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and other fabrication required for the installation to be successful.
During the process, Weitzel also notes
units are stripped of all rust and paint by
media blasting.
" Then all required fabrication can be
completed. This is when test fitting and
mockups should happen to ensure all body
panels can be refitted to the unit, " Weitzel
says. " Once the fabrication, paint prep and
test fitting are complete, the unit can be sent
off to paint, where the frame, suspension,
axles and all other components requiring
paint can be finished.
" After paint, the unit can be reassembled, " he continues. " Upon completion of
the refurbishment process, the unit will
need to undergo extensive testing to ensure
it will perform as intended. After the testing
is completed, then the unit can be returned
to the operation.
" The length of time it takes for a GSE unit
to complete the refurb process depends on
the refurbishment required, the process is
always delivered in a timely manner, " add
Mallon and McElhone.
Headset repairs are treated similarly,
beginning with a cleaning, inspection and
electrical testing.
" Once all problems are identified, a cost
analysis is performed to determine if the
unit is economical to repair. Damaged parts
are removed and replaced with genuine
OEM components, " Donaldson says.
Preventative maintenance is also performed during the process.
" For example, if a plug is close to failure or cords show advanced wear, they are
replaced. Performing preventive maintenance while units are in the shop for repair
reduces out-of-service time and cost to customers over the unit's lifespan, " Donaldson

says, adding headsets
can take between 15
and 60 minutes to be
refurbed, depending on
their condition. " A failed microphone takes
very little time. A headset with advanced
wear, water damage and intermittent components requires much more time to diagnose
and restore to factory specifications. "
Parts availability, shop workload and
upgrade requirements can impact the time
required for any refurb project. Weitzel
notes that newly exacerbated supply chain
problems for many parts and components have been created by the COVID-19
pandemic.
If a unit is being repowered or converted
to an electric power train, Bosserman says
the refurbishment timeline can be extended
by several weeks or more.
Weitzel says it's worth noting, however, that OEMs are currently working on
drop-in packages for converting older GSE
to electric units.
" But they are not as readily available as
traditional internal combustion power train
conversions or upgrades, " Weitzel says. " In
time, the drop-in kits will catch up as
momentum for zero emission GSE grows. "
If done correctly, refurbished equipment
requires no additional maintenance.
" There would be no additional maintenance requirements other than updating
the maintenance schedules and manuals to
reflect the difference in the engine/transmission configurations, " Weitzel says.
" We treat refurbished equipment the
same way we would treat new equipment, "
agrees Bosserman.
" Care for refurbished headsets and accessories is no different from when they left
the factory, " Donaldson adds. " We suggest

Photos courtesy of PrimeFlight Aviation Services

COVER STORY

regular cleaning and inspection of all equipment to extend its' lifespan. "
Mallon and McElhone say that following
any refurbishment at Mallaghan, a piece of
GSE undergoes the same rigorous testing as
required for new equipment, to ensure it's
fit to return to service.

Additional Considerations
Refurbished GSE can solve many challenges
faced by a ground handling operation. However, Donaldson notes that smaller, more
frequent refurb projects can reduce out-ofequipment condition.
" Airlines should not wait until they are
short on working headsets before sending
them in to be repaired, " she says.
The refurb process is an advantageous time
to evaluate potential upgrades to equipment.
" This could range from ensuring equipment meets all current standards to taking
the opportunity to perform new technology
upgrades, " Bosserman says.
The skill level of the GSE mechanics is
also a key factor, advises Weitzel.
" The global pandemic placed many highly
skilled people out of work. Many have moved
on to different career paths, which leaves a
skill and experience vacuum in the industry, "
he says, adding Xcēd is fortunate in that the
company did not have to furlough any employees during the economic downturn.
" This will temporarily impact refurbishments until those positions can be filled.
Refurbishments are time-consuming and
do not always go as smoothly as planned, so
having highly skilled individuals is essential
for success. "

APRIL 2021

AviationPros.com

19
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april2021

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