1 - 3

1.4 Safety Responsibilities...................................................................................... Safety - 1 - 4

1.5 Operator Safety Responsibility ......................................................................... Safety - 1 - 5

1.6 Mechanic Safety Responsibility ........................................................................ Safety - 1 - 7

1.7 Emergency Procedures .................................................................................... Safety - 1 - 8

1.7.1 Disabled or Stalled Vehicle ...................................................................... Safety - 1 - 8

1.7.1.1 Operational Engine ......................................................................... Safety - 1 - 8

1.7.1.2 Operational Engine - Unable to Move............................................. Safety - 1 - 9

1.7.1.3 Inoperable Engine With Electrical Power ...................................... Safety - 1 - 10

1.7.1.4 Inoperable Engine With Loss of Electrical Power ......................... Safety - 1 - 10

1.7.2 Recommended Fire Procedure.............................................................. Safety - 1 - 11

1.7.3 Collisions................................................................................................ Safety - 1 - 12

Section 2: IATA Flightline Safety Guidelines ..................................................Safety - 2 - 13

2.1 IGOM Chapter 4: Aircraft Handling Procedures.............................................. Safety - 2 - 13

Introduction - 1 - vi CD397-Oper

Mobile Belt Loader Model 660

Operation Manual

Introduction

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

2.2 General Ramp Safety ..................................................................................... Safety - 2 - 13

2.2.1 Danger Areas......................................................................................... Safety - 2 - 13

2.2.2 Engine Intake Area ................................................................................ Safety - 2 - 14

2.2.3 Equipment Restraint Area & Equipment Restraint Line ......................... Safety - 2 - 17

2.2.3.1 FOD - Foreign Object Debris ........................................................ Safety - 2 - 17

2.2.3.2 FOD Checks.................................................................................. Safety - 2 - 18

2.3 Safety Instructions for Operating Motorized Vehicles on Ramp ..................... Safety - 2 - 19

2.3.1 General Safety Instructions for Ground Support Equipment (GSE)....... Safety - 2 - 19

2.3.2 Basic Operating Requirements for GSE ................................................ Safety - 2 - 19

2.3.3 Belt Loader Aircraft Loading Equipment ................................................ Safety - 2 - 20

2.3.4 Ground Support Equipment Safety Driving and Parking Inside ERA..... Safety - 2 - 21

2.4 Adverse Weather Conditions .......................................................................... Safety - 2 - 21

2.4.1 Winter or Slippery Apron Conditions...................................................... Safety - 2 - 21

2.4.2 Thunderstorms....................................................................................... Safety - 2 - 22

2.4.3 High Wind Conditions ............................................................................ Safety - 2 - 22

2.5 ISO 7000 and 7010 Safety Guidelines............................................................ Safety - 2 - 22

2.5.1 International Decals and Symbols. ........................................................ Safety - 2 - 22

Material Data Safety Sheet Information ............................................................... Safety - 2 - 25

2.5.2 Links for products:.................................................................................. Safety - 2 - 26

Operation ...........................................................................................Operation - 1 - 1

Section 1: System Overview ........................................................................ Operation - 1 - 4

1.1 Safety Precautions.......................................................................................Operation - 1 - 4

1.2 Purpose of Equipment .................................................................................Operation - 1 - 4

1.3 General Description .....................................................................................Operation - 1 - 4

1.4 Major Components.......................................................................................Operation - 1 - 4

1.4.1 Power Package...................................................................................Operation - 1 - 4

1.4.2 Engine.................................................................................................Operation - 1 - 4

1.4.2.1 Gasoline and LPG - Ford 2.5L ...................................................Operation - 1 - 4

1.4.2.2 Diesel - Deutz 2.9L.....................................................................Operation - 1 - 5

1.4.3 Transmission.......................................................................................Operation - 1 - 5

1.4.4 Drive Shaft ..........................................................................................Operation - 1 - 5

1.4.5 Drive Axle............................................................................................Operation - 1 - 5

1.4.6 Steer Axle ...........................................................................................Operation - 1 - 5

1.4.7 Brakes.................................................................................................Operation - 1 - 5

1.4.7.1 Hydraulic ....................................................................................Operation - 1 - 5

1.4.7.2 Park Brake .................................................................................Operation - 1 - 5

1.4.8 Chassis ...............................................................................................Operation - 1 - 5

1.4.9 Body....................................................................................................Operation - 1 - 5

1.4.10 Conveyor...........................................................................................Operation - 1 - 6

1.4.11 Operator’s Compartment ..................................................................Operation - 1 - 6

1.4.12 Electrical System ..............................................................................Operation - 1 - 7

1.4.13 Hydraulic System ..............................................................................Operation - 1 - 7

1.4.13.1 General Hydraulics Operation..................................................Operation - 1 - 7

1.4.13.2 Steer and Braking ....................................................................Operation - 1 - 7

1.4.13.3 Lift Cylinders and Conveyor Motor...........................................Operation - 1 - 8

Section 2: Operational Procedures ........................................................... Operation - 2 - 11

2.1 Instrument Panel Controls and Indicators..................................................Operation - 2 - 11

2.1.1 Ford 2.5L...........................................................................................Operation - 2 - 11

2.1.2 Deutz 2.9L Tier 4F ............................................................................Operation - 2 - 11

CD397-Oper Introduction - 1 - vii

Mobile Belt Loader Model 660

Operation Manual

Introduction

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

2.1.4 Conveyor Controls ............................................................................Operation - 2 - 16

2.1.5 Electrical Supply ...............................................................................Operation - 2 - 17

2.1.6 Preliminary Checks ...........................................................................Operation - 2 - 17

2.1.7 Maneuvering Procedures..................................................................Operation - 2 - 18

2.1.7.1 Engine Start Procedure (Gas)..................................................Operation - 2 - 18

2.1.7.2 Engine Start (Diesel)................................................................Operation - 2 - 19

2.1.7.3 Release parking brake. ............................................................Operation - 2 - 19

2.1.7.4 Transmission Drive (FWD/REV) Selection...............................Operation - 2 - 19

2.1.7.5 Depress foot throttle.................................................................Operation - 2 - 20

2.1.7.6 Maneuver vehicle with steering wheel. ....................................Operation - 2 - 20

2.1.7.7 Maneuvering the baggage loader around the aircraft ..............Operation - 2 - 21

2.1.8 Belt Loader Towing Instructions........................................................Operation - 2 - 21

2.1.8.1 Towing Requirements ..............................................................Operation - 2 - 21

2.1.9 Conveyor Safety Props .....................................................................Operation - 2 - 23

2.2 IATA...........................................................................................................Operation - 2 - 24

2.3 SAE............................................................................................................Operation - 2 - 24

2.4 ISO EMC Evaluation..................................................................................Operation - 2 - 24

2.5 ISO Product Safety Evaluation ..................................................................Operation - 2 - 25

2.6 Locations of Technical Construction Files .................................................Operation - 2 - 25

Section 3: Specifications ........................................................................... Operation - 3 - 27

3.1 General Specifications of the 660..............................................................Operation - 3 - 27

3.1.1 Dimensions .......................................................................................Operation - 3 - 27

3.2 Torque Values............................................................................................Operation - 3 - 28

3.2.1 Metric Fasteners ...............................................................................Operation - 3 - 28

3.2.2 Graded Bolts .....................................................................................Operation - 3 - 29

3.3 Performance ..............................................................................................Operation - 3 - 31

3.3.1 Specifications....................................................................................Operation - 3 - 31

3.3.2 Environmental Operating Limits........................................................Operation - 3 - 32

3.3.3 Environmental Vibration Information.................................................Operation - 3 - 32

3.3.4 Environmental Sound Information.....................................................Operation - 3 - 32

3.4 Engines......................................................................................................Operation - 3 - 35

3.4.1 Gasoline............................................................................................Operation - 3 - 35

3.4.1.1 Ford MSG-425 2.5L .................................................................Operation - 3 - 35

3.4.2 Diesel ................................................................................................Operation - 3 - 35

3.4.2.1 Deutz D2.9L .............................................................................Operation - 3 - 35

3.5 Transmission..............................................................................................Operation - 3 - 36

3.5.1 Gear Ratios.......................................................................................Operation - 3 - 36

3.6 Standard Conveyor Heights and Angles....................................................Operation - 3 - 37

3.7 Compatible Aircraft ....................................................................................Operation - 3 - 38

3.8 Fluids .........................................................................................................Operation - 3 - 42

3.9 Coolant.......................................................................................................Operation - 3 - 43

3.10 Recommended Spare Parts.....................................................................Operation - 3 - 43

3.11 Safety Features........................................................................................Operation - 3 - 44

3.11.1 Shifter / Parking Brake Safety.........................................................Operation - 3 - 44

3.11.2 Shifter Guard...................................................................................Operation - 3 - 44

3.11.3 Neutral Safety Start Switch .............................................................Operation - 3 - 44

3.11.4 Anti-Restart Ignition Switch.............................................................Operation - 3 - 44

3.11.5 Engine Control Module (ECM) Starter Protection ...........................Operation - 3 - 45

3.11.5.1 Ford 2.5L................................................................................Operation - 3 - 45

Introduction - 1 - viii CD397-Oper

Mobile Belt Loader Model 660

Operation Manual

Introduction

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

3.11.6 Emergency Stop Switch..................................................................Operation - 3 - 45

3.11.7 Park Brake ......................................................................................Operation - 3 - 45

3.11.8 Pilot-Operated Hydraulic Check Valves..........................................Operation - 3 - 45

3.11.9 Safety Props ...................................................................................Operation - 3 - 46

3.11.10 Side / Hand Rails ..........................................................................Operation - 3 - 46

3.11.11 Finger Guards ...............................................................................Operation - 3 - 46

3.11.12 Rubber Bumper Roll .....................................................................Operation - 3 - 46

3.11.13 Steel Hoop Guard (Optional) ........................................................Operation - 3 - 46

3.11.14 Grit Paper......................................................................................Operation - 3 - 46

Section 4: Shipping .................................................................................... Operation - 4 - 47

4.1 Shipping Preparation .................................................................................Operation - 4 - 47

4.1.1 Fuel Tank Preparation .....................................................................Operation - 4 - 47

4.1.2 Battery Preparation ..........................................................................Operation - 4 - 47

4.1.3 Pre-shipping Verification ..................................................................Operation - 4 - 47

4.2 Receiving ...................................................................................................Operation - 4 - 48

4.2.1 Preparing for Operation ....................................................................Operation - 4 - 48

4.2.1.1 Battery......................................................................................Operation - 4 - 48

4.2.1.2 Emergency Hydraulic Pump.....................................................Operation - 4 - 48

4.2.1.3 Radiator....................................................................................Operation - 4 - 48

4.2.1.4 Fuel Cell...................................................................................Operation - 4 - 48

Section 5: Storage ...................................................................................... Operation - 5 - 49

5.1 Short Term Storage ...................................................................................Operation - 5 - 49

5.1.1 Gasoline Engine................................................................................Operation - 5 - 49

5.1.1.1 Ford 2.5 L Engine.....................................................................Operation - 5 - 49

5.1.1.2 Transmission............................................................................Operation - 5 - 49

5.1.1.3 Drive Axle.................................................................................Operation - 5 - 49

5.1.1.4 Tires .........................................................................................Operation - 5 - 50

5.1.1.5 Lubrication................................................................................Operation - 5 - 50

5.1.1.6 Battery......................................................................................Operation - 5 - 50

5.1.1.7 Fluid Levels..............................................................................Operation - 5 - 50

5.1.2 Diesel Engine....................................................................................Operation - 5 - 50

5.1.2.1 Deutz 2.9L Engine....................................................................Operation - 5 - 50

5.1.2.2 Transmission............................................................................Operation - 5 - 50

5.1.2.3 Drive Axle.................................................................................Operation - 5 - 50

5.1.2.4 Tires .........................................................................................Operation - 5 - 51

5.1.2.5 Lubrication................................................................................Operation - 5 - 51

5.1.2.6 Battery......................................................................................Operation - 5 - 51

5.1.2.7 Fluid Levels..............................................................................Operation - 5 - 51

5.2 Returning the Vehicle to Operation After Short Term Storage...................Operation - 5 - 51

5.2.1 Tires ..................................................................................................Operation - 5 - 51

5.2.2 Battery...............................................................................................Operation - 5 - 51

5.2.3 Engine...............................................................................................Operation - 5 - 52

5.2.4 Transmission.....................................................................................Operation - 5 - 52

5.3 Long Term Storage....................................................................................Operation - 5 - 52

5.3.1 Gasoline Engine................................................................................Operation - 5 - 52

5.3.1.1 Ford 2.5L Engine......................................................................Operation - 5 - 52

5.3.1.2 Engine Exterior.........................................................................Operation - 5 - 53

5.3.2 Transmission.....................................................................................Operation - 5 - 53

5.3.2.1 Drive Axle.................................................................................Operation - 5 - 54

CD397-Oper Introduction - 1 - ix

Mobile Belt Loader Model 660

Operation Manual

Introduction

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

5.3.4 Lubrication ........................................................................................Operation - 5 - 54

5.3.5 Fluid Levels.......................................................................................Operation - 5 - 54

5.3.6 Battery...............................................................................................Operation - 5 - 54

5.3.7 Diesel Engine....................................................................................Operation - 5 - 55

5.3.7.1 Deutz 2.9L Engine ...................................................................Operation - 5 - 55

5.3.8 Transmission.....................................................................................Operation - 5 - 56

5.3.9 Drive Axle..........................................................................................Operation - 5 - 56

5.3.10 Exhaust ...........................................................................................Operation - 5 - 57

5.3.11 Tires ................................................................................................Operation - 5 - 57

5.3.12 Lubrication ......................................................................................Operation - 5 - 57

5.3.13 Levels..............................................................................................Operation - 5 - 57

5.3.14 Wheel Bearings...............................................................................Operation - 5 - 57

5.3.15 Battery.............................................................................................Operation - 5 - 57

5.3.16 Fuel System ....................................................................................Operation - 5 - 58

5.3.17 Engine Exterior ...............................................................................Operation - 5 - 58

5.3.18 Tagging ...........................................................................................Operation - 5 - 59

5.4 Returning the Vehicle to Operation After Long-Term Storage...................Operation - 5 - 59

5.4.1 Tires ..................................................................................................Operation - 5 - 59

5.4.2 Battery...............................................................................................Operation - 5 - 59

5.4.3 Engine...............................................................................................Operation - 5 - 59

5.4.4 Transmission.....................................................................................Operation - 5 - 60

5.4.5 Drive Axle..........................................................................................Operation - 5 - 60

5.4.6 Pre-Operational Checks....................................................................Operation - 5 - 60

5.5 Cold Weather Storage ...............................................................................Operation - 5 - 60

5.6 Returning the Vehicle to Operation After Cold Weather Storage...............Operation - 5 - 61

5.6.1 Refill Fluids .......................................................................................Operation - 5 - 61

Introduction - 1 - x CD397-Oper

Mobile Belt Loader Model 660

Operation Manual

Introduction

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