00 Preface Part 2
00 Preface Part 2
00 Preface Part 2
OWNER'S
MANUAL
PART 2 - SERVICING and PARTS
Edition 25
01 Feb. 2014
Capture Table
15 July 2009
COPYRIGHT
Copyright
Apart from any fair dealing by the owner of a Lektro vehicle referenced by this
publication, or a direct agent thereof, for the purpose of familiarization, train-
ing, operating, service and maintenance reference, no part may be reproduced,
transmitted, transcribed, stored in a retrieval system, or translated into any lan-
guage or computer language in any form or by any means, electronic, mechani-
cal, magnetic, optical, chemical, manual, or otherwise, without the prior written
permission of the Lektro Inc.
Copies may be obtained only from and with the permission of:
Lektro Inc.
1190 S.E. Flightline Drive
Warrenton, Oregon
97146- 9692, U.S.A.
Printed in USA
LEKTRO
PREFACE - 2 15 July 2006
CHAPTER TITLES
2B Capture Table
3 Operations Alerts All "Ramp Operations Alerts" issued to the date of this edition
are included here. Future Alerts received by mail should be inserted here, in reverse
Date / Alert # order (latest at front).
NOTE: Each numbered chapter and the appendix has its own index
at the front, immediately after each chapter divider.
10 Service Bulletins When received via mail, insert here, in reverse date order
(latest at front).
LEKTRO PREFACE - 4
YOUR VEHICLE'S IDENTIFICATION
LEKTRO PREFACE - 5
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LEKTRO PREFACE - 6
COMPONENT SUPPLIER WARNINGS
IMPORTANT:
LEKTRO PREFACE - 7
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LEKTRO
PREFACE - 8
LETTER OF INTRODUCTION
Congratulations on taking delivery of your new Lektro Model AP8600 "Airline" Aircraft
Tug. Thank you for the decision to purchase a Lektro Tug and for entrusting the safety
and ground handling of your aircraft with Lektro. Lektro is known around the world
as the safest, most efficient, best designed and highest quality tow vehicle available.
It is our goal for you to feel the decision to purchase the AP8600 was one of the best
decisions ever made.
The use of a Lektro towbarless tug in your operation will result in a variety of benefits
and savings. Lektro's user-sensitive design of towbarless nose wheel capture and smooth,
quiet, pollution-free battery power results in safe, gentle and exceptionally maneuver-
able towing with a high level of employee and customer acceptance. A spin-off feature
of our towbarless design is the versatility of your Lektro's variable drawbar pull which
adjusts to the traction requirements as the nose weight of the aircraft changes. Addition-
ally, the electronic drive system will provide direct benefits in energy and maintenance
cost reduction as well as in meeting present and future environmental emission control
requirements.
Complete customer satisfaction has been a policy of Lektro's since beginning operation
in 1945. We welcome and encourage your questions, comments and suggestions relating
to our products, service and future development. Please feel free to contact us anytime
on our toll free number, 1-800-535-8767 (U.S. and Canada), or at 503-861-2288 world
wide. Additionally, you can reach us by fax at 503-861-2283 or by Email at sales@
lektro.com .
With safety of your airline's aircraft and the operator being a top concern of Lektro, it is
vital that all personnel involved with the operation and servicing of your new Lektro be
fully trained and qualified. Detailed procedures on operation and service of the Lektro
AP8600 are contained within this manual. It is recommended that anyone associated
with your Lektro Tug read this manual prior to operating or servicing. Should changes
occur, revisions will be issued, insuring that your manual is kept current. Please review
and understand the operating and servicing procedures before placing your new Lektro
Tug in use.
Thank you for placing your confidence with Lektro. We will strive to ensure your con-
tinued satisfaction. Welcome to the Lektro Family !!
Eric W. Paulson
President & CEO
Lektro, Inc.
LEKTRO PREFACE - 9
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LEKTRO
PREFACE - 10
HOW TO USE THIS MANUAL
The information contained in this manual is organized into chapters, each dealing with
general functions. Each chapter is further divided into the following:
• Sections which are titled and numbered from (1).
• Subsections which are titled and numbered from (.01).
• Items which are titled and numbered from (a).
Thus, the procedure for operating the Winch Assembly is described in Chapter 1 (Tug
Operating), Section 2 (Component Description and Function), Subsection 04 (Cradle and
Winch Assembly), Item f (Winch Assembly). The Manual reference for this is Chapter
1, Section 2.04f.
When the need arises, such as an improvement in our product or a change in procedures,
this manual will be revised. Revisions will be forwarded automatically. Please review
the changes and insert the new manual pages promptly, following the instructions on
the Revision Notice and on the Record of Revision on the following page, to ensure
your manual is current. You will note that for control purposes, each page has the date
of first issue, or revision effective date, at the lower right corner.
LEKTRO PREFACE - 11
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LEKTRO PREFACE - 12
RECORD OF REVISIONS
Instructions:
• Verify the revision number and write in the effective date on the corresponding line.
• Remove old pages and insert new pages as instructed on the revision cover page.
• Write in the date inserted and initial the "Inserted By" column.
• File the removed pages and revision cover page.
Revision Effective Date Inserted Revision Effective Date In- Inserted
Number\ Date Inserted by Number Date serted By
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2 27
3 28
4 29
5 30
6 31
7 32
8 33
9 34
10 35
11 36
12 37
13 38
14 39
15 40
16 41
17 42
18 43
19 44
20 45
21 46
22 47
23 48
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LEKTRO
PREFACE - 13 01 Nov. 96
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LEKTRO PREFACE - 14
WARRANTY
1 Warranty
LEKTRO PREFACE - 15
RECEIVING AND INSTALLATION
LEKTRO PREFACE - 16
RECEIVING AND INSTALLATION
1. After the first 30 hours, open all access panels and decks. Check for loose bolts, chafe
points and loose wire connections. Also check all hydraulic line connection fittings for
leaks. Check the hydraulic reservoir level and add fluid as required. Subsequently, revert
to the Service Schedule, Chapter 4-A, Subsection 3.01.
IMPORTANT: Don't forget that for optimum battery performance and life span of your tug's
battery bank, it is very critical not to expose the batteries to excessively deep discharges well
below 20% charge level. However when your batteries are new they have not yet built up
to full specification endurance. It takes at least 30 discharge / recharge cycles for your new
motive battery bank to progressively build up to their full rated endurance performance. Also,
the risk of over-depletion is higher because when new these motive batteries will deplete
quicker under load, especially as they progress below the 50% charge level. Therefore the
battery manufacturer has recommended that for the first 15 charge cycles (after which the
battery endurance will have increased acceptably closer to design optimum), you do not let
batteries deplete below 50% charge level while in operation.
Note: Refer to Chapter 4-A "Servicing", Section 4.01 "Batteries" for routine service de-
tails.
LEKTRO PREFACE - 17
MODEL SPECIFICATIONS
LEKTRO
1190 S.E. Flightline Drive, Warrenton, Oregon 97146-9692
Model AP8600A-EZ
AIRCRAFT TOWING VEHICLE
1-800-535-8767 y 503-861-2288 y Fax 503-861-2283
FOR AIRCRAFT UP TO 30,000 LBS/13,608 KG
E-mail: [email protected]
http://www.lektro.com
AP8600A-EZ FEATURES:
Vehicle Drive: 6.8 HP/5.1 kW, 36 VDC Traction Motor mated with Dana Operator’s Compartment: Two person configuration, Stand-Up
44 Differential. 11.8 HP/8.8 kW Motor and Limited Slip Differential, Operation with Restraint.
optional. Construction: Welded Steel Plate and Polymers preserved by
Motor Speed Control: EV-100 LX SCR with On-Board Diagnostics. Primer and Automotive High-Gloss Red or White Enamel Paint with
Speed controlled by combination Hand Throttle/Directional Lever. special protective Polyurethane Coating to prevent rust, scratches and
Batteries: Six 6 VDC, 350 AMP-HR Batteries (20 hr rate), wired in corrosion. Custom colors, optional.
series. Single Point Watering System, optional.
GPU: Built-in 12/24/30 VDC / 800 CCA Motive/GPU Batteries. 12/24/28 SPECIFICATIONS:
VDC and 1175 CCA, optional. An Independent 1175 CCA Battery and Length ........................................................................................150.25 in / 381.4 cm
Charging System also optional. Width .........................................................................................41.5 in / 105.1 cm
Motive Battery Charger: External Fully Automatic 36 AMP DC / 110 Height (at top of steering wheel).............................................49 in / 124.6 cm
VAC / 60 Hz / 1-PH Charger. 230 VAC / 50 Hz, optional. Turning Radius .........................................................................127.5 in / 323.9 cm
Nose Gear Lift Cradle: Patented Universal Nose Gear Lift Cradle Wheel Base...............................................................................79.25 in / 201.2 cm
activated by an Electric/Hydraulic Pump Assembly capable of handling Vehicle Speed, Empty ............................................................6.6 MPH /10.6 KPH
dual and single wheel aircraft. A Hold Down provision for light-nosed Vehicle Speed, Loaded (To max. Vehicle Capacity) .....4.5 MPH / 7.2 KPH
aircraft, Wheel Faring Package and Aircraft Selection System, **Lift Cradle Capacity ...............................................................3000 LBS / 1361 KG
optional. Nose Gear Cradle Lifting Height ............................................9 in / 23 cm
Winch: Heavy-duty 2-speed Hand Winch. Winch and Strut Straps Ground Clearance ...................................................................3.5 in / 9 cm
included. Shipping Weight w/ Batteries & Charger...............................2700 LBS / 1225 KG
Steering: Automotive-type Wheel coupled to an Automotive Gear Box
resulting in very responsive steering action. **Lift Capacity is calculated with 14 in / 35.6 cm diameter aircraft tire
Service Brakes: Foot Operated Hydraulic Disc-Type Service Brakes in lift cradle. Aircraft tire centerline at 18.5 in / 47 cm from drive tire
acting at Differential Pinion Shaft. centerline.
Parking Brake: Hand/Foot activated Electric Deadman Parking Brake.
Drive Tires: Dual 4.80/4.00 x 8 6-ply Pneumatic Highway Tread. Traction ADDITIONAL OPTIONS:
Tread, Poly-Foam and Chains, optional. Draw Bar Pin, Specialized Aircraft Towing Adapters and Custom Highlift
Steer Tires: Dual 4.80/4.00 x 8 6-ply Pneumatic Highway Tread. Adapters are available (consult factory). Illustration may show some
Poly-Foam and Steer Axle Suspension, optional. optional equipment.
Lighting: Single 360° Rotating Spotlight mounted on Cowl and Five *LEKTRO reserves the right to make changes and improvements in
Amber Reflectors. 2nd Spotlight, Rear Headlight, Four Flashing Amber products and specifications without notice or obligation.
Running Lights and LED Bulbs, optional. Patent Nos. 5,151,003/5,302,075. Other Patents Pending. 02/13
Extension Ladder: Step Ladder attached to operator’s back rest,
optional.
LEKTRO
1190 S.E. Flightline Drive, Warrenton, Oregon 97146-9692
Model AP8600A
AIRCRAFT TOWING VEHICLE
1-800-535-8767 y 503-861-2288 y Fax 503-861-2283
FOR AIRCRAFT UP TO 30,000 LBS/13,608 KG
E-mail: [email protected]
http://www.lektro.com
AP8600A FEATURES:
Vehicle Drive: 6.8 HP/5.1 kW, 36 VDC Traction Motor mated with Dana Extension Ladder: Step Ladder attached to operator’s back rest.
44 Differential. 11.8 HP/8.8 kW Motor and Limited Slip Differential, Operator’s Compartment: Two person confi guration, Stand-Up
optional. Operation with Restraint.
Motor Speed Control: EV-100 LX SCR with On-Board Diagnostics. Construction: Welded Steel Plate and Polymers preserved by
Speed controlled by combination Hand Throttle/Directional Lever. Primer and Automotive High-Gloss Red or White Enamel Paint with
Batteries: Six 6 VDC, 350 AMP-HR Batteries (20 hr rate), wired in special protective Polyurethane Coating to prevent rust, scratches and
series. Single Point Watering System, optional. corrosion. Custom colors, optional.
GPU: Built-in 12/24/28 VDC / 800 CCA Motive/GPU Batteries. 1175
CCA, optional. An Independent 1175 CCA Battery and Charging System SPECIFICATIONS:
also optional. Length.................................................................151.5 in / 384.6 cm
Motive Battery Charger: External Fully Automatic 36 AMP DC / 110 Width .................................................................41.5 in / 105.1 cm
VAC / 60 Hz / 1-PH Charger. 230 VAC / 50 Hz, optional. Height (at top of steering wheel).........................49 in / 124.6 cm
Nose Gear Lift Cradle: Patented Universal Nose Gear Lift Cradle Turning Radius ...................................................127.5 in / 323.9 cm
activated by an Electric/Hydraulic Pump Assembly capable of handling Wheel Base ........................................................79.25 in / 201.2 cm
dual and single wheel aircraft, those with or without wheel farings, Vehicle Speed, Empty .......................................6.6 MPH /10.6 KPH
and a Hold Down provision for light-nosed aircraft. Aircraft Selection Vehicle Speed, Loaded (To max. Vehicle Capacity) .4.5 MPH / 7.2 KPH
System, optional. **Lift Cradle Capacity .........................................3000 LBS / 1361 KG
Winch: Heavy-duty 2-speed Hand Winch. Winch and Strut Straps Nose Gear Cradle Lifting Height.........................9 in / 23 cm
included. Ground Clearance ..............................................3.5 in / 9 cm
Steering: Automotive-type Wheel coupled to an Automotive Gear Box Shipping Weight w/ Batteries & Charger ..............2750 LBS / 1247 KG
resulting in very responsive steering action.
Service Brakes: Foot Operated Hydraulic Disc-Type Service Brakes **Lift Capacity is calculated with 14 in / 36 cm diameter aircraft tire
acting at Differential Pinion Shaft. in lift cradle. Aircraft tire centerline at 18.5 in / 47 cm from drive tire
Parking Brake: Hand/Foot activated Electric Deadman Parking Brake. centerline.
Drive Tires: Dual 4.80/4.00 x 8 8-ply Pneumatic Traction Tread. ADDITIONAL OPTIONS:
Poly-Foam and Chains, optional. Draw Bar Pin, Specialized Aircraft Towing Adapters and Custom Highlift
Steer Tires: Dual 4.80/4.00 x 8 6-ply Pneumatic Highway Tread. Adapters are available (consult factory). Illustration may show some
Poly-Foam and Steer Axle Suspension, optional. optional equipment.
Lighting: Dual 360° Rotating Spotlights mounted on Cowl, One Rear *LEKTRO reserves the right to make changes and improvements in
Headlight mounted on Back of Operator’s Platform and Four Flashing products and specifications without notice or obligation.
Amber Running Lights. LED Bulbs, optional. Patent Nos. 5,151,003/5,302,075. Other Patents Pending. 02/13
LEKTRO
1190 S.E. Flightline Drive, Warrenton, Oregon 97146-9692
Model AP8650AX-EZ
AIRCRAFT TOWING VEHICLE
1-800-535-8767 y 503-861-2288 y Fax 503-861-2283
FOR AIRCRAFT UP TO 40,000 LBS/18,143 KG
E-mail: [email protected]
http://www.lektro.com
AP8650AX-EZ FEATURES:
Vehicle Drive: 11.8 HP/8.8 kW, 36 VDC Traction Motor mated with Operator’s Compartment: Two person configuration, Stand-Up
Dana 44 Differential. Limited Slip Differential, optional. Operation with Restraint.
Motor Speed Control: EV-100 LX SCR with On-Board Diagnostics. Construction: Welded Steel Plate and Polymers preserved by
Speed controlled by combination Hand Throttle/Directional Lever. Primer and Automotive High-Gloss Red or White Enamel Paint with
Batteries: Six 6 VDC, 350 AMP-HR Batteries (20 hr rate), wired in special protective Polyurethane Coating to prevent rust, scratches and
series. Single Point Watering System, optional. corrosion. Custom colors, optional.
GPU: Built-in 12/24/30 VDC / 800 CCA Motive/GPU Batteries. 12/24/28
VDC and 1175 CCA, optional. An Independent 1175 CCA Battery and SPECIFICATIONS:
Charging System also optional. Length................................................................. 174.25 in / 442.4 cm
Motive Battery Charger: External Fully Automatic 36 AMP DC / 110 Width ................................................................. 41.0 in / 104.1 cm
VAC / 60 Hz / 1-PH Charger. 230 VAC / 50 Hz, optional. Height (at top of steering wheel)......................... 49 in / 124.4 cm
Nose Gear Lift Cradle: Patented Universal Nose Gear Lift Cradle Turning Radius ................................................... 151.5 in / 384.8 cm
activated by an Electric/Hydraulic Pump Assembly capable of handling Wheel Base ........................................................ 103.25 in / 262.2 cm
dual and single wheel aircraft. A Hold Down provision for light-nosed Vehicle Speed, Empty ....................................... 6.8 MPH /10.9 KPH
aircraft, Wheel Faring Package and Aircraft Selection System, optional. Vehicle Speed, Loaded(To max. Vehicle Capacity)... 4.1 MPH / 6.6 KPH
Winch: Heavy-duty 2-speed Hand Winch. Winch and Strut Straps **Lift Cradle Capacity ......................................... 4000 LBS / 1814 KG
included. Hydraulic Winch with Automatic Safety Cut-Off, optional. Nose Gear Cradle Lifting Height......................... 9 in / 23 cm
Steering: Automotive-type Wheel coupled to an Automotive Gear Box Ground Clearance .............................................. 3.5 in / 9 cm
resulting in very responsive steering action. Shipping Weight w/ Batteries & Charger .............. 2870 LBS / 1302 KG
Service Brakes: Foot Operated Hydraulic Disc-Type Service Brakes
acting at Differential Pinion Shaft. **Lift Capacity is calculated with 14 in / 35.6 cm diameter aircraft tire
Parking Brake: Hand/Foot activated Electric Deadman Parking Brake. in lift cradle. Aircraft tire centerline at 18.5 in / 47 cm from drive tire
Drive Tires: Dual 4.80/4.00 x 8 6-ply Pneumatic Highway Tread. centerline.
Traction Tread, Poly-Foam and Chains, optional. ADDITIONAL OPTIONS:
Steer Tires: Dual 4.80/4.00 x 8 8-ply Pneumatic Traction Tread. Draw Bar Pin, Specialized Aircraft Towing Adapters and Custom Highlift
Poly-Foam and Steer Axle Suspension, optional. Adapters are available (consult factory). Illustration may show some
Lighting: Single 360° Rotating Spotlight mounted on Cowl and Five optional equipment.
Amber Reflectors. 2nd Spotlight, Rear Headlight, Four Flashing Amber *LEKTRO reserves the right to make changes and improvements in
Running Lights and LED Bulbs, optional. products and specifications without notice or obligation.
Extension Ladder: Step Ladder attached to operator’s back rest, Patent Nos. 5,151,003/5,302,075. Other Patents Pending. 02/13
optional.
AP8650AX FEATURES: Extension Ladder: Step Ladder attached to operator’s back rest.
Vehicle Drive: 11.8 HP/8.8 kW, 36 VDC Traction Motor mated with Operator’s Compartment: Two person configuration, Stand-Up
Dana 44 Differential. Limited Slip Differential, optional. Operation with Restraint.
Motor Speed Control: EV-100 LX SCR with On-Board Diagnostics. Construction: Welded Steel Plate and Polymers preserved by
Speed controlled by combination Hand Throttle/Directional Lever. Primer and Automotive High-Gloss Red or White Enamel Paint with
Batteries: Six 6 VDC, 350 AMP-HR Batteries (20 hr rate), wired in special protective Polyurethane Coating to prevent rust, scratches and
series. Single Point Watering System, optional. corrosion. Custom colors, optional.
GPU: Built-in 12/24/28 VDC / 800 CCA Motive/GPU Batteries. 1175
CCA, optional. An Independent 1175 CCA Battery and Charging System SPECIFICATIONS:
also optional. Length.................................................................175.25 in / 445.4 cm
Motive Battery Charger: External Fully Automatic 36 AMP DC / 110 Width .................................................................41.0 in / 104.1 cm
VAC / 60 Hz / 1-PH Charger. 230 VAC / 50 Hz, optional. Height (at top of steering wheel).........................49 in / 124.2 cm
Nose Gear Lift Cradle: Patented Universal Nose Gear Lift Cradle Turning Radius ...................................................151.5 in / 384.8 cm
activated by an Electric/Hydraulic Pump Assembly capable of handling Wheel Base ........................................................103.25 in / 262.2 cm
dual and single wheel aircraft, those with or without wheel farings, Vehicle Speed, Empty .......................................6.8 MPH /10.9 KPH
and a Hold Down provision for light-nosed aircraft. Aircraft Selection Vehicle Speed, Loaded(To max. Vehicle Capacity)...4.1 MPH / 6.6 KPH
System, optional. **Lift Cradle Capacity .........................................4000 LBS / 1814 KG
Winch: Heavy-duty 2-speed Hand Winch. Winch and Strut Straps Nose Gear Cradle Lifting Height.........................9 in / 23 cm
included. Hydraulic Winch with Automatic Safety Cut-Off, optional. Ground Clearance ..............................................3.5 in / 9 cm
Steering: Automotive-type Wheel coupled to an Automotive Gear Box Shipping Weight w/ Batteries & Charger ..............2870 LBS / 1302 KG
resulting in very responsive steering action.
Service Brakes: Foot Operated Hydraulic Disc-Type Service Brakes **Lift Capacity is calculated with 14 in / 36 cm diameter aircraft tire
acting at Differential Pinion Shaft. in lift cradle. Aircraft tire centerline at 18.5 in / 47 cm from drive tire
Parking Brake: Hand/Foot activated Electric Deadman Parking Brake. centerline.
Drive Tires: Dual 4.80/4.00 x 8 8-ply Pneumatic Traction Tread. ADDITIONAL OPTIONS:
Poly-Foam and Chains, optional. Draw Bar Pin, Specialized Aircraft Towing Adapters and Custom Highlift
Steer Tires: Dual 4.80/4.00 x 8 8-ply Pneumatic Traction Tread. Adapters are available (consult factory). Illustration may show some
Poly-Foam and Steer Axle Suspension, optional. optional equipment.
Lighting: Dual 360° Rotating Spotlights mounted on Cowl, One Rear *LEKTRO reserves the right to make changes and improvements in
Headlight mounted on Back of Operator’s Platform and Four Flashing products and specifications without notice or obligation.
Amber Running Lights. LED Bulbs, optional. Patent Nos. 5,151,003/5,302,075. Other Patents Pending. 02/13
LEKTRO PREFACE - 26