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Baggage cart
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Baggage cart
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Luggage carts in Ivory Coast
Baggage carts available for a deposit at a German train station
Railway baggage cart from the 1800s
Baggage cart mover
A luggage cart in a hotel hallway

Baggage carts, luggage carts, luggage trolleys or trolleys are small vehicles pushed by travelers (human-powered) to carry individual luggage,[citation needed] mostly suitcases. There are two major sizes: One for big luggage and one for small luggage.[clarification needed] Carts have usually two parts for carrying luggage: A small section (basket) for carry on luggage at the same level as the handle, and a lowered large section for suitcases a small and large bags.[citation needed]

The carts are provided in airports, large bus stations,[1] hotels, or train stations for transporting luggage and may be free of charge. They are sometimes owned by the operator of the establishment. In some facilities carts may be provided by a contractor such as Smarte Carte for a rental fee. Baggage carts are usually built out of steel and equipped with three or four wheels. For safety reasons, they are generally fitted with a brake.[citation needed] Usually, a handle has to be pushed down in order to move the cart, however, in some cases, such as London airports, the handle activates the brake. Very few carts, e.g. in developing countries such as Sri Lanka, do not have this feature.[citation needed]

Where a charge is made, this can be either a deposit, which is returned automatically when the cart is returned; or a rental fee can be charged.

Parts

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In airports, boarding baggage cart parts are:[2]

Baggage tugs

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A baggage tug is a small tractor, sometimes an electric vehicle, used by the airline industry to tow baggage carts to and from the terminal/cargo facility and the aircraft.[3]

See also

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Notes

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Revisions and contributorsEdit on WikipediaRead on Wikipedia

Baggage cart

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A baggage cart is a specialized trailer used as (GSE) in to transport checked luggage, , , and other materials between terminals, sorting facilities, and on the . These carts are typically towed by dedicated vehicles called baggage tugs and are designed for high-volume handling in congested and weather-exposed environments. Unlike smaller trolleys used inside terminals, baggage carts prioritize durability, with capacities often reaching 8,000 pounds (3,629 kg) to support efficient loading and unloading operations. Baggage carts come in various configurations to meet operational needs, including open-frame models for quick access and enclosed versions with protective covers to shield contents from elements like rain or debris. They feature standardized hitch systems, such as E-type or hooks, ensuring secure attachment to tugs while allowing for train formations of multiple carts to maximize throughput. Constructed from heavy-gauge steel with pneumatic tires and corner bumpers, these carts are engineered to endure the abrasive conditions of ramps, including frequent at low speeds on service roads. In airport logistics, baggage carts play a critical role in streamlining ground handling by enabling rapid transfer of items post-check-in or upon arrival, reducing turnaround times for flights and minimizing delays. Compliance with international standards, such as those from the (IATA), ensures interoperability across global airports, while ongoing safety protocols emphasize secure hitching, brake usage, and operator training to prevent accidents like tip-overs or collisions. As demand grows, advancements in cart design focus on lighter materials and electric tugs for sustainability, though traditional models remain dominant for their reliability.

Overview and History

Definition and Purpose

A baggage cart is a wheeled platform designed for use by to transport multiple pieces of , , or other packaged between terminals, , and support facilities. These carts are typically towed by powered vehicles known as baggage tugs, enabling efficient movement across the apron and service roads. Unlike passenger-facing equipment, baggage carts are built for heavy-duty, professional operations in the demanding environment of ground handling. The primary purposes of baggage carts include facilitating the bulk transport of to minimize manual labor, streamline loading and unloading processes, and support the high-volume throughput required at busy airports. By allowing ground handlers to move large quantities of items quickly and safely, these carts contribute to faster turnaround times for , reducing delays and enhancing overall . Baggage carts differ from passenger luggage trolleys, which are lightweight, human-powered devices intended for individual travelers to maneuver their own bags within terminal areas. They also contrast with cargo containers, such as unit load devices (ULDs), which are standardized, pallet-like enclosures used primarily for securing bulk freight and mail directly in holds rather than for loose baggage transport on the ground. Typical load capacities for baggage carts range from 2,000 to 8,000 pounds (approximately 900 to 3,600 kilograms) per unit, varying by model and configuration to accommodate different airport needs.

Historical Development

The origins of baggage carts trace back to the 19th century, coinciding with the rapid expansion of rail travel following the introduction of steam locomotives around 1830. These early carts, often simple wooden or metal platforms with wheels, were essential for transporting passengers' luggage and goods within train stations and depots, allowing porters to move multiple items efficiently without dedicated rail cars for all baggage. By the mid-1800s, they had become a standard feature of railroad operations, evolving from hand-pushed designs to those that could be towed by horses or early mechanical aids, reflecting the growing demands of the passenger rail industry. As emerged in the early , handling practices adapted from rail and industrial settings, with in the and relying on similar wheeled trolleys and carts inspired by and . These manual or horse-drawn prototypes were pushed by ground crews to ferry luggage from terminals to , mirroring the station-based systems of railroads but scaled for smaller volumes at nascent airfields like those used by early airlines such as Pan American. The 1923 introduction of the Clark Duat Tow Tractor by Clark marked an early powered innovation, initially designed for freight towing in industrial contexts but soon applied to operations for pulling trains. A pivotal milestone occurred in the 1940s with the development of dedicated powered baggage tugs, exemplified by the Clark "Clarktor" series, which revolutionized ramp efficiency by enabling faster towing of cart trains loaded with luggage. Introduced in 1927 as an industrial truck but refined during World War II for military use in towing munitions and aircraft, the Clarktor CT-6 model featured a 62-horsepower Chrysler engine and reached speeds up to 15 mph, allowing ground crews to handle heavier loads with greater speed than manual methods. This shift supported the postwar boom in air travel, as airlines adopted these robust machines to manage increasing passenger volumes. Following , the growth of aviation infrastructure in the 1950s and 1960s drove standardization of baggage handling equipment, with many airlines repurposing surplus military tugs for civilian use to meet rising demands. For instance, acquired a 1940s Clarktor from the U.S. Navy in 1961 for $5,000, deploying it at airports like New York-LaGuardia and Denver until 1989, after which it was integrated into following their 1972 merger; this tug alone logged over 53,000 miles during service. Innovations like FMC Corporation's Flite-Line Loader in the 1950s introduced containerized baggage systems, unloading in about 15 minutes and promoting uniform cart designs across carriers such as Delta, which installed forklifts and conveyor belts for baggage in major cities by the late 1950s. In the , from the 1980s to the , tug and technology shifted toward electric and propane-powered models to comply with stricter environmental regulations and reduce emissions at busy airports. Early electric tugs, such as Lektro's 1967 model, paved the way, but widespread adoption accelerated in the with towbarless designs from TracMa and , followed by propane and lithium-battery options in the ; for example, committed to $20 million in electric tugs and carts by the early , while introduced rechargeable lithium-polymer tugs in 2012. Companies like TUG Corp., founded in 1973, led these innovations with models such as the MA tractor, emphasizing efficiency and lower emissions for sustainable ramp operations.

Design and Components

Key Parts of Baggage Carts

Baggage carts are designed with a core set of structural and functional components that enable safe , secure baggage containment, and maneuverability on ramps. The primary towing interface consists of the , a hinged hitch arm that extends from the front of the cart and connects to a baggage tug, allowing for efficient of multiple carts in a train formation. This pivots up to 360 degrees for enhanced and includes an adjustable height to avoid ground contact during operation. At the end of the tongue is the pintle hook, a robust device that securely latches onto the tug's receiver, ensuring stable linkage under load and preventing disconnection during movement. The brake assembly integrates directly with the tongue via a tow arm latch mechanism, which automatically engages the brakes when the tongue is raised or detached from the tug, locking the wheels to prevent unintended rolling. This tongue brake system is critical for safety, as it halts the cart immediately upon disconnection, and the latch allows operators to manually engage or disengage it during towing or parking. Supporting the cart's base are four heavy-duty wheels, typically arranged in a rectangular configuration for optimal stability and 360-degree swivel capability on uneven ramp surfaces. These wheels, often fitted with pneumatic rubber tires, provide shock absorption and support loads up to 8,000 pounds (3,629 kg) per cart while minimizing . For protection and accessibility, bumpers line the cart's edges, including reinforced corner and lower rail bumpers made of durable rubber or composite materials to absorb impacts during loading, unloading, or close maneuvering. Curtains or side panels, usually constructed from heavy-duty PVC or vinyl with interior reinforcements, enclose the baggage area on closed models to secure loads against shifting and shield them from weather elements, featuring easy-open mechanisms and anti-clog rails for quick access. Hand holds, integrated into the curtains or frame as reinforced grab points, facilitate manual positioning and adjustment of the cart by without machinery. These components assemble into a modular frame, with the tongue and system mounting to the front undercarriage, wheels affixed to the base axles, and protective elements along the perimeter, forming a cohesive unit optimized for repeated high-stress use in environments. Components are designed to comply with (IATA) standards for interoperability, such as standardized hitch dimensions and load capacities. Materials such as high-grade for the frame and rubber for tires contribute to longevity, as detailed in the materials and manufacturing section.

Materials and Manufacturing

Baggage carts are primarily constructed using for their frames to provide the necessary strength and load-bearing capacity in demanding environments, often employing heavy-gauge that supports up to 8,000 pounds (3,629 kg) per cart. To enhance against environmental factors, frames are frequently galvanized through hot-dip processes compliant with BS EN ISO 1461 standards, forming a protective coating that resists from exposure to and de-icing chemicals. Aluminum alloys are commonly used for shelves and structural elements where weight reduction is prioritized, offering a lighter alternative to while maintaining structural integrity, as seen in hardened tubular aluminum designs that reduce overall cart weight by approximately 500 pounds (227 kg) compared to equivalent models. Wheels on baggage carts are typically made from rubber or materials to ensure traction, shock absorption, and resistance to punctures on uneven surfaces, with options including 100% tires on reinforced rims or solid variants for no-flat performance. Additional weather-resistant features include powder-coated or galvanneal finishes on components to protect against rain, UV exposure, and chemical agents, while elements in hybrid designs provide inherent resistance without additional coatings. Manufacturing of baggage carts involves welded fabrication for the frames, where certified welders join high-grade or aluminum components to create robust, seamless structures capable of withstanding repeated stresses. Modular assembly techniques allow for , such as wheels and shelves, facilitating easy replacement and customization during production or maintenance. adheres to ISO 9001 standards and related specifications like BS EN ISO 1461 for , ensuring consistent performance and safety in global airport operations. Baggage cart materials have evolved from traditional all-steel constructions, which prioritized but added significant weight, to hybrid designs incorporating aluminum alloys and advanced composites for improved . This shift has enabled weight reductions of up to 20% in modern carts through the use of composites in panels and non-structural elements, enhancing savings for operations while maintaining load capacities.

Types and Variations

Standard Baggage Carts

Standard baggage carts represent the foundational equipment in airport ground handling for transporting checked luggage in everyday operations. These carts typically feature a single-level open or closed platform supported by four wheels, facilitating straightforward loading and unloading of baggage. Dimensions generally approximate 60 inches in width and 120 inches in length, enabling maneuverability on busy aprons while accommodating standard suitcase sizes. Designed for general , standard carts have a capacity to hold approximately 40 to 50 standard suitcases, often secured by side curtains to contain items during movement and prevent spillage. Load limits reach 8,000 pounds, balancing efficiency with safety to avoid structural strain or tipping. These features make them versatile for routine tasks without requiring specialized modifications. Common models include flatbed carts without shelves, which prioritize simplicity and durability, allowing quick adaptation to different baggage volumes. This design ensures compatibility with various tow vehicles. In operational contexts, standard baggage carts are suited for a range of flights including short-haul and smaller regional aircraft, supporting efficient ground handling for varying baggage volumes.

Specialized Carts

Specialized baggage carts are engineered variations of standard designs, incorporating modifications to accommodate unique types, environmental conditions, or aircraft-specific requirements in operations. These carts enhance by addressing limitations in general-purpose models, such as the need for greater , , or during ground handling. Double-shelf carts incorporate a two-tier platform to maximize loading capacity, typically supporting up to 8,000 pounds while enabling stacked arrangements for bulkier items like or additional mail bags. This design, often featuring reinforced brackets for the upper shelf, allows operators to transport more in a single trip compared to single-level carts, reducing the number of tows required on the . Open baggage carts feature an unenclosed structure without side panels, providing unobstructed access for loading and unloading oversized or irregularly shaped , such as loose cartons or that exceeds standard dimensions. Constructed from heavy-gauge with capacities reaching 8,000 pounds, these carts are commonly deployed in handling areas where quick placement and retrieval are prioritized over protection. Removable end panels further aid in maneuvering large items, ensuring compliance with IATA standards for safe transport. Carts with side doors offer enclosed configurations equipped with accessible panels or curtains, ideal for securing sensitive items like valuables, perishables, or during exposure to elements or unauthorized access. These models, often with full-length rain gutters and reinforced frames supporting 8,000 pounds, facilitate controlled loading via side entry points, enhancing security in transit from terminals to . Such designs are particularly useful for weather-vulnerable operations, where the doors or curtains can be easily opened and closed without full unloading. Niche variations include custom adaptations like narrower carts suited for regional jets, with compact dimensions such as 4x8 feet to navigate tighter spaces, and high-sided models with elevated walls for widebody aircraft like the to contain taller cargo loads securely. Manufacturers provide these tailored options in steel or aluminum to meet specific airline needs, maintaining standard capacities around 8,000 pounds while optimizing for type.

Associated Equipment: Baggage Tugs

Types of Baggage Tugs

Baggage tugs, also known as baggage tractors, are powered vehicles designed to tow baggage carts across aprons and ramps, and they are primarily categorized by their power sources: , diesel, , and electric. Each type offers distinct advantages in terms of power delivery, efficiency, emissions, and operational suitability, influencing their selection based on size, environmental regulations, and usage demands. Gasoline-powered baggage tugs deliver high power suitable for handling heavy loads in demanding environments, though they produce higher emissions compared to alternative fuels. These tugs have been a staple in large hubs since the mid-20th century, with early models like the "Clarktor" from the exemplifying their role in baggage handling. Their internal engines provide reliable performance for short to medium hauls but require frequent refueling and contribute to air quality challenges on busy aprons. Diesel baggage tugs are valued for their during extended operational shifts and superior , which enables effective towing on inclines or uneven surfaces common at international airports. This advantage, often exceeding 2,500 daN in models like the TLD JST-25, supports heavy-duty applications and makes diesel variants a standard choice for global hubs handling high volumes of . While more efficient than counterparts, they still emit pollutants, prompting gradual shifts toward cleaner options in regulated environments. Propane baggage tugs serve as a cleaner-burning alternative to gasoline models, featuring refillable tanks that allow quick on-site fueling without extensive infrastructure. They reduce harmful emissions like , improving air quality in confined spaces. Their lower particulate output compared to diesel or makes them suitable for areas with strict ventilation requirements, though they require periodic tank exchanges. Electric baggage tugs operate on batteries, providing zero tailpipe emissions and quieter performance, which minimizes on grounds. Their popularity has surged since the early 2000s, driven by advancements in technology that enable longer run times and opportunity charging during shifts. Models such as the TLD JST-E can tow up to 10 carts in series, with drawbar pulls reaching 2,000 daN, supporting sustainable operations at modern s focused on . This shift aligns with global efforts to reduce gases, as seen in early adoptions like WestJet's 2012 lithium-polymer tugs. As of 2025, electric baggage tugs continue to gain , with the global electric tow tractor segment projected to reach USD 141 million, reflecting broader electrification initiatives and hybrid options emerging for extended range.

Components of Baggage Tugs

Baggage tugs, also known as baggage tractors, incorporate a range of mechanical and control components designed to facilitate the safe and efficient of baggage carts across ramps. These elements enable precise maneuvering, reliable power delivery, and operator in demanding environments. Key systems include the drive mechanism for and attachment, power sources tailored to type, interlocks to prevent accidents, and adaptations for operational stability. The drive system forms the core of a baggage tug's towing capability, typically featuring a for directional control, a gear shift to select forward or reverse modes, and dual pedals for acceleration and braking. At the rear, a hook serves as the primary attachment point, allowing secure connection to baggage carts via a compatible ring, which ensures stable even under load. These components are engineered for responsive handling on congested ramps, with gear shifts often mounted on the or depending on the manufacturer. Power-specific parts vary by propulsion type to support sustained operation. Electric models include a dedicated battery compartment, usually located under the or in the rear frame, along with a charger port and for recharging, enabling zero-emission performance suitable for indoor and ramp use. Propane-powered tugs feature mounted propane tanks, typically two 33-pound cylinders secured in a protective enclosure, providing clean-burning fuel for extended shifts. Gas or diesel variants incorporate a —often 5 to 10 gallons capacity—and an , such as a 75-horsepower unit, for higher in heavy-duty applications. Safety controls are integrated to mitigate risks during high-traffic operations. An emergency stop (E-stop) , standard on electric tugs and often red and prominently placed on the , instantly cuts power to halt the in emergencies. A hand , mechanically linked to the service brakes, provides parking functionality, particularly on gas or diesel models, while foot-operated pedals offer hydraulic stopping power. Seat belts for the driver and any passengers are mandatory, securing occupants against sudden stops or impacts, and are designed to meet standards. Chassis features emphasize durability and accessibility for environments. The low-profile , with floor heights around 20 inches (51 cm) and ground clearance of 8 inches (20 cm) in some models, allows easy operator entry and exit while maintaining stability under loaded conditions, facilitating ramp access near . Heavy-duty tires, such as solid rubber or pneumatic models like the Innacush or Kargo series, are fitted to handle uneven surfaces, offering low , even wear, and resistance to punctures from , ensuring reliable traction across tarmacs and inclines.

Operational Use

Procedures for Towing and Transport

The procedures for towing baggage carts begin with proper attachment to ensure secure connection between the tug and cart. Operators align the tug's pintle hook with the cart's tow arm or draw shaft eye, then secure the latch by pulling the hook up and allowing it to slide into the locked position, using all safety pins and devices to prevent disconnection. Before releasing the cart brakes, which are typically activated by raising the tow bar to a vertical position, operators verify the hitch assembly for wear, damage, or missing parts by performing a sharp upward pull on the tow bar to confirm it remains closed. During transport, tugs pull baggage carts at controlled speeds, typically limited to 10-15 mph (16-24 km/h) on ramps to maintain stability, with reductions on wet surfaces, sharp turns, or congested areas. Operators must follow and ramp signals at all times, maintaining a following (such as the 3-second rule) and using designated service roads where available. Multiple carts can be chained together, with limits of 4-10 depending on the tug's power and cart type, connected sequentially from the tug; the heaviest loaded cart should be positioned first, followed by lighter ones, to distribute weight evenly and prevent jack-knifing or tipping. Detachment requires the tug to come to a complete stop, followed by applying the cart's parking brakes via the tow bar and disengaging the or draw shaft. On inclines, operators must first engage the brakes, which are designed to hold on slopes up to 7%, and use wheel chocks against the tires if additional security is needed to prevent rolling. Best practices emphasize pre-tow inspections to verify load balance, with distributed evenly and secured to avoid shifting that could cause tipping during movement. These include checking tires, brakes, connections, and overall cart condition for damage or foreign object , ensuring safe operations as outlined in established ground handling protocols.

Integration in Airport Ground Handling

Baggage carts play a central role in the airport ground handling workflow, facilitating the movement of luggage from initial sorting areas to aircraft loading zones. After baggage is sorted at central facilities using automated systems and conveyor belts, carts are loaded with organized loads and towed by tugs to the ramp area near the aircraft. There, they coordinate with belt loaders, which bridge the gap between the cart and the aircraft hold, allowing ground crew to transfer bags efficiently without manual carrying over long distances. This process also integrates with cargo dollies for oversized or specialized items, ensuring seamless transitions in high-volume operations. Fleet management for baggage carts and tugs is scaled to size and passenger throughput, with major hubs maintaining substantial inventories to support concurrent operations. For instance, deploys 180 automated carts to handle its daily baggage volume, while larger facilities like those at international hubs may require hundreds of units to cover multiple gates and flights. Guidelines from aviation authorities recommend provisioning carts based on peak demand, often aligning one tug with every two to three gates to minimize delays. Technological aids enhance the integration of baggage carts within ground handling by enabling real-time oversight and automation. GPS tracking systems monitor cart locations across the ramp, allowing dispatchers to optimize routes and prevent bottlenecks, as implemented in solutions for ground vehicles at various airports. As of 2024, 44% of airlines had fully implemented IATA Resolution 753 baggage tracking standards, often using RFID technology, with tags on luggage enabling automatic identification during loading onto carts and verification at aircraft holds, reducing mishandling rates; a further 41% were in progress. In May 2025, IATA launched a 10-year Global Baggage Roadmap to further standardize data and automate tracking, potentially enhancing cart-based operations. The use of baggage carts in integrated ground handling contributes to , particularly by shortening turnaround times compared to fully manual methods. Automated cart systems have been shown to reduce baggage handling durations by 10-20%, allowing faster loading and unloading that supports overall turnaround reductions of up to 30% through streamlined processes.

Safety, Regulations, and Maintenance

Safety Features and Practices

Baggage carts and associated tugs incorporate several built-in safety mechanisms to minimize risks during operations. Automatic s on carts are a standard feature, activating upon detachment from the tug to prevent uncontrolled movement; for instance, the towbar-integrated engages if the cart breaks free, ensuring it remains stationary. Tugs feature reflective markings and lights to enhance visibility in low-light or congested conditions, complying with FAA requirements for to use retroreflective tape, such as an 8-inch wide white band of ASTM D4956 Type 3 material. Modern electric tugs often include anti-collision sensors, like ultrasonic systems that detect obstacles and automatically reduce speed or stop the vehicle to avoid impacts. Operational protocols emphasize training and standardized procedures to ensure safe handling. Training covers load securing techniques, such as properly hitching carts and inspecting for wear to prevent shifting during transit, with guidelines requiring loads to be balanced and restrained to avoid overhangs that could destabilize the cart. On slopes, chocks or brakes must be applied to immobilized carts or tugs, preventing rollout and maintaining stability. stop protocols mandate immediate activation of dedicated buttons or quick-release systems on tugs, halting operations in response to hazards like personnel proximity or equipment failure. Common hazards in baggage cart operations include tipping during sharp turns and foreign object debris (FOD) from unsecured loads. Tipping risks arise from high-speed maneuvers, but are mitigated by designing carts with a low center of gravity to keep the load's stability within safe limits. Unsecured baggage can dislodge and create FOD, potentially damaging aircraft engines or injuring personnel; prevention relies on thorough load checks to eliminate loose items that contribute to runway debris. Overall aviation accident rates have declined by 40% over the past two decades (2005–2024), as reported by , amid broader safety improvements in commercial jet operations.

Standards and Maintenance Requirements

Baggage carts and associated tugs used in operations are subject to regulations under the Federal Aviation Administration's (FAA) 14 CFR Part 139, which governs certification and requires procedures for the safe operation of ground vehicles. Under §139.329, must establish procedures for the safe and orderly access to and operation in movement areas and safety areas by pedestrians and ground vehicles, including requirements. Complementing these, §139.327 mandates that maintain records of self-inspections for at least 12 consecutive calendar months, documenting conditions found to prevent hazards in movement and safety areas. The (IATA) establishes standards in its Airport Handling Manual (AHM) for ground support equipment, emphasizing safe baggage handling practices and equipment specifications to standardize operations across airlines. Certification requirements include annual inspections of critical components such as brakes and hitches on baggage carts and tugs to verify operational integrity and compliance with safety protocols. The (OSHA) provides guidelines on ergonomic hazards in baggage handling operations. These certifications ensure that equipment meets federal and industry benchmarks before deployment. Routine maintenance protocols for baggage carts and tugs involve daily visual checks at the start of each shift to identify defects in tires, hitches, and overall structure, promoting immediate issue resolution. Quarterly servicing typically covers systems and tire conditions, while logbooks track service intervals, such as comprehensive 500-hour overhauls for mechanical and electrical components. For electric tugs, batteries require replacement every 2-3 years to maintain performance, aligning with lead-acid battery lifespans under intensive use. Post-2020 developments have intensified focus on sustainable maintenance practices, driven by U.S. Environmental Protection Agency (EPA) standards for heavy-duty vehicles, encouraging conversions to electric baggage tugs to reduce operational emissions at airports. This shift includes updated protocols for battery and charging system upkeep to comply with Phase 3 rules effective for model year 2027 and later, supporting broader environmental goals in ground handling.

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