TowFLEXX TF1 24V LiFePO4 Battery Upgrade BCI Standard Steel Box Drop in Replacement Pack for Electric 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 TowFLEXX Upgrade Project        

                                                       Solution -TowFLEXX Aifcraft Tug models        

* Contact us for a full list

Model	Voltage	Capacity (Ah)	L × W × H (inch)	BCI / DIN
TF1 (TF-1)	24V	200Ah+	26.0 × 12.0 × 9.5	BCI GC2 / Custom Box
TF2 (TF-2)	24V / 48V	200Ah+	28.5 × 13.5 × 10.0	BCI GC2 / Custom Box
TF3 (TF-3)	48V	300Ah+	32.0 × 15.0 × 11.5	DIN 43535 / 48V 3PzS
TF4 (TF-4)	48V	300Ah+	36.0 × 16.0 × 11.5	DIN 43535 / 48V 4PzS
TF5 (TF-5 / Essential)	48V	400Ah+	38.5 × 20.5 × 12.0	DIN 43535 / 48V 5PzS
TF6 (TF-6)	80V	500Ah+	40.5 × 28.5 × 16.0	DIN 43536 / 80V 4PzS

                                  RJ Charger for Aircraft Tug Battery      

TowFLEXX Aircraft Tug Lithium Upgrade FAQ

Q1: Will the BMS trip during intense nose-gear clamping on TowFLEXX tugs?

A: No. Engaging and lifting aircraft nose gears creates immediate 3x to 4x current surges. Our specialized industrial BMS features a heavy-duty power stage that handles continuous peak discharges over 4C (1200A+), preventing voltage dropouts and false drive-controller fault codes.

Q2: TowFLEXX tugs have extremely low chassis hatches. Will this lithium battery fit properly?

A: Yes. Our packs are engineered to match exact original lead-acid battery compartment footprints (BCI Group GC2 and DIN 43535/43536 standards). They feature low-profile steel enclosures and factory-matching REMA/Anderson connectors for 100% plug-and-play installation.

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

A: We engineered internal steel counterweight ballast plates directly inside the battery enclosure. This retains the exact ground-pressing force needed for maximum tire traction when maneuvering 85-ton aircraft on slick or icy aprons.

Q4: Can this battery be charged or operated in sub-zero winter flightline conditions?

A: Yes. Every pack incorporates an automated internal PTC self-heating system. When temperatures drop below freezing (down to -30°C / -22°F), the BMS utilizes charger energy to pre-warm the internal cells to safe operational zones before enabling fast charging or high-current discharge.

Q5: Can we perform opportunity charging during short shift breaks?

A: Absolutely. LiFePO4 cells have zero memory effect and support 1C fast charging. FBO operators can "top-off" the battery during 15-to-30-minute crew breaks, achieving a 0-100% full charge in about 60 minutes for continuous 24/7 hangar positioning.

Q6: Does installation require modifying TowFLEXX onboard electronics or wiring?

A: No modification is necessary. The BMS includes pre-configured CANbus / RS485 communication protocols designed to interface with industrial drive controllers, transmitting real-time State of Charge (SOC), voltage telemetry, and fault diagnostic alerts directly to your operator interface.

Q7: What flightline safety standards back these batteries near high-value aircraft?

A: Safety is paramount near multi-million-dollar jets. Our complete battery units are fully certified under UN38.3, UL2580, and CE standards. They feature IP65-rated water/dust sealing, active thermal runaway suppression, and automated cell-balancing circuitry.

Q8: How do I select the right lithium replacement pack for my specific TowFLEXX model?

A: Simply provide your TowFLEXX model number (TF1 through TF6), system operating voltage (24V, 48V, or 80V), and target capacity requirement. Our GSE engineering team will provide the exact matching part number and plug-and-play conversion harness.

Q9: How does converting our TowFLEXX fleet from lead-acid to LiFePO4 lower operating costs (ROI)?

A: Upgrading eliminates daily battery watering, acid leak cleanup, and frequent battery replacements. Delivering over 8000 full charge cycles (6–8x longer lifespan than lead-acid) alongside 95%+ energy efficiency, most flightline operations achieve complete ROI within 12 to 18 months.

Q10: Are high-voltage platforms like the 80V TF5 HD and TF6 supported?

A: Yes. We offer dedicated 80V LiFePO4 modules designed for heavy-duty commercial airliners. Higher operating voltage reduces motor heating, boosts torque efficiency, and provides smoother throttle response when pushing back narrow-body aircraft.

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