LYfTow Liftow Model 2500 Technical Manual ProprcorRISiarke‘Ta: (1sas) s9s272 “Fae (01986) 893938 LifTow Electric Towbarless TUG/GPU Operators, Parts and Maintenance Manual ‘Model Number Serial Number Capacity Battery Votts Model ‘Serial Number Battery Charger ‘Model Serial NumberLifTow “Thank you for choosing “LifTow” - THE Blectric Towbaress aircraft Tug withthe unique difference - QUALITY. Preface ‘But that’s not all the ONE finger-tip power lever controls Direction - Forward to Reverse, and vise versa, and is immediate and smooth and provides the Operator with an EXTRA braking system: - “pathout a cuteh or gear change - also the speed, “Dead Man”, Parking brake and a duplicated lighting "stem which altemates automatically with direction ~ ALL from the ONE lever! “The Maintenance fee Drive axle with builtin Limited Slip Diffeential as standard, and wet Steel Disc ‘Brakes (NO peds to change!) virually elimisates axle maintenance. Dual drive wheels are fitted 35 standard thereby doubling the “LifTow 's “adhesion capability. “The various spesd ratios provide a wider range of hauling capacity with greater speed for positioning ‘We have wilised three whee steering system, wit the ultimate in manoeuvring ability in mind. “The loading winch is mounted ON the Nosewhesl Cradle, and therefore keeps the same initial casle tension regardless of eradle eight - with the control buttons on each sde for operator convenience. ‘We hope you willbe very satisfied with your “Li/Tow” Mod 2500 TioLiffow CONTENTS Section Page 1 Ll INTRODUCTION Mt Overall View of LifTow Vehicle 12 2 ‘OPERATION 21 General 21 22. Operator Indicators and Controls - Location and Postion 2a Layout of Control Panel 22 23 Geting Started 23 24 Lining Up Nosowheel Gear 24 "Notewheel Gear Overllview 24 25 Loading -Aireraft Onto Cradle and Up To Bulkhead 25 26 Unloading 25 Wiring Diagram -Relay/Fuse Panel 267 3 MAINTENANCE 3.1 Maintenance Schedule 34 3.2. Steering Mechanism 32 33, OilLevels and Lubrication 33 3.4 Servicing Schedule Chart 34 3.5 Inspection/Servicing Schedule 35 3.6 Head, Side, Tai, Reversing, Flashing, Indicator and Hazard 36 Lamps 3.7 Batteries 36 Inspection and Service 36 Care and Maintenance 37 38 Charger 37 3.9. OllsLubricants and Capacities a7 3.10 Trouble Shooting 38 Mode 2500 Paget. Tene L MayCONTENTS Page 41 Pats Ordering a 42 Chassis Astembly -2500 426 43° Front Axle 4469 44 GearBox 410 44 Hydraulic Pump saans 45 Series Wound Reversable Motor ane 46 Stoning System Axle sass 47 Sexice Brake Master Cylinder (post 1997) 42021 43 EMPatking Brake azans : 49° Bleue Wins 428 Section 5 GENERAL 5 “Liftow"— Warranty 330 52 Caricats of Competence s32 53 Record of Revisions 535 54 Model. 2500 Page 0.2 Issue 1 May 1998Section 1 IntroductionLY Tow Introduction “The “Liftow""is a precision built electric towbasless aircraft TUG/GPU which is used for loading and unloading of aircraft It has an extremely smooth one man operation with excellent manouverabilty and safe handling incorporating ear Whee steering and dual font traction drive, and comes supplied with top quality "European batteries, warranty anda superior fish All operating conteols, switches, gauges and inicators are located on a Dash Panel in front of the iver seat “The Liffow has a compartment which houses, the batteries in both the le-hand and right-hand sie, ‘access to these compartments canbe gained by two large panels which hinge atthe centre spine, tke Power Microprocessor and Cooling Fan inthe lower left-hand side, andthe Fuse and Relay Board in the upper le-band compartment. “The right-hand compartment houses the Brake Master Cylinder and Hydraulic Power Peck and Reservoir, Centrally mounted on the LifTow chassis are the Motor and Gearbox, Cooling Fan and EM brake. Access for routine servicing can be gained by removing the cover treadplate, Med 2500 Paget et May 38monmasny NORE BY, ERVIONINEV I CHYZVEE aaa us anoripuanisys YAEL Fas i a & a rl walsvavad —_ (pds so} 5000) et “HNVa AVIS 7 ox sunrises ee siiorravatt anv ‘ti0:100. onisamacrt oe ma S woLvor0N! wo ‘NOUIINOD ‘owe xoruvan 29, oatn0) Novara ODS. Introduction i 3 é tee oa 2500Section 2 Operation.Liffow Operation 24 22 General Before operating or driving the LifTow the DriverOperator should firstly familiarise themselves with the postion and functioning of all the controls and once this has been lchieved it is then recommended that before attempting to load an aircraft he fel of driving the LifTow sould be obtained. Operator Indicators and Controls - Location and Position Bmergency Power Cut-Omt ‘This ist RED pushbutton knob aad is located on the top leftshand side of the dass panel, Side/Bead Lights ‘These are two toggle switches located on the far left-hand side of the dash panel "Nosewheel Cradle Lever -LIFT UP/LOWER DOWN. ‘This lever loceted on the top left-hand underside of the dash panel is used for Lifing/Lowerng, the Nosewbeel Cradle Gear Ratio Lever ‘This is a lever operated contol located on the Ieft-hand/cente, infront ofthe drivers seat and is used in conjunction with driving ofthe vehicle. Battery Condition Indicator ‘Ths is guuge located onthe left-hand side immediately infront of the driver ands used to monitor the condition ofthe battery Foot Operated Horn ‘This is a pedal loceted to the let of the driver’s seat and is sed as an audible warning to other vehicles and pedestrians. Hour Meter ‘Ths ia a gauge which is used to measure the amount of time that has elapsed end Tocated in front ofthe driver onthe dash panel. Tguition Key Swite ‘Ths is used for stating the vehicle and i located on the top right-hand side of she panel Parking Brake Lights ‘These af two indicators located on the top right ofthe panel. Wren the RED ligt is iiuminated this indicates thatthe brake is ON and the vehicle cannot be driven until the startup procedure has ben carried out (see section 2.3, Getting Started). Wien the GREEN light is illuminated this indicates that the brake is OFF and the vehcle can be driven Mosel 2500 Page May 98sIDE/HEAD \LIGHTS| PARKING BRAKE, EMERGENCY HOUR METER LIGHTS "RED" ON POWER CUT-OFF ELAPSED TIME "GREEN" sarrenyconprtion —toxrtTon | INDICATOR KEY START | FOOT OPERATED HORN |seoet 2500 fame vee | veecran, \ Ls OOS TR «GEAR. «SERVICE POWER LIFT “UP RATIO BRAKE CONTROL Lonenmbown «LEVER PEDAL «LEVER Layout of Control Panel Pye 22 May 98LifTow Operation Power Control Lever/Throttle Control ‘Tuislever controls the amount of power tothe vehicle. When pushed the vehicle will rave forward, ovhen pulled back it will revere. This lever activates the parking rake ON/OFF lights (see aboveit selfcentres to NEUTRAL once the throttle is released, “hiss located oa th right ofthe diver. ‘THIS CONTROL MUST BE OPERATED GENTLY. Service Brake Pedal ‘Ths is foot pedal located to the right of the driver and should only be used for EMERGENCY situations KEEP THE RIGHT-HAND FOOT OFF THE SERVICE BRAKE EXCEPT IN AN EMERGENCY. 2.3 Getting Started Proceed as follows: © ® ® Sit onthe diver's set and adjust until a comfortable postions reached. ‘Lower the restraining arm rests and with your left-hand pull up the RED knob fer POWER ON and with your right-hand quarter tum clockwise the IGNITION - key fri, The “Red” parking brake Kh wil lluminate to indicate thatthe brake is ON. Check NOSEWHEEL CRADLE HEIGHT for travel and place your left-hand on tte Steering wheel spinac, right-hand index finger ané thumb to throtle control ard ‘GENTLY casein the desied direction (PUSH for FORWARD, PULL for REVERSE) Note: On moving the THROTTLE LEVER the parking brake light should immediatly Mt 2500 fel Change to GREEN (Parking Brake OFF) indicating that tis clear to proceed, (On releasing the throttle, the lever will selentre to NEUTRAL and the brake will ‘then be applied automaticaly KEEP THE RH. FOOT OFF THE SERVICE BRAKE EXCEPT IN ‘AN EMERGENCY. Before steering the driver must gain some movement thereby saving tyre wear end fefort, A straight lin of travel should be maintained before carrying out various res ‘of tumboth LIL and RLH. a8 well s practice of cautious approaches to nosewheels Pages ‘Ma 98Liffow Operation 24 Lining up Nosewheel Cradle ‘Athough the Lifow is exremely manoeuvrable sufficient space should be allowed wien lining up square tothe nosewheel gear Proceed as follows (1) Approach the aircraft lowly and lower cradle just clear ofthe ground (approx. Lem) tht atop the TUG just short of Nosewheel tyre (20/30em), (2) Dismount, the parking brake will apply automatically in about 1 second. (0) Adjust the cradle tyre side guides for single or dovble width and take hold ofthe nylon Cable and stout strap and pull out whist pressing the WINCH OUT pushbutton, (4). Secure the strut strap around a suitable place on the nosegear (usually around the Oe). (6). Hold the sap in postion with one hand and with the other operate the WINCH IN psutton so that itis just taught (©) Check that Arora brakes are OFF and chocks away. HYDRAULIC CYLINDERS yyy ‘WINCH CONTROL “IN” ‘WINCH CONTROL"OUT™ OSWEEE mame __ NYEONCABLECOINCHD Nosewheel Cradle Model 2500 PagetOperation ee] ae Mee | | cows ee ee =| [pms $ \ (O:c:9) c= te Tt ae sae itt Sacrimmecs] Cuba i Bae Senet SSroeis weg. 1 139! [Fat Mode 2500 Pages Ieee MaySection 3 MaintenanceLYfTow Maintenance 3.1 Maintenance Schedule Daily Before use, check battery levels in all cell and use only de-ionised or distilled water to top up to approximately Lom above the electrode plates WARNING [SWITCH OFF BEFORE MAKING ANY ADJUSTMENTS OR SECURITY ‘CHECKS. [Also check EMERGENCY and power ON switches, auto brake light will show RED for Parking Brake ON and GREEN for Brake OFF. Monthly Front Drive Wheels ‘These are pocunatic and shouldbe checked regularly for tyre pressure and ll four checked for equal presrare at batwoun 6 ba. Rear Wheels ‘Thee are semi-solid and should be checked for security nd wear very 6 Months ‘Steering System [Becesive slack sald be taken up by the ‘tensioner’. Apply small amount of medium grease Mods 2500 Pages. lest M398Liffow ie 3.2. Steering Mechanism Se ee ey noe “Toinspectiservce, securely chock the Tug with Nosewhee! Cradle lowered to ground - use at feast a2 Toaae Trolley Jack atthe rear jacking point - lit and BEFORE servicing put safety ‘cocks in place. “The stering mechanism should also be checked at monthly intervals for security - particularly the taper lock sprocket and chains. Use the chain tensioner as required - do NOT overtighten, secure afer reseting tension. ade 2500 Pages2 fea Mis 98‘Maintenance 33. Oil Levels and Lubrication Liffow Faype of Control Tak ‘Oilkbreaon ‘Gear Shit Lever | Lubricate Tight Ot Wear ole Geese Nipples Grease Every 6 Months Tere ‘Grease apples, ea Dave Shaft, on ‘Sterng Colum Bearings, 2 on Chain ‘Sprockets, 3 oa the Steering Axle ' Yearly Front Ae Tepiacsaamoally ToVaD Fgpaid OF (vax. 2s) Gabor Replace eamally 20/80 Fypoid Ow (vax. 1.5 ts) Tipiaalis Pump | Replace annually wi minal ol (pec, 150 V32- Resevoit Onl max. $18) ‘Brake Master | Bled the brakes annually, Refl | (Spee. 150 V32) Conger ‘eservoir wt fsh mineral Only Front Axle Transmission Oil - ‘Esso 56 Mobil 22 or AgCastrol AS Power Micro Processor Speed Control see “SEVCON" manual ‘Winch and Strut Straps - Mote 2500 ae (Check for wear particularly the hook security catch and replace as necessary Page.3 Man 98LY Tow Maintenance 3.4 Servicing Schedule Chart wEEKLy | Moray] pi-annuar| ANNUALLY Mater Switch Key Switch ATL ¥ v Hour Meter ~ x v x Battery Ineator Batery Water Baty Terminal Tights Fenton Packing rake Service Braker Service Brake Of Nosewiel Cradle "Cradle Hyd. O11 Whee Not secre ‘Tyre Presuees To Winch Conicis | Winch Carot | ‘Winch Strap Con! Strat Strap Codon Rear Ster Wheel Z vx ‘Steering Mechanism \ N \ KN “Ss Steering Axle Differential Axle O11 Gear Box O81 t Prop. Shaft Grease ‘Motor BL-Contacts “iydraulc Hose laspect KAS 5 g Mate 2500 Pages lane May 98Liffow ‘Maintenance 3.5 _ Inspection/Servicing Schedule [NOSEWHEEL CRADLE - WINCH CONTROLS - WHEELS - AXLES FRONT- BRAKES: STEERING - NOSEWHEEL CRADLE- RH. ‘COMPARTMENT - MoTOR- GEARBOX- PROPSHAFT. Mode 2500 Ise Check thar @ sie plats sie fealy (“Alen Serew holding ws bar-sseure Choc that @ INDOUT is operating conesty (i) EMERGENCY CUT-OUT is operating (Gi) Nylon strap and Hook are serviceable (Gv) Strut strap is serviceable (@ Pressure 3-6 bar ower for slippery surfaces) (Gi) Rear Sterng ae semi solid - heck foe wer, (Check that i evel et plug (@) Grease ade column (I nipple) (Gi) Grenze Habs each (nipple) Service -no adjustment needed Parking - Check waning ike (@) Remove ear cover and grease 3 nipples (Gi) Also lubricate Geant lever guide (Gee chart of land lubricants) (Hydric PowerPack - Check oil evel (i) Hydeaulc Bake reservoir Chock ol level © Airblat to remove dust (i) Inspee brushes for wear (© Check il evel cap. (1.7 (ol and Ibricant char) (@) Grease US pois (2) and shat (1) Pages MyLiffow ‘Maintenance cranes wie nua RRoNr Seabees aCroNve RARE MASTER canizor VALv CEUNDER ELD (CRADLEOP VALVE, ee EADLAME ee ggg ee AM se ‘STEERING > ome EDDIEATOR MECHANISM & AXLE 3.6 Head, Side, Tail, Reversing, Flashing, Indicator ‘And Hazard Lamps (Check that ty reali working ode. 3.7 Batteries Inspection and Service (Check and maintain as follows:- (Check cable security Check fui level of ALL Celis Gi) Specific ravty check DO NOTUSE BELOW 1.155 Note: Keep fuid level above the cl plates Mote 2500 Pages Tame MayLifTow Maintenance 3.7 Batteries (Cont’..) Care and Maintenance [eis of the UTMOST importance that ALL battery clls are regularly inspected and topped ‘upto approx. lem above the electrode plates AFTER charging - particularly in hot weather [USE ONLY DE-IONISED OR DISTILLED WATER. Regular checks should be made ofthe cables for security, failure to do so will ender the Battery warrenty INVALID. ‘The batteries are situated in both LH and RH compartments 3.8 Charger -(230v, 240y, SOHz. 13amp) (© With input power ON plugin yellow connector to LifTow yellow adapter and check that ampmeter registers (DO NOT LEAVE ON INDEFINITELY 3.9 Oils Lubricants and Capacities ‘Type of Control, OiLubricant Capacity AXLES. Transmission oil-Esso $6 3S Litees Froat Mobil 422 or AgCastol AS Rew GP Grease Bateres Distilled or de-Tonised water T0amps pes el 48V DC with 12V- 24V-28V GP Steering GP Grease Gearshift Lever Guide Light Oi! Hiyéraulie Power Pack. Mineral ISO VG-32 6 Litres iydralic Brakes Mineral ISO VG32 Gearbox Trans. Oil Esso 46 17 Litres Mobil 422, AgCastol AS Propshaft GP Grease Mose 2500 Page 3.7 wet May‘Maintenance 3.10 Trouble Shooting General “This section gives recommended procedures for locating faults on the LifTow 2500. Tkis injended tht wouble shooting should be carried out with reference tothe relevant electrical rout diagram, ‘Trouble Shooting Charts 1 Noresponse Control fuse has blown fom motor, on tuning key No battery supply 2 Vehicle lights do Defective light, change rot operate, but over selay hazard lampfindicators Fuse has blowa 3 Motor Defective feed relay fanloontrol fanfhora/hazard lamp do not operate Fuse has blown, 4 Hiazardlamp Faulty beacon lamp doesnot operate although other lights are 0k. 5 Individual lamps Defective bulb donot light Defective switches o wiring Mode! 200 Liffow Check for cause of blown fuse, Replace fuse ‘Check wiring. Check that batteries are ‘connected and are charged. IF discharged, replace or re-charge es necessary Replace Relay, Check for cause of blown fuse, Replace fase Replace Relay ‘Check for eause of blown fuse. Replace fuse ‘Replace lamp Replace bulb (Check switches and wiring continuity. Replace or repair as necessary. Pages ay 38Section 4 Parts ListParts List Papi May Mode 2500 lene4.1 Chassis Assembly - 2500 tem SESSSURSRRRURESSEGTGEGHES eesosseRe Mods 2500 Description Amber Strobe Warning Light Flash Tube Rear Headlights Rear Bulb Pintle Towing Hook Seat all Weather ~ Lumbar Adjust Seat Pedestal ‘Non-Slip Pate Gear Ratio Lever Hydraulic Valve - Cradle Operating Steering Wheel Spinner Steering Wheel Steering Wheels - Semi Solid Drive Motor Drive - Coupling Cooling Fan Gearbox EM Brake Drive Prop Sha ‘Traction Wheels Reversing Lights Forward Headlights “Hydraulic Motor/Pump Nosewheel Cradle ‘Nosewiheel Cradle Side Restraining Plates Handgrps - Console Sideftesd Light Switches Power Cut-OfF Battery Condition Indicator Hour Meter Hydraulic Service Brake Pedal “iycaulic Service Brake Master Foot Switch - Home Air Homs Winch ‘Charge Battery Input Connector Part Number L1s37 LTs3120811 Lree71 TTs894 Lip Lies LTT LrTea LITeb ETVI000 LTbsa ETBren LTCar LICR Liven Las LT40m LTdana beat Li watt Lress-24 L871 Limon LrTe LrTce Lire Line Liss Lirse LTbps LiTebp Lie Laie LTsictt Linde LTandr CE TOW Parts List PageLifTow Parts List 42 Pinion Cartridge Assembly (202-9620, 1 off) Front Axle Item Deserption Al Pinion Carcidge ‘A2_——_Bevel Whoa! and Psion AS & AS Input Drive Flange ‘Ad Drive Flange Washer AS Drive Flange Nut AS Seal Cover AT Pisin Bening 3 Pinion Bearing Spacer 49° Pinion Ol Sea AlO. Shin 030mm AML Shim 025mm Ai Shim04dam Diff Assembly Item Description BL Dif Case BL Diff Wheel, B> Diff Pinion Bt Diff Whee Thrust Washer BS Diff Pinion Thrust Washer BS Diff. Spider BT Spit Fin BE Sad BS Tab Washer BIO Nut BIL DifCaseRH. Planet Carrier Assy em a a G oo cs cs a cs Mowe 2500 Description Planet Corie Planet ese Planet Pia ‘Axle Shaft Spacer iecp Planet Cage Roller Planet Thirst Washer Dowel art Number 022301, 200-9820 200-2180, (09-0090 007.0130 200.0910, 01-0270 200-1050 02-0440 200-2210 2002350 200290 Part Number 2002072 360.2090, 360.2100, 250-2110 250-2120, 201.2130 onss6ss 200-1911 200-1921 ‘ost001 201-2080 Part Number 220.0060 200-0080 200.0251, 20-1320 003-0140, 001-0310 40-0270 100210 BbBe nee 8 ay age 4sLiffow Parts List 42 (Cont..) Hub Assembly Item Description Part Number Qy DL Hiab 203-0041, H D3 Hu ine Bearing 01.0170 i De V" Ring Seal oa1v100H, 1 DS Oil Seal 400781 DS Seve 200-0150 2 Dé Oil Sea Housing 200.0140 z D7 Giri 340800 Ds Bearing Spacer 200.1680 1 D9 Hub Outer Bearing os4os02 1 Dio Hub Bearing Spacer 200-481 1 DIL Lockwasher 115.1920 1 DIZ Leelee o10NS01 1 Dis smd 20041810 i Dison Nut 051006 % ‘Main Case Assy Item Description Part Number oy Ade Casing 202-0011 T Brake Psion 200-0780 2 Bo ‘O'Ring 002.0350, 2 Ho -O'Ring 002-0360, 2 Nw 200.2150 2 15 Bearing Housing 200.4370, 2 57 Leckpate 2002160, 2 Seem 041009 6 SSDI Nut 051006 26 M0 Dowel Fin 910-0040 2 S11 Adsptar- Brake Pipe 201-1070 4 12 Screw ‘oosos08 2 13 Spring Waster o1g1i0s n Td Dowty Waster 02.0260 4 nS Vane 008-0070 1 M16 Socket Pressure Pag 08-0020 2 7 Vane 008.0240 2 18 Beating Ossuosivosseons 2 General Parts Item Description Part Namber ry Kl Adeshat 205-0100 2 2 Dowel Pin 10-9160 4 KS Annis 200-0070 2 KS Spacer Plate 207.0880 2 KS Brake Pite 200.0890 2 Ké Bake Dise 200.0750 2 K7 SunGear 205.0091 2 Mode 2500 Paes?Liffow Item Description Part Number Qty HL Axle Arm Ascy-Welded 216-0032 2 Sud 200.1810 2» HRI Nat os1008, 26 HA Shield 200-1360 2 ages May 98 Mods! 2500Parts 43 40M2FSL281 -GearBox em sigs Made 2500 32 3 2nd Speed Gear -21T Revers Speed Gear 167 2nd Speed Gear 18T Ise Reducion Gear -29T Girly Spice Beacing Cirip Soap Ring Selector Fok Datent Spring Daten Ball Seleor Stadt Beating Saap Ring Ist Speed Gear-29T Spacer 2nd Speed Gear- 237 (OutpeNain Shae urput Gear- 267 ‘Sele Fore Tock Stud Safety Plate Assy Bote Tatras Plate Drain Pag Sealing Washer 1/2" BSP Gasket Rear Cover Boit Boit Selector Loking Strip Washer Spacer Oil Sea Dust Shialé Output Couping Sel Naner Pte Washer ‘Tab Waster Primary Shaft Assy - 14 Bearing Bearing LYTow Part Number 409245 0562512 4oMo2s ems aoMiis sons 40360 ccaa053, +40M30 amide 330200 0203 40Ms01 cxzi03 cpio77 40135 cemz052 ‘exz060 40726 aom7as coms «oss sosr22 ‘4oMs02 4031 oME94S/A SESS «oto celiss onoinis 40Mi71 oMuo7sia USES USF2L 4oMs wi 40M38 4oMie7 cMas37 CMS3ES/A, Piss ccPio03 exai2s exanso sOMLIISIA 40MSI3, 0MUS ay Page satLifTow & G C &Parts List 44 Hydraulic Pump Item Description Part Number Qty 1 Pump Assembly, Gear (Cove 62) e312 1 Pump Assembly, Gear (Code $1) 02625 1 Pump Assembly, Gear (Code 43) 02650 1 Pump Assembly, Gear (Code $2) 2624 1 Pump Assembly, Gexe (Code 05) 02629 1 Pump Assembiy, eae (Code 03) 02659 1 2 O'Ring 03s 1 3 Pats Kit, Check Valve (nin) 00075 1 6 sSel anise 1 5+ Pants Kit, Relic Valve 03766 L FOR FURTHER BREAKDOWN OF PUMP ‘ASSEMBLY, SEE PUMP SECTION 6 Site, Slenod, 12V DC, 3-Post Groundedto Can 03427 1 Switch, Solenoid, [2V DC, 3 Post(Coued) Grounded to Can 03481 1 ‘Switch, Solenoid, [2V DC 3-Postlasulated Ground 03336 1 Switch, Solenoid, 12V DC 3-Post (Coated) Isulied Ground 03340, 1 Swite, Solenoid, 2V DC Post Ioated Ground 03535 1 ‘Shite, Solenoid, 12V DC (Post (Coated) Isolated Ground 03342 1 ‘Shite, Solenoid, 24V DC, 3-Post, Grounded to Can 03467 1 Switch, Solenoid, 24V DC Pos, (Coat) Grounded to Can 03652 L Swite, Solenoid 24V DC }-Post Insulated Ground 3343 1 Switch, Solenoid, 24V DC 3-Post (Coated) Insulated Ground 03346 1 7 Swap, Motor-Soenoid 01349 1 Seow, Round Head Maine 10-32 x 14" ores 2 9 Moto, Electric, 2 DC oat 1 Mois, Elec, 12V DC ost 1 Motor, Eleezc, 24V DC 08120 L Motor Bec, 48V DC nos 10 «Bearing, Base, Motor 02318 1 MeN, Hex 516-24 reas L 12+ Washer, Leck S16 ors 1 13 Washer, Star U2" ons 4 ‘Model 2500 enLiffowParts List Lif Tow 44° Hydraulic Pump (Cont'd...) Item 14 is 20 a a Py 26 n 2” Moa 2500 Description + Washer, Loc 14" 1 Serew, Hex Head Cap 1/420 x 6-12" FOR FURTHER BREAKDOWN OF MOTOR, SEE MOTOR SECTION Bracket, Mounting Bracket Plato Mout 5.00" C to C ‘Brace, Pate Mount 3.25°C 0 C Screw, oot Head Cap, Taread Forming, Torx Drive, Sni6-8x FYB" Sere, Hex Head, Tread Forming 1-20 178" Sees, Fer Suction) “Tate, Fier Section 378 NPT 90 Deg Adapter, Pump Mouatng Bracket ‘Tue, Reta (1/8 NPT) Reservoir, $12" Dia x 10 Reservoit,€12"Dia x 12" 10283 Usable 273 Usable Resarvoi, "x 5" 10", 2113 Usable Reservoir, 5x 5" 12", 249in3 Usable Reservoir, "x 5° 15", 306.3 Usable hug, Vet (Plastic) hug, Vet, 3/8" NPT “Tube Assembly, Downspout, Return (1 NPT MxF) Sere, Tred Forming 10-24 3/8" Part Number 07195 o7738 on238 04559 04560 o7as4 om ous4 1209 01329 ors 06661 06663 6665 6678 668s 05686 ouas 03866 ous 7703 oy Pages ‘May 58LY Tow. Parts List “SG € Page 16 Mode 2300 “4 Tis =Page 416,Parts List 4.5 Wound Rotor Motor Item Description Part Namber Quy Tr Socket Sew 2 Split Washer 3 Flange 4 Bearing 5 Tab 6 © Amane 7 Bearing 3 Stator Winding 3 Boty 10 BrushHolder 1 Connecting Cable 12 Washer 13 Split Waster 1 Serew 13 Pale Shoe 16 Socket Sew 17 Bakelite Washer 18 Connecting Teminat 1 Washer 20 Bsklte Washer 21 Bake Tube 22 Spring Washer 2 ONe 24 Brush Spring 25 Brush! 26 Split Washer 2 Nw 28 Socket Screw 28 Guard Band 30 Cooling Fan 31 Fun Cover Serow 32 FanCover 53 Cable 34 ‘Brush older Head 3s 36 3 38 39 4 Page 4.17 Model 2500 ae leneMode 2500, rays leneParts List 46 Steering Axle Item Mode! 2500 et Description Sterag Column Reduction Sprocket 15 Teeth Greas Nipple Duplex Chain ‘Taper Lock Bush Reuction Sprocket 45 Tea ‘Reduction Sprocket 45 Teeth (Chain Tensioner Bracket (Cini Tensioner Adjuster Screw Gear 45 Tee Key Wee Whee Nas Axle Grease Nipple Tye Gea 15 Tenth Key (Sub Sia) Sob Shalt Bearing Pia ‘rior Joie Liffow Part Number wewne§ 1 1 1 1 1 2 Page 9 ‘May 58Parts List [MASTER CYLINDER-1998 Onwards em 1 Master Cynder complete 2 Cover -Past-rod 3 Chevis—Paoh rod 4 Pincers SNat-locking Lif; Tow & Part Number Lt he Lr tere Lr cpa Lr went WARNING ~ Use oly Mineral Hydraic Oil~ Spee. 180 2 Mote 2500 Tis Page ad 98Parts List 4.7 Brake Master Cylinder [MASTER CYLINDER Pre=1998 models Item PareNember 1 Master Cynder complete vtmeo 2 Seal-ovehaal kit Lrmcomta WARNING ~ Use only Mineral Hydric Oi1~ Spee. 180 3, Page s2i Modes 2500 a te |WARNES Electrically released brakes Ruhestrombetatigte Bremsen Freins 4 manque de courant | Service Manual ERD Betriebsanleitung Manuel de Service | WARNER ELECTRIC Page 422Ps Accessories ‘bust cover you are sing tere in ‘kan envsenent or the Serounnguinaeohee'e (Ged th dato hui @& Zubehér ABDECKRING Falla de Brome sinor UUgebung arin staubiger doe feacter ingsbung ingots wr wet an © Accessoires ‘BAGUE DE PROTECTION Evite la projection de pou sire tentow oufinck= ‘Son de cope sang ele ‘que poussires nulls oo tmerecommend he usec he Abdacking anpohlen. Serpe ome Sixt cover IER -—-REIBSCHEIBENTRAGER SUPPORT DE DISQUEDE, A FRICTION DISC CARE support ‘ios 8 and 10 a8 standard se eopald wit shee Fenn, version On request talc ee ei den Gestan5 und 10 Weird tanedmtig cn neater glo. Aut Snirage it en retaochor rage ire Graben 8 wd TO emasion Puree andes 5 ot 12,2 ‘Sarcarden en mae ‘Srihein Sur demand pout rr on version etal THIN FRICTION FLANGE Fhe reuning elas don rot at etalon fe eee z “harénose 180 A6 roughness 32 Ra (128 miooinehd = ates 0,08 ren thane thn ore eton {ange hae tobe use, NOME: frst 80 and above tn ange ot eval, ‘DONNER FLANSCH Pate Montages loht ‘igende secrgengen tat (425 wrainen) ~ Ebene 08 inuB en eta’ oder chor Fanech ergsshen worcen ‘BEMERKUNG: Fir Modal 6 fd greet an donnon Fangch ie tetbar FLASQUE MINCE ‘ila face de mortage rere Ph pasleccendions ses: Psatecs fons ou acter Suet 180 40 Sagoste R32 (128 mereinen) = plansté orn {eat eve tage roe cusps. NOTE: peurla grands #0 ot isle flasque mines rst Das depois THICK FRICTION FLANGE ‘Thi fange lee meting at the ner sma Wit he the tn ange ha move lng acrewe ar cats DICKER FLANSCH DiaoorPanscheaub cine Montag am hrencroerascar, Savers oem nen Fansch ‘da Botesigungechrauben Sieh aon betndsn FLASQUE EPAts Cofaasus se a a8 Same nti, lor U6 loos de hatenpourle Nfs mince oo rower Sameer MOUNTING SCREW KIT The shed oining soe it “ES Mbplea win the ik ange Sfermourting onthe era ‘Samet aso ole <= Tong maining cow nt ipo wit in ange (efor mounting tough he The ange o taal ater br dered spar tor “tact meaning witout ange ‘SCHRAUBEN SATZ ‘Kree Seraubangohoren fur dekenAanach, feo Montage don suBaron Geuindechen. Oi gen ‘Schrauben gauven zum ‘onnen asec, fe Montage den aubaron Uschem oder wenn sparat bestail reine date Montage oie Paraoh ‘usTRALIA aeneLUX caeruane ‘SWEDEN Jeu DE WS Sec fasque mnie ot ceo hues actus de fete du dupave enor Powrin frontage det sae tang, ievis tots commence Sexier (02) cors3 (oro aarenny (0221) 2070 (a9) 948851 (4a) 0008 (on sezrrens (oa) @sis880 (ea) 248700 (200) e0c000 {on encossa (010) 7ssen (osaas) aera (22) 3130390 (4s) 5510 (om ssce0 (o21) 630500 (04 24035 (oan sospe2 Page 423Mounting Instructions Montageanleitung Instructions de montage @ rot vane Tevgueacusenent by ‘il Drnnamentenstaon ts Eanes fégege du coupe pa ! FeSorcanval eel Fo? VaR VaR vara Notucueadhainentgeasle Torque astray sew Neaning wah taco Kino rcnsmartEnsetung__Enstung das Detnomantss Mortage Tacho medics sich Sehrauben Pasdorseesdecoslepoetle _Réglage du couple paris Nostage aes tachymate ee | Poor 428Mounting instructions {ttn eon tenge 200 p90 86 ‘sipping mount aang eet, 2. Ft otha shat then si the al (1 FIG. ont the sha 2 ot hana). Secure hub axl 4. Side tho ftion oe cari (2) FG, | onto th hu 1 ening toe axl movement fa hand rasse AG. Sis ved, mount this tow, 30 nother the ut Seo poi, 4. Fhe magnstarmature assembly ‘yimaane ofthe eee (8) FG. ‘rd ightan the othe torque peciod in TABLE 1. Remove anspor clips. 5 Proceed o SETTING ARGAP U. tf ‘hand release upp rocood {SETTING ARGAP L 6, Hacuet covers supped carly ino grooves ‘SETTING AIRGAP U (FG. 1 page 1) Wan nw brake th ga i fatory se Rachockg is done by using non ‘tagnte fel gauges wren the aa i ot oni LEU iter rom ha val gon in TABLE 1 then loosen sews (3) FIG. 1 and ast spacer srews (8). “ahteneoewe 4) 0 the torque speoed TABLE 1 TOROUE ADJUSTMENT Trea i factor eat thesia torque TABLE 1 Wah VAR 1 andVARA, 616.2 ‘org cn be recon by maximo £0 by unscrewing tha foe serewe (@,. Win VAR2 FIG. 1 torque can bo ‘edad by nosing the cena Nut (0) Tre eduction of torgue tes TABLE @ Montageanteitung 1. Faia Ranch soho Sai 5) gsafer wurde, sit ia 2, Palade in Wels enlgon, dann Nabe (1) FIG. 1 act e Welle ian nicht Miner), Nabe seslschor- 23. Rekscheiborriger (2 FIG. aut ia Nabe (1 stisbon, 20 da ine frais Bewegung mogich st. Fale sine Handlotung FIG. 3 mi ‘einer wurda toc ott Imoncen. Muto richt ‘shen Sioho Punt 5. Magnet: Ankopisten- Ene tile der Schrauben (FIG. t, grechond dor in TABELLE { ‘ngegebonen Diehmerant betigen, Transport Sicherurgsng sntemon Eetling Lutepat Uvorhian, Falls Hanaitung mitgoicfert ede Enetlng Luftepat 6. Fala ein Abdockrng mitgtiefet wurde at iver sort ‘sechiben, EINSTELLUNG LUFTSPALT U (FIG. 1, Sete 1) ei ener nauan Brome wurde doe ata Wark egestall. Ene behing elt miele ung {intro Fohlotrer, wer ie ren nicht arogt ict Falla vom Wet TABELLE 1 sich, Seraubo (4) FG. sen Cd Mowtandeacraubon (5) werden Season (@) mit damn der TABELLE 1 angegebenan Drabmament ansehen DRENMONENTEINSTELLUNG Die rome ward en Wark aur as noma Drehmomenteingostlt (eho TABELLE BeVAR 1 und VAR FIG, 2 kare {d= Orhnorman um masial 80% ‘euaiet werden, in dom di ¢ Sehauven (gees werden. Bei \VAR2 FIG, 1 kann daz Drehnomon: ch Lean der Zener) feoicert werden De Reduionng et InTABELLE tangeaeben eS Instructions de montage 1. Siun aque ets irpage S lrvodire Ia tavet dine frre Gisele moyeu (FG. 1 sur arbre (ne pas marie Aasuror mmoyeu 8, sere suppor da que de fon 2) PG. sorte moyou fn permetant un céplcament ‘6 Fir. S un lov cba FRG. S est, ean en prom Ne pas soma 6c (7, pont 4, Assembla Cunt indstouram ‘ure au mayan desis @) FIG. 1 les werat avec un copie elon ‘TABLEAU I, lovers sanesi> do wanspor, 65, Prooéder au rélago deter Shum ever de dablocie eat or procédar au rglage cs court 6. Sine bagus deprotection ast Ivete areomble soigeeusomer REGLAGE DE LENTREFER U (FI. 1, page 1) ‘vec un oven fi, ear 0 ‘ale sine. Un conte defect. ‘er uilsat dos anges ce stance tmvagnetques quand nest Sila valour de U ost trent do ole donnée dane Ie TABLEAU 1, lessee ls ve (@) BG. 1 et100" lop via de distance (3). 2esarer! + (@)avecun couple sen TABLEAU 1 REGLAGE DU COUPLE Lefrein ast regia dire dun cos romina! slan Ia TABLEAU 1 Aveo VAR 1 et VARS.FIG2. ec plo peut re rit do 6045 ax Segeatrant in i (6 Aree VA FAG. 1 a couse put treet dessert eer conral OL "ductin et donnée arse TABLEAU | Page 425Hand release mounting SETTING ARGAPT 6.9) -Arelis ly fr a brake with hand raeae ‘Once the airgap Ui eet or aE, hack gap f when tho brak isnot rgd nacaeery act at (7) teen he proper ap. anTENANCe Note the brake must be tee from cok grease and abrasive dust! Regular matance wl ensure pope pean of th bra, ‘Th msitonansintoale dapend on ‘hesunber af apertona/ve: @ Montage der Handltiftung EINSTELLUNG LUFTSPALT fas) Git ct ene Bramoe wit Handout Nachdem dorLutepaU in oer ahgetolt wordt der Lttopat ‘Bu aberrofen wen ie Brenoe erat fat Fa efrdec, Mater (2) ‘vordrtan bi kook Lutepa cries WARTUNG Anmeskungs ie Bromse mu fre von Fett, Ol und schmirgenen Stotfn ein! RegenaBige Warung gant sine simienicia Afstewsica dr Sromse Die Wartingentralle ingen von er Aczal der Schatungen pro ‘Stunde b: econ oe So ee ia tone ms se eee) fee] 2) ale js mm) 8 | 8 | 10 a al 3} Montage du levier de déblocage REGLAGE DE VENTREFERE (a.3) A sfactuer uniquement iu evr ¢ sbblocage ost ins! Une ois error aust ou jst. omar Fates ait es horstanson. Si néoasssie tuner Feerou (pour bteni un onefr consct ENTRETIEN Notee ten dot re re de raise hulle ou do matigre aeasive! Un entrain rdgutor gant un fenctionnemant corect a re, Lesintanles enti dependor 6 nombre de manaeues phat =Voir REGLAGE DE LENTREFER = Avec ua evr de dblecage, ot REGLAGE DE L'ENTREFER Cone fpsieaueminirum MAC du suppor de daque de ton. Fig. aREP 5000 Page 4.27SECTION 5 GENERALVO sess . yy N \ 17 Navwich Road, Ditchingham, Bungay, Sofft NR3S 20L_ England “eloods 1986 895272 Fax 0044 1986 893958, One Year Limited Warranty “This ONE year WARRANTY covers equipment manufactured by “LitTow” and warrants thit the product i flee ftom defects in material and ‘workmanship, andi fit for the purpose for wich it is recommended {| PROVIDED, that the equipment is used in accordance with our servicing ‘guidelines, “LifTow” agrees that, fora period of ONE year ater the date of ‘elvery to the pany that intially purchases the equipment from us, “LifTow” will repair or replace at our option, any parts tht in our judgement, do not conform 10 this limited warranty. The equipment requiring. repair or replacement stall be sent to the above address and returned atthe owner"s expense £, ~ In the event that a technician is required to travel fo effet the repair under ‘his limited warranty, the owner will be responsible forthe cost of travel and lodaing for him | Not withstanding the aforegoing, no warranty is made in respect of Tyres, Batteries, othor wear items, oF any parts or accessories used with, oF incorporated into, the equipment which Was not manufactured by “LifTow” However, LifTow” agrees to assign to the original purchaser all ofits rights under the warranties given by the manufacturers of such parts and “x ‘This limited warranty sets forth all the obligations of “LifTow” should defects appear in the equipment. In the event that epai/eplacement of csuipment is in “LifTow's" judgement impossible, “LifTow's” liability is limited to the amount “Liffow” actually received for such equipment “LifTow” shall notin any event, be liable to any party for any lost profits, iminution of good will for other consequential damages, loss of use, however oocasioned, CAAA AAA. Ss J° of 205 saBeuryy eID 0087 POW . fi 241 AAUP 01 WaredwOD PesePIHOD spe Suomag souspadig Sac, wots sayy uct pur B30 Spa ose PON ‘napyon sayy, tog 03 ssn po Buypury ay uo ORDA 30 B10 UOAS® poreyO se poy fifyps97 07 TD apaiprpagLY Tow RECORD OF REVISIONS ev] SUE No| bare Mode 2500 Paged.t Tae May