The TowFLEXX TF3 is an all-electric, towbarless aircraft tug designed for towing and maneuvering aircraft. It is suitable for both hangar and apron operations, allowing for multiple towing operations per day without intermediate charging, depending on the aircraft's weight. The tug is capable of handling aircraft up to 9,000 kg (20,000 lbs) MTOW.

Function Description:

The TF3 is controlled by two differentially driven wheels, which, combined with a fixed castor at the front, enable it to turn 360 degrees on the spot. The directional indicators on the tug show the direction in which the nose of the tug is moving, activating before the tug starts to move if the joystick is gently pushed. All functions are electronic or mechanical, with no hydraulics. The tug is braked via energy recovery, where the motors act as generators to slightly recharge the batteries. If normal deceleration is insufficient, an opposite control command can increase deceleration. A magnetic brake engages automatically when the vehicle is at a standstill or on slopes and inclines, and no driving command is given. It releases automatically with a new driving command. In case of a system failure, the magnetic brakes can be released manually by pulling marked levers on the motors, but the aircraft and tug must be adequately secured first.

Important Technical Specifications:

Length: 1,700 mm (66.93″)
Width: 1,200 mm (47.25″)
Height: 450 mm (17.72″)
Wheelbase: 1,050 mm (41.34″) (drive wheels, one castor in the middle)
Ground Clearance: 133 mm (5.24″)
Turning Radius: 1,400 mm (55.12″)
Shipping Weight (incl. Batteries): 360 kg (794 lbs)
Speed (not loaded): 6 km/h (3.83 mi/h)
Speed (loaded): 4 km/h (2.49 mi./h) (in slow mode)
Range: Approximately 8 km (5 mi.) (when used at intervals)
Battery Life: 3-4 days (depending on load and interval use)
Operating Temperature: -15°C to +50°C (5°F to 122°F)
Operating Humidity: Max. 90% (Relative Humidity)
Drive Motors: Two 2.2kW 24 VAC motors with flanged spur gear and chain drive.
Tires: Two 18" air-filled drive wheels.
Energy Supply: Two 12VDC maintenance-free, sealed lead-gel batteries, charged by an integrated 115-230VAC charger.
Ground Power Unit (GPU) Connection: Located behind the right side lid, maximum power 50 amps (batteries have a total power of 24V). Not for starting engines.

Usage Features:

The TF3 is operated via a radio remote control, which transmits driving commands and other functions using a country-specific safety frequency. Two joysticks control forward/backward and left/right movement independently. An EMERGENCY OFF switch, located centrally on the remote control, immediately interrupts the radio connection and stops the tug with maximum braking power. The remote control features a "dead man's mode" safety function: if no control pulse is transmitted for 60 seconds, the remote control enters safety mode, requiring the "Horn-Button" to be pressed once to reactivate commands.

To pick up an aircraft, the mechanical ramp of the nose wheel mount is lowered by pulling a lever at the rear. The tug is then slowly moved to align straight with the aircraft's nose wheel, allowing it to pass over the ramp into the cradle. The ramp closes automatically once the nose wheel is in position. The turntable, which allows 360-degree rotation around the nose gear, can be fixed with a safety bolt, especially recommended during aircraft pick-up to prevent twisting. The nose wheel mount is available in different sizes (e.g., 5", 6", PC24", King Air").

Before operation, users must unlock both battery disconnect switches, unlock the emergency stop on the remote control, and deactivate the dead man's mode. To switch off, both battery disconnect switches and the emergency stop on the remote control must be pressed. The tug should only be operated in slow mode (turtle) when an aircraft is attached. When crossing gate rails, the tug should be positioned at a 90° angle to prevent damage. Joysticks should be used gently to avoid abrupt acceleration or braking.

Maintenance Features:

The operating manual emphasizes regular maintenance to ensure safety and longevity. Maintenance intervals are specified for various components:

Batteries: Charge at least once per month (10h interval), check plug for damage, function, and tightness annually (25h interval).
Lighting: Check function annually (50h interval).
Wheels: Check drive wheels for wear and damage annually (50h interval), tighten wheel nuts (220Nm) half-yearly (25h interval), check castors for wear and damage annually (50h interval), check air pressure of pneumatic tires (9 bar) monthly (10h interval).
Turntable: Lubricate flanged rollers half-yearly (25h interval), check folding mechanism and ramp seating without load half-yearly (25h interval), check bolts and screws annually (50h interval).
Drive Chain: Lubricate half-yearly (25h interval), visual inspection and tension check annually (50h interval).
Chassis & Assemblies: Visual inspection annually (50h interval), check bolts and screws annually (50h interval), check readability and completeness of labels annually (50h interval).
Functional Check: Functional test of all commands on remote control half-yearly (25h interval), driving check annually (50h interval).

Maintenance products are minimal, including Glygoyle 220 CLP VG 220 for helical gears and Interflon Lube EP+ Teflonspray for drive chains. Repairs and modifications must only be carried out by trained personnel using original spare parts. Batteries should be charged at least once a month to prevent deep discharge, which can shorten their life or destroy them. Battery replacement involves loosening bolts, opening the cover, disconnecting and removing old batteries, and inserting new ones, ensuring correct polarity. Nose wheel cradle replacement requires removing 8 bolts. The MDI display shows operating hours, software version, and error codes if a malfunction occurs.

TowFlexx TF3 - Page 15

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