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TowFlexx TF3 Operating Manual

Aircraft tug
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Aircraft Tug TF3
Operating Manual
Version 20-02

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Summary of Contents for TowFlexx TF3

  • Page 1 Aircraft Tug TF3 Operating Manual Version 20-02...

  • 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 TF3 - 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 Pulling the Battery Disconnect Switch Tests and Actions before Daily Startup Preparing the Nose Wheel Mount for Capturing Capturing an Aircraft During Operation Release the Aircraft Possibilities of Nose Wheel Pickup 5.10 Releasing the Magnetic Brakes 6.
  • Page 5 TF3 - Manual 8. Packaging and Transport Unloading the Aircraft Tug 9. Disposal...

  • Page 6: Introduction

    1. Introduction 1.1 Yout Aircraft Tug The TowFLEXX TF3 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 TF3 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

    TF3 - 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

    TF3 - 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 TF3 - 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.

  • Page 16: Vehicle Description

    3. Vehicle Description 3.1 Application The TowFLEXX TF3 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

    TF3 - 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

    The nose wheel is moved onto the mount over a mechanical ramp. The wheel size is determi- ned by the mount. This mount is assembled on a 360 degree turntable that allows to rotate the tug freely around the nose gear. The following mounts are currently available for the TF3: Mount 5“...

  • 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

    Bat. Rating Manufactured at TowFLEXX GmbH Wöstendöllen 95-96 D-49429 Visbek WARNING AVERTISSEMENT Type Plate Warning Sign - Danger - Crush Hazard...

  • 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 TF3 - Aircraft Tug up to 9.000kg towing capacity Identification No.: TF32001XX - ... 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 TF3 - Manual Back View Side View Length 1.700 mm (66,93”) Width 1.200 mm (47,25”) Height 450 mm (17.72”) Wheelbase 1.050 mm (41,34”) Antriebsräder, ein Stützrad in der Mitte Ground Clearance 133 mm (5.24”) Turning Radius 1.400 mm (55.,12”) Shipping Weight incl. Batteries...

  • 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)

    TF3 - Manual 3.17 Groundpower Unit (GPU) The TF3 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 TF3 - 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.

  • 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: Removing The Battery Pack

    TF3 - 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

    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. Battery Charger TF3 Start charging Process WARNING! When charging, the batteries emit a mixture of oxygen and hydro- gen (oxyhydrogen gas).

  • Page 31: Direction Indicator Lights

    TF3 - 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 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

    TF3 - Manual 5.2 Pushing the Battery Disconnect Switch 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 If both battery disconnectors are unlocked by pulling, all electrical functions will be switched on.

  • Page 34: Preparing The Nose Wheel Mount For Capturing

    5.5 Preparing the nose Wheel mount for capturing In order to pick up the aircraft, the mechanical ramp of the nose wheel mount must be brought into position. To lower the ramp, pull the lever at the rear of the mount (see picture). Pull the handle at the rear to lower the ramp Fix the turntable before picking up the aircraft ATTENTION! When preparing the nose wheel mount there is hazard of crushing!
  • Page 35 Slowly move the aircraft tug to the nose wheel of the aircraft or helicopter. Make sure that the TF3 is aligned as straight as possible to the aircraft to ensure smooth pick-up. If the unit is correctly positioned in front of the nose wheel, move it slowly and carefully forward, so that the nose wheel can pass over the ramp into the cradle.

  • 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

    TF3 - Manual Unlock the mount´s ramp using the handle at the back of the cradle and lower the ramp. If the handle is blocked, move the tug a slightly forward or backward (depending on the posi- tion) to reduce the pressure of the nose wheel on the mount.

  • Page 38: Release The Aircraft

    Not observing can lead to personal injury and damage to property! ATTENTION: If the tug has to be repositioned in an emergency, the TowFLEXX TF3 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: Maintenance

    TF3 - Manual 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 40 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 •...

  • Page 41: Repair And Overhaul

    TF3 - Manual 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 42: Working On The Electronics

    The quality of the tires influences the stability and the handling of the aircraft tug. The TF3 has two air-filled drive wheels which influence the straight running of the tug. The air pressure should be checked at regular intervals. If there is a deviation from the target value of 9 bar per tire, this must be corrected immediately, to guarantee a smooth operation.

  • Page 43: Battery Replacement

    TF3 - Manual 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 defective batteries, they can be replaced in a few easy steps. The following proce- dures should be followed: 1.

  • Page 44: Nose Wheel Cradle Replacement

    8 bolts have to be removed, which are marked in the following picture. Attachment of the TF3 nose wheel mount The installation of a new nose wheel mount is performed in reverse order. This principle is the same for all different types of mounts.
  • Page 45 TF3 - Manual 8. Packaging and Transport 8.1 Unloading the Aircraft Tug In order to provide the best possible protection for the aircraft tug during transport, it is stored in a reusable wooden transport box. The following steps are necessary to move the aircraft tug out of the transport box.
  • Page 46 The front wall can then be removed and put to the side. Inside the box, the tug is secured with several straps. First loosen and remove the straps on the front side. Make sure that after removing the front strap, the fixing piece is removed.
  • Page 47 TF3 - Manual ATTENTION! Use a forklift with sufficient capacity and fork length to transport the transport box. The box has the following specifications: Weight: 630kg (1386lbs) Dimensions: 1950mm (76,77“) x 1720mm (67,71“) x 730mm (28,74“) ATTENTION Only lift the transport box from the front side! Note: Before driving the aircraft tug for the first time, the operator must have read the entire manual carefully and become familiar with its contents.
  • Page 48 Towflexx TF3 - up to 9.000kg / 20.000lbs MTOW www . towflexx . de www . towflexx . com...

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