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Summary of Contents for TowFlexx TF5.5
- Page 1 TF5.5 Aircraft Tug Manual...
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Page 2: Table Of Contents
InDEX Table of content 1. Introduction Your Aircraft Tug Notes for the Operating instructions Target group and prior knowledge Scope of Delivery Use of Symbols in Safety Instructions Safety 1.6.1 General Safety 1.6.2 Important service note Storage of the operating instructions Copyright 2. - Page 3 TF5 - Manual 3. Vehicle Description Application Assemblies and Functions General Vehicle Description Drive Lighting Brake Nose Gear Cradle and Lifting platform e-Cube Control statement 3.10 Warnings and Typeplates 3.11 EC-Declaration of Conformity 3.12 More Certifications 3.13 Specifications 3.14 Remote Control 3.15 Power supply 3.16 Connections 3.17 Supplies...
- Page 4 5. TowFLEXX Operation Switching the Aircraft Tug on and off Battery Disconnect Switch Activation (e-Stop) Release Battery Disconnect Switch Tests and Activities before daily Startup Set Nose Wheel Adapter Capturing the Aircraft Aircraft Release Turntable Motor Nosewheel Approach Configurations 5.10 Towing Ground Support Equipment 5.11 Emergency Release of the Winch...
- Page 5 TF5 - Manual 8. Packaging and Transport Unloading the Aircraft Tug Transport Without Crate 9. Disposal 10. Appendix 10.1 Error Codes 11. Training Certificate...
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Page 6: Introduction
1. Introduction 1.1 Your Aircraft Tug The TowFLEXX TF5 has been in development for a long time and offers the best in security, ease and comfort when towing an aircraft. It is in your hands to preserve these features and to take advantage of the resulting benefits. -
Page 7: Scope Of Delivery
It is highly recommended to attend a certified product training to understand all operating procedures described in this manual. Please read and understand this manual. 1.4 Scope of Delivery Generally included in delivery: • TowFLEXX TF5 Aircraft tug • Remote Control • Integrated Charger • Operating Manual • Optional ordered Accessories/Attachments 1.5 Use of Symbols in Safety Instructions... -
Page 8: Safety
1.6 Safety This operating manual contains safety instructions which draw attention to possible dangers and thus enable the safe operation of the electric aircraft tug. Please pay attention to these safety instructions! This section contains general safety instructions that are not related to regular operation. Special information can be found in the specific sections. -
Page 9: Important Service Note
1.6.2 Important service note Only OEM accessories are approved! These may only be installed by qualified and officially TowFLEXX certified personnel! The use of non-OEM accessories voids the warranty! The user may only replace cables with OEM cable assemblies. Further changes must be carried out by authorized, factory trained companies. -
Page 10: Risk And Security Statements
2. Risk and security statements 2.1 Intended Use The aircraft tug may only be used as intended. It serves to lift and move aircrafts by cradling the nose wheel. It is important to pay attention to the carrying capacity (max load). Possible aero- space ground equipment can be towed when authorized with appropriate OEM equipment. -
Page 11: Ramps, Slopes And Inclines
TF5 - Manual WARNING: Risk of accident / injury when in the danger zone of the aircraft tug. 2.4 Ramps, Slopes and Inclines All ramps, slopes or inclines must not exceed more than 1% as stated on the warning stickers on the tug. -
Page 12: Attachments Or Additional Equipment
The operator must ensure that the aircraft tug is only used as intended and that all types of dangers to the life and health of the operator or third parties are avoided. In addition, attention must be paid to compliance with accident prevention regulations, other safety regulations, as well as the operating, maintenance and repair guidelines. -
Page 13: Protective Measures
2.11 Driving permit The aircraft tug may not be used to reposition aircraft until the mandatory training by official TowFLEXX personnel has been completed. This training takes place either on site or online if requested. Failure to comply with this regulation may void the manufacturer‘s warranty. -
Page 14: Repairs And Maintenance
Under no circumstances may the operator deactivate or remove safety devices or switches. 2.16 Persons at Risk All personnel operating the TowFLEXX tug must have received adequate and comprehensive training. Operating under the influence of alcohol, drugs or other substances that impair the ability to perceive is strictly prohibited! 2.17 Fire protection... -
Page 15: Vehicle Description
TF5 - Manual 3. Vehicle Description 3.1 Application The TowFLEXX TF5 is a purely electric, towbar-less aircraft tug intended for towing and maneuvering general aviation aircraft and aerospace ground equipment when properly equip- ped with OEM accessories. The aircraft tug can be operated both in the hangar and on the apron and allows several towing operations per day, depending on the load without intermediate charge. -
Page 16: General Vehicle Description
3.3 General Vehicle Description The aircraft tug frame is made of steel and is galvanized, thus completely weatherproof. Two individually driven solid rubber tires together with the heavy-duty fixed castors make the aircraft tug extremely maneuverable so that it can be rotated 360 degrees on the spot without restrictions. -
Page 17: Nose Gear Cradle And Lifting Platform
WARNING: The e-Cube is sealed and only accessible to specifically designated TowFLEXX personnel. If the seal is broken without written confirmation or by unqualified personnel, any warranty claim is voided! The e-Cube is the Heart of the TF5 Aircraft Tug... -
Page 18: Control Statement
3.9 Control statement The Aircraft Tug in general is controlled by two differentiated driven wheels. Together with two castor wheels in the front of the tug the allows to turn 360 degrees on the spot. The Indicator Lights of the TF5 always show the direction in which the nose of the tug is moving. Driving Mode: normal Driving Mode: Inverted This graphic is just an extract of all the possible control variations. - Page 19 TF5 - Manual Plan of Fuses for Plan des fusibles pour Towflexx TF5 Weight /kg DESIGNATION AMPERAGE ASSIGNED TO RESPONSIBLE FOR APPELLATION AMPÉRAGE ASSIGNÉ À RESPONSABLE DE Weight /lbs 350A Control Unit U1 Drive Motor 1 Unité de contrôle U1 Moteur d'entraînement 1...
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Page 20: Ec-Declaration Of Conformity
Designation of the device Towing tractor for aircraft, trailers or other non-self-propelled rolling devices. Device Type: TowFLEXX TF5 - Aircraft Tug up to 60.000kg towing weight Identification No.: TF52001XX - ... Applied directives and standards... -
Page 21: More Certifications
TF5 - Manual 3.12 More 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 •... - Page 22 Rear View Side View Length 2630 mm (103.54”) Width 1925 mm (75.79”) Hight 450 mm (17.72”) Wheelbase 940 mm (37”) Support W., 1600 mm (62.99”) Drive W. Ground Clearance Back: 132 mm (5.20”); Front: 90mm (3,54“) Turning Circle 2.050 mm (80.70”) Hight of the Lifting Platform 100 mm (3.94”) Shipping Weight incl.
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Page 23: Remote Control
TF5 - Manual 3.14 Remote Control Frequency Range see Plate Baudrate 1.200 - 9.600 Baud (Bit/sec) Operating Voltage Battery 7.2V Power Consumption 0 - 100 mA RF Performance < 10 mW ERP Safety Class IP 65 Working Temperature -20°C to +70°C / -4°F to +158°F Weight (without Battery) 1.000g Dimensions (L x W x H) -
Page 24: Supplies
3.17 Supplies The fluids used in the aircraft are reduced to a minimum, thereby minimizing the risk of leaking: • Door Latch & Gate: regular high Temperature Chain Grease • Drive Chain: regular high Temperature Chain Grease 3.18 Ambient Temperature & working environment With constant use under extreme temperature changes and condensing air humidity special equipment and approval is required for the aircraft tug. -
Page 25: Operation And Use
TF5 - Manual 4. Operation and use 4.1 Remote control The radio remote control of the aircraft towing vehicle is used to transmit any movement com- mands and other functions to the aircraft tug. Country-specific security radio is used. The direction of travel (forward / backward & left / right) is determined via two joysticks. Both can be operated independently of each other. - Page 26 See Section 5.8 GREEN = Default Position *2 By default, the TowFLEXX TF5 brakes will be released when the platform is lifted or lowered and can move BLACK = Selection slightly, this allows for movement of the landing gear...
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Page 27: Turning The Remote Control On And Off
TF5 - Manual Side View Right Side View Left Channel Switch (at Radio Interference) Must be operated simulatneously Backup-Cable Channel Switch Connection Power Switch Force Reset of (at Radio Interference) electrical Components Press for 5 Secons Reactivate from Secure Mode 4.2 Turning the Remote Control On and Off To turn on the radio transmitter, the side-mounted rotary switch is moved to the corresponding position. -
Page 28: Manual Channel Change
4.5 Manual channel change The radio remote control has a safety channel feature. This automatically selects a trouble-free channel when switching on. Should there nevertheless be more interruptions in the radio con- nection, the channel can be changed manually. To do this, press the „Channel change“ buttons on the left and right at the same time. -
Page 29: Aircraft Tug Charger
TF5 - Manual Always make sure the red marked locking pin is locked in correctly to it´s final position, after closing the turntable gate. 4.8 Aircraft tug charger A charger is integrated to charge the aircraft tug. This is located in the front storage compart- ment (see 3.2 Assemblies and functions, page 16). -
Page 30: Direction Indicators
Solid blue: AC power available Solid Red: Charger fault Flashing green: Low state of charge Solid Amber: External error condition - caution Solid green: High state of charge Flashing green: USB Port active Flashing green: High state of charge Solid green: Safe to remove USB flash drive Solid green: Charge complete 4.9 Direction Indicators In the front part of the aircraft tug is a direction indicator which indicates the direction in which... -
Page 31: Towflexx Operation
TF5 - Manual 5. TowFLEXX Operation 5.1 Switching the aircraft tug on and off In general, the aircraft tug is de-energized via both battery disconnect switches. In addition, to protect against unauthorized access, a key switch is installed. Before starting the unit via key switch, make sure both e-Stops are pulled, otherwise no current is flowing. -
Page 32: Battery Disconnect Switch Activation (E-Stop)
5.2 Battery Disconnect Switch Activation (emergency-Off / e-Stop) If one of the battery disconnect switches is pressed, all electrical functions are switched off. The aircraft tug is braked to a standstill. An errorcode 1-1 is shown. 5.3 Release battery disconnect switch If both battery disconnect switches are unlocked by pulling, all electrical functions are switched on. -
Page 33: Set Nose Wheel Adapter
TF5 - Manual 5.5 Set nose wheel Adapter For a safe working process it is very important to adjust the nose wheel adapters and spacers to the corresponding nose wheel. Various options are available. ATTENTION! Failure to comply will prevent proper towing operations and may result in damage to the aircraft and the aircraft tug. - Page 34 Make sure that there is nothing under the platform! Ensure that the mark on the gate points to the mark on the platform. Then move the lifting platform to the lowest position. Unlock the gate by turning the lock pin 180 °. Use the handle to open the gate.
- Page 35 TF5 - Manual Close and lock the turntable gate. DANGER! An improperly closed turntable gate can cause the aircraft to slip out of the cradle while to- wing! This is a risk of injury or death! Lift the nosewheel. ATTENTION! Release the parking brake from the aircraft and remove the chocks in front of the aircraft wheels.
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Page 36: Aircraft Release
5.7 Aircraft release The unloading of the aircraft is carried out in reverse order to the setting. Before unloading, make sure that the aircraft is properly secured. To do this, the chocks on the main landing gear and the aircraft parking brake must be applied. Release the safety strap (or safety bar) to prevent possible damage to the nose wheel or to the aircraft tug. -
Page 37: Turntable Motor
TF5 - Manual 5.8 Turntable motor The turntable motor enables active control of the turntable. The remote control offers three different control variants, which are described in the following section. Turntable Motor Switch to disengage on the backside Switch to disengage turntable motor Disengaged motor A rotary switch on the back of the turntable motor allows it to be disengaged. -
Page 38: Nosewheel Approach Configurations
GSE, make sure the turntable is locked. The lifting platform must be brought into the upper- most position against the limit switch. ATTENTION! Failure to comply may result in damage to the TowFLEXX unit. Recess for locking Bolts Locking for the Turntable... -
Page 39: Emergency Release Of The Winch
TF5 - Manual 5.11 Emergency Release of the winch To lower the lifting platform in the event of a radio remote control failure, it can be manually switched to the power supply. The power supply is plugged behind the e-cube. ATTENTION: The direct connection of the winch to the power supply bypasses the limit switches. -
Page 40: Releasing The Magnetic Brake
ATTENTION! If the tug requires emergency repositioning do not tow or drag the TowFLEXX unit without following the emergency brake release procedure. Alternatively the tug MUST be repositioned by a capable forklift and forklift... -
Page 41: Maintenance
Maintenance and repair work exceeding the works specified in the maintenance schedule may only be performed by personnel certified by TowFLEXX and after explicit written confirmation. Failure to do so will void the warranty. -
Page 42: Plan Of Fuses
Assembly Persevering Activities Interval Batteries • min. 1 recharge a Month 10h or monthly • Check the Battery-Plug for Damage, Function and 25h or anually tight Fit 50h or anually Lighting • Lighting function Check Tires • Check Drive Wheels for Wear and Damage 50h or anually •... - Page 43 TF5 - Manual Maintenance Notes...
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Page 44: Repair And Overhaul
7. Repair and OverHaul 7.1 General Information Repairs or overhauls may only be carried out by personnel trained and certified by TowFLEXX. In order to ensure reliable operation of the aircraft tug use only certified and original parts from the manufacturer. Neglecting to do so will void the warranty. -
Page 45: Work On The Electronics
10 minutes. Before start working at the electrical systems: • Only personnel trained and certified by TowFLEXX is allowed to do these work • Before starting work, make sure that all precautions have been taken to avoid electrical accidents. -
Page 46: E-Cube Replacement
7.8 e-Cube Replacement The e-Cube of the TowFLEXX TF5 can be exchanged very quickly. This can happen in case of technical problems or when updating the electronic components (new security features, add- ons, etc.). Position of the e-Cube Just a few steps are needed to remove the e-Cube 1. - Page 47 TF5 - Manual Lift the gate and fix the position with a tool/object of your choice to keep the gate in a slightly elevated position. Retighten the screws that were previously loosened. The door should now be aligned again and close smoothly. If this is not the case, try the same procedure by lifting the gate a little bit more or less.
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Page 48: Steel Cable Realignment
7.10 Steel Cable ReAlignment In the unlikely event that the steel cable is twisted, it can be realigned within minutes with the- se easy to follow steps. Open the winch cover and check if the steel cable overlaps at any point. If this is similar to the picture on the right, follow the next simple steps to realign it. -
Page 49: Packaging And Transport
TF5 - 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 secu- red in a reusable wooden transport box. The following steps are necessary to safely drive the tug out of the transport box. - Page 50 Take off the crossbars ATTENTION! We recommend that this step be carried out by two persons to prevent the cross bars from falling onto the tug when removing them. Unwrap the aircraft tug. Each of the castors at the front is additionally secured with a wooden panel which must be removed.
- Page 51 ATTENTION! Pick up the crate only from the front side (front ramp) ATTENTION! If you are not familiar with using TowFLEXX equipment do only remove the unit out of the crate when a TowFLEXX employee is present. Failure to do so can cause irreversible damage to the unit or personal injury.
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Page 52: Transport Without Crate
8.2 Transport Without Crate If you are transporting the aircraft tug without a transport box, there are several options availa- ble to you. The aircraft tug can be lifted by crane via the four / six attachment points. Attachment Points Crane Safety Hook Additional Attachment Point in the Front Additionally, after releasing the magnetic brake, the aircraft tug can be towed via the two eye-... -
Page 53: Appendix 10.1 Error Codes
TF5 - Manual 10. appendix 10.1 Error Codes The TF5 has various safety features that help to prevent damages or injuries in emergency situations. Whenever one of these features is activated the user gets a notification on the screen of the remote control showing an error code. The following list shows the most common codes that can appear in everyday use. - Page 54 Code Explanation 3 - 30 Temperature Drive System Turntable/Winch 5°C over Limit 4 - 1 Battery Voltage below Limit 4 - 2 Battery Voltage of Remote Control below Limit 4 - 22 Temperature Motor right over Limit 4 - 23 Temperature Drive System right over Limit 4 - 26 Temperature Motor left over Limit...
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Page 55: Training Certificate
• Pick-up and handling of aircraft • 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 TF5 were addressed and understood. _________________________________... - Page 56 TowFLEXX TF5 - Up To 60.000kg / 132.000lbs MTOW www . TowFLEXX . de www . TowFLEXX . com...
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