TREPEL CHALLENGER550 User manual

PUSHBACK TRACTOR
CHALLENGER550
Operation manual
Docu-No.: 6750047_BA_us (en)
for CHALLENGER550
Property of American Airlines

Property of American Airlines

Page 1
1-0
General Information and Operating Instructions
PUSHBACK TRACTOR CHALLENGER550
Published by
TREPELAirport 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.
6750047_BA_us (en)
Chapter 1
Translation of the original manual
Date issued
28.01.2019
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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.
Jan 28/19
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General Information and Operating Instructions
PUSHBACK TRACTOR CHALLENGER550
Page 2
1-0 Jan 28/19
Copyright
© 2019 TREPELAirport 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.
Anyuse or modification of thisdocumentationorits contentsor ofpartsof the documentationoutside
of the confines of the copyright law is not permitted without the written approval by 
TREPELAirport 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.
TREPELAirport Equipment GmbH will not assume liability for damages due to unauthorized use of
the contents in the documentation by natural persons or corporate bodies. 
TREPELAirport Equipment GmbH reserves the right to change this documentation at any time.
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Chapter/Section Page
General Information and Operating Instructions
PUSHBACK TRACTOR CHALLENGER550
Page 1
1-CONTENTS
TABLE OF CONTENTS
Description 1-1 1
1. About this manual 1
A. General 1
B. Additional documents 1
C. Characters and symbols used 2
2. General safety instructions 3
A. Intended use 3
B. Qualification of the operator 5
C. Personal protective equipment of the operating personnel 5
D. Workplaces of the operating personnel 6
E. Danger area 7
F. Other dangers 8
G. Safety Regulations 9
3. Components of the CHALLENGER550 21
A. Components 21
4. Safety equipment 25
A. Operating and parking brakes 25
B. Safety equipment 26
C. Warning and instruction signs on CHALLENGER550 27
5. Operating and display elements 43
A. Safety information 43
B. Interior view CHALLENGER550 44
C. Cab doors 45
D. Seats and seat belts 48
E. Gas and brake pedals 50
F. Driver workplace 51
G. Preheater starter switch 52
H. Display elements 53
I. Operating elements 64
J. Main battery switch 78
K. Auxiliary power supply 79
Jan 28/19
CHAPTER 1
GENERAL INFORMATION AND OPERATING INSTRUCTIONS
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General Information and Operating Instructions
PUSHBACK TRACTOR CHALLENGER550
Page 2
1-CONTENTS Jan 28/19
Operation 1-2 1
1. Inspections before starting operation 1
A. Safety information 1
B. Inspections before beginning operation 4
2. Operating the CHALLENGER550 19
A. Safety information 19
B. Before starting the CHALLENGER550 24
C. Starting engine 30
D. Driving the CHALLENGER550 34
E. Regeneration of the particulate filter and the SCR catalyst 44
F. Storing/Parking the CHALLENGER550 48
G. Refueling the CHALLENGER550 51
3. Towing mode with CHALLENGER550 57
A. Safety information 57
B. Driving modes, CHALLENGER550 59
Specifications 1-3 1
1. Technical data 1
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General Information and Operating Instructions
PUSHBACK TRACTOR CHALLENGER550
1. About this manual
Read this manual carefully before operating the CHALLENGER550 for the first time. Observe in particular
the overall safety instructions (see Subsection 2 "General safety instructions", page 3).
A. General
These operating instructions will make you familiar with the basic operating steps of the CHALLEN-
GER550.
These operating instructions contain important information pertaining to the safe and proper opera-
tion of the CHALLENGER550.
Observe these instructions in order to:
• Avoid danger
• Reduce repair costs and downtime
• Increase the reliability and operating life of the CHALLENGER550
In addition to these operating instructions, also payattention to accident preventionand environmen-
tal protection regulations applicable in the land of use and at the place of operation.
A copy of the operating instructions must always be accessible to the operator.
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)
• Emergency operating measures
• Transport instruction manual
• Display instructions
• Maintenance manual – Maintenance instructions
• Electric diagrams
• Hydraulic diagrams
• Supplier documentation.
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Section 1
Description
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General Information and Operating Instructions
PUSHBACK TRACTOR CHALLENGER550
Page 2
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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.
Description of the pictogram meanings see Subsection 5 "Operating and display elements",
page 43.
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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General Information and Operating Instructions
PUSHBACK TRACTOR CHALLENGER550
2. General safety instructions
All important safety instructions for operating the CHALLENGER550 are summarized in the following.
All personnel who operate or work on the CHALLENGER550 are to read and implement the inst-
ructions outlined in this chapter. When the CHALLENGER550 is in operation, these instructions
must be implemented and followed at all times.
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.
Please consult your physician and inform your supervisor if you are taking medication.
A. Intended use
The CHALLENGER550 is intended exclusively for use as a tow bar tractor for moving aircraft
on the airport apron. The CHALLENGER550 is designed and intended for the following tasks:
• Push-back: Moving a fully loaded aircraft back from the terminal position to the tarmac.
• Repositioning: Moving the empty aircraft from its parked position to the terminal position.
• Maintenance towing: Moving an empty aircraft from the terminal position to the maintenance
hall or the from the maintenance hall to the terminal position.
The CHALLENGER550 may be operated only by two persons, the operator as driver and an accom-
panying person as wing walker.
The CHALLENGER550 is designed and constructed for the following loads and speeds:
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General Information and Operating Instructions
PUSHBACK TRACTOR CHALLENGER550
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Table 1: Driving modes of the CHALLENGER550
The CHALLENGER550 may
• Not be used for transporting persons.
• Not transport loads that are greater than the maximum permissible load.
• Not move loads at speeds that are higher than the maximum permissible speed.
• Not move loads that cannot be safely secured to the couplings on the CHALLENGER550.
Drivingmodeofthe
CHALLENGER550 Weight of the CHALLENGER550 Tractive force Permissible dri- ving speed Maximum aircraft weight
Empty driving 50 000 kg
(110,230 lb) 369 kN (82,959 lbf) 29 km/h (18 mph) –
55 000 kg
(121,254 lb)
Push-back 50 000 kg
(110,230 lb) 369 kN (82,959 lbf) 5 km/h (3 mph) 450 000 kg  (992,063 lb)
55 000 kg
(121,254 lb)
Repositioning 50 000 kg
(110,230 lb) 369 kN (82,959 lbf) Prescribed speed of the operator 450 000 kg  (992,063 lb)
55 000 kg
(121,254 lb)
Maintenance towing 50 000 kg
(110,230 lb) 369 kN (82,959 lbf) Prescribed speed of the operator 450 000 kg  (992,063 lb)
55 000 kg
(121,254 lb)
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B. Qualification of the operator
The CHALLENGER550 may only be operated by personnel qualified and authorized to do so.
The operator must:
• Be at least 18 years of age, unless federal, state, or local law or any other applicable law or
regulation prescribes a different minimum age..
• Possess the physical and mental capabilities required to drive an automotive vehicle.
• Have received instruction in and be able to perform First Aid.
• Know the accident prevention regulations and safety instructions of the airport and be able to
apply them.
• Know the traffic rules of the airport ramp area and be able to apply them.
• Possess good knowledge of the airport apron.
• Know the location of runways and roads, and in particular, all restricted areas that may not be
entered with the CHALLENGER550.
• Have received theoretical and practical training on the CHALLENGER550.
• Understand and be able to apply the Emergency Operating Measures.
Do not operate the CHALLENGER550 while under the influence of alcohol or drugs, including
prescription drugs.
C. 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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D. Workplaces of the operating personnel
From the driver's cab the CHALLENGER550 is:
• Driven (see Subsection 2 "Operating the CHALLENGER550", page 19)
• Connected/disconnected (see Subsection 3 "Towing mode with CHALLENGER550",
page 57).
Figure 1: Workplaces of the CHALLENGER550
1Driver's seat
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E. Danger area
To ensure safe operation no persons other than the operator are permitted to be in the danger area
of the CHALLENGER550. There is risk of injury or even death in the danger area.
Excluding the tow bar, no other objects may be located in the danger area of the CHALLENGER550
during operation.
Thefollowingdiagramshowsthedangerareaof theCHALLENGER550 andthe clearancesrequired
for safe operation of the CHALLENGER550.
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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General Information and Operating Instructions
PUSHBACK TRACTOR CHALLENGER550
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F. Other dangers
• A collision at high speed
• Person in the wheel case when the wheels are turned
Causes serious injury or death of the operator.
• Falling from the maintenance platform
Can lead to serious injury or death of the operator.
• Getting caught when connecting or disconnecting the tow bar
• Stumbling on the maintenance platform
Can lead to mild injury of the operator.
•Aircraft
• Other vehicles
• Other objects
Can be damaged by negligent operation of the CHALLENGER550.
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G. Safety Regulations
General
Danger of explosions and fires!
Fuels are easily inflammable and explosive.
Explosions or flames can lead to serious injuries or even death.
Do not smoke in the danger area of the CHALLENGER550.
No open flames or lights permitted in the danger area of the CHALLENGER550.
Personal injury!
Unauthorized persons may be seriously injured or killed in the danger area of the CHALLEN-
GER550 during operation.
Only the operator is permitted to be in the danger area during operation.
Technical defects! Operational safety!
If the CHALLENGER550 is operated even though there are technical defects, then serious injury or
even death may occur.
Always check the operability and safety of the CHALLENGER550 before beginning work and
at every shift change.
The operator has to perform these checks each time he or she takes over the CHALLEN-
GER550.
Every operator is responsible for the operational safety of the CHALLENGER550.
Untrained personnel!
Uncontrolled movement of the CHALLENGER550 by operating errors can cause serious injuries or
even death.
The operator must know all of the operating and display elements and be able to use them.
Unauthorized persons!
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.
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General Information and Operating Instructions
PUSHBACK TRACTOR CHALLENGER550
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Disregarding the regulations!
Disregarding the laws and regulations can result in serious injuries or even death.
Observe all accident prevention laws and regulations.
Observe all local airport safety rules and regulations with respect to runways.
The rules of the airport user regulation must be observed.
Riding outside the cabin!
Riding outside the cabin of the CHALLENGER550 can result in persons falling.
Falling can result in death or serious injuries.
Riding on the CHALLENGER550 outside the cabin is strictly prohibited.
Personnel for instruction or the wing walkers may only be transported in the passenger seat
in the cabin.
Danger of falling!
Persons can fall off of the CHALLENGER550 when stepping onto the roof of the cab.
Falling can result in death or serious injuries.
Stepping onto the roof of the cab of the CHALLENGER550 is strictly prohibited.
Perform maintenance work only from the maintenance platform.
Rolling CHALLENGER550!
The rolling CHALLENGER550 can collide with or run over persons.
Colliding with the rolling CHALLENGER550 can cause serious injury or death.
Make sure that no persons or objects are in the danger area or on the traffic routes.
Observe all of the local airport safety and work regulations regarding the airport apron.
The CHALLENGER550 may only be driven in permitted airport areas and traffic routes in
accordance with local airport regulations.
No protective clothing!
If the operator does not wear the prescribed personal protective clothing, then this can cause life-
threatening injuries or even death.
The operator must at all times wear all safety gear required by law or workplace regulations,
or common sense, as a safeguard against any foreseeable harm involved in performing a
given task.
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General Information and Operating Instructions
PUSHBACK TRACTOR CHALLENGER550
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Alcohol, drug, medication consumption!
Consuming alcohol, drugs, and medication may severely impair your ability to safely load, unload,
transport, or otherwise handle or operate the CHALLENGER550.
Please consult your physician and inform your supervisor if you are taking medication.
Do not operate or otherwise handle the CHALLENGER550 while under the influence of alco-
hol or drugs.
Consuming alcohol or drugs, or taking prescription medication is strictly forbidden at all times.
Low ground clearance!
The CHALLENGER550 can be damaged by driving on uneven roads due to the low ground clea-
rance.
The CHALLENGER550 may only be driven in permitted airport areas and traffic routes in
accordance with local airport regulations.
Never enter other traffic routes!
Folded-up guard railing!
When the guard railing of the CHALLENGER550 is folded up, it can come into contact with the
aircraft during driving operations.
This can damage the aircraft.
After completion of maintenance work, always fold the guard railing down.
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Operating the CHALLENGER550
Rolling CHALLENGER550!
The rolling CHALLENGER550 can collide with or run over persons.
Colliding with the rolling CHALLENGER550 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.
Seat belt has not been fastened!
A seat belt cannot fulfill its safety function if it has not been fastened, or has been put on incorrectly.
Driving without a fastened seat belt can lead to serious injuries or even death in the case of an acci-
dent.
For your own safety always wear a seat belt.
Make sure that the seat belt is not twisted.
Make sure that the buckle can be clearly heard clicking into the latch.
Note that you may only use seat belts that have been cleared by TREPELAirport Equipment
GmbH when retrofitting.
Danger of explosions and fires!
Fuels are easily inflammable and explosive.
Explosions or flames can lead to serious injuries or even death.
Do not smoke in the danger area of the CHALLENGER550.
No open flames or lights permitted in the danger area of the CHALLENGER550.
Leaking diesel!
Diesel is easily inflammable and explosive.
Explosions or flames can lead to serious injuries or even death.
Do not smoke in the danger area of the CHALLENGER550.
No open flames or lights permitted in the danger area of the CHALLENGER550.
Be aware of the maximum tank capacity (360 liters / 95 US gallons).
Inform the fire department immediately.
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Crush hazard!
When driving the CHALLENGER550 to the tow bar, persons can be crushed between the CHAL-
LENGER550 and the tow bar.
The resulting crushing can lead to death or serious injuries.
Ensure that, besides the operating personnel, no persons or objects are located between the
CHALLENGER550 and the tow bar.
Ensure that visual and radio contact is always maintained with the wing walker.
Tow bar coming loose!
If the tow bar is not correctly locked into the coupling of the CHALLENGER550, the tow bar can
become loose. The loose, swinging end of the tow bar can hit persons.
The loose, swinging end of the tow bar can kill or seriously injure persons.
Before starting to drive, make sure that the tow bar is correctly secured to the coupling with
the bolt.
Rolling CHALLENGER550!
The CHALLENGER550 can run over persons when starting to drive.
Running over persons can result in death or serious injuries.
Ensure that no persons are located between the CHALLENGER550 and tow bar.
Ensure that visual and radio contact is always maintained with the wing walker.
Technical defects!
Neglected or insufficient inspections can lead to technical defects on the CHALLENGER550.
Operating the CHALLENGER550 with technical defects may result in death or serious injuries.
Perform all inspections with due care.
Always observe the instructions as to whether to perform the inspections with the motor run-
ning or idled.
Danger of tripping or falling!
Risk of tripping or falling from the CHALLENGER550 when carrying out the inspections.
Falling from the CHALLENGER550 can result in death or serious injuries.
When entering the area of the ballast weights, secure the vehicle with railings.
Only use secured mounting ladders.
Assume a safe position on the grating during inspections.
Have the operator provide appropriate safety options.
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Danger of falling!
There is a danger of falling when climbing on the grating of the CHALLENGER550.
Falling from the CHALLENGER550 can result in death or serious injuries.
Only use secured mounting ladders.
Crush hazard!
Persons can be caught and crushed by steering movements of the wheels in the wheel case when
reading the hydraulic oil level in the viewing window.
The crushing can lead to death or serious injuries.
Inform operating personnel of the inspections to be carried out.
Switch off the motor of the CHALLENGER550 before inspection work.
Put up warning sign, "Service work! Do not switch on!".
Splashing hot coolant!
The cooling system is pressurized. When opening the cooling system, hot coolant may splash out.
The splashing coolant can scald the skin or the eyes.
Only open the cooling system when the coolant temperature is below 90 °C.
Unscrew the cap slowly and allow the pressure to escape completely before opening.
Wear suitable protective gloves, clothes, and goggles when handling coolant.
Danger of poisoning!
The coolant in the cooling system contains poisonous substances.
There is danger of poisoning when you swallow coolant.
Never swallow coolant; wash your hands after contact with coolant.
Never pour coolant into drinking containers.
Loosening of wheel nuts!
Before initial operation or after a wheel change, the wheel nuts can loosen due to material settling
and lead to serious accidents.
Persons can be seriously injured or even killed because of serious accidents.
Be sure to retighten all wheel nuts with the specified torque before the initial operation or after
the wheel exchange.
Retighten the wheel nuts with the prescribed tightening torque again after the first laden jour-
ney, at the latest after 24 operating hours.
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