What to Expect from an Aircraft Tug Overhaul

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Originally Posted On: https://pilotjohn.com/blog/what-to-expect-tug-overhaul

The aviation industry relies heavily on aircraft tugs, which play a crucial role in the safe and timely movement of aircraft in and around the hangar and tarmac. Over time, these tugs can deteriorate from the effects of usage, leading to a decline in performance, efficiency, and safety.

Worn-out tugs pose a significant threat to hangar operations. Their declining performance can lead to delays, excessive fuel consumption, and safety hazards.

Understanding the steps involved in performing a complete overhaul of an aircraft tug can help you confirm that your service crew or maintenance team completes the full scope of necessary inspections and restorations, thus ensuring that your tug meets the rigorous demands of the aviation industry.

Assuming the tug is operational, begin with a thorough test drive, followed by an exhaustive inspection. From tires to gaskets, inspect every element – brakes, hoses, belts, sensors, gauges, the engine itself, and all engine components. Anything that shows even a hint of wear or damage should be replaced.

Deconstruct the tug down to its bare frame. Replace all worn gaskets and seals. Pressure-test and clean the radiators. Update components like computers, digital dashes, and electric throttle assemblies to the latest versions.

Dismantle, inspect, and reassemble the axles. If needed, replace bearings, seals, and brakes. Rigorously check tow hitches for wear and tear, and renew all hardware.

Replace any damaged wires or terminals in the wire harnesses, and install new conduits when needed.

Degrease, clean, and paint both the engine and transmission by stripping the components to bare metal. Paint the frame with two coats of epoxy primer, and follow that with three coats of paint in your chosen color. Clear-coat with automotive-grade paint for a lasting finish. Powder-coat all tow hitches, rims, and tie-down hooks for durability.

Replace all rubber with new material on the floor and tops of the unit. Add decals or other custom touches.

Don’t forget the most crucial step – extensive testing in real driving conditions. Check for leaks, unusual noises, and anything out of the ordinary. It’s a good idea to have a second person double-check for anything that may have been missed.

At PJi, every detail counts – and our team of experts is here to keep you flight-ready with an aircraft tug that’s not just overhauled, but transformed and ready to serve efficiently and reliably. PJi’s experienced team is ready to advise, assist, guide, support, and provide the service you need to keep your equipment performing at optimal levels. Regular preventative and corrective maintenance are vital to keeping downtime to a minimum. PJi’s expert service team offers the ultimate solution to the challenge of overhauling your tug to transform it into a like-new machine. If you need to have your tug overhauled, contact us for a quote.

PJi also has a Mobile Service team, for servicing other ground support equipment (GSE), bringing maintenance expertise directly to your hangar and saving you time and effort. Contact us for our service area.

PJi provides a variety of rental options including short- or long-term rentals for an expansive selection of GSE including tugs, avionics test equipment, and tooling crafted by the aviation industry’s leading manufacturers.