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Summary of Contents for TowFlexx TF4
- Page 1 Aircraft Tug TF4 Operating Manual Version 20-06...
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Page 2: Table Of Contents
INDEX Table of content 1. Introduction Your Aircraft Tug Notes on the Operating Instructions Target Group and previous Knowledge Scope of Delivery Use of Symbols in Safety Instructions Safety Instructions 1.6.1 General Safety Instructions 1.6.2 Important Service Note Storage of the Operating Instructions Copyrights 2. - Page 3 TF4 - Manual 3. Vehicle Description Application Assemblies and Functions General Vehicle Description Drive Lighting Brake Nose Wheel Mount Control Unit Control Statement 3.10 Warning Signs and Type Plates 3.11 EC Declaration of Confirmatibility 3.12 Other Certifications 3.13 Technical Data 3.14 Remote Control...
- Page 4 5. Commissioning Turning the Aircraft Tug on and off Pushing the Battery Disconnect Switch (eStop) Pulling the Battery Disconnect Switch (eStop) Tests and Actions before Daily Startup Preparing the Nose Wheel Mount for Tire Size Capturing an Aircraft During Operation Release the Aircraft Possibilities of Nose Wheel Pickup 5.10 Emergency Brake Release...
- Page 5 TF4 - Manual 8. Packaging and Transportation Unloading the Aircraft Tug 9. Disposal Training Certificate...
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Page 6: Introduction
1. Introduction 1.1 Yout Aircraft Tug The TowFLEXX TF4 is a product of long development and offers the best possible safety, econo- my and comfort when towing aircraft. It is up to you to maintain these characteristics for a long time and to use the resulting advantages. -
Page 7: Scope Of Delivery
(according to training) - Reading these operating instructions 1.4 Scope of Delivery Always included: - TowFLEXX TF4 aircraft tug - Remote Control incl. charger and spare batteries - Integrated charger incl. charging cable - Operating Instructions 1.5 Use of Symbols in Safety Instructions This operating manual contains safety instructions with symbols that indicate possible hazards or residual risks. -
Page 8: Safety Instructions
1.6 Safety Instructions These operating instructions contain safety instructions that point out possible hazards and thus enable safe operation of the electric aircraft tug. Please follow these safety instructions at all times! In this section you will find general safety instructions which do not refer to any specific work step. -
Page 9: Important Service Note
Otherwise, warranty and guarantee claims will be void! Only cables with plug connections may be replaced by the user. Further modifica- tions must be carried out by specialist companies or official TowFLEXX personnel. 1.7 Storeage of the Operating Instructions This manual must remain somewhere close to the aircraft tug accessible for all users at any time. -
Page 10: Copyrights
1.8 Copyrights TowFLEXX GmbH Wöstendöllen 95-96 +49 4445 988-144 49429 Visbek info@towflexx.com Deutschland 2. Risik and Security Statements 2.1 Intended Use The aircraft tug may only be used for its intended purpose. It is used to move aircraft via the nose wheel. -
Page 11: Danger Area
TF4 - Manual - In case of storms (storm, lightning strike) the aircraft tug may not be operated outdoors or in endangered areas. Particular attention must be paid to the maximum crosswind com ponent of the towed aircraft. Excessive crosswind loads can lead to loss of traction and thus to loss of control of the tug. -
Page 12: Routes And Parking
2.5 Routes and Parking Driveways must be adequately secured, leveled and free from objects. The driveways must be clearly visible to the operator. Guide rails of hangar gates, drainage channels or similar must be leveled in such a way that they can be driven over without shocks. Maximum area and point- loads must not be exceeded. -
Page 13: Residual Risks
TF4 - Manual • Riding on the tug unless the tug is specially equipped for this purpose • Use in fire or explosion-hazard areas unless it has special certification for this • Exceeding the maximum capacity • Exceeding the restricted speed at max towing DANGER: Improper use can result in serious injuries or even death. -
Page 14: Rights, Obligations And Rules Of Conduct
The operator is responsible for the aircraft tug during the period of use. The operator must forbid unauthorized persons to drive or operate the tug. No persons are allowed to be transported on the TowFLEXX equipment or support equipment being towed. 2.14 Damage and Defects Damage and other defects to the aircraft tug or its attachments must be reported immediately to the supervisor. - Page 15 TF4 - Manual Risk of burns due to the use of unsuitable fire protection. In case of fire, reaction with battery acid may occur when extinguishing with water. This can lead to acid burns. - Never extinguish burning batteries with water.
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Page 16: Vehicle Description
3. Vehicle Description 3.1 Application The TowFLEXX TF4 is an all-electric, towbarless aircraft tug designed for towing and manoeuvring aircraft. The aircraft tug can be operated both in the hangar and on the apron and allows several towing operations per day, depending on the weight without intermediate charging. Weight restrictions and maximum capacities are indicated on the type plate. -
Page 17: General Vehicle Description
TF4 - Manual 3.3 General Vehicle Description The frame of the aircraft tug is a steel construction and is finished with a surface coating, making it fully weatherproof. Two individually driven wheels together with the fixed castor make the aircraft tug extremely manoeuvrable so that it can be turned 360 degrees on the spot without any restrictions. -
Page 18: Brake
3.6 Brake In general, the aircraft tug is braked via energy recovery. The motors work like generators and feed the batteries slightly with the regenerated energy. If this normal deceleration is not suffi- cient enough, the deceleration can be increased by an opposite control command. When the vehicle is at a standstill or on slopes and inclines, the magnetic brake is engaged as soon as no driving command is given. -
Page 19: Control Unit
The board can also be replaced with a few simple steps in order to incorporate any innovations in the control systems. This forms the heart of the aircraft tug. WARNING: Work on the control unit may only be performed by TowFLEXX personnel. If any works are carried out without written confirmation from the manufacturer, all warranty claims will be voided! 3.9 Control Statement... -
Page 20: Warning Signs And Type Plates
Max. tow. cap. /kg Max. tow. cap. /lbs Bat. Type Inspection Bat. Rating Manufactured at TowFLEXX GmbH Wöstendöllen 95-96 D-49429 Visbek Type Plate Warning Sign - Danger - Crush Hazard Warning Sign - Danger - Hazardous Voltage Attention - Read Manual... -
Page 21: Ec Declaration Of Confirmatibility
Designation of the device Towing tractor for aircraft, trailers or other non-self-propelled rolling devices. Device-Type: TowFLEXX TF4 - Aircraft Tug up to 14.000kg towing capacity Identification No.: TF42001XX - ... Applied directives and standards... -
Page 22: Other Certifications
3.12 Other Certifications • EN 292-1 • EN 55011 • EC Machinery Directive (89/392/EEC) • EN 292-2 • EN 50081-2, • EC Low Voltage Directive (73/23/EEC) • EN 60204-1 • EN 50082-2 • EC Directive of Electromagnetic • EN 50178 •... - Page 23 TF4 - Manual Back View Side View Length 1.800 mm (70,87”) Width 1.500 mm (59,06”) Height 450 mm (17.72”) Wheelbase 1.350 mm (53,15”) Drive Wheels, one Caster Wheel Ground Clearance 100 mm (3,94“) Turning Radius 1.400 mm (55.,12”) Shipping Weight incl. Batteries...
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Page 24: Remote Control
3.14 Remote Control Frequency Range see radio remote control Baud Rate 1,200 - 9,600 Baud (bit/sec) Operating voltage battery 7.2V Power Consumption 0 - 100 mA RF Power < 10 mW ERP Protection Class IP 65 Operating Temperature -20°C to +70°C (-4°F to 158°F) Weight (without batteries) 1.000g / 2,2lbs Dimensions (L x W x H) -
Page 25: Groundpower Unit (Gpu)
TF4 - Manual 3.17 Groundpower Unit (GPU) The TF4 has a ground power connection located behind the right side lid. However, the device cannot be used as a classic GPU, but should not exceed a maximum power of 50 amps. Please note that the batteries have a total power of 24V. -
Page 26: Impact On The Environment And Personnel
3.20 Impact on the Environment and Personnel The manufacturer confirms compliance with the limits for electromagnetic interference and immunity, as well as the static electricity discharge test according to EN. WARNING: Interference with medical devices by non-ionizing radiation Electri- cal equipment of the aircraft tug that emits non-ionizing radiation (e.g. wireless data transmission) can interfere with the functions of medical devices (pacema- kers, hearing aids, etc.) of the operator, as well as persons in the surrounding area, and lead to malfunctions. - Page 27 TF4 - Manual If the EMERGENCY STOP switch is activated while driving, the aircraft tug is braked to a standstill with maximum braking power. There is an increased risk of accidents and injuries. Do not use the EMERGENCY OFF switch as a service brake.
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Page 28: Radio Remote Control
4.2 Turning the remote control on and off To turn on the remote control, turn the emergency stop switch clockwise until it jumps up slightly. A small LED on the remote control will illuminate. Note: If it is foreseeable that the aircraft tug will not be used for more than 60 seconds, the remote control should be deactivated immediately! 4.3 Remote Control Charger and Battery A charger for the batteries of the remote control is loca-... -
Page 29: Safety Function (Dead Man's Mode)
TF4 - Manual 4.5 Safety Function (Dead Man´s Mode) If no control pulse is transmitted for a period of 60 seconds, the remote control goes into safety mode. If this mode is activated, the aircraft tug responds to no command from the remote con- trol, until the „Horn-Button“... -
Page 30: Battery Charger Of The Aircraft Tug
4.7 Battery Charger of the Aircraft Tug A charger is integrated into the aircraft tug. It is located behind the left side storage compart- ment. The charger is powered by 100-240 VAC. To start the charging process, plug the charging cable into an appropriate power supply. Then pull the battery disconnect switch on the left (in the driving direction) to start the charging process. -
Page 31: Direction Indicator Lights
TF4 - Manual ATTENTION! When the tug is not being used or charged, make sure that both battery disconnectors are deactivated (pressed). Otherwise there is a risk of the batteries becoming deeply discharged and irreparably damaged! 4.8 Direction Indicator Lights On top of the aircraft tug there are direction indicators, which show the direction in which the tug is moving. -
Page 32: Turning The Aircraft Tug On And Off
5. Comissioning 5.1 Turning the Aircraft Tug on and off Switch on: 1. unlock both battery disconnector switches (eStop) by pulling them up. 2. unlock the emergency stop on the remote control by pulling an twisting it clockwise to activate the transmitter. 3. -
Page 33: Pushing The Battery Disconnect Switch (Estop)
TF4 - Manual 5.2 Pushing the Battery Disconnect Switch (eStop) If one of the battery disconnect switches is pressed, all electrical functions are switched off. The aircraft tug is braked to a standstill immediately. 5.3 Pulling the Battery Disconnect Switch (Estop) If both battery disconnectors are unlocked by pulling, all electrical functions will be switched on. -
Page 34: Preparing The Nose Wheel Mount For Tire Size
5.5 Preparing the nose Wheel mount for Tire Size To pick-up an aircraft, the mount has to be set to the lowest position so that the arms are open and the access to the mount is not blocked by any objects. The mount is opened and closed via the remote control (see page 27) and will stop automatically as soon as the final position is reached. - Page 35 TF4 - Manual First open the wheel mount using the remote control so that the arms are in the outermost position. Move the tug care- fully and slowly towards the nose wheel so that the tug is as centered as possible. Depending on the wheel type (twin or single), first remove the nosewheel spacers (lateral limiters for the nose wheel).
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Page 36: During Operation
5.7 During operation While towing, there are a few points to take into account to prevent possible damage to the aircraft and the tug: - Only use slow mode (turtle) while an aircraft is on the tug. - When crossing gate rails, the aircraft tug should be positioned at a 90° angle to the rails if possible. -
Page 37: Possibilities Of Nose Wheel Pickup
TF4 - Manual We recommend securing the turntable with the locking pin before lowering it. First release the strap, otherwise the arms can not open auto- matically when lowering. WARNING! Failure to release the strap may result in damage to the aircraft tug. -
Page 38: Emergency Brake Release
Not observing can lead to personal injury and damage to property! ATTENTION: If the tug has to be repositioned in an emergency, the TowFLEXX TF4 must not be towed or pulled without following the procedure for releasing the magnetic brakes. Alternatively, the tug MUST be repositioned by an suitable forklift truck and forklift operator! Failure to do so may result in damage to the equipment. -
Page 39: Emergency Aircraft Release
TF4 - Manual 5.11 Emergency Aircraft Release In case there are problems with the electronics, or even mechanical problems, there is al- ways the possibility to remove the aircraft manually from the tug. This can be done either with a screwdriver or a power tool. -
Page 40: Maintenance
6. Maintenance Support Germany / International Support America TowFLEXX GmbH TowFLEXX Inc. Wöstendöllen 95-96 4901 Chester Creek Rd 49429 Visbek Brookhaven, PA 19015 Germany +49 4445 988-144 +1 (484) 662 3002 (24h) help@towflexx.com help@towflexx.com WARNING! Ignoring regular maintenance can lead to failure of the aircraft tug and is also a potential hazard for persons and operation. - Page 41 TF4 - Manual Assembly Action Interval Batteries • charge at least 1x per month monthly • check the battery plug for damage, function and anually tightness anually Lighting • Check the function of the lighting Wheels • Check drive wheels for wear and damage anually •...
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Page 42: Repair And Overhaul
7. Repair and Overhaul 7.1 General Information Repairs may only be carried out by trained personnel. Only original spare parts approved by the manufacturer must be used to ensure safe and reliable operation. WARNING! Any modification to the aircraft tug - especially to the safety equip- ment - is prohibited. -
Page 43: Working On The Electronics
The quality of the tires influences the stability and driving characteristics of the aircraft tug. The TF4 has two air-filled drive wheels which influence the straight-line stability of the tug. The air pressure should be checked at regular intervals. If there is a deviation from the target value of 9bar per tire, this should be corrected immediately to ensure smooth operation. -
Page 44: Battery Replacement
WARNING The user must check the air pressure of the tires at regular intervals according to the maintenance schedule, otherwise the warranty will be void. 7.8 Battery Replacement In case of a defective battery, the batteries can be replaced in a few easy steps. The following steps should be taken: 1. -
Page 45: Replacing The Castor Wheel
TF4 - Manual 7.9 Replacing the Castor Wheel 1. Press both emergency stop switches and secure the aircraft tug against rolling away. 2. First open the two lids on the sides to get access to the wing nuts highlighted below. -
Page 46: Troubleshooting
7.11 Troubleshooting Occurring Error Possible Cause Troubleshooting Tug does not start - eStop switch pressed - pull the eStop up - Voltage too low - charge the unit No radio connection (red LED on - Remote control is switched off - Turn on the remote control the tug) is lit, white LED is off ) - Battery of remote control is empty... - Page 47 TF4 - Manual 8. packaging and transportation 8.1 Unloading the aircraft tug In order to provide the best possible protection for the aircraft tractor during transport, it is se- cured in a reusable wooden transport box. The following steps are necessary to move the tug out of the transport box.
- Page 48 ATTENTION! The tug must be unloaded with absolute caution. The manufactu- rer will not be liable for any damages caused during unloading (unless this pro- cess is performed by a TowFLEXX employee).
- Page 49 TF4 - Manual 9. Disposal The final and proper decommissioning or disposal of the aircraft tug must be carried out in accordance with the respectively valid legal regulations of the user country. In particular, the regulations for the disposal of batteries, the equipment as well as the electronics and electrical system must be observed.
- Page 50 • Service and maintenance of the aircraft tug • Training of other colleagues Both the trainer and the trainee confirm that a professional and complete instruction of the functions as well as the dangers in dealing with the TowFLEXX TF4 were addressed and understood. _________________________________...
- Page 51 NOTES...
- Page 52 Towflexx TF4 - up to 14.000kg MTOW www . towflexx . de www . towflexx . com...
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