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TowFlexx TF5.5 - User Manual

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TF5.5 Aircraft Tug
Manual
Version 5.5-21-07-1
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Table of Contents

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Summary

3. VEHICLE DESCRIPTION

3.1 Application

Describes the intended use of the TowFLEXX TF5 aircraft tug for towing and maneuvering.

3.2 Assemblies and Functions

Details the various components and operational features of the aircraft tug.

3.3 General Vehicle Description

Provides an overview of the aircraft tug's construction, materials, and maneuverability.

3.4 Drive

Explains the drive system, motors, gearboxes, and traction forces of the aircraft tug.

3.5 Lighting

Lists the lighting components including headlights, platform lights, and indicators.

3.6 Brake

Describes the braking system, including energy recovery and deceleration.

3.7 Nose Gear Cradle and Lifting platform

Details the mechanism for securing and lifting the aircraft's nose wheel.

3.8 e-Cube

Explains the e-Cube housing electronic components, controls, and maintenance.

3.9 Control statement

Describes how the aircraft tug is controlled via differentiated wheels and castor wheels.

3.10 Warnings and Typeplates

Covers safety warnings, labels, and identification plates on the aircraft tug.

3.11 EC-Declaration of Conformity

Presents the manufacturer's declaration of conformity with EC directives.

3.12 More Certifications

Lists various European and international standards and certifications applied.

3.13 Specifications

Provides detailed technical specifications, including dimensions and top view diagram.

3.14 Remote Control

Details the specifications and features of the remote control unit for the aircraft tug.

3.15 Power supply

Explains the energy source for the aircraft tug, consisting of lead-gel batteries.

3.16 Connections

Identifies various connection points on the aircraft tug for accessories and operation.

3.17 Supplies

Lists the fluids and lubricants used in the aircraft tug's operation.

3.18 Ambient Temperature & Working environment

Specifies recommended operating temperatures and environmental conditions.

3.19 Pollution of the environment and surrounding personnel

Addresses electromagnetic interference and potential effects on medical devices.

1. INTRODUCTION

1.1 YOUR AIRCRAFT TUG

Introduces the TowFLEXX TF5, highlighting its security, ease, and comfort features.

1.2 NOTES FOR THE OPERATING INSTRUCTIONS

Provides guidance on the manual's structure and importance of training.

1.3 TARGET GROUP AND PRIOR KNOWLEDGE

Identifies intended users and necessary prerequisites for operating the tug.

1.4 SCOPE OF DELIVERY

Lists the items generally included with the TowFLEXX TF5 aircraft tug.

1.5 USE OF SYMBOLS IN SAFETY INSTRUCTIONS

Explains the meaning of safety symbols used throughout the manual for hazard communication.

1.6 SAFETY

Covers essential safety information and notes for personnel.

1.6.1 GENERAL SAFETY

Covers essential general safety precautions for operating the aircraft tug.

1.6.2 IMPORTANT SERVICE NOTE

Highlights crucial notes regarding approved accessories and qualified personnel for service.

1.7 STORAGE OF THE OPERATING INSTRUCTIONS

Describes where the operating instructions are stored on the aircraft tug.

1.8 COPYRIGHT

Provides copyright information for TowFLEXX GmbH.

2. RISK AND SECURITY STATEMENTS

2.1 INTENDED USE

Defines the specific purpose and limitations for operating the aircraft tug.

2.2 USE UNDER EXTREME CONDITIONS

Addresses potential issues and requirements when operating in harsh or unusual environments.

2.3 DANGER ZONE

Defines hazardous areas around the tug and recommends safety distances.

2.4 RAMPS, SLOPES AND INCLINES

Details limitations and risks associated with operating the tug on inclines.

2.5 ROUTES AND PARKING

Specifies requirements for safe routes and parking areas for the aircraft tug.

2.6 OBLIGATIONS OF OPERATOR

Outlines the responsibilities and duties of the person operating the aircraft tug.

2.7 ATTACHMENTS OR ADDITIONAL EQUIPMENT

Discusses the rules and permissions for adding external equipment to the tug.

2.8 IMPROPER USE

Lists prohibited uses of the aircraft tug and associated dangers.

2.9 RESIDUAL RISKS EVEN WITH CORRECT INSTRUCTION

Acknowledges inherent risks that remain even with proper operation and safety measures.

2.10 PROTECTIVE MEASURES

Specifies required personal protective equipment (PPE) for safe operation.

2.11 DRIVING PERMIT

Mandates training and certification for operating the aircraft tug.

2.12 RIGHTS, OBLIGATIONS AND RULES OF CONDUCT

Covers operator rights, obligations, and expected conduct during use.

2.13 PROHIBITION OF USE BY UNAUTHORIZED PERSONS

Prohibits operation by unauthorized individuals and transport of passengers.

2.14 DAMAGE AND DEFECTS

Outlines procedures for reporting and addressing damage or defects.

2.15 REPAIRS AND MAINTENANCE

Details restrictions on repairs and modifications, emphasizing trained personnel.

2.16 PERSONS AT RISK

Stresses the importance of qualified personnel and prohibition of impaired operation.

2.17 FIRE PROTECTION

Provides guidelines for fire safety, including clearance and extinguisher use.

4. OPERATION AND USE

4.1 REMOTE CONTROL

Explains how to use the radio remote control for commands and status monitoring.

4.2 TURNING THE REMOTE CONTROL ON AND OFF

Describes the procedure for powering the radio remote control on and off.

4.3 BATTERY CHARGER AND BATTERY OF THE REMOTE CONTROL

Details the charging system and batteries for the remote control unit.

4.4 BATTERY REMOVAL OF THE REMOTE CONTROL

Provides steps for safely removing and replacing the battery in the remote control.

4.5 MANUAL CHANNEL CHANGE

Explains how to manually change radio channels for the remote control.

4.6 SAFETY MODE; DEAD-MAN-MODE

Describes the safety feature that activates when no control input is detected.

4.7 TURNTABLE GATE AND LOCK

Details the operation of the turntable gate for securing the aircraft's nose wheel.

4.8 AIRCRAFT TUG CHARGER

Explains the integrated charging system for the aircraft tug and safety precautions.

4.9 DIRECTION INDICATORS

Describes the LED indicators that show the aircraft tug's direction of movement.

4.10 STATUS-LED

Explains the function of the status LEDs indicating operational readiness.

4.11 MDI DISPLAY

Details the multifunction display (MDI) for showing operating hours and error codes.

5. TOWFLEXX OPERATION

5.1 SWITCHING THE AIRCRAFT TUG ON AND OFF

Provides step-by-step instructions for powering the aircraft tug on and off.

5.2 BATTERY DISCONNECT SWITCH ACTIVATION (EMERGENCY-OFF; E-STOP)

Explains the function and activation of the emergency stop (e-stop) switches.

5.3 RELEASE BATTERY DISCONNECT SWITCH

Details how to release the battery disconnect switches to enable operation.

5.4 TESTS AND ACTIVITIES BEFORE DAILY STARTUP

Lists essential checks and procedures to perform before starting the tug each day.

5.5 SET NOSE WHEEL ADAPTER

Guides on adjusting nose wheel adapters for safe and proper towing operations.

5.6 CAPTURING THE AIRCRAFT

Describes the process of positioning and securing the aircraft's nose wheel onto the tug.

5.7 AIRCRAFT RELEASE

Details the step-by-step procedure for safely unloading the aircraft from the tug.

5.8 TURNTABLE MOTOR

Explains the turntable motor and its control variants: Disengaged, Counter Control, and Manual Control.

5.9 NOSEWHEEL APPROACH CONFIGURATIONS

Illustrates four different methods for approaching an aircraft's nose wheel.

5.10 TOWING GROUND SUPPORT EQUIPMENT

Describes how to tow auxiliary ground support equipment using the tug.

5.11 EMERGENCY RELEASE OF THE WINCH

Provides instructions for manually lowering the lifting platform in case of remote control failure.

5.12 RELEASING THE MAGNETIC BRAKE

Details the emergency procedure to release the magnetic brake for manual repositioning.

6. MAINTENANCE

6.1 MAINTENANCE SCHEDULE

Outlines the recommended maintenance intervals and tasks for the aircraft tug.

6.2 PLAN OF FUSES

Lists the fuses, their amperage, and assigned components within the aircraft tug.

7. REPAIR AND OVERHAUL

7.1 GENERAL INFORMATION

Stresses that repairs must be performed by certified personnel using original parts.

7.2 REQUIREMENTS FOR THE STORAGE ROOM

Specifies conditions for storing the aircraft tug for extended periods.

7.3 ACTIONS BEFORE AND DURING SHUT DOWN

Details necessary actions before, during, and after shutting down the aircraft tug.

7.4 REQUIRED ACTIONS DURING DECOMMISSIONING

Notes on battery self-discharge and the need for regular recharging.

7.5 RE-COMMISSIONING THE AIRCRAFT TUG

Outlines steps for bringing the aircraft tug back into service after storage.

7.6 WORK ON THE ELECTRONICS

Covers safety precautions and procedures for working on the tug's electrical systems.

7.7 BATTERY REPLACEMENT

Provides a step-by-step guide for replacing the batteries in the aircraft tug.

7.8 E-CUBE REPLACEMENT

Explains the process for exchanging the e-Cube for technical issues or updates.

7.9 TURNTABLE GATE REALIGNMENT

Details how to realign the turntable gate if it loses its correct positioning.

7.10 STEEL CABLE REALIGNMENT

Describes how to realign the steel cable on the winch drum if it becomes twisted.

8. PACKAGING AND TRANSPORT

8.1 UNLOADING THE AIRCRAFT TUG

Provides steps for safely removing the aircraft tug from its transport box.

8.2 TRANSPORT WITHOUT CRATE

Explains options for transporting the aircraft tug without using a crate, including lifting points.

9. DISPOSAL

Disposal

Details the procedures for the proper decommissioning and disposal of the aircraft tug.

10. APPENDIX

10.1 ERROR CODES

Lists common error codes displayed on the remote control and their explanations.

11. TRAINING CERTIFICATE

Training Certificate

Provides the template for the training certificate confirming skilled use of the TowFLEXX TF5.

TowFlexx TF5.5 Specifications

General IconGeneral
BrandTowFlexx
ModelTF5.5
CategoryIndustrial Equipment
LanguageEnglish