Benefits of Preventative GSE Maintenance - PJi GSE Service

Key Takeaways

1. Preventative GSE maintenance involves proactively identifying and addressing potential issues at scheduled intervals – before they develop into equipment failures, safety hazards, or costly unplanned downtime.
2. The six core benefits of preventative maintenance are minimized downtime, extended equipment lifespan, improved worker safety, reduced energy consumption, increased productivity, and significant long-term cost savings.
3. Effective preventative maintenance programs incorporate seven essential elements: testing, servicing, calibration, inspection, adjustment, alignment, and installation.
4. Ground support equipment – including aircraft jacks, hydraulic power units, ground power units, and aircraft tugs – each has its own set of recommended maintenance tasks and service intervals that should be followed consistently.
5. In virtually every case, the cost of routine preventative maintenance is significantly lower than the cost of repairing or replacing equipment that has failed unexpectedly – making it one of the smartest investments a ground operation can make.
6. PJi's GSE Service Center is staffed by factory-trained, certified technicians who can test, repair, and overhaul a wide range of ground support equipment to keep your fleet running at peak performance.

According to a recent survey, 83% of CFOs report a large portion of their equipment spending will go into repair and replacement efforts. While this is an alarming statistic, it probably comes as no surprise to the aviation community, particularly ground support crews.

Since aircraft ground support equipment (GSE) is consistently subjected to extreme conditions, keeping equipment running smoothly and efficiently for as long as possible is imperative. Preventative GSE maintenance plays a critical role in accomplishing this objective.

What Is Preventative GSE Maintenance?

Preventative GSE maintenance involves proactively identifying and addressing potential damage, repairs, or expenses to ground support equipment to ensure its continuous operation and reduce the risk of unexpected equipment failure. This type of maintenance is typically performed at predetermined intervals but might also be based on the utilization rate of a specific piece of equipment.

Effective preventative maintenance incorporates seven essential elements: testing, servicing, calibration, inspection, adjustment, alignment, and installation.

Benefits of Preventative GSE Maintenance

Preventative GSE maintenance yields substantial benefits, including reduced unplanned downtime, longer equipment life, improved workplace safety, reduced energy consumption, increased productivity, and significant cost savings.

1. Minimizes Unplanned Downtime
   Well-maintained equipment is less likely to break down – and having fewer breakdowns means less downtime due to unscheduled maintenance. By performing scheduled preventative maintenance, you can determine precisely when a particular piece of equipment will be out of service so you can plan accordingly.
2. Prolongs the Lifespan of Equipment
   Carrying out routine preventative maintenance keeps your GSE operating at optimal performance levels, helping extend the equipment's lifespan. While preventative maintenance doesn’t guarantee that major repairs will never be necessary, it does help you pinpoint and resolve issues quickly before they develop into more serious problems.
3. Improves Safety for Workers
   Ground support equipment with damaged or aging components can lead to sudden, catastrophic failure, bringing your operations to a standstill and posing a hazard to nearby workers. Properly maintained equipment helps reduce the likelihood of accidents and malfunctions, promoting a safer overall work environment for employees.
4. Reduces Energy Consumption
   Poorly maintained equipment typically consumes more energy than equipment that's routinely inspected and deemed to be in good working order. Keeping ground support equipment operating at peak efficiency helps reduce energy consumption, resulting in lower utility costs along with a host of environmental benefits.
5. Increases Productivity
   Routinely inspecting GSE while it’s fully operational gives you a better sense of what might need to be replaced or repaired before it becomes an issue. Conducting preventative maintenance ensures that equipment always performs as it should, maximizing productivity while minimizing disruptions to your operations.
6. Significantly Cuts Costs
   In most fields, but especially in the aviation industry, any amount of preventative maintenance is always going to be less expensive than repairing equipment that has completely stopped working. By regularly performing preventative maintenance on your GSE, you can significantly reduce the costs of unexpected repairs, unscheduled downtime, and other operational expenses.

What Can PJi Do for You?

At our GSE Service Center, PJi’s factory-trained and certified technicians can test, repair, and overhaul a wide range of ground support equipment, including aircraft jacks, hydraulic power units (HPUs), ground power units (GPUs), and gas, diesel, or battery-powered aircraft tugs.

Here’s a sampling of what PJi can do to help stretch the lifespan of your equipment.

Aircraft Jacks

• Perform a load test – pushing the jack to its maximum capabilities – to identify and potential safety issues. Load testing should be completed annually.
• Check the frame for corrosion, bending, cracking, and other signs of wear.
• Check the hydraulic system for leaks and contamination with dirt or water.
• Extend rams and visually inspect for corrosion, foreign matter, excessive wear, and leaks around the ram seals.
• Check the paint condition and touch up any exposed areas.

Hydraulic Power Units (HPUs)

• Perform a flow check at maximum pressure to ensure the desired pressure output is achieved.
• Change the air filter, pressure filter, and all other filters annually.
• Check hoses for dry rot, cracks, leaks, blisters, and dirt buildup.
• Calibrate all gauges/instrumentation annually.
• Change fluids as needed, ensuring they’re free from contaminants.
• Empty, inspect, clean, and refill the reservoir once a year.
• Check for possible leaks (hydraulic fluid, oil, etc.) in the pipe fittings.
• Examine electrical components, identifying any parts that are wearing out and need replacement.
• Inspect power cords for nicks, cuts, abrasions, and fluid damage – replace cords as needed.

Ground Power Units (GPUs)

• Perform a load bank test to verify proper operation of inputs, outputs, and other key parameters. This type of testing simulates the connection between an aircraft and the ground power unit to complete a specific task, such as an aircraft engine start. Load testing should be performed annually and after any GPU repairs.
• Change oil and fuel filters – and the oil itself – after every 300 hours of operation.
• Check the air filter and replace it if it’s very dirty.
• Calibrate the radiator cap to the correct system pressure.
• Ensure that the cap’s rubber seal is free of dents or cracks and that the radiator fins are clean and straight.
• Ensure the coolant level is at 100% with a 50/50 mixture of antifreeze and water.
• Check cooling hoses for possible leaks and hose clamps for tightness.
• Perform a pressure test, if needed, to address any coolant leaks identified.
• Ensure that the battery has the proper electrolyte levels, that terminals and cables are clean and tight, and clamps are suitably tightened.
• Check the engine for oil leaks.
• Carefully inspect all wiring, connections, and sensors for tightness and bare spots.
• Clean, inspect, and repack wheel bearings every two years or 2,000 hours of operation – whichever comes first.
• Inspect tires for proper inflation and signs of wear. If the front tires are wearing unevenly, check the alignment and toe settings.
• Check the brakes for safe operation and correct adjustment.
• Ensure the towbar doesn’t have excessive side play – if it does, repairs or adjustments will be made. Verify the latch locks the towbar firmly in place.
• Check cable plugs for scrapes or abrasions, and check the terminals inside the unit for wear and roundness.
• Check input/output cables for signs of wear, dry rot, cracking, or slicing.
• Ensure that the generator is correctly calibrated, clean, and free of debris.
• Verify that gauges and current limiters are working correctly.
• Check accessory belts for tightness and cracking.
• Inspect all safety features of the unit, including emergency shutoffs, door sensors, and safety switches.

Batteries

• Determine if the battery has gone (or is going) bad.
• Check for signs of corrosion, cracks, leaks, or swelling.
• Maintain proper water and electrolyte levels.
• Ensure that all terminals, screws, clamps, and cables are clean, tight, and free of corrosion.

Gas/Diesel Engines

• Clean grime, grease, dirt, oil, and soot from engine components.
• Check air, fuel, and oil filters and replace them if necessary.
• Change the oil regularly.
• Maintain proper fluid levels, including the coolant/antifreeze in the radiator as well as oil, brake fluid, and power steering fluid.
• Inspect belts and hoses for cracks, tears, fraying, or loose connections.
• Check for signs of oil, coolant, or other fluid leaks.

Aircraft Tugs

• For tugs with towbars, inspect the towbar for missing, loose, or broken bolts and shear pins.
• Inspect the towbar for bends, dents, and scratches and ensure that the lift cylinder is free of leaks or cracks.
• Check engine oil, transmission, brake, and power steering fluids and coolant levels.
• Check the cradle for potential loose connections between the tug and the aircraft.
• Examine straps and winches for signs of wear.
• Inspect the steering wheel and related components for tightness.
• Check cylinders, hoses, and tanks for evidence of fluid leaks.
• Inspect brakes for cracks and other signs of imminent failure.
• Check tires for dry rot, cuts, breaks, proper inflation, and signs of abnormal wear.
• Ensure that all safety features – including headlights, warning lights, flashers, beacons, horns, and backup sounds – are functioning properly.
• For tugs with cabs, verify that windshield wipers, heaters, air conditioners, and fans are operating as they should.