TUG MZ User manual

OPERATION, MAINTENANCE
& PARTS MANUAL
MODEL MZ
TOW TRACTOR
CD373

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NOTE: The information contained in this publication is intended
exclusively for the use of TUG and its customers. Disclosure to non-TUG
customers may result in legal action by TUG.
NOTE: The information contained in this document is intended to be
accurate and up to date at the time of original issue. TUG reserves the
right to update the information in this document, without warning, as
deemed prudent or necessary by TUG.
Note
Note

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RECORD OF REVISIONS
Property of:
Company:
Address:
City: State: ZipCode:
REVISION DATA
Check each revision received, and insert the revised and supplementary pages in your manual. TUG assumes
no liability for personal injury or equipment failure due to any operation performed without heed to manual
revisions.
Date of original publication: September 2008
Revision Number Date Brief Description
1
2 February 2010 IPL Changes; Appendix Amended
3 June 2010/December 2010 IPL Revisions; Schematics
4
5
6
February 2009 Added Maintenance Towing

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MANUAL TABLE OF CONTENTS
INTRODUCTION
Record of Revisions............................................................................................................... INTRO-iii
List of Effective Pages............................................................................................................INTRO-iv
Manual Table of Contents ..................................................................................................... INTRO-viii
CopyrightNotice................................................................................................................... INTRO-xvi
Introduction.......................................................................................................................... INTRO-xvii
UnitIdentification ................................................................................................................. INTRO-xvii
Technical Assistance...........................................................................................................INTRO-xviii
Warranty Policy Statement................................................................................................... INTRO-xix
How to Use This Manual..................................................................................................... INTRO-xxix
SAFETY ............................................................................................................................... SAFETY-I
A. General .......................................................................................................... SAFETY-i
B. Safety Features ............................................................................................. SAFETY-i
C. General Responsibilities ............................................................................... SAFETY-ii
D. Operator Responsibilities ............................................................................. SAFETY-ii
E. Mechanic Responsibilites ............................................................................ SAFETY-iv
F. Warning Statements ....................................................................................SAFETY-vii
G. Cautionary Statements ...............................................................................SAFETY-viii
CHAPTER 1: GENERAL INFORMATION &
OPERATING INSTRUCTIONS
SECTION 1: DESCRIPTION ..................................................................................................... 1-1-1
A. Introduction ........................................................................................................... 1-1-1
B. System Description .............................................................................................. 1-1-2
1. Components ............................................................................................. 1-1-2
2. Axle Drive System .................................................................................... 1-1-3
3. Battery ...................................................................................................... 1-1-3
4. Lighting and Horn Systems....................................................................... 1-1-3

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5. Hydraulic Steering System........................................................................ 1-1-3
6. Brakes ...................................................................................................... 1-1-3
7. Chassis .................................................................................................... 1-1-3
SECTION 2: OPERATION ......................................................................................................... 1-2-1
A. Introduction ........................................................................................................... 1-2-1
B. Controls and Indicators......................................................................................... 1-2-2
1. MultifunctionDisplay ................................................................................. 1-2-2
2. Master (“Ignition”) Switch .......................................................................... 1-2-3
3. Headlight Switch ....................................................................................... 1-2-3
C. Maneuvering Controls ........................................................................................... 1-2-4
1. Steering Wheel ......................................................................................... 1-2-4
2. Service Brakes ......................................................................................... 1-2-4
3. Accelerator / Foot Throttle ........................................................................ 1-2-4
4. Turn Signal (Optional) ............................................................................... 1-2-4
5. Drive Direction Selector ............................................................................ 1-2-5
6. Inching Controls (Optional) ....................................................................... 1-2-5
7. Parking Brake ........................................................................................... 1-2-6
D. 12 VDC Electrical Supply Panel ........................................................................... 1-2-6
E. Preoperational Checks ......................................................................................... 1-2-6
1. Battery ...................................................................................................... 1-2-6
2. Brakes ...................................................................................................... 1-2-7
3. Tires.......................................................................................................... 1-2-7
4. Power Steering ......................................................................................... 1-2-7
F. Starting Procedure................................................................................................ 1-2-8
G. Operating Characteristics .................................................................................... 1-2-8
1. Parking Brake ........................................................................................... 1-2-8
2. Power Steering Pump............................................................................... 1-2-8
3. Seat Safety Switch.................................................................................... 1-2-9
H. Shutdown Procedure............................................................................................ 1-2-9
I. MaintenanceTowing ............................................................................................. 1-2-9
SECTION 3: SPECIFICATIONS ................................................................................................ 1-3-1
A. General ................................................................................................................. 1-3-1
1. Dimensions............................................................................................... 1-3-1
2. Weight ...................................................................................................... 1-3-1
3. Performance............................................................................................. 1-3-1
4. Electrical Components ............................................................................. 1-3-1

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5. Brakes ...................................................................................................... 1-3-1
6. DriveAxle .................................................................................................. 1-3-1
7. Steering..................................................................................................... 1-3-2
8. Gear Ratio................................................................................................. 1-3-2
B. Safety Features .................................................................................................... 1-3-2
SECTION 4: SHIPPING............................................................................................................. 1-4-1
A. Introduction ........................................................................................................... 1-4-1
B. Preparation for Shipment...................................................................................... 1-4-1
C. Receiving.............................................................................................................. 1-4-1
SECTION 5: STORAGE ............................................................................................................ 1-5-1
A. Introduction ........................................................................................................... 1-5-1
B. Short Term Storage............................................................................................... 1-5-1
C. ExtendedStorage ................................................................................................. 1-5-1
SECTION 6: BATTERY CHARGING......................................................................................... 1-6-1
A. Battery Charging Cycles....................................................................................... 1-6-1
1. Guidelines for Your Charging Regimen..................................................... 1-6-3
2. Equalize Charging Procedure................................................................... 1-6-3
B. Storage and Cold Weather Considerations .......................................................... 1-6-4
CHAPTER 2: MAINTENANCE
SECTION 1: MAINTENANCE.................................................................................................... 2-1-1
A. Introduction ........................................................................................................... 2-1-1
B. General Preparations for Use ............................................................................... 2-1-1
1. Battery ...................................................................................................... 2-1-1
2. Brakes ...................................................................................................... 2-1-1
3. Tires.......................................................................................................... 2-1-2
4. Power Steering ......................................................................................... 2-1-2

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C. PeriodicMaintenance Schedule ........................................................................... 2-1-2
1. Daily Check.............................................................................................. 2-1-2
2. Weekly or 50-Hour Check......................................................................... 2-1-3
3. Two-Week or 100-Hour Check ................................................................. 2-1-4
4. Two Months or 400-Hour Check ............................................................... 2-1-4
5. Yearly or 3000-Hour Check ....................................................................... 2-1-5
D. Lubrication Chart .................................................................................................. 2-1-6
E. Lubricants............................................................................................................. 2-1-7
F. Adjustments.......................................................................................................... 2-1-8
1. Park BrakeAdjustment ............................................................................. 2-1-8
2. Service Brake Adjustment......................................................................... 2-1-8
G. Instructions for Jacking and Positioning Vehicle ................................................... 2-1-9
1. Safety prerequisites .................................................................................. 2-1-9
2. Procedure ................................................................................................. 2-1-9
SECTION 2: TROUBLESHOOTING ........................................................................................ 2-2-1
A. DriveAxle.............................................................................................................. 2-2-1
B. Horn ...................................................................................................................... 2-2-1
C. Lights .................................................................................................................... 2-2-2
D. Steering................................................................................................................. 2-2-3
E. Wiper Motor .......................................................................................................... 2-2-3
F. Wiring Diagrams................................................................................................... 2-2-4
Figure 1-3. Electrical Schematic (Sheet 1 of 6).................................................... 2-2-5
Figure 1-4. Electrical Schematic (Sheet 2 of 6).................................................... 2-2-6
Figure 1-5. Electrical Schematic (Sheet 3 of 6).................................................... 2-2-7
Figure 1-6. Electrical Schematic (Sheet 4 of 6).................................................... 2-2-8
Figure 1-7. Electrical Schematic (Sheet 5 of 6).................................................... 2-2-9
Figure 1-8. Electrical Schematic (Sheet 6 of 6).................................................. 2-2-10
Figure 1-9. MZ Quick Charge Option (Sheet 1 of 3) ........................................... 2-2-11
Figure 1-10. MZ Quick Charge Option (Sheet 2 of 3) ......................................... 2-2-12
Figure 1-11. MZ Quick Charge Option (Sheet 3 of 3).......................................... 2-2-13
Figure 1.12 MZ Main Wiring Harness Diagram ................................................... 2-2-14
Figure 1.13 MZ Body Wiring Harness Diagram .................................................. 2-2-15

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SECTION 3: REMOVAL / INSTALLATION................................................................................ 2-3-1
A. Introduction ........................................................................................................... 2-3-1
1. Capacitor Discharge Procedure ............................................................... 2-3-1
B. Removal / Installation............................................................................................ 2-3-2
1. Operator/Passenger Seat......................................................................... 2-3-2
2. Drive Direction Selector ............................................................................ 2-3-2
3. Main Power("Ignition") Switch .................................................................. 2-3-3
4. Master Cylinder ......................................................................................... 2-3-3
5. Steering Wheel ......................................................................................... 2-3-4
6. Steer Valve ................................................................................................ 2-3-4
7. Tires and Wheels...................................................................................... 2-3-5
8. Hydraulic Steering Pump .......................................................................... 2-3-6
9. Battery Removal/Replacement................................................................. 2-3-7
10. Service Brakes Removal/Installation ........................................................ 2-3-8
CHAPTER 3: OVERHAUL
SECTION 1: OVERHAUL SCHEDULES................................................................................... 3-1-1
A. Recommended Overhaul Periods ........................................................................ 3-1-1
1. General ..................................................................................................... 3-1-1
B. SteerAxle.............................................................................................................. 3-1-1
C. Hydraulic Pump .................................................................................................... 3-1-1
D. MasterCylinder..................................................................................................... 3-1-1
E. Disc Brake Calipers.............................................................................................. 3-1-2
F. Powertrain ............................................................................................................ 3-1-2
SECTION 2: STEER AXLE OVERHAUL................................................................................... 3-2-1
A. General ................................................................................................................. 3-2-1
B. Inspection and Overhaul ....................................................................................... 3-2-1
C. Bearings and Seals .............................................................................................. 3-2-1
D. FrontAxle Spring Bushings Removal/Replacement ............................................. 3-2-2
E. Tie Rod Ends ........................................................................................................ 3-2-2
SECTION 3: HYDRAULIC PUMP OVERHAUL ........................................................................ 3-3-1
A. General ................................................................................................................. 3-3-1
B. Pump Removal..................................................................................................... 3-3-1

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C. PumpInstallation .................................................................................................. 3-3-7
SECTION 4: MASTER CYLINDER DISASSEMBLY AND ASSEMBLY ................................... 3-4-1
A. Master Cylinder Removal ..................................................................................... 3-4-1
B. Master Cylinder Disassembly............................................................................... 3-4-1
C. Inspection and Repair........................................................................................... 3-4-1
D. Master Cylinder Re-Assembly .............................................................................. 3-4-2
E. Bleeding The Master Cylinder ............................................................................... 3-4-2
F. Master Cylinder Installation ................................................................................... 3-4-3
SECTION 5: DISC BRAKES ..................................................................................................... 3-5-1
A. Introduction ........................................................................................................... 3-5-1
B. Brake Pad Replacement ...................................................................................... 3-5-1
1. Unit Preparation ........................................................................................ 3-5-1
2. Front Caliper Removal .............................................................................. 3-5-1
3. Brake Pad Removal.................................................................................. 3-5-2
4. CleaningandInspection............................................................................ 3-5-2
5. BrakePadInstallation ............................................................................... 3-5-3
6. CaliperInstallation..................................................................................... 3-5-4
7. Check-Out ................................................................................................ 3-5-5
C. Caliper Overhaul................................................................................................... 3-5-5
1. Disassembly............................................................................................. 3-5-5
2. CleaningandInspection............................................................................ 3-5-8
3. Reassembly.............................................................................................. 3-5-8
4. Installation ................................................................................................. 3-5-9
5. Check-Out ................................................................................................ 3-5-9
D. Front Rotors ......................................................................................................... 3-5-9
1. Rotor Removal.......................................................................................... 3-5-9
2. Cleaning.................................................................................................... 3-5-9
3. Inspection................................................................................................ 3-5-10
4. Reassembly............................................................................................ 3-5-10
5. Installation ............................................................................................... 3-5-10
6. Check Out............................................................................................... 3-5-10
E. Bleeding the Disc Brake System ........................................................................ 3-5-11
1. General ................................................................................................... 3-5-11
2. ManualBleeding...................................................................................... 3-5-11
3. Pressure Bleeding .................................................................................. 3-5-12
4. Check-Out .............................................................................................. 3-5-12

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CHAPTER 4: ILLUSTRATED PARTS LIST
SECTION 1: DESCRIPTION ..................................................................................................... 4-1-1
A. Introduction ........................................................................................................... 4-1-1
B. Using the Illustrated Parts List .............................................................................. 4-1-2
1. FigureandIndex Number.......................................................................... 4-1-2
2. Part Number ............................................................................................. 4-1-3
3. Description and Quantity .......................................................................... 4-1-3
4. Effectivity................................................................................................... 4-1-4
C. Ordering Spare Parts............................................................................................ 4-1-4
SECTION 2: ILLUSTRATED PARTS LIST............................................................................... 4-2-1
Introduction ....................................................................................................................... 4-2-1
Figure 2-1. Body Components.............................................................................. 4-2-2
Figure 2-2. Body Components - Rear................................................................... 4-2-6
Figure 2-2a. Body Components - Bottom View .................................................... 4-2-8
Figure 2-3. CabAssembly (Optional).................................................................. 4-2-10
Figure 2-4. Cab Assembly Components (Optional)............................................ 4-2-12
Figure 2-5. DoorAssembly - Left Side (Optional) ............................................... 4-2-14
Figure 2-6. DoorAssembly - Right Side (Optional)............................................. 4-2-16
Figure 2-7. Instrument PanelAssembly.............................................................. 4-2-18
Figure 2-8. SeatAssembly.................................................................................. 4-2-20
Figure 2-9.Accelerator PedalAssembly............................................................. 4-2-22
Figure 2-10. Hydraulic System ........................................................................... 4-2-24
Figure 2-11. Hydraulic Pump Installation............................................................. 4-2-26
Figure 2-12. Steering ColumnAssembly ............................................................ 4-2-28
Figure 2-13. ControllerAssembly ....................................................................... 4-2-30
Figure 2-14. Circuit Breaker Panel Components................................................ 4-2-32
Figure2-15. Battery Installation .......................................................................... 4-2-34
Figure 2-16. Battery Connectors ........................................................................ 4-2-36
Figure 2-17. Rapid ChargeAssembly (Optional) ................................................ 4-2-38
Figure 2-18. Front and Rear Lights..................................................................... 4-2-40
Figure 2-19. Inching ControlAssembly (Optional) .............................................. 4-2-42
Figure 2-20. Dual Wipers Assembly (Optional) .................................................. 4-2-44
Figure 2-21. HornAssembly ............................................................................... 4-2-46
Figure 2-22. Front Suspension ........................................................................... 4-2-48
Figure 2-23. FrontAxleAssembly ....................................................................... 4-2-50
Figure 2-24. FrontAxle Components .................................................................. 4-2-52

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Figure 2-25. Rear Suspension............................................................................ 4-2-54
Figure 2-26. Wheels and Tires ........................................................................... 4-2-56
Figure 2-27. Park BrakeAssembly ..................................................................... 4-2-58
Figure 2-28. Park Brake CableAssembly........................................................... 4-2-60
Figure 2-29. Brake PedalAssembly ................................................................... 4-2-62
Figure 2-30. Front Brake Lines ........................................................................... 4-2-64
Figure 2-31. Rear Brake Lines............................................................................ 4-2-66
Figure 2-32. Front Brake Calipers ...................................................................... 4-2-68
SECTION 3: NUMERICAL INDEX ............................................................................................ 4-3-1
SECTION 4: ALPHABETICAL INDEX ....................................................................................... 4-4-1
CHAPTER 5: APPENDICES
SECTION 1: PERIODIC MAINTENANCE CHECKLIST .......................................................... 5-1-1
SECTION 2: ADDITIONAL INFORMATION & PUBLICATIONS .............................................. 5-2-1
A. Description ........................................................................................................... 5-2-1

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COPYRIGHT NOTICE
This manual is copyrighted as an unpublished work.
This manual contains the confidential and proprietary information of TUG.
Neither this document, nor any information contained herein, may be reproduced or redistributed in any form
whatsoever without the express, written consent of an authorized agent of TUG.
Any attempt by any person other than an authorized agent of TUG to alter the contents of this manual in any
way shall be construed as copyright infringement, punishable by 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 operation and maintenance manual.
© Copyright 2010 by TUG.All rights reserved.

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INTRODUCTION
The information and instructions in this handbook are intended to acquaint the operator with the important
operating features of the TUG model MZ Tow Tractor. The various controls, gauges, switches, and operating
features are explained and illustrated throughout this handbook. Personnel responsible for operation of the
vehicle should read this manual carefully to become familiar with vehicle operation.
UNIT IDENTIFICATION
To aid the technician in repair or service work on this unit, a TUG identification plate is located on the
operator's compartment of the unit.
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 on the data plate with 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:
MODEL:
SERIAL NO:
DRAWBAR CAP.:
MANUFACTURE DATE
LBS.
TUG TECHNOLOGIES CORPORATION
1995 DUNCAN DRIVE
KENNESAW, GEORGIA 30144
PH: 770 422−7230

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TECHNICAL ASSISTANCE
Direct any questions concerning the operation of the MZ Tow Tractor to:
TUG Technologies Corporation
P.O. Box 3028
Kennesaw, GA 30156
Domestic:1-800-989-8499
International:[phone]
Fax: [phone]
All information in this manual is based on the latest production information available at the time of publication.
Direct any questions concerning the contents or format of this manual to:
TUG Technologies Corporation
ATTN: TUG Shop
P.O. Box 3028
Kennesaw, GA 30156
Domestic:1-800-989-8499
International:[phone]
Fax: [phone]
Email:T[email protected]

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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 Warranty Statements and this
manual. Customers who recognize the manual as the "heart" of the warranty system and train their personnel
in its use may expect service personnel qualified to submit claims that are properly completed and fully-
substantiated, resulting in prompt claims payment.
NOTE: The guidelines and requirements in this manual apply to warranty claims submitted to TUG
Technologies for reimbursement to the customer.
PRE-DELIVERY PROCEDURES
Establish pre-delivery procedures that ensure the appropriate inspections and adjustments are made prior to
equipment being placed in service.
AUTHORIZATION REQUIREMENTS - REPAIRS REQUIRING PRIOR APPROVAL
Certain repairs and claims require prior approval.Any repair which will take more then 2 hours labor to
complete must have prior approval.
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 pro rata basis.
3. Extension of coverage by any manufacturer does not change what is covered in the basic,
expressed limited warranty.

INTRO-xx
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Introduction MZTowTractor
WARRANTY STATEMENTS
TUG Technologies Warranty Statements provide detailed information regarding coverage & usage limitations
for TUG products.
WARRANTY POLICY & 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.
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.
Warranty Cancellation
Certain situations cause a warranty to be canceled. Examples of such situations include, but are not limited to:
•Damaged due to accidents.
•Damage due to abuse, improper operation or poor maintenance practices.
Total or partial warranty cancellation is registered in TUG Technologies’records.
WARRANTY EXCLUSIONS
The following items are examples of some of the non-reimbursable items under the Warranty and Policy
Program.
Non-reimbursable repairs include:
•Any repair to a unit on which the mileage/hours or date of first use reported has been misrepresented.
•Any repair to a unit on which the odometer/hour meter has been altered so that the true mileage/hours
cannot be determined. (Applies only to cases in which mileage/hours are a condition of the warranty.)
•Any repair for which the date on the order has been misrepresented or altered to place an out-of-
warranty component within the warranty provisions.
•Any repair made to a product that has been misused or mistreated, or upon which a conversion,
modification or installation of a non-TUG part has been made so as to affect the performance,
reliability or stability of a part.Any failure to a TUG-supplied part resulting from such action is not
covered by the warranty.
•Parts handling charges.