TREPEL CHALLENGER550 Operation Manual Download

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General Information and Operating Instructions

PUSHBACK TRACTOR CHALLENGER550

Jan 28/19

Unintended rolling of the CHALLENGER550!

The CHALLENGER550 can roll when the motor is running and run over persons or crush them.

Running over or crushing persons can result in death or serious injuries.



Secure the CHALLENGER550 with the parking brake against rolling.



Always shift into "neutral" before exiting the driver's cab.



Do not leave the CHALLENGER550 unsupervised when the motor is running.

Danger of crushing!

When the vehicle is in motion, open cab doors can close uncontrolled and crush limbs of persons.

Crushing can lead to serious injuries.



Make sure that all cab doors have been closed before starting to drive the CHALLEN-
GER550.

Toxic gases and vapors!

Toxic gases and vapors may be released when handling fuel.

Breathing in toxic gases and vapors could cause serious injury or even death.



Do not inhale gases and vapors.

Incorrect seat adjustment!

If the driver's seat is not set to the correct position, this may impair the person operating the CHAL-
LENGER550 and result in serious accidents.

Persons can be seriously injured or even killed because of accidents.



Check to ensure the seat is in the correct position before starting the CHALLENGER550.



Adjust the seating position of the driver's seat if necessary.

Driver's seat not locked in place!

If the driver's seat is not locked in place, it may move suddenly while driving and result in a loss of
control over the CHALLENGER550. Loss of control can lead to serious accidents.

Persons can be seriously injured or even killed because of accidents.



All locking devices for the seat should be clearly heard clicking into place.

Property of American Airlines

Summary of Contents for CHALLENGER550

Page 1: ...PUSHBACK TRACTOR CHALLENGER550 Operation manual Docu No 6750047_BA_us en for CHALLENGER550 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 2: ...P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 3: ...efax 49 93 41 899 339 E maill tae service trepel airport de Docu No 6750047_BA_us en Chapter 1 Translation of the original manual Date issued 28 01 2019 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...

Page 4: ...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 du...

Page 5: ...ther 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 ...

Page 6: ...LLENGER550 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 P...

Page 7: ...downtime Increase the reliability and operating life of the CHALLENGER550 In addition to these operating instructions also pay attention to accident prevention and 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 instr...

Page 8: ... 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 Informati...

Page 9: ...cohol 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 follo...

Page 10: ...iving mode of the 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 ope...

Page 11: ...rea 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 alco...

Page 12: ... 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 1 Driver s seat P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 13: ...e 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 The following diagram shows the danger area of the CHALLENGER550 and the clearances required for safe operation of the CHALLENGER550 Figure 2 Danger area of the CHALLENGER550 500 mm 1 ft 500 mm 1 ft 500 mm 1 ft 500 mm 1 ft P r o p e r t...

Page 14: ... 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 P r o p e r t y o f A m e r i c a n A i r ...

Page 15: ...ed 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 mo...

Page 16: ...n 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 o...

Page 17: ...s 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 Whe...

Page 18: ...at 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 TREPEL Airport 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 ...

Page 19: ...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 CHALLENG...

Page 20: ...d 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 swall...

Page 21: ...xic gases and vapors may be released when handling fuel Breathing in toxic gases and vapors could cause serious injury or even death Do not inhale gases and vapors Incorrect seat adjustment If the driver s seat is not set to the correct position this may impair the person operating the CHAL LENGER550 and result in serious accidents Persons can be seriously injured or even killed because of acciden...

Page 22: ...d because of accidents Never adjust the driver s seat while driving Never adjust the steering wheel while driving Never adjust the outside mirrors while driving Loose objects in the footwell of the driver seat Loose objects that have been left in the footwell of the driver s stand can slide onto the pedals This can significantly impair operation of the CHALLENGER550 and cause a loss of control Los...

Page 23: ... the tow bar Crushing can lead to serious hand injuries Make sure that operating personnel only grip the tow bar on the handgrips intended for this purpose Make sure that the operating personnel wear protective gloves Caustic fuels When filling up fuel may get onto clothing or skin Fuel on the skin can cause minor injuries Always wear personal safety gear Clothing that has become wet with fuel sho...

Page 24: ...he nose landing gear of the aircraft When driving with an aircraft attached adapt the driving speed to the respective conditions Drive in such a way that the CHALLENGER550 with attached aircraft can be safely braked at any time Reduce the speed before reaching a curve Make sure to keep an adequate safety distance when driving around obstacles Make sure that the driving surface is clean and has suf...

Page 25: ...ction system and starter could get damaged if the engine is started when the fuel tank is empty After refueling with clean fuel the fuel system of the CHALLENGER550 has to be bled by authorized technicians in accordance with the manual of the engine manufacturer Do not let the tank run empty Excessive speed Due to excessive speeds during push back maintenance towing repositioning during an empty d...

Page 26: ...GER550 and or the aircraft Always drive with caution Do not abruptly brake the CHALLENGER550 with an aircraft attached Before braking the train consisting of the CHALLENGER550 the tow bar and the aircraft should be in as straight a line as possible There must be constant radio contact between the operator and the aircraft pilot P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 27: ...ts of the CHALLENGER550 The following describes all of the components relevant to the operation of the CHALLENGER550 A Components Figure 3 Chassis components front view Figure 4 Chassis components rear view 10 17 18 19 15 13 12 11 14 16 20 Jan 28 19 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 28: ...ction indicators and pins can be stored in the open box 7 Windscreen washer water container The windscreen washer water container stores the water for the windscreen washer system 8 Front towing coupling The aircraft tow bar is attached to the towing coupling 9 Work light The work light illuminates the work area 10 Headlights The headlights illuminate the front of the CHALLENGER550 and the traffic...

Page 29: ...rive axle Steering axle 17 Rear axle The rear axle serves as Drive axle Steering axle 18 Rear lights The rear lights illuminate the rear of the CHALLENGER550 19 Rear towing coupling The aircraft tow bar is attached to the towing coupling 20 Reversing camera The reversing camera makes it possible to view the rear area while reversing display occurs on the monitor in the driver s cab Pos Designation...

Page 30: ...This page intentionally left blank General Information and Operating Instructions PUSHBACK TRACTOR CHALLENGER550 Page 24 Blank Jan 28 19 1 1 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 31: ...550 A Operating and parking brakes Operating brake The brake pedal on the operator platform brakes the moving CHALLENGER550 Parking brake The parking brake secures the parked CHALLENGER550 against unintentional rolling Without hydraulic oil pressure the parking brake which is a spring loaded brake will automatically act on the rear axle wheels Jan 28 19 P r o p e r t y o f A m e r i c a n A i r l ...

Page 32: ...itch strip prevents damage to the hull of the aircraft by the raised driver s cab As soon as the safety switch strip touches the hull of the aircraft the raising of the cab is immediately halted The following message is displayed DANGER OF COLLISION The cab has to be lowered 2 Guard railing The guard railing is folded upright for control and maintenance work and protects the service personnel agai...

Page 33: ...warning and instruction signs are provided for safety reasons The operator is responsible for their completeness The CHALLENGER550 is only to be operated with all of the safety and warning signs mounted Figure 6 Warning signs cab exterior 610 015 0788 610 015 0785 610 015 0785 610 015 0505 610 015 0785 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 34: ...HBACK TRACTOR CHALLENGER550 Page 28 1 1 Jan 28 19 Figure 7 Warning signs cab exterior Figure 8 Warning signs cab interior 610 015 0782 610 015 0789 610 015 0780 610 015 0781 610 015 0498 610 015 0497 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 35: ... 19 Figure 9 Warning signs avoid injury Figure 10 Warning signs crush hazard 610 015 0497 610 015 0497 610 015 0784 4 8 7 0 5 1 0 0 1 6 4 8 7 0 5 1 0 0 1 6 610 015 0784 610 015 0501 610 015 0911 610 015 0501 610 015 0501 610 015 0501 610 015 0788 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 36: ...l Information and Operating Instructions PUSHBACK TRACTOR CHALLENGER550 Page 30 1 1 Jan 28 19 Figure 11 Warning signs hot surfaces 610 015 0504 610 015 0504 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 37: ...ructions PUSHBACK TRACTOR CHALLENGER550 Jan 28 19 Figure 12 Warning signs mounting ladder Figure 13 Warning signs rear towing coupling 610 015 0779 610 015 0791 610 015 0779 610 015 0791 610 015 0788 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 38: ... PUSHBACK TRACTOR CHALLENGER550 Page 32 1 1 Jan 28 19 Figure 14 Warning signs emergency operation battery and switch cabinet Figure 15 Warning signs overview 610 015 0499 610 015 0497 610 015 0790 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 39: ...Page 33 1 1 General Information and Operating Instructions PUSHBACK TRACTOR CHALLENGER550 Jan 28 19 Figure 16 Warning signs overview P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 40: ...nstructions and signs have to be attached on the CHALLENGER550 Safety instructions Designation Color Quantity Safety instructions normal operation White black green 1 Safety instructions emergency operation White black green 1 Read manual Blue white orange 1 Authorized service personnel White black red orange 2 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 41: ...nel White black red orange 2 Crush hazard stabilizers Yellow black orange 4 Rolling vehicle no brake engaged Yellow black orange 1 Danger of injury driving without a seatbelt Yellow black orange 2 Fall hazard Yellow black orange 2 Safety instructions Designation Color Quantity P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 42: ...ellow black orange 4 Crush hazard lowering cab Yellow black orange 3 Danger of crushing feet lowering cab Yellow black orange 2 Crush hazard towing couplings Yellow black orange 2 Electrical system switch cabinet Yellow black orange 2 Safety instructions Designation Color Quantity P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 43: ...ystem switch cabinet fuse Yellow black orange 1 Leaking batteries and risk of acid burn Yellow black red 1 Hot surface exhaust Yellow black orange 6 Pressure accumulator brakes Yellow black orange 2 Pressure accumulator front axle suspension Yellow black orange 1 Safety instructions Designation Color Quantity P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 44: ...ion signs are located on the CHALLENGER550 Instruction sign Designation Color Quantity Vehicle identification plate Black silver 1 Battery White blue 1 Main battery switch White blue 1 Remote start White blue 1 AdBlue yellow black 1 Low Sulfur Fuel Green white 1 Diesel Green white 1 Hydraulic oil Yellow blue 1 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 45: ... Lashing point White blue 8 10 bar 145 psi White blue 4 Lifting point White blue 4 Support point chassis White green 4 Maximum aircraft weight White black 2 Maximum tractive power White black 2 Tightening torque 480 lbf ft 650 Nm Grey black 4 Instruction sign Designation Color Quantity P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 46: ... step White red 5 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 Instruction sign Designation Color Quantity P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 47: ...operating equipment Retract extend stabilizers White black 1 Emergency operating equipment Steering rear axle White black 1 Emergency operating equipment Steering front axle White black 1 Emergency operating equipment Cooler engine White black 1 Emergency operating equipment Normal operation brake hydraulic White black 1 Instruction sign Designation Color Quantity P r o p e r t y o f A m e r i c a...

Page 48: ...This page intentionally left blank General Information and Operating Instructions PUSHBACK TRACTOR CHALLENGER550 Page 42 Blank Jan 28 19 1 1 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 49: ... 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 TREPEL Airpo...

Page 50: ...ht and warning buzzer 3 Analog displays 4 Rocker switch Toggle switch 5 Preheater starter switch 6 Display 7 Battery charge indicator 8 Rocker switch Diesel pre heating 9 Heater Ventilation 10 Gear selector lever 11 Rocker switch for setting the suspension and cab 12 Parking brake 13 Rocker switch steering program 14 Pedals 14 9 8 1 2 3 4 5 10 6 12 13 11 7 P r o p e r t y o f A m e r i c a n A i r...

Page 51: ...uter door opener The door opener for opening from the outside is located on the left and right cab door respectively Figure 18 Outer door opener 1 Outer door opener 2 Locking cylinder Using door from the outside Opening cab door 1 Press in locking cylinder 2 2 Press door opener 1 and open cab door towards the outside The cab door is open Closing cab door 1 Press cab door at the door opening until ...

Page 52: ...ight cab door respectively Figure 19 Inner door opener 1 Handle 2 Door opener Using door from the inside Closing cab door 1 Grip the cab door on the handle 1 and pull the cab door towards the inside until the door clicks in The cab door is closed Opening cab door 1 Press the door opener 2 upwards and open the cab door towards the outside The cab door is open 1 2 P r o p e r t y o f A m e r i c a n...

Page 53: ...sliding windows are secured with one snap lock each This clicks in when the window is closed Figure 20 Window handle with snap lock 1 Window handle 2 Snap lock 3 Click in notch 1 Press together the window handle 1 2 Slide the window left or right to open it or close it 3 Let the snap lock 2 click into one of the click in notches 3 1 2 3 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 54: ...ts and seat belts Seats Figure 21 Driver s seat Table 4 Driver s seat Pos Designation Description 1 Locking lever Setting the back rest 2 Lever Setting body weight front 3 Locking lever Forward Backward adjustment 4 Lever Setting body weight back 1 2 3 4 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 55: ...isted 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 TREPEL Airport Equipment GmbH when retrofitting Figure 22 Fastening Releasing seat belt 1 Latch 2 Release button 3 Buckle 4 Seat belt Fastening the seat belt 1 Pull the seat belt over your lap 2 Push the buckle into the latch until it can be clearly heard cli...

Page 56: ...CHALLENGER550 Page 50 1 1 Jan 28 19 E Gas and brake pedals The gas and brake pedals are located in the feet area in front of the driver seat Figure 23 Gas and brake pedals in feet area 1 Gas pedal 2 Brake pedal 2 1 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 57: ...nd warning buzzer 3 Analog displays 4 Rocker switch Toggle switch 5 Preheater starter switch 6 Display 7 Battery charge indicator 8 Rocker switch Diesel pre heating 9 Heater Ventilation 10 Gear selector lever 11 Rocker switch for setting the suspension and cab 12 Parking brake 13 Rocker switch steering program 14 Pedals 14 9 8 1 2 3 4 5 10 6 12 13 11 7 P r o p e r t y o f A m e r i c a n A i r l i...

Page 58: ...e of the steering column Figure 25 Preheater starter switch Table 5 Switch positions INFORMATION As soon as the ignition is switched on the parking lights and the rotating beacons switch on auto matically Switch positions Description 0 Ignition off I Ignition on Drive position engine is preheated if necessary II Start engine II 0 I P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 59: ...rsing camera Displays the rear area of the CHAL LENGER550 Provides a better over view when reversing the CHALLENGER550 Operating hour counter Displays the operating hours perfor med until now by the CHALLEN GER550 Fuel gauge Indicates the current diesel fuel level Battery charging display Displays the charging status of the battery P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 60: ...als INFORMATION The faults are indicated in part simultaneously on the display and or the analog displays Fault signal Fault description Continuous warning signal emitted CHALLENGER550 parked with released parking brake Continuous warning signal emitted and control light lit Possible faults Engine oil pressure too high or too low Coolant temperature too high Parking brake pressure fault Warning si...

Page 61: ...ay Figure 27 Reception screen display Figure 28 Display overview 1 Display area 1 top 2 Display area 2 middle 3 Display area 3 bottom AIRPORT EQUIPMENT MB H G CHALLENGER 0 0 100 100 100 100 50 50 50 50 1 2 3 km h 0 10 20 30 40 1 min 0 600 1200 1800 2400 0 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 62: ... 5 Control light Brake circuit 1 Red Lights up when brake pressure is too low in brake circuit 1 6 Control light Brake circuit 2 Red Lights up when brake pressure is too low in brake circuit 2 7 Wear to brake linings Red Lights up where there is wear to brake linings at front and or rear 8 Control light Parking brake control Red Lights up when parking brake is engaged 9 Stabilizers extended Red Li...

Page 63: ... and for reversing the drive positions 1 and 2 are released 16 Hydraulic oil temperature Red Lights up where the temperature of the hydraulic oil is too high 17 Hydraulic oil level Red Lights up when hydraulic oil level is too low 18 Hydraulic filter cont rol light high pressure filter Red Lights up with the high pressure filter is soiled 19 Hydraulic filter control light refluent filter Red Light...

Page 64: ...he dri ving speed is greater than 10 km h 23 Active front axle suspension at drive level light blue DRIVING RANGE Lights up when suspension is adjus ted to drive level Active front axle suspension not at drive level orange WARNING RANGE Flashes if the front axle suspension deviates from the drive level Active front axle suspension not at drive level red ALARM RANGE Flashes if the front axle suspen...

Page 65: ...ng coupling closed green Rear towing coupling is closed Rear towing coupling undefined status red The status of the rear towing coupling is undefined 26 Turn signal indicator left Green Flashes when left turn signal is active 27 Driving light Green Lights up when the driving light or low beam headlight is on 28 High beam Blue Lights up when the driving light is switched on at the main switch and t...

Page 66: ... Turn signal indicator right Green Flashes when right turn signal is active 30 Gearbox malfunction Red Lights up if there is a gearbox malfun ction 31 Gear temperature Red Lights up if the temperature of the gearbox is too high Pos Picto gram Designation Light color Description P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 67: ...d As soon as the newly selected stee ring program is activated the upper symbol lights up and replaces the old steering program 2 Steering program rear wheel steering Light blue selected steering program Red steering fault 3 Steering program four wheel steering circular drive Light blue selected steering program Red steering fault Orange wheel position not recognized 4 Steering program diagonal dr...

Page 68: ...heel shows the selected operating mode A for automatic or M for manual mode 8 Converter clutch Light blue clutch closed No color clutch open Displays the position of the conver ter clutch closed or open 9 Steering position of axles Black red stee ring pro gram change not possible The arrow shows the steering lock in The top scale shows the front axle the bottom scale the rear axle 10 Driving direc...

Page 69: ...yst The particulate concentration in the particulate filter is too high The SCR catalyst and the particulate filter are regenerated by pressing the Start Stop stationary regeneration switch see Subsection I Operating elements Page 58 The control light goes off once the SCR catalyst and the particulate filter are cleaned If the particulate concentration gets too high the engine of the CHAL LENGER55...

Page 70: ...If a lock is displayed next to the scale the suspension of the front axle is blocked The raising lowering of the front CHASSIS is switched off 8 Steering and safety fault messages Red Displays steering and safety fault messages 9 Warning and fault messages Red Displays warning and fault messa ges 10 Fault messages and instructions Red Displays fault messages and instruc tions Pos Picto gram Design...

Page 71: ...tentional movement Figure 29 Parking brake 1 Parking brake 2 Release Releasing parking brake 1 Pull release 2 upwards and simultaneously push the parking brake lever forward The parking brake has been released Engaging the parking brake 2 Pull the parking brake lever 1 backwards until it can be felt to snap in Parking brake is engaged 1 2 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 72: ...R CHALLENGER550 Page 66 1 1 Jan 28 19 Gear selector lever Select operating mode gear levels and drive positions of the CHALLENGER550 with the gear selector lever Figure 30 Gear selector lever 2 1 F R N 2 1 F R N P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 73: ...ds to be moved into the corresponding position to set the driving direction If the selector lever is in the neutral position the selector lever must be unlocked keep button 2 pressed and select the driving direction V Forward gears Pull selector lever Select the driving direction forwards for the driving gears 1 to 6 selection with and Indicated in display N Neutral Position selector in center Sel...

Page 74: ...wn to leaf through menu 3 Display button Press upwards back ESC Press downwards select return 4 Button Cab up down Raise lower driver s cab by touch 5 Switch Work headlights and rear work lights Switch work headlights and rear work lights on off 6 Switch Switch front axle suspension on and off Press switch upwards Switch off front axle suspension The Front axle suspension off indicator in the disp...

Page 75: ...ights up 8 Button Raise Lower front axle suspension Press the button up Raise front axle suspension Press the button down Lower front axle suspension The Front chassis level indicator in the display shows the current height of the suspension 9 Low beam headlights switch Switch on off low beam headlight 10 Switch Diesel pre heating Switch heating at the fuel filter on off 11 Switch Front wheel stee...

Page 76: ...teering Select rear wheel steering The selection is indicated in the display 13 Switch Diagonal steering Select diagonal steering The selection is indicated in the display 14 Switch Four wheel steering Select four wheel steering The selection is indicated in the display Pos Pictogram Designation Description P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 77: ...d for this and be pressed for about two seconds Press the switch again to end the regeneration INFORMATION The particulate filter and the SCR catalyst can be regenerated only while the CHALLENGER550 is running at idle with the parking brake engaged gear selector lever in Neutral INFORMATION If the Regeneration necessary control light flashes carry out the stationary regeneration as soon as possibl...

Page 78: ...p if there is a motor malfun ction The button must be held pressed down in order to activate the Override function Engine damage Overriding the engine stop for longer periods of time leads to engine damage Engine stop may be overridden only by authorized service personnel Only override the engine stop to drive the CHALLENGER550 out of the work area OVERRIDE P r o p e r t y o f A m e r i c a n A i ...

Page 79: ...w 25 the tank symbol lights up and a warning message is shown in the display Additionally a warning sound is emitted If the fuel supply drops below 15 the engine switches off The bypass button low fuel level can bypass the engine stop and move the CHALLENGER550 towards refueling Motor damage A longer bypass of the motor stop leads to motor damage Only bypass the engine stop to move the CHALLENGER5...

Page 80: ... 1 Jan 28 19 Heater Ventilation Figure 34 Operating elements heating ventilation Table 13 Heater Ventilation Pos Designation Description 1 Fan Blower Setting the fan intensity 2 Temperature Setting the interior temperature warm cold 1 2 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 81: ...tion Notes on the optimal setting To defrost the windows keep the main outlet nozzles closed To heat the cabin keep the drum type outlet nozzles closed If the air conditioner is on direct the air flow of the main outlet nozzles upwards Pos Designation Description 1 Main vents instrument panel Ventilation of driver seat and passenger seats 2 Rolling vents Ventilation or front windscreen de icing 3 ...

Page 82: ...t left 0 turn signal off A turn signal right touch B turn signal lock in C turn signal left touch D turn signal left lock in Front windscreen wiper 0 windscreen wiper off A windscreen wiper interval B windscreen wiper level 1 C windscreen wiper level 2 Front windscreen was her Press to activate the washing system Low beam High beam 0 low beam E headlight flasher touch F high beam lock in Horn A ho...

Page 83: ...justment Table 16 Steering wheel adjustment Figure Designation Description 1 Adjustment lever Release the steering wheel adjustment by pressing the lever V Locking steering wheel adjustment After adjusting the steering wheel the steering wheel adjustment needs to be locked N Tilt adjustment Unlocked tilt adjustment setting by hand H Height adjustment Unlocked height adjustment setting by hand 1 H ...

Page 84: ... the stabilizers Pos Designation Description 1 Key switch emergency operation Switching on the electro hydraulic emergency operation 21 1 only when engine is running Retract stabilizers Select retract stabilizers touch Indicator in display goes out as soon as the stabilizers have been completely retracted 31 Extend stabilizers Select extend stabilizers touch Indicator in display lights up as soon ...

Page 85: ...d parking position 3 Switch off the engine 4 Switch on the ignition start switch to I 5 Press the brake pedal about 15 to 20 times until the control lights brake circuit 1 and brake circuit 2 light up 6 Press the parking brake about 10 to 15 times until the control light parking brake control lights continuously 7 Turn the start switch to 0 8 Make sure that the engine is standing still 9 Set the m...

Page 86: ...19 K Auxiliary power supply The auxiliary power supply X serves to start the CHALLENGER550 if the battery is discharged Only authorized service personnel may start the CHALLENGER550 with the auxiliary power supply Figure 39 Auxiliary power supply P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 87: ...l 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 engine 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 a...

Page 88: ...w 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 Loo...

Page 89: ...eutral before exiting the driver s cab Do not leave the CHALLENGER550 unsupervised when the engine is running Incorrectly performed inspection work Failure to follow the given sequence may result in damage to the CHALLENGER550 First perform all the checks for which the engine has to be off Engine or gearbox damage If the oil level is too high or too low this can result in damage to the engine or g...

Page 90: ...rrectly performed inspection work Failure to follow the given sequence may result in damage to the CHALLENGER550 First perform all the checks for which the engine has to be off Vehicle general Damage to vehicle leaks body cab towing couplings Engine coolant engine oil battery Lighting brake lights turn signals Fuel level indicator All safety equipment in functioning condition Warning instruction s...

Page 91: ...vel 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 The operator must provide appropriate sa...

Page 92: ...eacons for proper functioning and obvious damage Loss of fluid 1 Look under the CHALLENGER550 and check if pools of oil or water are visible If this is the case check more thoroughly and find the cause Possible causes are Oil loss at engine gearbox axle transmission Loss of coolant Battery acid Fuel 2 In the case of fluid loss consult with maintenance personnel Designation Description OFF Voltage ...

Page 93: ...this can result in damage to the engine Make sure that the oil level is never above the MAX marking and never below the MIN marking Use only authorized types of oil 2 Pull the oil dip stick 3 Wipe the oil dip stick with a clean lint free cloth 4 Reinsert the oil dip stick completely 5 Pull the oil dip stick out again 6 Hold the oil dip stick vertically downwards 7 Check if the oil level is between...

Page 94: ... screw cap 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 Open the cooling system 15 to 20 minutes after switching off the engine Unscrew the cap slowly and allow the pressure to escape completely before opening Wear suitable protective gloves clothes and goggles when handling c...

Page 95: ...r pour coolant into drinking containers Figure 4 Coolant fill level 3 Check if the coolant fill level is between the MIN and MAX marking MAX marking end of the filler nozzle pipe MIN marking coolant fill level approx 30 mm from compensating reservoir base 4 If necessary refill with coolant INFORMATION Only use approved coolants that contain anti frost and anti corrosion agents If coolant needs to ...

Page 96: ...wipers Figure 5 Windscreen wiper water container INFORMATION If there is a possibility that the temperature might drop to freezing temperatures add anti freeze agent to the washer water to keep the water from freezing 1 Open the container for the washer water open screw cap 2 Check if there is enough washer water in the container P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 97: ... 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 specified torque after the first laden journey at the ...

Page 98: ...ling Always shift into neutral before exiting the driver s cab 1 Remove the grating on position 1 2 Check the gear oil level on the dip stick 2 Figure 6 Gearbox oil level 1 Grating 2 Oil dip stick Unintended rolling of the CHALLENGER550 The CHALLENGER550 can roll when the engine is running and run over persons or crush them Running over or crushing persons can result in death or serious injuries S...

Page 99: ...and never below the MIN marking Use only authorized types of oil 1 Run the engine at idling speed 2 Pull the dip stick up 3 Wipe the dip stick with a clean lint free cloth 4 Reinsert the dip stick completely 5 Pull the dip stick out again 6 Hold the dip stick vertically downwards 7 Check if the oil level is between the MIN and MAX marking INFORMATION Only qualified technicians may top up the gearb...

Page 100: ...nalog fuel gauge 1 Fuel gauge 3 Check the fuel supply on the instrument panel display The fuel supply indicator is not lit the fuel supply is OK The fuel supply indicator is red the fuel supply is 25 Refill fuel Figure 8 Checking fuel supply 1 Display 2 Fuel supply indicator 4 Fill the fuel tank with fuel if required 5 Ensure that enough fuel supply is always available 1 1 0 100 50 1 1 1 2 P r o p...

Page 101: ... the DEF SCR indicator 1 DEF SCR indicator 2 AdBlue DEF tank fill level indicator 2 Check the DEF SCR indicator on the instrument panel display 3 If the DEF SCR indicator lights up yellow and the AdBlue DEF tank fill level indicator shows less than 25 fill AdBlue DEF into the AdBlue DEF tank INFORMATION When refueling the CHALLENGER550 observe the listed safety information and step by step inst ru...

Page 102: ...rument panel display The hydraulic oil fill level indicator is not lit the fill level is OK The hydraulic oil fill level indicator is red check fill level in the viewing window of hydraulic oil tank Figure 10 Checking hydraulic oil level 1 Display 2 Hydraulic oil fill level indicator 0 0 0 0 50 50 50 50 1 1 1 2 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 103: ...ON The hydraulic oil tank viewing window can be accessed from the maintenance platform To do so the fifth grating viewed from the rear has to be removed 1 Remove the grating on position 1 2 Check the oil level in the oil viewing window 2 The oil level must be located in the top part of the oil viewing window Refilling hydraulic oil INFORMATION Use only authorized types of hydraulic oil 2 2 2 1 P r...

Page 104: ...1 Screw cap 2 Oil filler nozzle 1 Open the screw cap 1 on the oil filler nozzle 2 2 Refill the hydraulic oil at the oil filler nozzle of the hydraulic tank 3 Check the oil level in the oil viewing window The oil level must be located in the top part of the oil viewing window 2 1 2 2 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 105: ...n and collide with or run over persons Collisions with or the running over of persons can cause serious injury or even death Check the set driving direction before driving Make sure that no people or objects are in the danger area or on the traffic routes Make sure that there is a good line of sight to all sides Danger of crushing During steering persons can be crushed between wheel and wheel case...

Page 106: ...moke 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 c...

Page 107: ...t steering wheel adjustment If the steering wheel is not set to the correct position this may impair the person operating the CHALLENGER550 and result in serious accidents Persons can be seriously injured or even killed because of accidents Check to ensure the steering wheel is in the correct position before starting the CHALLEN GER550 Adjust the position of the steering wheel if necessary Adjustm...

Page 108: ...th slow and continuous movement to prevent damage to the nose wheel and to prevent the shear pin of the towbar from breaking Select the correct driving gear Driving behavior not adapted Driving behavior that is not adapted to the respective situation can cause damage to the CHAL LENGER550 and the nose landing gear of the aircraft When driving with an aircraft attached adapt the driving speed to th...

Page 109: ... just subjected the CHALLENGER550 to high loads Run the engine at idle speed for a few more minutes with the transmission in neutral Unsuitable or dirty fuel Unsuitable and dirty fuel can damage the injection system and the fuel pump Only refuel using commercially available diesel fuel with a sulfur content of less than 0 5 Pay attention to cleanliness when refueling If refueling from canisters or...

Page 110: ...correct position before starting the CHALLENGER550 Adjust the seating position of the driver s seat if necessary Adjustments while driving Adjusting the driver s seat while driving may cause the driver to lose control and result in serious accidents Persons can be seriously injured or even killed because of accidents Never adjust the driver s seat while driving Driver s seat not locked in place If...

Page 111: ...Jan 28 19 Figure 13 Driver s seat Table 2 Driver s seat Pos Designation Description 1 Locking lever Setting the back rest 2 Lever Setting body weight front 3 Locking lever Forward Backward adjustment 4 Lever Setting body weight back 1 2 3 4 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 112: ...e front part of the seat has now been set Resetting the weight 1 Press lever 4 down below the lowest notch until it stops The setting is reset to 50 kg 110 lb 2 Pull lever 2 out until it stops The setting is reset to 50 kg 110 lb Forward backward adjustment 1 Press lever 3 to release forward backward adjustment 2 Move the seat to the required position 3 Allow lever 3 to snap into the required posi...

Page 113: ...f accidents Check to ensure the steering wheel is in the correct position before starting the CHALLEN GER550 Adjust the position of the steering wheel if necessary Adjustments while driving Adjusting the steering wheel while driving may cause the driver to lose control and result in serious accidents Persons can be seriously injured or even killed because of accidents Never adjust the steering whe...

Page 114: ...t the outside mirrors while driving The outside mirrors are adjusted manually 1 Adjust the outside mirrors so that there is a clear view of the CHALLENGER550 s rearward areas Figure Designation Description 1 Adjustment lever Release the steering wheel adjustment by pressing the lever V Locking Steering wheel adjustment After adjusting the steering wheel the steering wheel adjustment needs to be lo...

Page 115: ...isted 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 TREPEL Airport Equipment GmbH when retrofitting Figure 15 Fastening Releasing seat belt 1 Latch 2 Release button 3 Buckle 4 Seat belt Fastening the seat belt 1 Pull the seat belt over your lap 2 Push the buckle into the latch until it can be clearly heard cli...

Page 116: ...arting the engine Engine is not running yet Main battery switch is in position ON The parking brake is engaged The gear selector is set to N neutral No objects are in the danger area No persons are in the danger area No loose objects are in the footwell of the driver s cab Main battery switch Figure 16 Main battery switch 1 Main battery switch is in position ON Main power supply is on OFF ON P r o...

Page 117: ...o a standstill Figure 17 Preheater starter switch 1 Turn preheater starter switch to position I Ignition is on Parking lights and rotating beacons switch on automatically Display boots up If required the engine is preheated automatically and the Preheat control light goes out after wards INFORMATION After switching on the ignition the steering system is tested The display shows a yellow bar with t...

Page 118: ... bar 2 lights up The diesel in the fuel filter is pre heated INFORMATION When the light bar 2 goes off the diesel in the fuel filter has been pre heated The engine can be started Starting the engine 1 Turn preheater starter switch to position II Engine starts 2 Release preheater starter switch Indicators on the display are active INFORMATION After the engine starts the second test phase test steer...

Page 119: ... be equated with the steering wheel and the bar displays for the front and rear axles The warning disappears as soon as the axes are equali zed INFORMATION At low outside temperatures allow the engine to warm up a few minutes while idling If the diesel pre heating has been switched on before starting the engine switch it off now 3 Press the Diesel pre heating rocker switch to switch off the diesel...

Page 120: ...ditions Danger of crushing When the vehicle is in motion open cab doors can close uncontrolled and crush limbs of persons Crushing can lead to serious injuries Make sure that all cab doors have been closed before starting to drive the CHALLEN GER550 Requirements The following points must be fulfilled before driving the CHALLENGER550 Engine is running No objects are in the danger area No persons ar...

Page 121: ...ALLENGER550 can move unintentionally in the wrong direction and collide with or run over persons Collisions with or the running over of persons can cause serious injury or even death Check the set driving direction before driving Make sure that no people or objects are in the danger area or on the traffic routes Make sure that there is a good line of sight to all sides With the gear selector lever...

Page 122: ...ar selector lever 3 Press and hold down red control 2 in order to unlock selector lever 1 in the Neutral N position 4 Set gear selector lever 1 to the desired driving direction V Forward driving direction Pull back the selector lever R Reverse driving direction Press selector lever forward The driving direction has been set Shifts between drive positions are performed automatically 5 Press toggle ...

Page 123: ...rive positions are made based on the speed and load on the engine Selecting the drive position in manual mode Driving direction Drive position M Manual mode Requirement Forward or reverse driving direc tion automatic mode has been selected Select drive position using toggle switch Higher drive position press control Lower drive position press control Manual mode drive position have been set V 1 6 ...

Page 124: ...d INFORMATION When the driving direction is set to reverse the hazard lights are switched on automatically Selecting steering program Danger of crushing During steering persons can be crushed between wheel and wheel case The crush injuries can be life threatening or even fatal Steer only if no persons are in the vicinity of the wheels Visual contact has to be maintained between the operator and wi...

Page 125: ...ogram Designation Description 1 Switch Front wheel steering Select front wheel steering The selection is indicated in the display 2 Switch Rear wheel steering Select rear wheel steering The selection is indicated in the display 3 Switch Diagonal steering Select diagonal steering The selection is indicated in the display 4 Switch Four wheel steering Select four wheel steering The selection is indic...

Page 126: ...nsion to drive level Figure 22 Front axle suspension The front axle suspension must always be set to drive level before traveling Proceed as follows for that 1 Press the Switch front axle suspension on off 1 switch downwards The front axle suspension is switched on the Front axle suspension on indicator in the dis play lights up 2 Press the Front axle suspension button upwards or downwards until t...

Page 127: ...ey the traffic rules of the airport ramp area Driving direction incorrectly set If the driving direction is not set correctly the CHALLENGER550 can move unintentionally in the wrong direction and collide with or run over persons Collisions with or the running over of persons can cause serious injury or even death Check the set driving direction before driving Make sure that no people or objects ar...

Page 128: ...arefully Only use towbars that have been approved for the aircraft Always keep radio contact with the aircraft s pilot 1 Release the brake pedal 2 Press the gas pedal slowly The CHALLENGER550 drives in the selected driving direction with the selected driving gear Drive the CHALLENGER550 in the desired direction using the steering wheel Braking the CHALLENGER550 Jerky brake movements Jerky brake mo...

Page 129: ...mes to a full stop 3 Hold brake pedal down 4 Set the gear selector of the CHALLENGER550 to N Neutral 5 Pull the parking brake lever 1 backwards until it can be felt to snap in Parking brake is engaged 6 Release the brake pedal Towing recovering the CHALLENGER550 Refer to the documentation entitled Emergency Operating Measures Chapter 2 for towing and emergency operation 1 P r o p e r t y o f A m e...

Page 130: ...no longer be achieved Fig 24 Regeneration necessary control light Starting the stationary regeneration Fire hazard Very high exhaust temperatures 970 C are generated during stationary regeneration and the exhaust system becomes very hot approx 700 C Flammable materials can easily ignite and persons may be seriously injured Park the CHALLENGER550 on a clean concrete or gravel surface Do not park on...

Page 131: ... Park the CHALLENGER550 on an even clean and solid surface 2 Apply the parking brake 3 Shift the transmission to neutral 4 Run the engine at idle speed 5 Allow the engine to run warm until a coolant temperature of at least 75 C has been reached 6 Place chocks under the rear wheels Figure 25 Starting the stationary regeneration 0 0 100 100 50 50 km h 0 10 20 30 40 0 0 2 1 3 P r o p e r t y o f A m ...

Page 132: ...ter necessary warning light lights up the particulate filter needs to be replaced A stationary regeneration is not possible Pos Pictogram Designation Description 1 Warning light Replace ment of particulate filter neces sary Lights up if a replacement of the particu late filter is necessary Goes out when the particulate filter has been replaced 2 Indicator Regeneration necessary Flashes when Crysta...

Page 133: ... a thinning of the engine oil Under normal operational condi tions the number of stationary regenerations will not however lead to a critical thinning of the engine oil The motor controller monitors the time of the stationary regeneration and issues a fault message if a critical threshold is reached P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 134: ...is clean and level Engine is running Parking brake is engaged No objects are in the danger area No persons are in the danger area Turning off the engine 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 Engine damage ...

Page 135: ...rating Instructions PUSHBACK TRACTOR CHALLENGER550 Jan 28 19 Figure 26 Preheater starter switch 1 Turn preheater starter switch to position 0 Engine switches off 2 Close cabin doors II 0 I P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 136: ...ing position 3 Switch off the engine 4 Switch on the ignition start switch to I 5 Press the brake pedal about 15 to 20 times until the control lights brake circuit 1 and brake circuit 2 light up 6 Press the parking brake about 10 to 15 times until the control light parking brake control lights continuously 7 Turn the start switch to 0 8 Make sure that the engine is standing still 9 Turn the main b...

Page 137: ...0 on the airport runway area Requirements The following points must be fulfilled before refueling the CHALLENGER550 Parking brake is engaged Turn preheater starter switch to position 0 Main battery switch is in position OFF Fire extinguishers are ready The measures prescribed in the airport regulations for refueling have been taken Figure 28 Fuel tank 1 Gas pump nozzle 2 1 P r o p e r t y o f A m ...

Page 138: ...pors could cause serious injury or even death Do not inhale gases and vapors Leaking diesel Diesel is easily inflammable and explosive Explosions or flames can lead to serious injuries or even death Smoking is strictly prohibited 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 ...

Page 139: ...mmercially available diesel fuel with a sulfur content of less than 15 ppm Pay attention to cleanliness when refueling If refueling from canisters or barrels filter the fuel in advance Never mix fuel with water Fuel tank empty The injection system and starter could get damaged if the engine is started when the fuel tank is empty After refueling with clean fuel the fuel system of the CHALLENGER550 ...

Page 140: ...age 54 1 2 Jan 28 19 6 Remove the fuel nozzle 7 Fold the tank cap downwards 8 Fold the lock upwards and turn it 90 9 Make sure that the tank cap has been closed properly The fuel tank is closed The CHALLENGER550 has been refueled P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 141: ...t refill the tank with AdBlue DEF that has been pumped out of the tank e g during repair work The purity of AdBlue DEF is no longer guaranteed Do not mix AdBlue DEF with tap water under any circumstances Figure 30 AdBlue DEF tank Risk of injury At high outside temperatures ammoniac fumes may escape when the fuel tank cap is opened Ammoniac fumes have a pungent odor and irritate the skin mucous mem...

Page 142: ...r if you swallo wed any AdBlue DEF Consult a doctor right away Consult a doctor right away if allergic reactions occur Keep AdBlue DEF away from children Only fill up the AdBlue DEF tank in well ventilated areas Corrosion AdBlue DEF is extremely corrosive to many materials Do not spill AdBlue DEF when refilling the AdBlue DEF tank Always use a filling nozzle when refueling with a canister Absorb a...

Page 143: ...ly locked into the coupling of the CHALLENGER550 the towbar can become loose The loose swinging end of the towbar can hit persons The loose swinging end of the towbar can kill or seriously injure persons Before starting to drive make sure that the towbar is correctly secured to the coupling with the bolt Rolling CHALLENGER550 The CHALLENGER550 can run over persons when starting to drive Running ov...

Page 144: ...e cab of the CHALLENGER550 is completely lowe red In Maintenance towing and Repositioning modes do not raise cab to a height where it could come to a collision with the hull of the aircraft when reversing Jerky driving and sudden steering movements The aircraft nose gear can be damaged or the shear pin on the towbar broken because of jerky driving and sudden steering movements Drive continuously a...

Page 145: ... modes from the driver s seat in the cab The towbar is connected with the nose gear of the aircraft beforehand The CHALLENGER550 is operated in the following driving modes Empty driving Figure 31 Empty driving CHALLENGER550 INFORMATION For empty driving see Subsection 2 Operating the CHALLENGER550 page 19 The maximum speed is 29 km h 18 mph P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 146: ...be dama ged Only use towbars that have been authorized for this type of aircraft Make sure that the coupling of the towbar is parallel to the ground s surface and level with the towing coupling of the CHALLENGER550 Do not exceed maximum towed load 1 Drive the CHALLENGER550 in a straight line to the towbar and the attached aircraft until a distance of approx 10 m 33 feet has been reached P r o p e ...

Page 147: ...ed with the wing walker Raised driver s cab The raised driver s cab can touch and damage the hull of the aircraft during coupling In Push back mode only couple when the cab of the CHALLENGER550 is completely lowe red 2 Pull the bolts of the towing coupling at the front of the CHALLENGER550 Crush hazard When coupling the CHALLENGER550 hands can be crushed in the coupling device of the towbar Crushi...

Page 148: ...ER550 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 CHALLENGER550 and towbar Ensure that visual and radio contact is always maintained with the wing walker Jerky driving and sudden steering movements The aircraft nose gear can be damaged or the shear pin on the towbar broken beca...

Page 149: ...that the coupling of the towbar is parallel to the ground s surface and level with the towing coupling of the CHALLENGER550 Do not exceed maximum towed load 1 Drive the CHALLENGER550 in a straight line to the towbar and the attached aircraft back wards until a distance of approx 10 m 33 feet has been reached INFORMATION For a better view you can raise the cab of the CHALLENGER550 When a reverse ge...

Page 150: ...nd the cab will now automatically lower 50 mm 2 inches Carefully drive the CHALLENGER550 forward away from the aircraft The message DANGER OF COLLISION disappears Lower the cab completely CHALLENGER550 and aircraft remain undamaged 2 Carefully drive the CHALLENGER550 backwards until it is 10 m 33 feet in front of the towbar 3 Pull the bolts of the towing coupling at the rear of the CHALLENGER550 C...

Page 151: ...ies Ensure that no persons are located between CHALLENGER550 and towbar Ensure that visual and radio contact is always maintained with the wing walker Jerky movements when starting Sudden steering movements The aircraft nose gear can be damaged or the shear pin on the towbar broken because of jerky driving and sudden steering movements Drive continuously and slowly Select the correct drive positio...

Page 152: ...This page intentionally left blank General Information and Operating Instructions PUSHBACK TRACTOR CHALLENGER550 Page 66 Blank Jan 28 19 1 2 P r o p e r t y o f A m e r i c a n A i r l i n e s ...

Page 153: ...dard 50 000 kg 110 230 lb optional 55 000 kg 121 254 lb Tractive power 369 kN 82 959 lbf Turning radius With all wheel steering 6 800 mm 267 inches With front wheel steering 10 700 mm 421 inches Driving speed Maximum 29 km h 18 mph Braking ratio See factory settings record Stopping distance See factory settings record Incline capability 6 8 2 batteries Voltage 12 V Capacity 150 Ah Control voltage ...

Page 154: ...brake Knott TM 485 Parking brake Knott TM FSG90 14145 Electrical control system master and slave IFM CR0032 Steering selection all wheel stee ring front axle steering Front Directly via Orbitrol Rear axle steering diagonal steering Back Electronically controlled Tires Goodyear 16 00R25 EV 4R 206A5 TL Maximum relative air humidity 95 Reference value Value Jan 28 19 P r o p e r t y o f A m e r i c a...

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