AIRLIFT Tugs Model 5 24V 48V LiFePO4 Battery Upgrade Custom Low Profile Steel Tray Drop in Pack for Towbarless Aircraft Tug

          

                     8000CYCLES - 10YEARS WARRANTY - FACTORY PRICE         

Lithium Battery Solution for Electric Aircraft Tug

Engineered specifically for demanding FBO and airfield ramp operations, 

our premium LiFePO4 battery pack is the ultimate drop-in replacement upgrade for electric towbarless aircraft tugs. 

Advantages

1:1 Direct  Drop-in Fit 

Designed as a drop-in replacement for BCI & DIN standards

Internal steel weights ensure your Aircraft Tug maintains its original center of gravity and safety ratings.

Ruggedized GSE Safety, Quality & Unbeatable ROI

our UL2580, UN38.3, and CE certified cells delivering over 8000 deep cycles 

with zero watering maintenance, operators slash annual operating costs by 60% 

High-Efficiency Opportunity Charging

Experience consistent power without voltage drops. 

Support for opportunity charging during crew breaks enables 24/7 multi-shift operations without battery swapping.

Intelligent BMS Integration

Seamless OEM Integration & Smart Cloud Diagnostics,

Optional 4G/WiFi Telematics allow fleet managers for real-time monitoring.

Key Metrics

Cell Type: Grade A LiFePO4

Voltage: 36V / 48V / 72V / 80V

Cycle Life: >8000+ 

Charge Time: Full charge under 1-2 hours

Reduce energy consumption by 30% and significantly lower your Total Cost of Ownership (TCO). 

Contact us for a compatibility assessment and BCI/DIN measurement guide.

                                       RJ Lithium Battery For AIRLIFT Upgrade Project        

                                                       Solution -AIRLIFT Aifcraft Tug models        

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Model	Voltage	Capacity (Ah)	L × W × H (inch)	BCI / DIN
AIRLIFT AL45	48V	300Ah+	32.0 × 15.0 × 11.5	DIN 43535 / 48V 3PzS
AIRLIFT AL65	48V / 80V	500Ah+	38.5 × 20.5 × 12.0	DIN 43535 / 48V 5PzS
AIRLIFT AL100	80V	600Ah+	40.5 × 28.5 × 16.0	DIN 43536 / 80V 4PzS / 5PzS
AIRLIFT AL100 Twin Steer	80V	600Ah+	40.5 × 28.5 × 16.0	DIN 43536 / 80V 4PzS / 5PzS

                                  RJ Charger for Aircraft Tug Battery      

AIRLIFT Aircraft Tug Lithium Upgrade FAQ

Q1: Will these LiFePO4 packs fit directly into AIRLIFT Tugs without modifying the battery tray?

A: Yes. Our lithium replacement modules are engineered inside steel enclosures matching original BCI Group GC2 and DIN 43535/43536 footprints. They drop directly into AIRLIFT battery bays using factory-matching Anderson or REMA connectors.

Q2: AIRLIFT Tugs feature heavy hydraulic nose-gear clamping. Will high current spikes trip the BMS?

A: No. Capturing and lifting heavy aircraft nose landing gear creates intense current surges. Our industrial BMS supports over 4C continuous peak discharge (1200A+), preventing voltage dropouts or unexpected controller trips during clamping operations.

Q3: Lithium is lighter than lead-acid. Will reduced weight cause drive-wheel slippage on AIRLIFT Tugs?

A: To maintain critical tire traction, we integrate internal steel counterweight ballast plates directly inside the battery tray. This ensures optimal ground-pressing force when towing heavy aircraft on wet or icy flightlines.

Q4: Can AIRLIFT Tugs equipped with these batteries operate in severe sub-zero winter weather?

A: Yes. Every pack includes an automated internal PTC self-heating system. In arctic conditions down to -30°C (-22°F), the BMS uses charger energy to pre-warm the cells to safe operating temperatures before high-current discharging or fast charging begins.

Q5: How fast can an AIRLIFT Tug be recharged between aircraft movements?

A: Unlike lead-acid batteries requiring 8–10 hours plus cooling, our LiFePO4 cells support 1C fast charging. FBO crews can opportunity charge during 15-to-30-minute breaks, reaching a 0–100% charge in about 60 minutes.

Q6: Does the battery communicate with AIRLIFT onboard drive controllers and displays?

A: Yes. The BMS features pre-configured CANbus / RS485 communication protocols compatible with industrial motor controllers, feeding accurate real-time State of Charge (SOC), system voltage, and diagnostics directly to the dash.

Q7: What safety standards back these lithium batteries during high-value hangar operations?

A: Our packs are fully certified under UN38.3, UL2580, and CE standards. They feature IP65-sealed heavy-duty steel casings, active cell balancing, and automated multi-tier thermal runaway protection.

Q8: How do I select the right lithium conversion kit for my specific AIRLIFT model?

A: Simply specify your AIRLIFT model number， operational voltage (24V, 48V, or 80V), and daily towing duty cycle. Our team will match the exact plug-and-play kit.

Q9: What is the ROI timeline when replacing lead-acid batteries with lithium on AIRLIFT Tugs?

A: Eliminating battery watering, acid corrosion, and frequent replacements yields complete ROI within 12 to 18 months. Our LiFePO4 packs deliver over 8,000 full cycles (6–7x longer lifespan) at 95%+ energy efficiency.

Q10: Are high-voltage 80V platforms supported for heavy-duty AIRLIFT models?

A: Yes. We offer dedicated 80V LiFePO4 modules for heavy-duty models like the AIRLIFT Model 50, reducing motor heat, increasing torque efficiency, and enabling smooth towing of regional airliners.

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