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GSE Maintenance Manual - Operationsmanuals.atsconnect.com/manual/files/GSE MX Manual.pdf · 12/2011...

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GSE Maintenance Manual Originally Published May 2010 OPERATIONS
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Page 1: GSE Maintenance Manual - Operationsmanuals.atsconnect.com/manual/files/GSE MX Manual.pdf · 12/2011 1. GSE Appearance The appearance of the GSE equipment is very important to the

GSE Maintenance Manual 

OP

ER

ATIO

NS

Originally Published May 2010

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REVISION: DATE:

Rev 4 12/2011

GSE MAINTENANCE MANUAL (GMM) Master Table of Contents

0. Introduction

0.1 Master Table of Contents

0.2 Record of Revision

0.3 Revision Policy

0.3.1 Distribution of Revisions

0.3.2 Identification of Revision

0.3.3 Proposed Revisions

0.3.4 Recording Revisions

0.4 Introduction

0.4.1 Authority

0.4.2 Responsibility

0.4.3 Manual Distribution

1. GSE Appearance

1.1 Paint

1.2 Logos

1.3 Equipment Numbering

1.4 Decals

1.5 Placement of Logos, Equipment Numbering and Decals

2. Equipment Inventory

2.1 Equipment Inventory

3. Maintenance Forms

3.1 History Files

3.2 Work Orders

3.3 Daily Vital Fluid and Safety Inspection

3.4 Weekly Vital Fluid and Safety Inspection

3.5 Monthly Non-Motorized Equipment Check

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

3.6 Equipment Discrepancy Sheet

4. Preventative Maintenance

4.1 Preventative Maintenance Inspections

4.2 Preventative Maintenance Forms

5. Tools

5.1 Tool Inventories

6. Shop and Environmental Safety

6.1 Lock-out / Tag-out – Shop Equipment

6.2 Lock-out / Tag-out – GSE

6.3 Waste Oil Storage and Disposal

6.4 Paint and Chemical Storage

6.5 Material Safety Data Sheets

6.6 Fire Extinguishers

6.7 First Aid Kit

6.8 Eyewash

6.9 Tire Cage

6.10 Specialized Equipment Safety

6.10.1 Bench Grinder

6.10.2 Oxy/Acetylene Torch

6.10.3 Arc Welder

6.10.4 Air Compressors and Hoses

6.10.5 Electric tools, extension cords and shop wiring

6.10.6 Parts washer

6.10.7 Drill Press

7. GSE Parts

7.1 Maintenance Budget

7.2 Parts Purchasing

7.3 Parts Storage, Stock Parts Inventory and Stock Parts Sheet

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

7.4 Three Bid / Three Bid Waiver Forms

7.5 Capital Request

7.6 Transferring or Purchasing Equipment

8. Third Party Maintenance

8.1 Agreement

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

0.2 Record of Revision

Revision Number Date of Revision Revision Item Initials Original N/A MW

Revision 1 05/2010 Manual Restructure MW Revision 2 10/2010 0.4, 1.2, 1.4, 1.5, 8.1 MW Revision 3 03/2011 7.6 MW Revision 4 12/2011 1.1, 1.2, 1.4, 1.5 MW

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

0.3 Revision Policy and Procedure ATS requires that all of its manuals be maintained current, reflecting applicable governmental regulations and Company policies. To ensure that manuals are current, the revision procedures outlined herein have been established.

0.3.1 Distribution of Revisions

• The Manual Custodian is responsible for ensuring that the electronic version of the manual is revised. Each manual holder will be contacted via e-mail ASAP when a revision is made, but not later than ten (10) days after issuance.

0.3.2 Identification of Revision

• One each revised page the new or changed information will be identified by a vertical

line in the right margin. This line will appear opposite the changed material. 0.3.3 Proposed Revisions

• The procedures that follow are to be used for the control of the contents of ATS

manuals. 1. The Department Head is responsible for initiating changes for manuals for which they are responsible. This is accomplished by completing a Manual Change Order (form #xxx), which is forwarded, along with the contents of the proposed revision, to the Manual Custodian. 2. Proposed revisions will be issued by the Manual Custodian on yellow paper, marked DRAFT and circulated to affected parties, in accordance with the distribution list on the Manual Change Order. Reviewing parties will be given ten (10) days to comment. 3. Following comments from affected parties, the proposed revision will be forwarded to the ATS Executive Committee for final approval. 4. When the review and approval process is complete, the Manual Custodian will make the approved changes to the affected/new pages. The Manual Custodian is also responsible for ensuring that changes are made to electronic versions of the affected manual.

0.3.4 Recording Revisions

• The Manual Custodian will record the revisions on the Record of Revisions page.

Example: Revision #1 – MAY 2010, Item revised was Section 2.3.1, revised by MW.

Revi ber sion Num Date of Revision Revision Item In itialsOriginal N/A MW

1. Revision 1 05/2010 Section 2.3.1 MW

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

0.4 Introduction This GSE Maintenance Manual (GMM) will serve as a guideline for Airport Terminal Services (ATS) specific procedures. In the event that compliance with ATS policy or procedure is not possible due to airline or airport policy or procedure an “Exception Request” shall be submitted and approved. Equipment shall be maintained in accordance with instructions or guidance from the manufacturer as well as established ATS procedures. Employees of ATS shall be responsible for familiarization, understanding and compliance with all policies and procedures in this GMM, ATS training, and other manuals.

0.4.1 Authority

• The Vice President, Customer Service and Operations is responsible for ensuring that the content of this manual provides personnel with the policies, procedures and information to properly conduct themselves in a manner consistent with a safe and efficient operation. The Vice President, Customer Service and Operations is also responsible for ensuring that the contents of this manual are in compliance with all applicable regional and national regulations.

0.4.2 Responsibility

• The following policies apply to those persons to whom this manual is distributed:

• Station Managers are responsible for the security of manuals at their location.

• Station Managers are to make the Manual available to employees for their reference.

• Manuals are the property of ATS and remain such under all circumstances. They may not be loaned or given to any person outside the Company, nor may they be copied or reproduced in any manner without the approval of an officer.

0.4.3 Manual Distribution

• A copy of the GSE Maintenance Manual is available online. All references to the Manual should be accessed through the ATS Connection portal. Printed and downloaded copies of the Manual should not be kept. By accessing the Manual online the most up to date version will be guaranteed.

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

1. GSE Appearance The appearance of the GSE equipment is very important to the company image as well as the customers and airports that are served. Because of this every effort should be made to insure the GSE equipment looks good at all times. All GSE equipment should be identified with company logos, equipment numbers and, where applicable, safety placards. 1.1 GSE Paint • Washing the GSE equipment and keeping the scratches touched up accomplish this. • When the equipment is due an inspection we should, if needed, repaint the entire unit at

that time. • In many areas it is not permissible to spray paint without the use of an approved spray

paint booth. Because of this ATS has the standard policy that all paint shall be applied with a brush and roller in a well-ventilated area.

• All GSE is to be painted fleet white unless otherwise instructed by the GSE Manager of Maintenance.

The wheels/rims are to be painted gloss black and black wing walk paint s• hould be

. • sed in the particular piece of

pment shall be painted blue.

ite Paint

loss Black Paint art # 7779

loss Yellow Paint art # 7747

etal Primer (Brown)

Make sure to get an MSDS sheet, with French copy in Canada, on all paints at the time of purchase and place it in your MSDS manual in the GSE shop.

applied to all steps, floors, and walking surfaces on the GSE equipment. • All hitches and tongues are to painted safety yellow at least 12 inches down from eyelet

Fuel caps shall be color coded according to the fuel type uequipment: Gasoline shall be red. Diesel shall be green.

• The fill-port on lavatory service equi• Types of paint used are as follows:

Rust-o-leum Gloss Whart # 7797 P

ust-o-leum GR

P ust-o-leum GR

P Rust-o-leum MPart # 7769

• All the above paints can be purchased from any Home Depot or Grainger stores. •

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

1.2 Logos • There are four sizes for company logos. They are as follows:

Small Logo: 6” high x 9” long Medium Logo: 10” high x 15” long Large Logo: 24” high x 35” long

• The specifications for the size and placement of logos, numbers and placards are covered in this section 1.5 of this manual.

• When applying the logos it’s recommended to use a soap and water solution along with a brush to smooth out all wrinkles and air bubbles.

• All logos shall be applied as neatly as possible. Logos may be ordered from the Safety and Training Department at Corporate Office. •

.3 Numbering and Asset Tags 1

• All GSE equipment is assigned an asset number, which is also the equipment number.

Each piece of GSE equ• ipment shall have the equipment number stenciled on both front

• ice versa, check the station

• ould sed from any Home Depot,

• All numbering shall be applied as neatly as possible.

and rear of the unit. An asset tag will be affixed to each piece of GSE equipment. This tag will have the company name along with a bar code and a number of digits on the bottom of the tag. The asset tag details should correspond with equipment number painted on the unit. If the number on the equipment is different from the tag, or vequipment inventory form to see which number is correct.

• All numbers and letters shall be 3 inches high and should be gloss black unless otherwise required by local airport authority. The best way to make the numbers is to use a 3-inch stencil set which the shop shalready have. If one is not on hand one can be purchaGrainger, or Office Depot.

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

1.4 Decals • Decals may be ordered from the Safety and Training Department at Corporate Office.

Keep Hands Clear Decal Shall be placed at any hitch and other specified pinch point hazards, for example beside rotating beltloader belts.

Low Clearance Decal Shall be placed in driver view in all vehicles with a cab or have other structure which requires vertical clearance.

Make Turns Slowly Decal Shall be placed on all vehicles where there is significant hazard stability loss during turns.

By-Pass Pin Installed Decal Shall be placed on all pushback tractors.

Stop Have You Disconnected Decal Shall be placed on all pieces of equipment that require a connection to an aircraft, for example lavatory and water servicing vehicles, ground power units and pre-conditioned air, heat or airstart units. If the unit is drive-able this shall be in view of the driver while seated at the controls. If the unit is designed to be towed this shall be positioned at the tongue end of the equipment.

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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PAGE: REVISION: DATE:

12 Rev 4 12/2011

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

1.5 Placement of Logos, Equipment Numbering and Decals • Placement of logos, numbering and caution placards is described for specific equipment. • If your equipment is not yet listed but is similar to one documented, use a similar

positioning methodology or contact your Regional GSE Supervisor for guidance. Tug Inc and TLD Beltloaders Logo Caution Placards Caution Placards

Equipment Numbering Caution Hot Exhaust placard at exhaust outlet

Equipment number stenciled or placed at front and rear bottom

right.

See 1.3 for number and letter requirements

Medium ATS Logo Placed on both sides of unit centered between the wheels

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

Gear shift painted or otherwise color

Disc

Pinch placards, one each on top of belt at corners

Wollard Beltloader

Small ATS Logo placeboth sides of the unit

All other items and requirements are the same as Tug beltloaders detailed above

GSE MAINTENANCE MANUAL

Battery onnect Switchidentified

Pinch placards, one each on top of belt at corners

coded in yellow to aid with

identification

Disc

d on the boom on

Caution Hot placard at e

outle

Uncontrolled when downloa

Battery onnect Switchidentified

Exhaust xhaust t

ded or printed

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REVISION: DATE:

Rev 4 12/2011

Tug Inc Bag Tug Logo

Small ATS Logo Placed on both sides of hood Centered from front to back Centered from top to bottom of panel

Caution Placards Equipment Numbering

Low Clearance placard in covered cab tugs

Covered tugs also require one rubber

bumper on each corner of the cab

Equipment number stenciled or placed at front and rear bottom

right.

See 1.3 for number and letter requirements Pinch placard at hitch

All hitches painted yellow

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

Tiger Bag Tug (with and without cab) Logo

Caution Placards

Equipment Numbering

f

Low Clearance placard in covered cab tugs

Covered tugs also require one rubber

bumper on each corner of the cab

Pinch placard at hitch

All hitches painted yellow

GSE MAINTENANCE MANUAL Uncontrolled

Equipment number stenciled or placed at ront and rear bottom

right.

See 1.3 for number and letter requirements

Small ATS Logo Placed on both sides of hood Centered from front to back Centered from top to bottom of panel

when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

Baggage Cart Logo

Equipment Numbering Caution Placards

All hitches painted yellow

Equipment number stenciled or placed at

front and rear top right.

See 1.3 for number and

letter requirements

Tongue painted yellow at least 12 inches down from

eyelet

Pinch placard at hitch

Amber reflectors on front of unit

Red reflectors on rear

of unit

(Unless local airport requires different configuration)

Medium ATS Logo Placed on front and back of cart Centered from left to right Positioned twelve inches down from top of cart

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

Ground Power Unit, Heat and Pre-Conditioned Air Carts Logo

Medium ATS Logo Placed on each side of unit Centered from left to right on most practical panel Positioned twelve inches down from top of cart

Caution Placards

Equipment Numbering

Equipment number stenciled or placed at front and rear bottom

right.

See 1.3 for number and letter requirements

Make Turns Slowly sticker on front of unit

Hitchlock or functional GPU alarm required

Tongue painted yellow at least 12 inches down from

eyelet

10lb ‘BC’ Fire Extinguisher checked

monthly by station and annual inspection by

qualified external company. Inspection tags must be present

Have You Disconnected sticker on front of unit

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

Airstart Unit Logo Large ATS Logo

Placed on each side of unit Centered from left to right Positioned twenty four inches down from top of cart

Caution Placards

Equipment Numbering

10lb ‘BC’ Fire Extinguisher checked

monthly by station and annual inspection by

qualified external company. Inspection tags must be present

Hitchlock, painted red, required on all airstart

units.

Tongue painted yellow at least 12 inches down from

eyelet

Equipment number stenciled or placed at front and rear bottom

right.

See 1.3 for number and letter requirements

Make Turns Slowly sticker on front of unit

Have You Disconnected sticker on front of unit

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

Pushback Tractor – All types (With and Without Cab) Logo Caution Placards Equipment Numbering

10lb ‘BC’ Fire Extinguisher checked

monthly by station and annual inspection by

qualified external company. Inspection tags must be present

Equipment number stenciled or placed at front and rear bottom

right.

See 1.3 for number and letter requirements

Low Clearance placard in covered cab

pushbacks

Covered pushbacks

also require one rubber bumper on each corner

of the cab

All hitches painted yellow

Pinch placard at front and rear hitches

By-Pass Pin Installed sticker in view of driver

while seated at controls

Relevant pushback capability sticker in

view of driver

Medium ATS Logo Placed on side of unit if no doors or on door if unit is equipped with cab Centered from left to right and twelve inches from top of side or door

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

Additional Requirement for Diesel Powered Pushback Tractors in California

An EIN number for vehicles registered as Off-Road Diesel (ORD). The EIN needs to

be white on a red background, and located in clear view on the right side of the outside of the vehicle, approx 5 feet above ground. If the vehicle is not 5 feet

tall, the label may be placed lower. Each character of the EIN needs to be at least 3 inches tall and 1.5 inches wide.

The EIN must be maintained so that it is consistently legible.

Cargo Loader – All types

Caution Markings

Equipment Numbering

Logo

Best Practice Caution tape to

highlight movable rails closest to aircraft

Equipment number stenciled or placed at front and rear bottom

right.

See 1.3 for number and letter requirements

Medium ATS Logo Placed on front of unit on engine access doors Centered from left to right and twelve inches from top of door

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

Potable Water Cart – All types

Equipment Numbering

Caution Placards

Have You Disconnected sticker on front of unit

Make Turns Slowly sticker on front of unit

Tongue painted yellow at least 12 inches down from eyelet

Equipment number stenciled or placed at

front and rear top right.

See 1.3 for number and

letter requirements

Side of unit marked on both sides with “Drinking Water”, “Potable Water” or equivalent

designation

See 1.3 for number and letter requirements (FDA requirement)

Logo

Small ATS Logo

Placed on sides of unit

Centered from left to right below the “Potable Water”

designator

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

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Lavatory Cart – All types

Equipment Numbering

Caution Placards

Have You Disconnected sticker on front of unit

Make Turns Slowly sticker on front of unit

Tongue painted yellow at least 12 inches down from eyelet

Equipment number stenciled or placed at

front and rear top right.

See 1.3 for number and

letter requirements

Side of unit marked on both sides with ”Lavatory Service”

designation or equivalent

See 1.3 for number and letter requirements (FDA requirement)

Logo

Fill port (not shown) painted blue

Small ATS Logo

Placed on each side of unit

Centered from left to right and below

the lavatory service designator

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

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Lavatory Truck – All types Caution Placards

Have You Disconnected

sticker in view of driver

Make Turns Slowly sticker in view of driver

Side of unit marked on both sides with ”Lavatory Service”

designation or equivalent

See 1.3 for number and letter requirements (FDA requirement)

Equipment Numbering

Equipment number stenciled or placed at front and rear right of

vehicle

See 1.3 for number and letter requirements

Low Clearance placard in view of driver

Fill port (not shown) painted blue

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

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Water Truck – All types Caution Placards

Have You Disconnected

sticker in view of driver

Make Turns Slowly sticker in view of driver

Equipment Numbering

Equipment number stenciled or placed at front and rear right of

vehicle

See 1.3 for number and letter requirements

Low Clearance placard in view of driver

Side of unit marked on both sides with ”Potable Water Service” designation or

equivalent

See 1.3 for number and letter requirements (FDA requirement) Medium ATS Logo

Placed on each

side door of unit

Centered from left to right

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

Rev 4 12/2011

Fuel Tanker – All types

Flammable, No Smoking signs on

front, rear and each side of truck

Hazard Warning placards on front, rear and each side

of truck

Large ATS Logo

Placed on each side of unit

Centered from left to right and top to

bottom

Fire Extinguisher location labeling

Unit requires at least 2 x 20lb Purple K fire extinguishers

Emergency Shut-Off labeling

Product identification

labeling

Low Clearance placard in view of driver

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

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2. Equipment Inventory 2.1 Equipment Inventory • All stations are required to have an accurate inventory of the GSE at that location. • Once a year the corporate office will send out a request for an updated GSE inventory.

This is the responsibility of the local Station Manager since he or she is responsible for all GSE at their location.

• In the event of a manager change it is very important that both managers perform an accurate GSE inventory to assure all equipment is accounted for.

• An accurate equipment inventory is used when making up the Preventative Maintenance Inspection (PMI) schedule.

. Maintenance Forms 3 .1 History Files 3

History files are used to• keep an accurate record of what repairs have been performed

• ipment shall be entered in the History File

• he equipment and transferred accordingly

• e mechanic

ce

In the event of an accident or an injury involving GSE equipment, the history file will sent to the corporate office to aide in the investigation.

• ype of equipment, date work

f the

the history card in the equipment file. It is very important that the work orders are filled out properly to assure that the

information entered on the card is correct.

on all GSE equipment. All work performed on a piece of equaccurately and in a timely manner. The file shall be maintained for the lifetime of tif the equipment is moved to another station. The information that is entered in the on the History Card is invaluable to th for troubleshooting as well as trending any problems with the equipment.

• In addition, the equipment cost is also tracked. • This information is also very important when trying to justify the replacement of a pie

of GSE equipment. •

most likely be 3.2 Work Orders

• The ATS work order is used to record the repairs that are performed on the GSE equipment. The form has sections to record equipment number, tbegan, date work completed, description of work performed, person performing repairs, parts used, total labor hours, and the cost of parts.

• The information on the work order is then entered on the history card in the front ofile (brief description of work, labor hours, parts cost) in the appropriate columns. The work order shall then be placed behind •

GSE MAINTENANCE MANUAL Uncontrolled when downloaded or printed

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REVISION: DATE:

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3.3 Daily Vital Fluid and Safety Inspection

the vital fluids equipment.

These checks are to and documented daily by the ramp. • The following fl items are checked:

o • In addition ing safety related items shall be inspected:

ake, ency brake

• on of the form shall

• eck shall sign in the “Complete By” column

The form shall be dated and signed by a Supervisor as a verification of completion and

3.4 Safety Inspection

be performed and documented once each

The checks hose conducted on a daily basis by the ramp but include some additional it s

• The following fl e checked:

antifreeze

o hydraulic fluid

• In addition ds the following safety related items shall be inspected:

ake,

cy brake

o horn

• The Daily Vital Fluid and Safety Inspection checklist is used for checkingand basic safety features on the all motorized GSE

• be performed uid related

o engine oil

antifreeze

to vital fluids the follow

o foot bro emergo lights o horn o tires o hitches o hitch-lock or GPU alarm

Forms may have the equipment numbers pre-filled but no other sectibe completed prior to commencement of daily checks. The agent or agents completing each chadjacent to each piece of equipment that they personally inspected.

•then turned into the Station Manager.

• The completed checklist shall be kept on file in the station for at least thirty (30) days.

Weekly Vital Fluid and • Weekly Vital Fluid and Safety Inspections shall

week by a mechanic. • are similar to t

em . uid related items ar

o engine oil o o transmission fluid

o brake fluid

to vital flui

o foot bro emergeno lights

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o tires o hitches o hitch-lock or GPU alarm

ll

ent of daily checks.

hey personally inspected. upervisor as a verification of completion and

.

• This check i e to insure that all safety items are working properly on all non-motorized e ip , for example bag carts and dollies.

• The check s ll rmed at least once each month. • The following items are checked for correct function:

tires

o tongues

t on file in the station for twelve (12) months. Safety

The form should be placed in an area that is accessible to all employees who operate GSE.

• Mechanics shall check the discrepancy sheet on a daily basis and make all needed repairs.

• Once completed, the mechanic shall indicate that the equipment is returned to service by signing and dating the discrepancy sheet adjacent to the relevant entry.

• Forms may have the equipment numbers pre-filled but no other section of the form shabe completed prior to commencem

• The agent or agents completing each check shall sign in the “Complete By” column adjacent to each piece of equipment that t

The form shall be dated and signed by a S•turned into the Station Manager.

• The completed checklist shall be kept on file in the station for at least thirty (30) days 3.5 Monthly Non-Motorized Equipment Check

s d signed qu mentha be perfo

o brake oo hitches o curtains o corner bumpers

• A copy of the form shall be kep• In addition a copy of the form shall be forwarded to the relevant Regional

Manager along with the station safety committee meeting minutes at the end of each month.

3.6 Equipment Discrepancy Sheet • The discrepancy sheet is used to report problems with GSE equipment. •

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4. Preventative Maintenance 4.1 Preventative Maintenance Inspection • Preventative maintenance inspections (PMI) are designed to avoid equipment breakdown

by inspecting and finding faults before they break and interrupt usage. • The PMI program is effective in that it saves money by better controlling maintenance

costs and makes for safer, more reliable equipment. • ATS has a preventive maintenance inspection program in place and it works very well

when everyone does there part. • Each location has a schedule in place that includes the month, equipment number, type

e. of equipment, and type of inspection du• ATS performs two types of inspection:

“B” Inspections are performed once each year.

• ch type of inspection. The inspection

• each item on the inspection they shall complete the relevant

• rea that will have a major impact on the operation, on safety, and on the bottom

2 P

o “A” Inspections are performed twice per year. o

Each piece of equipment has a specific form for eais completed using the relevant inspection form. As mechanics complete area of the paperwork. When all repairs have been made, the inspection form and work order are stapled together and entered into the history file the same as the work orders discussed earlier. Stations shall remain on schedule with the preventative maintenance inspections as this is an aline.

4. reventative Maintenance Forms • Relevant PMI Forms are available on the ATS Connection website. • At the end of each month the station manager is required to report the status of their

PMIs to the Senior Manager, GSE Maintenance using the Monthly PMI Reporting Form.

1 • submit a tool

s for

ries shall be updated whenever there is a change to equipment on station. Once a year the corporate office will send out a request for an updated inventory for all

5. Tools 1. Tool Inventories

All ATS stations that have their own mechanics on staff are required toinventory for each mechanic to the Senior Manager, GSE Maintenance. This iinsurance reasons and protects both the company and the mechanic.

• If the station has any company owned tools they shall also be inventoried. • A copy of the company tool inventory shall be kept on file in the manager’s office.

Both invento••

mechanics.

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6. Shop and Environmental Safety

6.1

• more than one. For

urce and air pressure as a stored energy. A comprehensive written procedure details each of the potential sources and how to isola t ipment is safe to work on.

• The written following items:

chinery o ces

is broken

• ut of

• be filled out and attached to the steering wheel of the vehicle. ble is to be disconnected and a yellow can placed on

tie through the eyelet provided on the can. ed

• ruction it shall be grounded to earth.

• ge

Lock-out / Tag-out – Shop Equipment

• Many types of machines are used in a GSE shop. Because of this certain safety

procedures need to be followed when using them. Each hard wired machine is required to have a written Lock-out / Tag-out procedure.

others have• Most machines have only one source of energy but example an air compressor has electricity as a power so

te hem so that the equ procedure defines the

o ake and model mo type of ma

energy souro correct procedure for Lock-out / Tag-out.

6.2 Lock-out / Tag-out – GSE • If a piece of equipment is considered unserviceable because of a safety item or

down, it shall be tagged out of service. The Out Of Service tag is used to identify any piece of GSE equipment that is oservice. The tag should

• In addition the negative battery cathe end of the cable. Insert a zip

This applies to vehicles out of service in the GSE shop and to those that are still locaton the ramp.

6.3 Waste Oil Storage and Disposal • Waste oils and other hazardous liquids shall be stored and disposed of in the proper

manner. Federal governments, provinces and states all have guidelines that must be followed.

• Waste oil shall be stored in a container that has been properly marked with contents (example: Waste Oil Only).

• Containers shall be placed on a spill containment pallet that will hold one and one half (1½) times the barrel capacity. If the container is of metal const

• Waste oil disposal shall be conducted by a reputable waste hauler that is licensed by both the state and the federal EPA. Each time a pickup is made, a waste generator form shall be obtained from the haulacompany and filed in the station indefinitely. For some companies the form and the invoice are one and the same.

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• Items shall never be mixed in one barrel. An example of this would be mixing anti freeze

icals are present the hauler may

s

5

• d chemicals that are purchased for use in the GSE maintenance shop are

• e that had accidentally ingested or splashed it into their eyes.

type of product. with the numbered with the corresponding MSDS manual sheet

.6 F

All fire extinguishers in the shop shall be easily accessible in case of a fire. A three (3) the clear zone.

In addition the each unit shall be inspected monthly for proper pressurization and signs or damage. The inspection shall be recorded on a monthly inspection

tag attached to the unit.

• Ea G it stored in an accessible location. • n v ll be completed on a regular basis to insure supplies

with motor oil. This could require the hauler to perform an expensive chemical analysisof the material. If the test results show other chemrefuse the barrel. It may then be considered hazardous waste and disposal becomemore complicated and expensive.

6.4 Paint and Chemical Storage • All chemicals, for example paints, solvents, thinners, or any other flammable product

shall be stored in an approved flammable cabinet. • Cans containing gasoline should not be stored in the cabinet with other chemicals. • The cabinet shall remain closed at all times except when removing or replacing an item. 6. Material Safety Data Sheets All paint an

required to have a Material Safety Data Sheet (MSDS) on file. An MSDS sheet should beobtained at the time of purchase. The MSDS sheet contains information about the product that would be used to treat someon

• MSDS sheets are to be kept in a manual. The front page in the manual should be a product index to include item number and

• All products are to be number.

In Canada MSDS sheets shall also be available in French unless the manufacturer does not produce one in that language. In this event a letter stating this fact should be placed

on file. In addition, all MSDS sheets must have an effective date within the last three years.

• All mechanics are required to complete annual Right to Know / WHMIS training which includes details of MSDS manual location.

ire Extinguishers 6 •

foot clear zone shall be established around each extinguisher to facilitate• Extinguisher units shall be subject to an annual inspection performed by an approved

fire service company. •

of obvious usage

6.7 First Aid Kit

ch SE shop shall have a first aid kA in entory of each first aid kit shaare sufficient and replenished when required.

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6.8 Eyewash Station • All GSE shops are required to have an eyewash station in place.

There are two types of eyewash stations:

ash has a minimum 15 minute flow time.

Units shall be checked monthly for proper water level as well as for proper operation.

• In e repairs are performed a tire containment cage shall be ut ed when inflating tire and rim assemblies. If working with two-piece rims the lock sh

6.10 S c Certain a the GSE shop. must be followed when using certain p

• tion and the surface must have even wear.

• The tool rest must have no more than 1/8 of an inch clearance between it and the

If equipped with a top guard, the guard should have no more than ¼ inch

• to be painted safety yellow.

• e. These should be placed at eye level on wall behind the

• er there are safety procedures that must be followed. The unit must be equipped with flash back valves at both the torch base and at

he valve prevents the flame from traveling back through the hose and into the tanks.

equired to wear s.

o hard plumbed to water supply o plastic tank fitted to the wall

• The requirement is that the eyew• • The unit should have an inspection tag to record inspections. 6.9 Tire Cage

the locations where tirilizall be inspected for proper seating prior to inflating the tire.

pe ialized Equipment Safety

s fety precautions must be taken to avoid injury when operating equipment in The following is a list of safety guidelines that

ty es of shop equipment.

6.10.1 Bench Grinder

The grinder wheel must be in good condition. There shall be no cracks or excessive contamina

grinder wheel. •

clearance between it and the grinder wheel. Both guards need

• A face shield shall be utilized when using any form of grinder. • These should be worn at all times when operating the machine.

Placards are available that read Eye Protection Must Be Worn At all Times When Operating This Machingrinder if possible.

6.10.2 Oxy/Acetylene Torch

• This tool is used for cutting and gas welding items when making repairs on the GSE equipment. Like the grind

• the regulators. T

• When using the torch for cutting are welding the operator is rwelding goggles along with gloves and an apron to prevent burn

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• After use the tank valves need to be closed completely and both hoses should be

purged.

ld be chained to prevent them from

This tool has safety procedures that must be followed as well. checked to be sure they are in good condition.

They should be checked for bare spots where the wire may be showing through.

ves, and

• on hand in case of a fire. • After use the cables should be wrapped up neatly and stored properly.

hen not in use.

• • not be repaired. If this is required purchase a replacement.

er

6.1

sulation has a tear or if the plug is damaged the unit should be discarded and a new one purchased.

cludes all cords used any

• Electrical outlets shall be kept in good repair with all faceplates in place. • Receptacle boxes shall not have holes exposing internal wiring.

the shop shall be easily accessible in case of a fire. A three (3) foot clear zone shall be established around each panel to facilitate the clear zone.

• Eye protection shall be worn while using the parts washer.

When not is use the eye protection shall be stored in a protective pouch. covers shall be closed on parts washer when not in use.

6.10.7 Drill Press

• When storing spare bottles always store oxygen and acetylene separately. They need to have the caps installed and shoufalling over.

6.10.3 Arc Welder • This tool is used for welding repairs on the GSE equipment. • • The cables and clamps should be

• At no time should the cable be taped up to repair it. If the wires have tears are rips they must be replaced completely.

• When using this tool the operator must wear a welding hood, welding gloa welding apron to prevent burns. They should also have a fire extinguisher

• Make sure to remove welding rod from electrode w

6.10.4 Air Compressors and Hoses

• All air hoses should be in good condition and free of tears, burns, and repairs. At no time should an air hose be cut off and clamped back onto the fitting. Hoses shall

• All air compressors shall be secured to the ground or be equipped with othmeans to avoid inadvertent movement.

0.5 Electric tools, extension cords and shop wiring

• If electrical cord in

• Field repairs are not permitted on any electrical cord. This inon the vacuum cleaners, drop lights, or any other electrical device used byemployee.

• Electrical panels in

6.10.6 Parts washer

• • Lids/

• Eye protection shall be worn while using the drill press.

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• When not is use the eye protection shall be stored in a protective pouch. • All drill presses shall be secured to the ground.

.1 Maintenance Budget

All stations are given a maintenance budget to work from.

e

asing

The majority of the GSE parts should be purchased through local accounts, for example

• t

• • are considered stock parts and will include items such as

The t all

parts be stored in a secured area to prevent theft. l not to stock more than is needed.

7. GSE Parts

7 •• Included in the budget amount are the mechanics wages and GSE parts. • The GSE Maintenance Manager will give the breakdown for the budgets to th

managers. • In the locations that out-source their maintenance, the manager should pay close

attention to invoice timeliness and content. • It’s much easier to control maintenance cost when the manager communicates with the

mechanic, or the out-source company on a daily basis.

7.2 Parts Purch •

NAPA. • For specialty items we have national accounts that supply all of stations.

When ordering through the national supplier, please advise them your station and make ensure the invoice is sent to the station. This will aid in effective account managemenand on-time payment.

• When ordering parts for equipment a Purchase Order number is required. The equipment number is used as the Purchase Order number and should be noted on the invoice. This allows for easier tracking of parts purchasing.

7.3 Parts Storage, Stock Parts Inventory and Stock Parts Sheet

All GSE shops shall keep a current inventory of parts on hand. This applies to parts thatfilters, tune up parts, starters, alternators, bolts, nuts, clamps, bulbs, etc.

• These are parts that are used on a daily basis and will save time by having them on hand.

• Some suppliers like NAPA will provide storage cabinets for the products they sell.cabinets have a hasp so you can secure with a lock if needed. It is recommended tha

• When ordering stock parts, be carefu As stock parts orders arrive at the GSE shop the parts shall be added to the Stock Parts •

Inventory. The sheet should have part #, description, price, and number on hand. On items such as bolts, nuts, washers, wire connectors, etc, it is not necessary to count

every one. These items are pennies and should be noted on the work orders and stockparts sheet when used. The Stock Parts Sheet is used to track parts that are used from inventory.

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• Only parts that are purchased for stock, not parts purchased for a specific repair should

be recorded on these forms. has sections to record the equipment number, date, part

monthly and kept on file.

is also simple to fill out, and the following information is needed: item being purchased, cost, reason three bids could not be obtained, company, contact, and phone

Both forms require a Regional Vice President signature.

7.5 • 0 or more.

• te, of repair, description of project, justification, and the estimated cost.

will require the signature of the Regional Vice President. After that it is sent to the Sr. Manager, GSE Maintenance, and accounting before final

e Sr. Manager, GSE maintenance will issue a Purchase Order number for the project.

7.6 • nsferring any equipment to a station for use in the operation an

evaluation shall be made to ensure that the equipment meets the functional specification for the tasks to be performed. Guidance on equipment functional specifications may be found in the IATA Airport Handling Manual.

• When purchasing new GSE which interfaces with aircraft cabin access doors, one of the considerations in the purchase decision should be that it has platforms of sufficient width to allow the aircraft door to open and close when the equipment is in position at the aircraft.

8. Third Party Maintenance 8.1 Agreement • At stations where GSE maintenance is contracted to a third party, ATS will execute an

agreement with that third party which establishes minimum expectations for service delivery and permits for ATS to inspect the work premises as part of a standard station audit.

• The Stock Parts Sheetdescription, and part cost. A new form should be filled out

7.4 Three Bid / Three Bid Waiver Forms • Anytime a part or a repair cost is $1000.00 or more, three bids shall be obtained. • The form is very simple to fill out, and the following information is needed: item being

purchased, company names, contact, phone number, warranty, freight cost, and price.If for some reason three bids cannot be obtained, a three bid waiver form is required. This form

number. •

Capital Request Form

This form is required for purchases of $2,50• The three bids and three-bid waiver form should be attached to the capital request when

submitting for approval. The information needed on the capital request is as follows: department, location, daand type

• After completing the form, it•

approval. Th

Transferring or Purchasing Equipment

When purchasing or tra

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