TUG Technologies 660 User manual

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
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 - 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

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Mobile Belt Loader Model 660
Operation Manual
Introduction
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CD397-Oper Introduction-1-xi
Introduction Mobile Belt Loader Model 660
Operation Manual
LISTOFFIGURES
Figure Introduction - 1 - 1 - TUG Identification Plate .........................................Introduction-1-1
Figure Introduction - 1 - 2 - Model Numbers ......................................................Introduction-1-2
Figure Safety - 2 - 1 - Idle Power - Engine Intake Area NO Zone............................. Safety-2-15
Figure Safety - 2 - 2 - Breakaway Power - Engine Blast Area NO Zone .................. Safety-2-16
Figure Safety - 2 - 3 - Equipment Restraint Area...................................................... Safety-2-17
Figure Safety - 2 - 4 - Fasten Seat Belts (White on Blue Background)..................... Safety-2-24
Figure Safety - 2 - 5 - Use Hearing Protection (White on Blue Background)............ Safety-2-24
Figure Safety - 2 - 6 - Hot Surface (Yellow Field with Black Border) ........................ Safety-2-25
Figure Operation - 2 - 1 - Instrument Panel - Ford 2.5L.......................................Operation-2-12
Figure Operation - 2 - 2 - Instrument Panel - Deutz 2.9L.....................................Operation-2-14
Figure Operation - 2 - 3 - Maneuvering and Conveyor Controls..........................Operation-2-16
Figure Operation - 2 - 4 - Conveyor Controls.......................................................Operation-2-17
Figure Operation - 2 - 5 - Belt Loader with Props Engaged.................................Operation-2-23
Figure Operation - 3 - 1 - Capscrew Examples....................................................Operation-3-28
Figure Operation - 3 - 2 - Sound - Engine Idle - Conveyor Down - Belt Stationary .....................
.............................................................................................................................Operation-3-33
Figure Operation - 3 - 3 - Sound - Engine Max - Conveyor Down - Belt Max Speed ..................
.............................................................................................................................Operation-3-33
Figure Operation - 3 - 4 - Sound - Engine Idle - Conveyor Up - Belt Stationary ..Operation-3-34
Figure Operation - 3 - 5 - Sound - Engine Max - Conveyor Up - Belt Max Speed .......................
.............................................................................................................................Operation-3-34
Figure Operation - 3 - 6 - Conveyor - Full Down Rear, Full Up Front ..................Operation-3-37
Figure Operation - 3 - 7 - Conveyor - Full Up Rear, Full Up Front.......................Operation-3-37
Figure Operation - 3 - 8 - Conveyor - Full Down Rear, Full Down Front..............Operation-3-38
Figure Operation - 3 - 9 - Conveyor - Full Up Rear, Full Down Front ..................Operation-3-38

Introduction-1-xii CD397-Oper
Mobile Belt Loader Model 660
Operation Manual
Introduction
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CD397-Oper Introduction-1-xiii
Introduction Mobile Belt Loader Model 660
Operation Manual
LISTOFTABLES
Table Introduction - 1 - 1: Revisions ................................................................. Introduction-1-iii
Table Introduction - 1 - 2: List of Effective Pages ............................................. Introduction-1-iv
Table Introduction-1-1: Service Recalls/Notification ...........................................Introduction-1-4
Table Introduction-1-2: Flat Rate Labor Guide .................................................Introduction-1-10
Table Safety-1-1: Standard Safety Equipment ........................................................... Safety-1-1
Table Safety-1-2: Optional Safety Equipment............................................................. Safety-1-3
Table Safety-1-3: Operator Safety Responsibilities .................................................... Safety-1-5
Table Safety-1-4: Mechanic Safety............................................................................. Safety-1-7
Table Safety-2-1: Examples of FOD ......................................................................... Safety-2-18
Table Safety-2-2: FOD Checks................................................................................. Safety-2-18
Table Operation-2-1: Instrument Panel Description - Ford 2.5L ..........................Operation-2-12
Table Operation-2-2: Instrument Panel Description - Deutz 2.9L ........................Operation-2-14
Table Operation-3-1: Dimensions and Measurements ........................................Operation-3-27
Table Operation-3-2: Torque Values for Metric Fasteners ..................................Operation-3-28
Table Operation-3-3: Torque Values for Graded Bolts ........................................Operation-3-29
Table Operation-3-4: Performance Data..............................................................Operation-3-31
Table Operation-3-5: Specification Data.............................................................Operation-3-31
Table Operation-3-6: Environmental Limits .........................................................Operation-3-32
Table Operation-3-7: Ford MSG-425 (2.5 L).......................................................Operation-3-35
Table Operation-3-8: Deutz D2.9L.......................................................................Operation-3-35
Table Operation-3-9: Gear Ratios........................................................................Operation-3-36
Table Operation-3-10: Conveyor Positions..........................................................Operation-3-38
Table Operation-3-11: Aircraft Compatibility........................................................Operation-3-39
Table Operation-3-12: Hydraulic Fluid ................................................................Operation-3-42
Table Operation-3-13: Engine Oil .......................................................................Operation-3-42
Table Operation-3-14: Fluids ...............................................................................Operation-3-42

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CD397-Oper Introduction - 1 - 1
Mobile Belt Loader Model 660
Operation Manual
Introduction
UNITIDENTIFICATION
The information and instructions in this manual are intended to acquaint the operator with the
important operating features of the TUG Mobile Belt Loader Model 660. The various controls,
gauges, switches, and operating features are explained and illustrated throughout this manual.
Personnel responsible for operation of the vehicle should read this manual carefully.
To aid the technician in repair or service work on this unit, a TUG identification plate is located in
the operator's compartment.
The serial number identification of each unit will appear on the nameplate along with the date of
manufacture. The mailing address of TUG is also located at the top of the data plate opposite
the TUG logo. This necessary information will ensure the customer a fast and accurate response
to any parts and/or service request.
Please verify the serial number on the identification nameplate of the unit and enter your unit
serial number here:______________________________________________________
If applicable, enter your company identification number here:
______________________________________________________________________
SERIAL
NUMBER
3,175
3,266
40
907
227500
2,000
25
7,200
7,000
KILOGRAMS
POUNDS
KILOGRAMS
POUNDS
660−4−3728
KPH
KILOGRAMS
KILOGRAMS
MPH
POUNDS
POUNDS
MAXIMUM SINGLE LOAD ON THE BOOM IS
PERMISSABLE TOTAL PAYLOAD EVENLY DISTRIBUTED ON THE BOOM AT MAXIMUM AND MINIMUM ANGLE IS:
MAXIMUM SPEED
WITH CAB
UNLADEN WEIGHT w/OUT CAB
MFG DATE
MODEL #
TUG TECHNOLOGIES CORPORATION
1995 DUNCAN DRIVE
KENNESAW, GEORGIA 30144
FigureIntroduction-1-1:TUGIdentificationPlate

Introduction - 1 - 2 CD397-Oper
Mobile Belt Loader Model 660
Operation Manual
Introduction
MODELNUMBER
Tug numbers models according to the diagram in Figure Introduction - 1 - 2 Model Numbers.
660 44
Conveyor Variations
660 = 34 in Wide x 24 ft Long
663 = 31.5 in. Wide x 24 ft Long
Engine Variations
28 = Ford MSG-425 (2.5 L) 4 Cylinder Gasoline/LP
44 = Deutz TCD 2.9 L Diesel Tier IV Final
_
Conveyor Engine
Model Number Coding
FigureIntroduction-1-2:ModelNumbers
660 44
Conveyor Variations
660 = 34 in Wide x 24 ft Long
663 = 31.5 in. Wide x 24 ft Long
Engine Variations
28 = Ford MSG-425 (2.5 L) 4 Cylinder Gasoline/LP
44 = Deutz TCD 2.9 L Diesel Tier IV Final
_
Conveyor Engine
Model Number Coding

Introduction Mobile Belt Loader Model 660
Operation Manual
CD397-Oper Introduction - 1 - 3
WARRANTYINFORMATION
INTRODUCTION
The primary goal of warranty adjustment is to satisfy our customers. Every satisfied customer
strengthens the components of our whole organization - all aspects of the products themselves
and the service that backs them up. This manual is directed to TUG Technologies’ distributors
and customers of TUG Equipment. It should be used to implement the Warranty Program at
every level.
This Warranty Policy and Procedures Manual includes the warranties of TUG Technologies’
products. It explains warranty policy and coverage, and describes the warranty claim process.
TUG Technologies is responsible for handling warranty and policy adjustments promptly and in
accordance with the provisions of the Sales and Service Agreement, TUG Technologies War-
ranty Statements and this manual. Customers who recognize the manual as the "heart" of the
warranty system and train their personnel in its use may expect service personnel qualified to
submit claims that are properly completed and fully-substantiated, resulting in prompt claims pay-
ment.
PRE-DELIVERYPROCEDURES
Establish pre-delivery procedures that ensure the appropriate inspections and adjustments are
made prior to equipment being placed in service.
AUTHORIZATIONREQUIREMENTS-REPAIRSREQUIRINGPRIORAPPROVAL
Certain repairs and claims require prior approval. Any repair which will take more then 2 hours
labor to complete must have prior approval.
NOTE: The guidelines and requirements in this manual apply to warranty claims sub-
mitted to TUG Technologies for reimbursement to the customer.

Mobile Belt Loader Model 660 Introduction
Operation Manual
Introduction - 1 - 4 CD397-Oper
WARRANTY
A warranty is a specific document that guarantees the quality of goods to a purchaser within a
specified length of time and according to usage limitations. The TUG Technologies warranty
statement defines the conditions of the warranty. A warranty:
1. Remains in force for the specified period, provided that an occurrence has not taken
place to render the warranty inapplicable.
2. Assures the owner that if, under the conditions specified, a defect in factory workmanship
or material is encountered, it will be corrected at no charge or on a prorata basis.
3. Extension of coverage by any manufacturer does not change what is covered in the
basic, expressed limited warranty.
WARRANTYSTATEMENTS
TUG Technologies Warranty Statements provide detailed information regarding coverage and
usage limitations for TUG products.
WARRANTYPOLICYANDCOVERAGE
ServiceRecallsorOwnerNotificationPrograms
TUG TECHNOLOGIES may establish a program to resolve extensive customer concern about a
component beyond warranty coverage. Owners are notified to contact TUG Technologies for
replacement/repair. Customers will be notified by TUG TECHNOLOGIES with information that:
• Identifies the component and condition.
• Outlines the inspection and repair procedure required to correct the condition.
• Defines reimbursement.
TableIntroduction-1-1:ServiceRecalls/Notification
Component Disposition
Shipment TUG will ship components for service recalls and / or approved warranty
claims free of charge.
Freight Charges Return of recalled components is covered when shipped via the prepaid
RGA tag or another approved, least-expensive method.
Labor for Service Reimbursed at the approved hourly warranty labor rate.
Non-TUG Parts Only covered with prior approval from TUG.

Introduction Mobile Belt Loader Model 660
Operation Manual
CD397-Oper Introduction - 1 - 5
WarrantyCancellation
Certain situations cause a warranty to be canceled. Examples of such situations include, but are
not limited to:
• Damaged due to accidents.
• Damage due to abuse, improper operation or poor maintenance practices.
Total or partial warranty cancellation is registered in TUG Technologies’ records.
WARRANTYEXCLUSIONS
The following items are examples of some of the non-reimbursable items under the Warranty and
Policy Program. Non-reimbursable repairs include:
• Any repair to a unit on which the mileage/hours or date of first use reported has been mis-
represented.
• Any repair to a unit on which the odometer / hour meter has been altered so that the true
mileage / hours cannot be determined.
• Any repair for which the date on the order has been misrepresented or altered to place an
out-of-warranty component within the warranty provisions.
• Any repair made to a product that has been misused or mistreated, or upon which a con-
version, modification, or installation of a non-TUG part has been made affecting the per-
formance, reliability or stability of a part.
• Parts handling charges.
• Parts damaged due to accident.
NOTE: This item applies only to cases in which mileage / hours are a condition of the
warranty.
NOTE: Any failure to a TUG-supplied part resulting from such action is not covered by
the warranty.
NOTE:
The warranty on parts damaged because of accident or an act of nature will be
canceled.
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.

Mobile Belt Loader Model 660 Introduction
Operation Manual
Introduction - 1 - 6 CD397-Oper
• Repairs required because of inadequate or incorrect protection in storage and / or prepa-
ration for storage.
• Repairs of damage or failure caused by poor outside workmanship.
• Any repair operation that changes the existing specifications of the equipment or compo-
nent.
• Repair techniques beyond the appropriate shop manual limits.
• Labor performed by anyone other than an authorized TUG technician without prior
approval, unless the situation is an emergency.
• Use of any other than genuine TUG parts, unless used in an emergency.
• A second or subsequent repair or adjustment necessitated by an incomplete or improper
original repair or adjustment.
• Adjustments made to improve appearance or performance beyond normal standards.
• Maintenance and normal replacement of service items. For example, replacement of fil-
ters and fluids, tightening of bolts, nuts, or fittings. Minor, labor-only repairs are reimburs-
able.
• Any repair to a part that is found not to be defective.
• Replacement of assembly rather than repair if replacement costs exceed repair costs,
and parts are available. Replacement requires prior approval.
• Labor operations such as additional diagnostic time, abnormal accessibility or diagnosis
time, hot testing and testing of new parts after repair. Standard labor allowances are
included in warranty labor time standards.
• Replacement parts damaged in shipment (carrier responsibility).
• Towing expense or transportation for moving equipment between the customer's location
and the repair location.
WARRANTYCLAIMPROCESS
ContactTUGTechnologies
Phone: [phone] Ext. 1 or 770-422-8021
Email (preferred): [email protected]
NOTE: No warranty invoice will be accepted unless TUG Technologies has been con-
tacted prior to the start of work being done to the unit.