1、_SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising theref
2、rom, is the sole responsibility of the user.”SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions.Copyright 2015 SAE InternationalAll rights reserved. No part of this publi
3、cation may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE.TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada)Tel: +1 724-776-4970 (out
4、side USA)Fax: 724-776-0790Email: CustomerServicesae.orgSAE WEB ADDRESS: http:/www.sae.orgSAE values your input. To provide feedbackon this Technical Report, please visithttp:/www.sae.org/technical/standards/AIR1599AAEROSPACEINFORMATION REPORTAIR1599REV. AIssued 1979-04Revised 1991-03Reaffirmed 2015-
5、10Superseding AIR1599Ground Equipment Rebuild ProgramRATIONALEAIR1599A has been reaffirmed to comply with the SAE five-year review policy.1. SCOPE:This Aerospace Information Report (AIR) is intended to be concerned with fleet programs rather than programs for individual units. Technical and administ
6、rative considerations in developing an approach to a program will be suggested. Organization of material possibly wanted in the form of a detailed specification for airline rebuilder communication is reviewed.1.1 Purpose:This AIR provides information for airline consideration when formulating in-hou
7、se or outside vendor rebuild programs for motorized and nonmotorized ground support equipment (GSE).2. REFERENCES:There are no referenced publications specified herein.2.1 Definition:REBUILD: Reworking of equipment to include all corrective action normally done during an overhaul, correction of know
8、n mechanical, electrical, hydraulic, as well as operational deficiencies, reinforcement of known structural deficiencies, replacement of obsolete parts and components, and necessary modifications to eliminate operational and maintenance deficiencies. The intent of rebuild is to return the equipment
9、to a serviceable condition having an expected or greater service life than when it was new. Latest American National Standards Institute (ANSI) and Occupational Safety and Health Administration (OSHA) requirements should be observed. High cost components probably should be evaluated by using availab
10、le technology. For example, a gasoline engines condition can be determined by a compression check and an oil analysis. Hydraulic test stands and electrical test equipment can be employed on a good percentage of other high cost components.3. DISCUSSION:3.1 Basic Philosophy:Automobiles are generally o
11、f light construction with emphasis on thin-gauge sheet metal paneling needed for high speed over the road transportation. In contrast, ground support equipment tends to be beefy; emphasis is on heavy structure. Their designs incorporate components of adequate capacity to insure sustained performance
12、 under severe operational and environmental demands.There is good evidence to believe that the most economical way to provide long-term support equipment needs is to accomplish major rebuilding of the present equipment when the useful life has been expended. The frames and structures of GSE are cost
13、ly to build. By required disassembly, structural repairs, replacement or renewing of components, refinishing and assembly, it is expected a unit very close to new quality can be achieved.3.2 Methods:To insure that parts which have a finite life, i.e., hoses, wiring, components, switches, cable, chai
14、ns, etc., are renewed, an understanding between the customer and the vendor must be established. High volume, relatively inexpensive parts such as wheel bearings, headlights, toggle switches, bushings, rollers, etc., might best be replaced on all units to facilitate planned quantity purchases, elimi
15、nate inspection and servicing, and permit a standard production sequence.3.3 Defining the Approach:Airlines have often found that the best method of procurement is by competitive bids. To insure that no surprises arise, either to the customer or the rebuilder, the work task and the expected results
16、need to be clearly understood. How the unit has been operated and maintained, damage, corrosion, and abuse will be reflected in the equipments condition. Several approaches are possible. The rebuilder can offer a fixed price by guessing at the scope of the work; the customer and the rebuilder can in
17、spect each unit together and agree on the job; or a rebuilt criterion can be agreed upon as to how to determine when to rebuild/replace with pricing accordingly. Manufacturers manuals and part supports should be utilized to the best advantage.3.4 Economics:3.4.1 Service Life: The time in service whe
18、n a unit is earmarked for rebuild will be helpful for planning programs. Hours of operation can be determined on motorized equipment directly from the hour meter (if installed) or by estimating annual utilization. Maintenance records often show many units within a fleet reach a time when costs escal
19、ate unreasonably rapidly. Nonmotorized equipment might best lend itself to a rebuild program by an on-condition approach.SAE INTERNATIONAL AIR1599A 2 OF 73.4.2 Inception: The decision to undertake a rebuild program will be governed by availability and pricing of new equipment, freight costs for new
20、equipment versus that of freight to the rebuild facility, and delivery times. A rule of thumb is that if the total unit cost (price, freight, support) of rebuild can be done for up to 70% of a new unit, the program is viable. However, in some cases, availability of new or replacement units due to de
21、livery time, freight costs, product support, etc., will justify over 100% of the new unit cost.3.4.3 Scheduling: A planned scheduling of units through the rebuild facility will insure best utilization of manpower and resources.3.4.4 Standardization: The firmer the definition of work to be accomplish
22、ed on each unit in the program, the more efficient the overall operation will be.3.4.5 Modular Replacement Packages: Control consoles, electrical panels, wiring harnesses, some mechanical assemblies, hydraulic components, etc., that have suffered from weathering, abuse, or severe use should be consi
23、dered to be completely replaced rather than custom troubleshooting and repair.4. METHODS:4.1 Steam clean and disassemble unit. (Remove assembly, hydraulic/electrical components, gauges, lights, etc., but not axles, springs, welded panels, and other heavy components.) Accomplish fair wear and tear st
24、ructural/body repairs as required. Remove loose paint, rust, and feather rough edges. Prime all bare metal. (If sandblasting is done, protect sensitive locations and parts - bearings, fluids, components, etc., must not be contaminated.) Reassemble as per the following requirements and paint per the
25、specification.4.2 Various aspects of a rebuild specification may not be applicable to each unit. Therefore, some items may be requested to be bid individually. An agreement can be arranged between the customer and the vendor as to how these replacements will be determined.4.3 Replacement parts and m
26、ethods used in a program should comply to documentation supplied by the customer in his original request for bids. These shall include schematics, operational characteristics, etc. Deviations can be mutually agreed upon by the customer and the vendor. Supplements to the original manuals should be pr
27、ovided for any modified features, assemblies, or parts updated during the rebuild process.4.4 All removed components can be retained at the vendors facility for possible salvage if desired by the customer. Disposition of parts not retained by the customer will be at the remanufacturers expense.5. (S
28、UGGESTED) COMPONENTS TO BE NEW OR REBUILT/RECONDITIONED:5.1 Engine (see 4.2)5.2 StarterSAE INTERNATIONAL AIR1599A 3 OF 75.3 Carburetor5.4 Fuel pump5.5 Alternators, generators5.6 Regulator5.7 Water pump5.8 Hydraulic cylinders5.9 Hydraulic pump5.10 Hydraulic valves5.11 Radiator (see 4.2)5.12 Brake dru
29、ms, shoes, cylinders, vacuum boosters, calipers, rotors5.13 Hydraulic motor5.14 Injection pump and injectors6. (SUGGESTED) COMPONENTS TO BE REPLACED NEW:6.1 Hydraulic hoses6.2 Battery6.3 Tires6.4 Muffler, tailpipe, catalytic converter6.5 Bushings and bearings6.6 Engine belts6.7 Wheel bearings6.8 Hyd
30、raulic fluid (new or recycled and tested for adequate presence of required additives)6.9 Radiator hoses6.10 Wiring and cablesSAE INTERNATIONAL AIR1599A 4 OF 76.11 Radiator pressure cap6.12 Fuel filter element6.13 Air filter element6.14 Oil filter element6.15 Refrigerant6.16 Brake fluid6.17 Transmiss
31、ion filter (screen)6.18 Disc brake pads6.19 Lift chain, power transmission chain6.20 Wiper blades6.21 Ignition points, spark plugs, condenser6.22 Electronic ignition modules (see 4.2)6.23 Electrical switches, relays, and other components (see 4.2)6.24 Flexplates6.25 Casters, ball transfers (see 4.2)
32、6.26 Governors7. (SUGGESTED) CHECK AND RECONDITION/REPLACE AS NECESSARY:7.1 Lights7.2 Reflectors7.3 Hitches7.4 Transmission7.5 Differential7.6 Exhaust pipeSAE INTERNATIONAL AIR1599A 5 OF 77.7 Instruments7.8 “U“ joints7.9 Horn7.10 Push/pull cable units7.11 Rubber bumpers7.12 Parking brake7.13 Seat an
33、d seat back7.14 Placards/stencils7.15 Fasteners/hardware7.16 Gas/oil caps7.17 Blower wheels (balance)7.18 Oil coolers, heat exchangers7.19 Rollers7.20 Pulleys, sheaves, and sprockets7.21 Scissor pins (see 4.2)7.22 Insulation7.23 Windows7.24 Heater/defroster components7.25 Wheels, studs, and nuts7.26
34、 Burner assemblies7.27 Torque converters7.28 AC generators7.29 Fluid dispensing valves and gunsSAE INTERNATIONAL AIR1599A 6 OF 77.30 SCR (silicon controlled rectifier) controls, modules, and cards7.31 Steering gears, linkages, hydrostatic steering control units7.32 Axle assemblies8. DECONTAMINATION:
35、8.1 Drain, clean, and flush the hydraulic reservoir and lines.8.2 Drain and clean the fuel tank.8.3 Drain and clean the refrigerant systems when applicable.8.4 Drain and clean the hydraulic brake circuit.8.5 Drain and clean the fluid tanks.9. OPTIONS - AS MAY BE DESIRED:10. IMPROVEMENTS - LIST UPGRA
36、DE PROJECTS:11. (SUGGESTED) ACCEPTANCE:11.1 At the customers discretion, the right to have a representative(s) inspect and test any or all of the rebuilt units for compliance to the specification.12. WARRANTY:12.1 Depending on the type unit and the scope of the overhaul, a suitable mutually agreed warranty can be negotiated.13. KEY WORDS:Ground equipment.PREPARED BY SAE SUBCOMMITTEE AGE-2C, VEHICLE MAINTENANCE ANDAIRCRAFT SERVICING OF COMMITTEE AGE-2, AIR CARGO ANDAIRCRAFT GROUND EQUIPMENT AND SYSTEMSSAE INTERNATIONAL AIR1599A 7 OF 7
