TREPEL CHALLENGER550 Emergency Operating Measures
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TREPEL CHALLENGER550 Emergency Operating Measures

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PUSHBACK TRACTOR
CHALLENGER550
Emergency Operating Measures
for CHALLENGER550
Docu-No.: 6750024-27_NB_us (en)

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  • Page 1 PUSHBACK TRACTOR CHALLENGER550 Emergency Operating Measures for CHALLENGER550 Docu-No.: 6750024-27_NB_us (en)
  • Page 3 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Published by TREPEL Airport Equipment GmbH Sales/Marketing Customer Service Hagenauer Str. 42 D-65203 Wiesbaden Telephone: +49 (6 11) 880 88-0 Telefax: +49 (6 11) 880 88-11 E-mail: airport@trepel.com Internet: http://www.trepel.com Plant/Purchasing Administration Hochhäuser Str. 18...
  • Page 4 TREPEL Airport Equipment GmbH and is liable to prosecution. This is valid in particular for copying, translating, micro-filming, and the storage and processing in electronic systems. All rights reserved.

  • Page 5: Table Of Contents

    Workplaces of the operating personnel Danger area Safety Regulations Warning signs emergency operation Towing the CHALLENGER550 Safety information Connecting the CHALLENGER550 with the towing vehicle Hydraulic emergency operation Electro-hydraulic emergency operation Emergency operation of the CHALLENGER550 Safety information Emergency operation features...
  • Page 6 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 This page intentionally left blank. Page 2 2-CONTENTS (Blank) Sep 30/17...

  • Page 7: About This Manual

    Reduce repair costs and downtime • Increase the reliability and operating life of the CHALLENGER550 Only the emergency features of the CHALLENGER550 are described in this manual. Additional documents In addition to these operating instructions, you also receive the following documentation for the CHALLENGER550: •...

  • Page 8: Characters And Symbols Used

    Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Characters and symbols used Pictograms All of the pictograms used on the CHALLENGER550 are based on internationally accepted IATA proposals. The meanings of the pictograms are explained in the instruction manual. Symbols Symbol Meaning Risk of personal injury.
  • Page 9 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Page 3 Sep 30/17...
  • Page 10 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Page 4 Sep 30/17...

  • Page 11: General Safety Instructions

    Do not operate the CHALLENGER550 while under the influence of alcohol or drugs, including prescription drugs. Some prescribed medication may impair your ability to safely operate the CHALLENGER550.

  • Page 12: Workplaces Of The Operating Personnel

    CHALLENGER550 is prepared for towing (see Subsection 3 "Towing the CHALLEN- GER550", page 15) • functions are carried out in emergency mode (see Subsection 4 "Emergency operation of the CHALLENGER550", page 45) During towing, the CHALLENGER550 is steered by the operator in the driver's cab. Page 6 Sep 30/17...

  • Page 13: Danger Area

    Only the operator and the service personnel required to recover the CHALLENGER550 are permit- ted to be in the danger area during emergency operation. Excluding the cargo, no other objects may be located in the danger area of the CHALLENGER550 during operation.

  • Page 14: Safety Regulations

    Standing in the CHALLENGER550's danger area is strictly prohibited for unauthorized per-  sons. Property damage! The CHALLENGER550 can be damaged by being towed on uneven roads due to the low ground clearance. When towing the CHALLENGER550 make sure that it is only towed along permitted traffic ...
  • Page 15 PUSHBACK TRACTOR CHALLENGER550 Towing the CHALLENGER550 Crush hazard! Persons can be crushed between the towing vehicle and the tow bar and/or CHALLENGER550 when coupling the towing vehicle to the CHALLENGER550. The resulting crushing can lead to death or serious injuries.
  • Page 16  GER550. Crush hazard! When hooking the tow bar into the coupling of the CHALLENGER550 or the towing vehicle, hands can be crushed in the coupling device of the tow bar. Crushing can lead to serious hand injuries. Only grip the tow bar on the hand grips intended for this purpose.

  • Page 17: Warning Signs Emergency Operation

    PUSHBACK TRACTOR CHALLENGER550 Rolling vehicle! The rolling towing vehicle or the CHALLENGER550 can collide with or run over persons. Colliding with one of the rolling vehicles can cause serious injury or death. Make sure that no persons or objects are in the danger area or on the traffic routes.
  • Page 18 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Instruction signs on the CHALLENGER550 The following instruction signs are located on the CHALLENGER550: Instruction sign Designation Color Quantity Emergency White, blue operating equipment Emergency White, blue operating equipment, inst- ructions Emergency White, black...
  • Page 19 Steering, front axle Emergency White, black operating equipment: Cooler, engine Emergency White, black operating equipment: Raise/Lower engine and gear- box unit Emergency White, black operating equipment: Normal operation, brake, hydraulic Table 1: Instruction signs on the CHALLENGER550 Page 13 Sep 30/17...
  • Page 20 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Page 14 Sep 30/17...

  • Page 21: Towing The Challenger550

    You need to carefully read this instructions before carrying out the preparatory measures in the emergency operation equipment and towing the CHALLENGER550 for the first time. Observe in particular the overall safety instructions (see Subsection A "Safety information", page 15).
  • Page 22  GER550. Crush hazard! When hooking the tow bar into the coupling of the CHALLENGER550 or the towing vehicle, hands can be crushed in the coupling device of the tow bar. Crushing could lead to serious hand injuries. Never grip the towing eyelet on the front of tow bar.
  • Page 23 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Tow bar coming loose! If the tow bar is not properly locked in the couplings, the CHALLENGER550 can unintentionally roll away and cause accidents. Persons can be seriously injured or even killed because of accidents.
  • Page 24 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Engaged spring-loaded brake! Insufficient hydraulic pressure to release the parking brake can result in backward movements or damage to the CHALLENGER550 during towing. Release the spring of the parking brake before towing.  Page 18...

  • Page 25: Connecting The Challenger550 With The Towing Vehicle

    PUSHBACK TRACTOR CHALLENGER550 Connecting the CHALLENGER550 with the towing vehicle Connect the CHALLENGER550 and the towing vehicle using a tow bar. Unauthorized towing equipment! The use of unauthorized towing equipment can result in increased steering forces and thus to acci- dents.
  • Page 26 • Ignition is off. Crush hazard! When hooking the tow bar into the coupling of the CHALLENGER550 or the towing vehicle, hands can be crushed in the coupling device of the tow bar. Crushing could lead to serious hand injuries.
  • Page 27 Make sure that the parking brake of the towing vehicle is engaged.  Tow bar coming loose! If the tow bar is not properly locked in the towing coupling, the CHALLENGER550 can unintentio- nally roll away and cause accidents. Persons can be seriously injured or even killed because of accidents.

  • Page 28: Hydraulic Emergency Operation

    Hydraulic emergency operation Requirements Make sure the following points are completed before carrying out hydraulic emergency operation: • CHALLENGER550 is connected to the towing vehicle by way of the tow bar. • Parking brake is engaged. • Steering and operating brake are fully functional.
  • Page 29 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Open fasteners 1 on cover 2 of emergency operation equipment on the right side of the CHAL- LENGER550. Lift cover 1 of the emergency operation equipment out of the holding device. Place the cover on the grating of the engine gearbox compartment.
  • Page 30 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Pos. Designation Description Hand valve "gearbox cooling" Push in hand valve: Activate cooling. Hand valve "Cab up/down" Push in hand valve: Raise cab. Pull out hand valve: Lower cab. Ball valve "Operating brake/ Two positions: "Operating brake", Release parking brake"...
  • Page 31 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Figure 8: Selector lever in 'Operating hydraulics - emergency operation' position 1 Position "Normal operation" 2 Position "Operating hydraulics - emergency operation" Press the selector lever to switch it from position 1 "Normal operation" and allow it to snap into position 2 "Operating hydraulics - emergency operation".
  • Page 32 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Straighten rear wheels Crush hazard! When the rear wheels are moved by the steering, persons can be caught in the wheel case. The resulting crushing can lead to death or serious injuries. Make sure that there are no persons between the tires and the wheel case.
  • Page 33 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Figure 11: Hand valve "Rear axle steering" Pull and hold hand valve "Rear axle steering" until the rear wheels steer to the left. Push and hold hand valve "Rear axle steering" in order to steer the rear wheel to the left.
  • Page 34 Release parking brake. Unintended rolling of the CHALLENGER550! The CHALLENGER550 that is not braked can unintentionally roll and collide with persons. Colliding with the rolling CHALLENGER550 can cause serious injury or death. Secure the CHALLENGER550 against rolling away before releasing or tightening the springs ...
  • Page 35 2 Position "Normal operation" Press the selector lever to switch it from position 1 "Release brake" and allow it to snap into position 2 "Normal operation". "Normal operation" has been set. CHALLENGER550 is ready to be towed. Page 29 Sep 30/17...
  • Page 36 GER550. Risk of accident when towing! The driver may lose control over the towing vehicle and the CHALLENGER550 if the CHALLEN- GER550 is towed at excessive speeds. The loss of control can result in accidents. Persons can be seriously injured or even killed because of accidents.
  • Page 37 Make sure that no persons or objects are in the danger area or on the traffic routes.  Obey the traffic rules of the airport ramp area.  When towing the CHALLENGER550 to the maintenance position, obey all traffic rules that apply on the airport ramp area. Page 31 Sep 30/17...
  • Page 38 Unintended rolling of the CHALLENGER550! Unintentional rolling of the non-braked CHALLENGER550 may occur if the towing connection is removed before the spring of the parking brake engages. The rolling CHALLENGER550 can collide with persons. Colliding with the rolling CHALLENGER550 can cause serious injury or death.

  • Page 39: Electro-Hydraulic Emergency Operation

    Requirements Make sure the following points are completed before carrying out electro-hydraulic emergency ope- ration: • CHALLENGER550 is connected to the towing vehicle by way of the tow bar. • Parking brake is engaged. • Steering and operating brake are fully functional.
  • Page 40 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Open fasteners 1 on cover 2 of emergency operation equipment on the right side of the CHAL- LENGER550. Lift cover 1 of the emergency operation equipment out of the holding device. Place the cover on the grating of the engine gearbox compartment.
  • Page 41 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Pos. Designation Description Hand valve "Gearbox cooling" Push in hand valve: Activate cooling. Hand valve "Cab up/down" Push in hand valve: Raise cab. Pull out hand valve: Lower cab. Ball valve "Operating brake/ Two positions: "Operating brake", Release parking brake."...
  • Page 42 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 2 Position "Operating hydraulics - emergency operation" Press the selector lever to switch it from position 1 "Normal operation" and allow it to snap into position 2 "Operating hydraulics". The "Operating hydraulics - emergency operation" position has now been set.
  • Page 43 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Straighten rear wheels Crush hazard! When the rear wheels are moved by the steering, persons can be caught in the wheel case. The resulting crushing can lead to death or serious injuries. Make sure that there are no persons between the tires and the wheel case.
  • Page 44 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Figure 22: Hand valve "Rear axle steering" Push and hold hand valve "Rear axle steering" until the rear wheels are set straight. The rear wheels are set straight. Release hand valve. Page 38 Sep 30/17...
  • Page 45 Release parking brake. Unintended rolling of the CHALLENGER550! The CHALLENGER550 that is not braked can unintentionally roll and collide with persons. Colliding with the rolling CHALLENGER550 can cause serious injury or death. Secure the CHALLENGER550 against rolling away before releasing or tightening the springs ...
  • Page 46 2 Position "Normal operation" Press the selector lever to switch it from position 1 "Release brake" and allow it to snap into position 2 "Normal operation". "Normal operation" has been set. CHALLENGER550 is ready to be towed. Page 40 Sep 30/17...
  • Page 47 GER550. Risk of accident when towing! The driver may lose control over the towing vehicle and the CHALLENGER550 if the CHALLEN- GER550 is towed at excessive speeds. The loss of control can result in accidents. Persons can be seriously injured or even killed because of accidents.
  • Page 48 Make sure that no persons or objects are in the danger area or on the traffic routes.  Obey the traffic rules of the airport ramp area.  When towing the CHALLENGER550 to the maintenance position, obey all traffic rules that apply on the airport ramp area. Page 42 Sep 30/17...
  • Page 49 Unintended rolling of the CHALLENGER550! Unintentional rolling of the non-braked CHALLENGER550 may occur if the towing connection is removed before the spring of the parking brake engages. The rolling CHALLENGER550 can collide with persons. Colliding with the rolling CHALLENGER550 can cause serious injury or death.
  • Page 50 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Unauthorized use! If unauthorized persons operate the CHALLENGER550, then persons may be run over. Unauthorized use of the CHALLENGER550 can cause serious injury or death. Ensure that the CHALLENGER550 is protected from unauthorized use.

  • Page 51: Emergency Operation Of The Challenger550

    The following safety information must be understood and observed when you operate the CHAL- LENGER550 in emergency operation. Unintended rolling of the CHALLENGER550! When releasing the parking brake, the CHALLENGER550 can roll unintentionally and collide with persons. Colliding with the rolling CHALLENGER550 can cause serious injury or death.

  • Page 52: Emergency Operation Features

    Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Emergency operation features Two separate operating modes are available for the emergency operation of the CHALLENGER550: • Hydraulic emergency operation • Electro-hydraulic emergency operation The following functions are performed in emergency operation on the CHALLENGER550.
  • Page 53 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Lift cover 1 of the emergency operation equipment out of the holding device. Place the cover on the grating of the engine gearbox compartment. Operating elements for emergency operation equipment 1 11 1 10 Figure 28: Operating elements for emergency operation equipment Pos.
  • Page 54 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Pos. Designation Description Hand valve "Rear axle steering" Pull out hand valve: Rear axle steers to the left. Push in hand valve: Rear axle steers to the right. Hand valve "Retract/extend Pull out hand valve: Extend stabilizers.
  • Page 55 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Selector lever The selector lever is used to release or block the emergency operation features. The selector lever has three positions: "Operating hydraulics - emergency operation", "Normal ope- ration", "Disengage brakes". Figure 29: Positions of the selector lever Pos.
  • Page 56 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Configuring hydraulic emergency operation In hydraulic emergency operation, the individual functions are performed by pressing or pulling the corresponding hand valve. The hydraulic power required for this purpose is generated by simulta- neously activating the hand pump using the pump lever.
  • Page 57 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Configuring electro-hydraulic emergency operation In electro-hydraulic emergency operation, the individual functions are performed by pressing or pul- ling the corresponding hand valve. The hydraulic power required for this purpose is generating by the electro-hydraulic drive unit.
  • Page 58 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Engine cooling INFORMATION To cool the engine, the electro-hydraulic emergency operation equipment needs to be configured. The hydraulic emergency operation equipment is unsuitable. To switch on electro-hydraulic emergency operation, turn the key switch to the right.
  • Page 59 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Steering the front axle Crush hazard! When the wheels are moved by the steering, persons can be caught in the wheel case. The resulting crushing can lead to death or serious injuries. Make sure that there are no persons between the tires and the wheel case.
  • Page 60 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Steering the rear axle Crush hazard! When the wheels are moved by the steering, persons can be caught in the wheel case. The resulting crushing can lead to death or serious injuries. Make sure that there are no persons between the tires and the wheel case.
  • Page 61 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Also activate the hand pump for hydraulic emergency operation. Rear axle steers to the right. Press and hold hand valve "Rear axle steering" until the rear axle steers to the left. Also activate the hand pump for hydraulic emergency operation.
  • Page 62 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Release hand valve "Retract/extend stabilizers" . Electro-hydraulic emergency operation: To switch on electro-hydraulic emergency operation, turn the key switch to the right. The electro-hydraulic drive unit is running. Electro-hydraulic emergency operation is on. Figure 39: Selector lever in "Operating hydraulics - emergency operation" position 1 Position "Normal operation"...
  • Page 63 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Cooling the gearbox INFORMATION To cool the gearbox, the electro-hydraulic emergency operation equipment needs to be configured. The hydraulic emergency operation equipment is unsuitable. To switch on electro-hydraulic emergency operation, turn the key switch to the right.
  • Page 64 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Driver's cab up/down INFORMATION To raise and lower the driver's cab, the electro-hydraulic emergency operation equipment needs to be configured. The hydraulic emergency operation equipment is unsuitable. To switch on electro-hydraulic emergency operation, turn the key switch to the right.
  • Page 65 PUSHBACK TRACTOR CHALLENGER550 Releasing the parking brake Unintended rolling of the CHALLENGER550! When releasing the parking brake, the CHALLENGER550 can roll unintentionally and collide with persons. Colliding with the rolling CHALLENGER550 can cause serious injury or death. Secure the CHALLENGER550 against rolling away before releasing or tightening the springs ...
  • Page 66 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Figure 45: Positions of the ball valve 1 Position "Operating brake" 2 Position "Release parking brake" Remove the seal on the ball valve. Press the ball valve from position 1 "Operating brake" to position 2 "Release parking brake".
  • Page 67 Engaging the parking brake Unintended rolling of the CHALLENGER550! When removing the anti-rolling devices, the CHALLENGER550 that is not braked may unintentio- nally roll. The rolling CHALLENGER550 can collide with persons. Colliding with the rolling CHALLENGER550 can cause serious injury or death.
  • Page 68 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 Restoring normal operation INFORMATION After ending the emergency operation, the "rear axle steering" hand valve has to be locked again otherwise the motor cannot be started. Screw the red knurled screw for the "rear axle steering" axle blocking valve all the way in.
  • Page 69 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 LIST OF EFFECTIVE PAGES Chapter/Section Page Date Chapter/Section Page Date Sep 30/17 Sep 30/17 Sep 30/17 Sep 30/17 2-Contents Sep 30/17 Sep 30/17 2-Contents 2 (Blank) Sep 30/17 Sep 30/17 Sep 30/17 Sep 30/17...
  • Page 70 Emergency Operation Measures PUSHBACK TRACTOR CHALLENGER550 This page intentionally left blank. Page 2 (Blank) Sep 30/17...

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