Textron GSE 660-28 User manual

CD397-Oper
June 2019 (Rev C)
MODEL660-28
MOBILEBELTLOADER
OPERATIONMANUAL

IntroductionIntroduction
Property of American Airlines

Introduction - 1 - ii CD397-Oper
June 2019 (Rev C)
Mobile Belt Loader Model 660-28 Introduction
Operation Manual
CALIFORNIAPROPOSITION65
WARNING:
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects or other reproductive harm.
For more information, go to:
www.P65Warnings.ca.gov/passenger-vehicle
WARNING
!
Operating, servicing and maintaining a
passenger vehicle or o-road vehicle can
expose you to phthalates and lead, which
are known to the State of California to
cause cancer and birth defects or other
reproductive harm. To minimize exposure,
wear gloves or wash your hands frequently
when servicing your vehicle.
Electric-powered, Other Equipment
Operating, servicing and maintaining a
passenger vehicle or off-road vehicle can
expose you to chemicals including engine
exhaust, carbon monoxide, phthalates, and
lead, which are known to the State of
California to cause cancer and birth defects
or other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not
idle the engine except as necessary, service
your vehicle in a well ventilated area and
wear gloves or wash your hands frequently
when servicing your vehicle.
For more information, go to:
www.P65Warnings.ca.gov/passenger-vehicle
WARNING
!
Operating, servicing and maintaining a
passenger vehicle or o-road vehicle can
expose you to chemicals including engine
exhaust, carbon monoxide, phthalates, and
lead, which are known to the State of
California to cause cancer and birth defects or
other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not idle
the engine except as necessary, service your
vehicle in a well ventilated area and wear
gloves or wash your hands frequently when
servicing your vehicle.
For more information, go to:
www.P65Warnings.ca.gov/passenger-vehicle
WARNING
!
For more information, go to:
www.P65Warnings.ca.gov/passenger-vehicle
WARNING
!
Operating, servicing and maintaining a
passenger vehicle or off-road vehicle
can expose you to phthalates and lead,
which are known to the State of
California to cause cancer and birth
defects or other reproductive harm.
To minimize exposure, wear gloves or
wash your hands frequently when
servicing your vehicle.
Electric-powered, Other Equipment
Property of American Airlines

CD397-Oper Introduction - 1 - iii
June 2019 (Rev C)
Introduction Mobile Belt Loader Model 660-28
Operation Manual
COPYRIGHTNOTICE
This manual is copyright ©2015, 2018& 2019 Textron Ground Support Equipment, Incorporated (Textron
GSE). 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 Textron GSE.
Any attempt to alter the contents of this manual in any way by anyone other than an authorized agent of
Textron GSE 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.
Property of American Airlines

Introduction - 1 - iv CD397-Oper
June 2019 (Rev C)
Mobile Belt Loader Model 660-28 Introduction
Operation Manual
RECORDOFREVISIONS
RevisionDate:June2019
Check each revision received, and insert the revised and supplementary pages in your manual.Textron
GSE assumes no liability for personal injury or equipment failure due to any operation performed without
heed to manual revisions.
Dateoforiginalpublication:December2015
Only pages that have been revised are listed in Table Introduction-1-2, “List of Revisions,”
Property of: _______________________________________________________________
Company: _______________________________________________________________
Address: _______________________________________________________________
City: ___________________________ State/Province: _____________
Country ___________________________ Zip/Postal Code: _____________
TableIntroduction-1-1:Revisions
Revision Date BriefDescription
ADecember 2015 Original Release
BAugust 2018
Removed 660-44 documentation
Updated Safety Section 2
Updated manual formatting
Added Smart Sense
Added California Proposition 65 pages
Updated logos and document formatting
CJune 2019
Update the front cover with Belt Loader Picture
Updated Safety_S2_IATA section with
Updated Section 2 - Operation Procedure from Chapter 2-
Operation with Smart Sense information.
Property of American Airlines

CD397-Oper Introduction - 1 - v
June 2019 (Rev C)
Introduction Mobile Belt Loader Model 660-28
Operation Manual
LISTOFEFFECTIVEPAGES
TableIntroduction-1-2:ListofRevisions
Page Revision Date Page Revision Date
All BAugust
2018
Front Cover
CJune
2019
Safety-2-1 to Safety-2-17
Operation-2-10 to Operation-2-11
Property of American Airlines

Introduction - 1 - vi CD397-Oper
June 2019 (Rev C)
THIS PAGE INTENTIONALLY BLANK
Mobile Belt Loader Model 660-28 Introduction
Operation Manual
Property of American Airlines

CD397-Oper Introduction - 1 - vii
June 2019 (Rev C)
Introduction Mobile Belt Loader Model 660-28
Operation Manual
MANUALTABLEOFCONTENTS
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Introduction-1-i
California Proposition 65 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Introduction-1-ii
Copyright Notice- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-iii
Record of Revisions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-iv
List of Effective Pages- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-v
Manual Table of Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Introduction-1-vii
List of Figures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-xiii
List of Tables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Introduction-1-xv
Unit Identification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-xvii
Model Number Coding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Introduction-1-xviii
Technical Assistance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-xix
Technical service bulletins- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Introduction-1-xx
Warranty Information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-xxi
Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-xxii
How to Use This Manual - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Introduction-1-xxvi
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-1-3
1.2: Safety Features- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-4
1.2.1: Emergency Stop Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-4
1.2.2: Pilot-Operated Hydraulic Check Valves - - - - - - - - - - - - - - - - - - - - - - Safety-1-4
1.2.3: Safety Props - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-4
1.2.4: Finger Guards - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-4
1.2.5: Rubber Roll Bumper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-4
1.2.6: Steel Hoop Guard (Optional)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-4
1.3: Safety Responsibilities- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-4
1.3.1: Operator Safety Responsibility - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-4
1.3.2: Mechanic Safety Responsibility- - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-6
1.3.2.1: LP and CNG Safety Information- - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-7
1.4: Emergency Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-8
1.4.1: Disabled or Stalled Vehicle- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-8
1.4.1.1: Operable Engine - Mobile Unit- - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-8
1.4.1.2: Operable Engine — Immobile Unit - - - - - - - - - - - - - - - - - - - - - - - Safety-1-8
1.4.1.3: Inoperable Engine With Electrical Power - - - - - - - - - - - - - - - - - - Safety-1-9
1.4.1.4: Inoperable Engine with Loss of Electrical Power - - - - - - - - - - - - - Safety-1-9
1.4.1.5: Belt Loader Towing Instructions- - - - - - - - - - - - - - - - - - - - - - - - Safety-1-10
1.4.2: Recommended Fire Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-11
1.4.2.1: Dry Chemical (Purple K) Fire Extinguisher Use and
Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-11
1.4.3: Collisions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-1-15
Section 2: IATA Safety Guidelines for Aircraft Handling Procedures Safety-2-1
2.1: Ramp Safety in Aircraft Handling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-1
2.1.1: General Ramp Safety- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-1
Property of American Airlines

Introduction - 1 - viii CD397-Oper
June 2019 (Rev C)
Mobile Belt Loader Model 660-28 Introduction
OperationManual
2.1.1.1: Engine Danger Areas - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-1
2.1.1.2: Engine Danger Area Diagrams - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-1
2.1.1.4: FOD - Foreign Object Debris - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-4
2.1.1.5: FOD Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-5
2.1.2.1: General Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-6
2.1.2.2: Basic Operating Requirements for GSE - - - - - - - - - - - - - - - - - - - Safety-2-6
2.1.2.3: Non-Motorized GSE - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-7
2.1.2.4: Ground Support Equipment Safety Driving and
Parking Inside the Equipment Restraint Area - - - - - - - - - - - - - - - Safety-2-7
2.1.2.5: Belt Loader - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-8
2.1.2.6: Tractor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-8
2.2: Adverse Weather Conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-9
2.2.1: General - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-9
2.2.2: Winter or Slippery Apron Conditions - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-9
2.2.3: Storms - Lightning Work Instructions - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-9
2.2.3.3: Counting Method - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-10
2.2.4: High Wind Conditions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-11
2.2.5: High Winds Activity Table- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-11
2.2.6: Sandstorms and Low Visibility- - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-12
2.2.7: Intense Heat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-12
2.3: Safety Cones - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-12
2.4.1: International Decals and Symbols. - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-13
2.5: Material Data Safety Sheet Information - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-16
2.5.1: Links for products: - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Safety-2-17
Operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-1
Section 1: General Description and System Overview- - - - - - - - -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
1.3.1: Power Package - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-1
1.3.1.1: Engine- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-1
1.3.2: Cooling System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-1
1.3.2.1: Engine Cooling System- - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-1
1.3.2.2: Transmission Cooling System - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-2
1.3.2.3: Hydraulic Cooling System - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-2
1.3.3: Hydraulic System- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-2
1.3.3.1: Hydraulic Brake System and Steering System- - - - - - - - - - - - -Operation-1-2
1.3.3.2: Lift Cylinders and Conveyor Motors - - - - - - - - - - - - - - - - - - - -Operation-1-2
1.3.3.3: Emergency Pump- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-3
1.3.4: Conveyor Belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-3
1.3.5: Suspension/Axles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-4
1.3.5.1: Front Axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-4
1.3.5.2: Rear Axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-4
1.3.5.3: Drive Shaft- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-4
1.3.6: Brake System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-4
1.3.7: Lubrication System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-4
1.3.8: Air Intake and Exhaust Systems - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-4
1.3.8.1: Ford Air Intake/Exhaust System- - - - - - - - - - - - - - - - - - - - - - -Operation-1-4
Property of American Airlines

CD397-Oper Introduction - 1 - ix
June 2019 (Rev C)
Introduction Mobile Belt Loader Model 660-28
Operation Manual
1.3.9: Fuel System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-4
1.3.10: Electrical System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-4
1.3.11: Cab - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-4
1.3.11.1: Full Cab- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-4
1.3.11.2: Economy Cab (Non-CE option only)- - - - - - - - - - - - - - - - - - -Operation-1-5
1.3.12: Smart Sense (Optional) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-5
1.3.12.1: GM Inching Transmission - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-6
1.3.12.2: Transmission Control Module (TCM) - - - - - - - - - - - - - - - - - -Operation-1-6
1.3.12.3: Collision Avoidance Module- - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-6
1.3.12.4: Ultrasonic Sensors and Pods- - - - - - - - - - - - - - - - - - - - - - - -Operation-1-7
1.3.12.5: Operator Indicator Light and Supervisor Light - - - - - - - - - - - -Operation-1-7
1.3.12.7: Conveyor Position Proximity Switch - - - - - - - - - - - - - - - - - - -Operation-1-9
1.3.12.8: Brake Pressure Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-9
1.3.12.9: Park Brake Switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-10
1.3.12.10: Conveyor up/down inhibit valve (Optional)- - - - - - - - - - - - - Operation-1-10
1.3.13: Additional Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-10
1.3.13.1: Frame - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-10
1.3.13.2: Wheels and Tires - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-10
1.3.13.3: Fasteners - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-1-10
1.3.13.4: Shift Inhibit- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-1-10
1.3.14: Standard/Optional Equipment/Features - - - - - - - - - - - - - - - - - - Operation-1-10
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: Instrument/Dash Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-4
2.2.1.1: Ford 2.5L- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-4
2.2.2: Conveyor Controls- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-6
2.2.2.1: Cylinder Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-6
2.2.2.2: Belt Drive Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-6
2.2.2.3: Pilot-Operated Hydraulic Check Valves - - - - - - - - - - - - - - - - -Operation-2-7
2.3: Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-7
2.3.1: Pre-Operation Checklist - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-7
2.3.2: Starting Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-8
2.3.2.1: Gas Engine Start Procedure - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-8
2.3.2.2: Release park brake - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-8
2.3.2.3: Anti-Restart ignition Switch - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-8
2.3.3: Driving Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-9
2.3.3.1: Transmission Selection- - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-9
2.3.4: Conveyor Maneuvering - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-9
2.3.4.1: Approaching the Aircraft with steering wheel- - - - - - - - - - - - - -Operation-2-9
2.3.4.2: Loading and Unloading baggage - - - - - - - - - - - - - - - - - - - - - -Operation-2-9
2.3.4.3: Departing the Aircraft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-9
2.3.5: Conveyor Maneuvering with Smart Sense - - - - - - - - - - - - - - - - -Operation-2-10
2.3.5.1: Activating Smart Sense- - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-10
2.3.5.2: Approaching the Aircraft - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-10
2.3.5.3: Loading and Unloading Baggage - - - - - - - - - - - - - - - - - - - - - Operation-2-11
2.3.5.4: Departing the Aircraft - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-11
2.3.5.5: Deactivating Smart Sense- - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-12
2.3.6: Conveyor Belt Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-12
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Mobile Belt Loader Model 660-28 Introduction
OperationManual
2.3.6.1: Conveyor Safety Props - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-12
2.3.7: Park Brake Operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-13
2.3.8: Shutdown Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-13
2.3.9: Emergency Hydraulic Pump - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-2-13
2.4: Preventive Maintenance- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-2-14
Section 3: Specifications and Capabilities - - - - - - - - - - - - - - - - -Operation-3-1
3.1: Unit Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-1
3.2: Conveyor Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-1
3.2.1: Conveyor Positions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-1
3.3: Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-3
3.4: Performance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-4
3.5: Compatible Aircraft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-4
3.6: Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-8
3.6.1: Ford MSG-425 2.5L Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-8
3.7: Transmission - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-8
3.7.1: GM 4L70 Gear Speeds/Ratios - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-8
3.8: Axles - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-9
3.8.1: Front Axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-9
3.8.2: Rear Axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-9
3.9: Steering System - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-9
3.10: Hydraulic System- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-9
3.11: Fluids and Lubricants- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-10
3.12: Critical Torque Values - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-3-11
3.12.1: Torque Values- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-11
3.12.2: Metric Fasteners - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Operation-3-12
3.12.3: Graded Bolts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-3-12
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: Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-2
4.1.4: .Engine- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-2
4.1.5: Fuel Tank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-2
4.1.6: Conveyor Belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-3
4.1.7: Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-7
4.2: Preparation for Operation- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-8
4.2.1: Tie-Down Points (Truck Shipping) - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-8
4.2.2: Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-8
4.2.3: Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-8
4.2.4: Conveyor Belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-8
4.2.5: Radiator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-10
4.2.6: Fuel Tank - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-10
4.2.7: Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-10
4.2.8: Additional Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-4-10
Section 5: Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-1
5.1: Short Term Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-1
5.1.1: Gasoline Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-1
5.1.1.1: Ford MSG-425 2.5L Engine- - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-1
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Introduction Mobile Belt Loader Model 660-28
Operation Manual
5.1.1.2: Transmission - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-1
5.1.1.3: Drive Axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-1
5.1.1.4: Tires.- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-1
5.1.1.5: Lubrication- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-2
5.1.1.6: Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-2
5.1.1.7: Fluid Levels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-2
5.2: Returning the Belt Loader to Operation After Short-Term Storage - - - -Operation-5-2
5.2.1: Engine and Engine Components- - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-2
5.2.2: Transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-2
5.2.3: Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-2
5.2.4: Tires- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-2
5.3: Long Term Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-3
5.3.1: Ford MSG-425 2.5L Engine - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-3
5.3.1.1: Engine Exterior - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-3
5.3.1.2: Transmission - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-4
5.3.1.3: Drive Axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-4
5.3.1.5: Lubrication- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-4
5.3.1.6: Fluid Levels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-4
5.3.1.7: Wheel Bearings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-4
5.3.1.8: Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-4
5.3.2: Conveyor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-5
5.4: Returning the Tractor to Operation After Long-Term Storage- - - - - - - -Operation-5-5
5.4.1: Tires- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-5
5.4.2: Battery - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-5
5.4.3: Engine and Engine Components- - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-5
5.4.4: Transmission- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-5
5.4.5: Drive Axle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-5
5.4.6: Pre-Operation Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-6
5.5: Cold Weather Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-6
5.6: Returning the Vehicle to Operation After Cold Storage - - - - - - - - - - - -Operation-5-6
5.6.1: Refill Fluids - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Operation-5-6
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Operation Manual
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Operation Manual
LISTOFFIGURES
Figure Introduction-1-1: Identification Plate .................................................... Introduction-1-xvii
Figure Introduction-1-2: 660-28 Model Number Coding .................................Introduction-1-xviii
Figure Introduction-1-3: Page Numbering System......................................... Introduction-1-xxvi
Figure Introduction-1-4: Table and Figure Numbering System......................Introduction-1-xxvii
Figure Safety-1-1: Removal of Fire Heat Source...................................................... Safety-1-13
Figure Safety-1-2: Ring Pin Removal ....................................................................... Safety-1-13
Figure Safety-1-3: Proper Use of a Fire Extinguisher............................................... Safety-1-13
Figure Safety-2-1: Engine Danger Area - Jet Aircraft ................................................. Safety-2-2
Figure Safety-2-2: Engine Danger Area - Propeller Aircraft........................................Safety-2-3
Figure Safety-2-3: Equipment Restraint Area............................................................. Safety-2-4
Figure Safety-2-4: Lightning Counting Method......................................................... Safety-2-10
Figure Safety-2-5: Fasten Seat Belts (White on Blue Background).......................... Safety-2-14
Figure Safety-2-6: Use Hearing Protection (White on Blue Background)................. Safety-2-14
Figure Safety-2-7: Hot Surface (Yellow Field with Black Border) ............................. Safety-2-14
Figure Operation-1-1: Collision Avoidance Module ...............................................Operation-1-6
Figure Operation-1-2: Left Hand Pod and Sensor .................................................Operation-1-7
Figure Operation-1-3: Right Hand Pod and Sensor...............................................Operation-1-7
Figure Operation-1-4: Operator Indicator Light......................................................Operation-1-8
Figure Operation-1-5: Supervisor Indicator Light...................................................Operation-1-8
Figure Operation-1-6: Seat and Seat Switch.........................................................Operation-1-9
Figure Operation-1-7: Conveyor Proximity Switch.................................................Operation-1-9
Figure Operation-2-1: Operator’s Compartment....................................................Operation-2-2
Figure Operation-2-2: 660-28 Instrument Panel - Ford 2.5L..................................Operation-2-4
Figure Operation-2-3: Cylinder Controls................................................................Operation-2-6
Figure Operation-2-4: Belt Drive Controls..............................................................Operation-2-6
Figure Operation-3-1: Front Up, Rear Down..........................................................Operation-3-2
Figure Operation-3-2: Front Up, Rear Up..............................................................Operation-3-2
Figure Operation-3-3: Front Down, Rear Down.....................................................Operation-3-3
Figure Operation-3-4: Front Down, Rear Up..........................................................Operation-3-3
Figure Operation-3-5: Capscrew Examples.........................................................Operation-3-11
Figure Operation-4-1: 660-28 Tie Down Points.....................................................Operation-4-1
Figure Operation-4-2: Conveyor Stacking Materials..............................................Operation-4-3
Figure Operation-4-3: Placing the Carrier Conveyor .............................................Operation-4-3
Figure Operation-4-4: Wooden Support Placing....................................................Operation-4-4
Figure Operation-4-5: Conveyor Belt Placement...................................................Operation-4-4
Figure Operation-4-6: Bubble Wrap.......................................................................Operation-4-5
Figure Operation-4-7: Stacked Conveyor Tie Down..............................................Operation-4-5
Figure Operation-4-8: Tied Down Conveyor Coils.................................................Operation-4-6
Figure Operation-4-9: Pinch Guard Wrap and Placement.....................................Operation-4-6
Figure Operation-4-10: Pinch Guard Securing ......................................................Operation-4-6
Figure Operation-4-11: Rear of Unit Tie Down......................................................Operation-4-7
Figure Operation-4-12: Chocked Wheels ..............................................................Operation-4-7
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Introduction- 1 - xiv CD397-Oper
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Operation Manual
Figure Operation-4-13: Threading Conveyor Lifting Strap.....................................Operation-4-8
Figure Operation-4-14: Conveyor Lift Support.......................................................Operation-4-9
Figure Operation-4-15: Removing “Carrier” Belt Loader........................................Operation-4-9
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Introduction Mobile Belt Loader Model 660-28
Operation Manual
Notes:
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Operation Manual
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CD397-Oper Introduction - 1 - xv
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Introduction Mobile Belt Loader Model 660-28
Operation Manual
LISTOFTABLES
Table Introduction-1-1: Revisions..................................................................... Introduction-1-iv
Table Introduction-1-2: List of Revisions............................................................ Introduction-1-v
Table Introduction-1-3: Service Recalls/Notification ...................................... Introduction-1-xxii
Table Safety-1-1: Standard Safety Features/Equipment ........................................... Safety-1-1
Table Safety-1-2: Optional Safety Items.................................................................... Safety-1-3
Table Safety-1-3: Operator Safety Responsibilities................................................... Safety-1-5
Table Safety-1-4: Mechanic Safety Responsibilities.................................................. Safety-1-6
Table Safety-1-5: Initial and 30 Day Visual Inspection ............................................ Safety-1-14
Table Safety-2-1: Examples of FOD.......................................................................... Safety-2-5
Table Safety-2-2: FOD Checks.................................................................................. Safety-2-5
Table Safety-2-3: Notification Levels....................................................................... Safety-2-10
Table Safety-2-4: High Wind Activity Table ............................................................. Safety-2-11
Table Operation-2-1: Operator Compartment....................................................... Operation-2-3
Table Operation-2-2: Instrument Panel Description - Ford 2.5L........................... Operation-2-4
Table Operation-3-1: Dimensions and Measurements ......................................... Operation-3-1
Table Operation-3-2: Conveyor Dimensions......................................................... Operation-3-1
Table Operation-3-3: Conveyor Positions............................................................. Operation-3-1
Table Operation-3-4: Specification Data............................................................... Operation-3-3
Table Operation-3-5: Performance....................................................................... Operation-3-4
Table Operation-3-6: Aircraft Compatibility........................................................... Operation-3-4
Table Operation-3-7: Front Axle ........................................................................... Operation-3-8
Table Operation-3-8: Transmission ...................................................................... Operation-3-8
Table Operation-3-9: Gear Speeds....................................................................... Operation-3-8
Table Operation-3-10: Front Axle ......................................................................... Operation-3-9
Table Operation-3-11: Rear Axle.......................................................................... Operation-3-9
Table Operation-3-12: Steering System ............................................................... Operation-3-9
Table Operation-3-13: Hydraulic System.............................................................. Operation-3-9
Table Operation-3-15: Hydraulic Fluids.............................................................. Operation-3-10
Table Operation-3-14: Hydraulic System Components ...................................... Operation-3-10
Table Operation-3-16: Critical Torque Values .................................................... Operation-3-11
Table Operation-3-17: Torque Values for Metric Fasteners ............................... Operation-3-12
Table Operation-3-18: Torque Values for Graded Bolts..................................... Operation-3-12
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CD397-Oper Introduction - 1 - xvii
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Introduction Mobile Belt Loader Model 660-28
Operation Manual
UNITIDENTIFICATION
The information and instructions in this manual are intended to acquaint the operator with the important
operating features of the Tug Mobile Belt Loader 660-28. The various controls, gauge, switches, and
operating features are explained and illustrated throughout this manual. Personnel responsible for the
operation of the vehicle should read this manual carefully.
To aid the technician in repair or service work on this unit, an identification plate is located in the operator's
compartment.
FigureIntroduction-1-1:IdentificationPlate
The serial number identification of each unit will appear on the identification plate along with the date of
manufacture. 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:_________________________________________
TUG TECHNOLOGIES CORPORATION
1995 DUNCAN DRIVE
KENNESAW, GEORGIA 30144
MODEL #
MFG DATE
UNLADEN WEIGHT w/OUT CAB
WITH CAB
MAXIMUM SPEED
PERMISSABLE TOTAL PAYLOAD EVENLY DISTRIBUTED ON THE BOOM AT MAXIMUM AND MINIMUM ANGLE IS:
MAXIMUM SINGLE LOAD ON THE BOOM IS
POUNDS
POUNDS
MPH
KILOGRAMS
KILOGRAMS
KPH
660-4-3728
POUNDS KILOGRAMS
POUNDS KILOGRAMS
SERIAL
NUMBER
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Introduction - 1 - xviii CD397-Oper
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Mobile Belt Loader Model 660-28 Introduction
Operation Manual
MODELNUMBERCODING
Units are numbered according to the diagram in Figure Introduction-1-2 660-28 Model Number Coding.
FigureIntroduction-1-2:660-28ModelNumberCoding
Model Number Coding
Conveyor
Conveyor Engine Variations Variations
EngineEngine
660
660 = 34 in Wide x 24 ft Long
663 = 31.5 in Wide x 24 ft Long
28 = Ford MSG-425 (2.5 L) 4 Cylinder Gasoline/LP
28
_
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