TREPEL CHALLENGER550 Instruction sheet

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

6750024-27_NB_us (en)
Property of American Airlines

Page 1
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Emergency Operation Measures
PUSHBACK TRACTOR CHALLENGER550
Published by
TREPEL Airport Equipment GmbH
Sales/Marketing
Customer Service
Hagenauer Str. 42
D-65203 Wiesbaden
Telephone: [phone]
Telefax: [phone]
E-mail: [email protected]
Internet: http://www.trepel.com
Plant/Purchasing
Administration
Hochhäuser Str. 18
D-97941 Tauberbischofsheim
Telephone: [phone]
Telefax: [phone]
E-maill: [e-mail]
Docu-No.
6750024-27_NB_us (en)
Chapter 1
Translation of the original manual
Date issued
30.09.2017
California Proposition 65 Warning California Proposition 65 Warning
Diesel engine exhaust and some of its consti-
tuents are known to state of California to
cause cancer, birth defects and other repro-
ductive harm.
Battery posts, terminals, and related access-
ories contain lead and lead compounds, che-
micals known to the state of California to
cause cancer and reproductive harm.
Wash hands after handling.
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Copyright
© 2017 TREPEL Airport Equipment GmbH
This documentation, including all of its parts and chapters is the intellectual property of
TREPEL Airport Equipment GmbH and is copyright-protected by national and international laws.
Any use or modification of this documentation or its contents or of parts of the documentation outside
of the confines of the copyright law is not permitted without the written approval by
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.
Infringements of these provisions will be prosecuted.
TREPEL Airport Equipment GmbH will not assume liability for damages due to unauthorized use of
the contents in the documentation by natural persons or corporate bodies.
TREPEL Airport Equipment GmbH reserves the right to change this documentation at any time.
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Chapter/Section Page
Emergency Operation Measures
PUSHBACK TRACTOR CHALLENGER550
Page 1
2-CONTENTS
TABLE OF CONTENTS
1. About this manual 1
A. General 1
B. Additional documents 1
C. Characters and symbols used 2
2. General safety instructions 5
A. Personal protective equipment of the operating personnel 5
B. Workplaces of the operating personnel 6
C. Danger area 7
D. Safety Regulations 8
E. Warning signs emergency operation 11
3. Towing the CHALLENGER550 15
A. Safety information 15
B. Connecting the CHALLENGER550 with the towing vehicle 19
C. Hydraulic emergency operation 22
D. Electro-hydraulic emergency operation 33
4. Emergency operation of the CHALLENGER550 45
A. Safety information 45
B. Emergency operation features 46
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EMERGENCY OPERATION MEASURES
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1. About this manual
Read this manual carefully before any emergency operation needs to be taken for the first time. Observe
in particular the overall safety instructions (see Subsection 2 "General safety instructions", page 5).
A. General
The Emergency Operating Measures will acquaint you with the basic emergency features of the
CHALLENGER550.
The Emergency Operating Measures contain important information on the safe and proper use of
the CHALLENGER550's emergency features.
Observe these instructions in order to:
• Avoid danger
• 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.
B. Additional documents
In addition to these operating instructions, you also receive the following documentation for the
CHALLENGER550:
• Factory settings / Production text documents (vehicle identification sheet)
• Instruction Manual
• Transportation Instructions
• Display instructions
• Maintenance manual – Maintenance instructions
• Electric diagrams
• Hydraulic diagrams
• Supplier documentation.
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C. 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. Failure to comply will result in death or serious injury.
Risk of personal injury. Failure to comply can result in death or serious injury.
Risk of personal injury. Failure to comply can result in minor injury.
Risk of property damage.
Necessary measures to avoid a risk.
(1)
(2)
...
Multi-step guide for action.
Observe the order of the steps.
INFORMATION Information for better understanding or optimization of the workflows.
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2. General safety instructions
In the following all important safety instructions and regulations regarding the emergency operating mea-
sures are described.
All personnel who use emergency functions on the CHALLENGER550 must read and apply these
safety instructions.
In addition, all other safety and accident prevention instructions contained in this manual must be obser-
ved at all times, including all Occupational Safety and Health Administration (OSHA), environmental and
all other federal, state, and local laws and regulations in effect at the operation site.
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.
Consult your physician and inform your supervisor if you take any prescription drugs.
A. Personal protective equipment of the operating personnel
The CHALLENGER550 operator is obliged to wear all safety gear provided by the employer and/or
that is mandated by law at all times while operating the CHALLENGER550.
The operator safety gear consists of at least:
• Highly visible work clothing
• Head protection
• Hearing protection
• Work gloves
• Safety shoes with metal toe caps
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B. Workplaces of the operating personnel
Figure 1: Workplaces for emergency operating measures of the CHALLENGER550
1Driver's seat in the driver's cab
2Hydraulic and electro-hydraulic emergency operation
In hydraulic and electro-hydraulic emergency operation:
• the 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.
2
1
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C. 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.
Figure 2: Danger area of the CHALLENGER550
500 mm (1 ¾ ft)
500 mm (1 ¾ ft)
500 mm (1 ¾ ft) 500 mm (1 ¾ ft)
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D. Safety Regulations
General
Personal injury!
Unauthorized persons may be seriously injured or killed in the danger area of the CHALLEN-
GER550 during emergency operation.
Only the operator and the service personnel required to recover the CHALLENGER550 are
permitted to be in the danger area during emergency operation.
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
routes and into permitted areas in accordance with all local airport rules, regulations, and res-
trictions.
Never enter other traffic routes!
Property damage!
During emergency operation there is a risk of damaging the outer hull of the aircraft.
Never come into contact with the outer hull of the aircraft.
Only the operator and specially-trained service personnel may carry out the emergency reco-
very of the CHALLENGER550.
Use relevant know-how during work.
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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.
Make sure that the CHALLENGER550 is secured against unintentional rolling before cou-
pling.
Firstly, hook and lock the tow bar onto the front coupling of the CHALLENGER550.
Make sure that no other persons are between the CHALLENGER550 and towing vehicle
when coupling.
Move the towing vehicle slowly towards the stationary CHALLENGER550 until the towing
eyelet of the tow bar hooks into the towing coupling and can be locked.
Unintended rolling of the CHALLENGER550!
When the parking brake is released, 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 opening the springs of the parking
brake.
Securely connect the CHALLENGER550 to the tow bar on the towing vehicle.
Make sure that the parking brake of the towing vehicle is engaged.
After towing, close the spring of the parking brake again.
Unauthorized towing equipment!
The use of unauthorized towing equipment can result in increased steering forces and thus lead to
accidents.
Persons can be seriously injured or even killed because of accidents.
Only use a sufficiently large tow bar for towing.
Do not use ropes or chains as towing equipment.
Make sure that the towing connection is able to withstand the stress caused by the weight of
the CHALLENGER550.
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Unauthorized tow vehicle!
The use of an unauthorized towing vehicle can result in the loss of control and thus lead to acci-
dents when towing or braking the CHALLENGER550.
Persons can be seriously injured or even killed because of accidents.
The towing vehicle must be able to securely pull and brake the weight of the CHALLEN-
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.
Never grip the towing eyelet on the front of tow bar.
Wear protective gloves.
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.
Before towing the CHALLENGER550, make sure that the tow bar is locked in the coupling of
the CHALLENGER550 and towing vehicle.
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.
Do not exceed the maximum towing speed of 10 km/h (6 mph).
Maintain contact to the towing vehicle driver (radio contact or hand signals).
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.
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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.
Obey the traffic rules of the airport ramp area.
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.
E. Warning signs emergency operation
Figure 3: Übersicht Hinweisschilder
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Instruction signs on the CHALLENGER550
The following instruction signs are located on the CHALLENGER550:
Instruction sign Designation Color Quantity
Emergency
operating
equipment
White, blue 1
Emergency
operating
equipment, inst-
ructions
White, blue 1
Emergency
operating
equipment: Fill
hydro accumula-
tor for parking or
operating brake
White, black 1
Emergency
operating
equipment:
Raise/Lower cab
White, black 1
Emergency
operating
equipment: Coo-
ler, gearbox
White, black 1
Emergency
operating
equipment:
Retract/extend
stabilizers
White, black 1
Emergency
operating
equipment:
Steering, rear
axle
White, black 1
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Table 1: Instruction signs on the CHALLENGER550
Emergency
operating
equipment:
Steering, front
axle
White, black 1
Emergency
operating
equipment:
Cooler, engine
White, black 1
Emergency
operating
equipment:
Raise/Lower
engine and gear-
box unit
White, black 1
Emergency
operating
equipment:
Normal
operation, brake,
hydraulic
White, black 1
Instruction sign Designation Color Quantity
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