🔧Maintenance Guides10 min read
Electric Aircraft Tug Maintenance: Battery Care and Drive System Best Practices
Sarah Torres, Lektro Certified Technician·May 10, 2026
Introduction
Electric aircraft tugs like the Lektro M-Series and PB-Series represent a growing share of the GSE fleet. Their lithium-ion batteries are the most expensive component to replace. Proper maintenance can double battery lifespan from 3 to 6+ years.
Battery Maintenance Schedule
Daily
- Check charge level before first use
- Inspect connectors for corrosion or damage
- Log charge/discharge cycles
Weekly
- Full charge cycle (100% then discharge to 20%)
- Clean battery terminals
- Check coolant levels (liquid-cooled systems)
Monthly
- Perform capacity test
- Balance cells (BMS-managed on modern units)
- Inspect battery enclosure seals
Drive System Care
The electric drive system in modern tugs uses permanent magnet synchronous motors (PMSM). Key maintenance points:
- Gearbox oil — Change every 500 hours or annually
- Motor bearings — Grease every 1000 hours
- Encoder alignment — Check if you notice jerky motion
- Regenerative braking — Test weekly; failure indicates controller issues
Common Issues
| Issue | Likely Cause | Fix |
| Reduced runtime | Battery degradation | Capacity test, replace if <80% |
| Jerky acceleration | Encoder fault | Clean/replace encoder |
| Error code E-24 | Motor overtemp | Check cooling fan |
| Won't charge | BMS fault | Cycle BMS, check cell voltages |
Winter Operation
Cold weather significantly impacts battery performance. Expect 20-30% range reduction below 32°F. Store tugs in heated areas when possible.
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