Mototok M 515 M 528 M28 24V 48V LiFePO4 Battery Retrofit Custom Low Profile Steel Box Drop in Replacement Battery for Remote 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 Mototok Upgrade Project        

                                                       Solution -Mototok Aifcraft Tug models        

* Contact us for a full list

Model	Voltage	Capacity (Ah)	L × W × H (inch)	BCI / DIN
Alligator 4000	24V / 48V	150Ah+	28.0 × 12.0 × 9.5	Ultra-Compact Custom Box
M 515	24V / 48V	180Ah+	30.0 × 13.0 × 10.0	Custom Compact Tray
M 528 / M28	24V / 48V	200Ah+	32.5 × 14.0 × 10.5	Custom Compact Tray
LB 528	48V	300Ah+	36.0 × 16.0 × 11.5	DIN 43535 / 48V 3PzS Low-Profile
LB 3900 NG / LB 6500 NG	48V	300Ah+	36.0 × 16.0 × 11.5	DIN 43535 / 48V 3PzS Low-Profile
LB 6600 NG / LB 7500 NG	48V / 80V	350Ah+	38.5 × 20.5 × 12.0	DIN 43535 Heavy Duty Navy Spec
LB 9500 / LB Wide 14	80V	400Ah+	40.5 × 24.0 × 14.0	DIN 43536 Heavy Duty Military
TWIN 3900 NG	48V	400Ah+	36.0 × 18.0 × 11.5	DIN 43535 / 48V 4PzS Low-Profile
TWIN 6500 NG FLAT	48V	400Ah+	36.0 × 18.0 × 11.5	DIN 43535 / 48V 4PzS Low-Profile
TWIN 6600 NG / TWIN 7500 NG / FLAT	48V	500Ah+	38.5 × 20.5 × 12.0	DIN 43535 / 48V 5PzS Low-Profile
T7000 Pushback Tug	48V / 80V	500Ah+	38.5 × 24.0 × 14.0	DIN 43535 / DIN 43536
SPACER 8600 MA	80V	500Ah+	40.5 × 28.5 × 16.0	DIN 43536 / 80V 4PzS Armour Plate
SPACER 8600 PB / 8600 NG	80V	600Ah+	40.5 × 28.5 × 16.0	DIN 43536 / 80V 5PzS High Rate
SPACER 200	96V	600Ah+	42.0 × 32.0 × 18.0	Heavy Duty Custom Industrial Steel Tray

                                  RJ Charger for Aircraft Tug Battery      

Mototok Aircraft Tug Lithium Upgrade FAQ

Q1: Will this LiFePO4 battery pack fit inside Mototok’s ultra-low-profile chassis without elevation issues?

A: Yes, 100%. Mototok tugs are famous for their extremely low ground clearance and tight battery compartments. Our LiFePO4 packs are custom-engineered into low-profile steel trays that match the exact footprint and ultra-compact height limits of original AGM/Gel lead-acid batteries across the M, LB, TWIN, and SPACER series.

Q2: Mototok tugs rely heavily on wireless radio remote controls. Will the BMS create electromagnetic interference (EMI)?

A: No. Our industrial BMS and internal power electronics are fully shielded and certified to automotive-grade EMC/EMI standards. 

They operate seamlessly alongside Mototok’s advanced microprocessor remote control systems without causing signal drops, radio lag, or diagnostic error codes.

Q3: How does upgrading to lithium improve Mototok’s remote-controlled nose-gear loading system?

A: Hydraulic loading doors and sliding tables demand instant high-current draw during the 10-15 second wheel-clamping phase. Unlike lead-acid batteries that suffer from sudden voltage sag (causing slow hydraulic door response), our high-rate LiFePO4 system maintains flat 100% discharge voltage, ensuring fast, crisp hydraulic lock-in every time.

Q4: Since Mototok tugs use deadweight for drive-wheel traction, will a lighter lithium pack cause tire slippage?

A: We engineered this into the design. To preserve the exact ground-pressing force required for Mototok's quartz-sand particle tires, our drop-in lithium packs include built-in internal counterweight steel plates. You get up to 2x the usable runtime without losing any drive traction when pulling 75-ton or 200-ton aircraft.

Q5: Can this battery handle continuous multi-shift operations in busy MRO hangars?

A: Absolutely. Mototok’s original AGM/Gel batteries require long recharge cycles and cannot be opportunity-charged without severe battery degradation. Our LiFePO4 chemistry supports 1C–2C fast charging during shift breaks (0-100% in ~1 hour) with zero memory effect, enabling continuous 24/7 hangar positioning.

Q6: What cold-weather features protect the battery when Mototok tugs operate on frozen aprons?

A: Every Mototok lithium retrofit pack features an automated internal PTC self-heating element. When ambient temperatures drop below freezing (down to -30°C / -22°F), the BMS automatically warms the cells to optimal operating temperatures before allowing fast charging or high-current discharge.

Q7: Does the lithium pack communicate battery status with Mototok’s onboard display or diagnostics?

A: Yes. The battery features integrated CANbus/RS485 communication protocols tailored to interface smoothly with Mototok's internal controller logic, providing accurate State of Charge (SOC), voltage telemetry, and fault reporting directly to your operator interface.

Q8: What safety certifications back these batteries when operating inside high-value aircraft hangars?

A: Safety near multi-million-dollar jets is non-negotiable. Our complete packs are UN38.3, UL2580, and CE certified, enclosed in an IP67-rated heavy-duty steel casing with built-in thermal runaway mitigation and automated cell-balancing protection.

Q9: How much maintenance is eliminated compared to original deep-cycle AGM/Gel batteries?

A: You eliminate battery capacity degradation from deep discharge, battery equalization downtime, and frequent battery replacements. LiFePO4 cells deliver 8,000+ full charge cycles—lasting 3 to 5 times longer than lead-acid—drastically lowering hangar maintenance overhead.

Q10: How do I order the exact lithium drop-in pack for my specific Mototok model (e.g., TWIN 6500 NG vs SPACER 8600)?

A: Simply provide your Mototok model number, serial tag, and system voltage (48V, 80V, or 96V). Our GSE engineering team will provide the exact plug-and-play part number, complete with factory-matching Anderson/REMA connectors and mounting brackets.

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