saej817_2v001

SAETechnicalStandardsBoardRulesprovidethat:“ThisreportispublishedbySAEtoadvancethestateoftechnicalandengineeringsciences.Theuseofthisreportisentirelyvoluntary,anditsapplicabilityandsuitabilityforanyparticularuse,includinganypatentinfringementarisingtherefrom,isthesoleresponsibilityoftheuser.”SAEreviewseachtechnicalreportatleasteveryfiveyearsatwhichtimeitmaybereaffirmed,revised,orcancelled.SAEinvitesyourwrittencommentsandsuggestions.QUESTIONSREGARDINGTHISDOCUMENT:(724)772-8512FAX:(724)776-0243TOPLACEADOCUMENTORDER;(724)776-4970FAX:(724)776-0790SAEWEBADDRESShttp://www.sae.orgCopyright1991SocietyofAutomotiveEngineers,Inc.Allrightsreserved.PrintedinU.S.A.SURFACEVEHICLE400CommonwealthDrive,Warrendale,PA15096-0001INFORMATIONREPORTJ817-2REV.MAR91Issued1962-04Revised1991-03SupersedingJ817JUL76(R)ENGINEERINGDESIGNSERVICEABILITYGUIDELINES—CONSTRUCTIONANDINDUSTRIALMACHINERY—MAINTAINABILITYINDEX—OFF-ROADWORKMACHINES1.Scope—ThisSAEInformationReportestablishesapointsystemthatencourageseaseofmaintenanceactionsonoff-roadworkmachines.ThepointsystemminimizessubjectivityinevaluatingmaintainabilityasdefinedinJ817-1.1.1ThisdocumentappliestomachinesdefinedinJ1057andcategorizedinJ1116.2.References2.1ApplicablePublications—Thefollowingpublicationsformapartofthisspecificationtotheextentspecifiedherein.ThelatestissueofSAEpublicationsshallapply.2.1.1SAEPUBLICATIONS—AvailablefromSAE,400CommonwealthDrive,Warrendale,PA15096-0001.SAEJ753MAY91—LubricationChart—ConstructionandIndustrialMachinerySAEJ817/1MAR91—EngineeringDesignServiceabilityGuidelines—ConstructionandIndustrialMachinery—ServiceabilityDefinitions—Off-RoadWorkMachinesSAEJ920SEP85—TechnicalPublicationsforOff-RoadWorkMachinesSAEJ1057SEP88—IdentificationTerminologyofEarthmovingMachinesSAEJ1116JUN86—CategoriesofOff-RoadSelf-PropelledWorkMachines3.MaintainabilityIndex—Asystemforestablishinganumbertorateanexistingornewconceptmachine.Withthissystem,lubricationandmaintenanceitemsareassignedapointvaluebasedoncertainrequirements.Theserequirementsinclude:location,access,operation,andmiscellaneous.Therequirementsaredefinedandaprocedurewithasimpledatasheetshowshowtodevelopthepointsubtotals.Aquantitymultipliermaybeappliedtothesubtotalwhererepetitious,nearlyidenticalitemsmakeitappropriate.Theproductofthesubtotaltimesthequantitymultiplier(whenused)ismultipliedbythefrequencymultiplier.SAEJ817-2RevisedMAR91-2-Frequencymultipliersarenumbersthatrepresentvariousserviceintervals.Thesubtotalofeachitemismultipliedbytheappropriatefrequencymultipliertoobtainthepointtotalforeachitem.Thepointtotalofallitemsisthemaintainabilityindexforamachine.Alowmaintainabilityindexisdesirable.3.1System—Thesystemtofilloutthedatasheetrequiresjudgmentfactorsandassignspointstoapproximatethevaluesusedtojudgemachinesinthefield.Thelimitsofapplicationare:a.Themaintainabilityindexisnotexpressedintimeorcost.b.Themaintainabilityindexisbestusedtocompareearlyandlateversionsofaparticularmachine,varioussizedmachinesinamodelline,orsimilarmachinesofothermanufacturers.Itissuggestedthatthemaintainabilityindexnotbeusedtocomparevastlydissimilarmachines.c.Thisisadesignguidelineandgeneralpracticeforusebydesignersofoff-roadworkmachinesascategorizedinSAEJ1057andJ1116,asitisfeltadherencetothisguidelinewillfacilitatemachinemaintenance.Thebestconsistencyofresultsincomparingmorethanonemachinewillbeobtainedbyusingthesameauditorforcomparisonaudits.d.Maintenanceinnovationandtechnologyareconstantlyimproving.Theparameterswhichmakeupthisdocumentmaynotbethelatest.e.Detailedcommentaryisessential,especiallyinhighpointareas,tofullyexplaintheacceptabilityorunacceptabilityofthemaintenanceitem.3.2Procedure—Listalllubricationand/ormaintenanceitemsonthemaintenanceindexdatasheet(s),exceptforthosenearlyidenticaloridenticalitemstobecoveredbythequantitymultiplier.TheitemstobelistedwillbethosedefinedintheMaintenanceInstructionsdefinedinJ920,whensuchinstructionsarepublished.TheMaintenanceChartdefinedbyJ753maybeusedintheabsenceofMaintenanceInstructions,butitwillprobablybelessinclusive.Excludeditemsarethefirstoilchangesatlessthanthescheduledintervalandretighteningduringthefirst100h.Theactualmachine(s)shallbeused.ItwillbetheresponsibilityoftheauditortoidentifyobviouserrorsoromissionsintheMaintenanceInstructionswhenpreparingmaintenanceindexdatasheets.Refuelingthemachineshouldbeincluded.Althoughnotessential,itisdesirabletolistaccordingtofrequency,shortestfrequencyfirst,assuggestedbytheformatinFigure1.Figure1willbeusedasareferencethroughoutthisprocedure.Itemsthatcanbecontinuouslymonitoredfromtheoperator'sstationareexemptfrompointassessments.Dipsticksorlevelindicatorsarestillneededatfillpointsandwillbeassessedpointsatthechangeinterval.Eachphaseofamultiple-stepoperationshouldbelistedandpointsassessed.Forexample,anoilchangerequiresdrainingthecrankcaseasoneoperationandfillingthecrankcaseasanotheroperation,soeachshouldbelisted.Eachitemshouldbelistedseparately,orcombinedifnearlyidentical,throughuseofthequantitymultipliertogivefullcreditwhenthenumberofitemsisreduced,exceptwhen"banking"isused.Bankedfittings(twoormoreofthesameinterval)shallreceiveonepointforeachbank.Bankedfittingsaredefinedasagroupoffittingsinacommonlocationremotefromthejointsbeinglubricated.Searchthelistunderthediscussionofrequirements—location,access,operation,andmiscellaneous—forthecharacteristicswhichmostcloselyresemblethoseoftheitembeingrated.Enterthecorrespondingpointvalueintheappropriatecolumn.Selectthefrequencymultiplierfortheproperintervalandenteritinthecolumnforeachofthemaintenanceitemslisted.Addthepointsacrossthechartforeachitemandenterthisinthesubtotalcolumn.Multiplybythequantitymultiplier,ifused,todeterminesubtotal2.Multiplysubtotal2bythefrequencymultipliertofindthetotalforeachitem.Whenthetotalshavebeenfoundforallmaintenanceitems,addthemdowntofindthemaintainabilityindexfortheentiremachine.SAEJ817-2RevisedMAR91-3-3.3Requirements—(SeeTables1through6.)3.3.1LOCATION—Locationreferstothepositioninwhichanindividualmustlocatehimselfinordertodothejob.Ifmorethanoneoperationcanbeaccomplishedfromthesamelocationatthesameserviceintervalormultiplethereof,thefirstoperationisassessedpointsapplicabletothatlocation,andtheremainderareassessedonepointeach.Table1showsthepositionsconsideredandtheirrespectivepointvalues.3.3.2ACCESS—Accessreferstotheeaseofreachingalubricationormaintenancepoint.Ifmorethanoneoperationcanbeaccomplishedthroughthesameaccessatthesameserviceintervalormultiplethereof,thefirstoperationisassessedpointsapplicabletothataccessandtheremainderareassessedonepointeach.AccessibilityconsiderationsalongwiththeirrespectivepointvaluesareshowninTable2.TABLE1—LOCATIONSANDRESPECTIVEPOINTVALUESPositionsPointsa.Groundlevel—workingupright,withinnormalreach1b.Groundlevel—bendingorstretchingoutsidenormalreach2c.Groundlevel—squatting,kneeling,orlying(exceptunderthemachine)3d.Mountmachine—normalreach10e.Mountmachine—bending,stretching,orsquatting15f.Anyposition(otherthanupright)underorwithintheconfinesofthemachine25g.Requiresclimbingintopositionwithouthandrailsand/orsteps/platformsbeingprovided50TABLE2—ACCESSIBILITYCONSIDERATIONSANDTHEIRRESPECTIVEPOINTVALUESAccessibilityConsiderationPointsa.Exposed1b.Exposed—throughopening2c.Flipupcoverorflap3d.Doororcover—handoperated4e.Doororcover—singlefastener10f.Doororcover—multiplefasteners15g.Hoodremoval35h.Multiplecovers—multiplefasteners50i.Radiatorguardremoval50j.Tiltcab75k.Crankcase/drivetrainguardremoval—hingedandbolted75—boltedonly100SAEJ817-2RevisedMAR91-4-3.3.3OPERATION—Operationreferstotheactionrequiredtoperformtheservicingofthelisteditems.Theoperationconsiderationsandtheirrespectivepointvaluesaregroupedintocategoriesofsimilaractionsforeasyreference.TheyareshowninTable3.TABLE3—OPERATIONCONSIDERATIONSANDTHEIRRESPECTIVEPOINTVALUESOperationConsiderationsPointsCompartmentChecking(Liquid)a.Visualcheck1b.Dipstick3c.Screwcap—handremovable4d.Multiplescrewcap—handremovable6e.Screwcaporplugrequiringtool8f.Multiplescrewcaporplugrequiringtool10ComponentCheckinga.Visualcheck1b.Handcheckofbelttension2c.Nonprecisiontool(includestirepressurecheckortorquewrench)5d.Precisiontool10Lubricatinga.Fitting(orbankoffittings)1b.Fittingrequiringspecialadapter3c.Brushonlube5d.Oilcanlube5e.Fittingrequiringsecondaryaction,suchashandrotatingshafttogetfittingtoaccessiblelocation5f.Handpacking(each)20Draininga.Drainvalve—handoperable1b.Drainvalve—toolrequired3c.Horizontalplug6d.Verticalplug8e.Coverplate10f.Multipleplugsorcovers15Fillinga.Handremovedcap1b.Toolremovedcaporplug—vertical3c.Awkwardaccesstofillerbecauseofinterferingpartsorexcessiveslopeoffillertube8d.Toolremovedplug-horizontal10e.Requirespumptofill(i.e.,differentialundermachine)10f.Multiplecapsorplugs15Cleaninga.Blowwithair3b.Singlebathwash5c.Multiplebathwashorwashandoil10d.Cleanreservoirbysolventsprayorsimilartechnique10SAEJ817-2RevisedMAR91-5-3.3.4MISCELLANEOUS—ItemsinthislistcannotbecategorizedundertheheadingsinTable3.Theserequirementsaregenerallyconsideredundesirableandassuchshouldbeavoidedifpossible.Ineffect,thepointvalueslistedformiscellaneousitemsarepunitivepoints.Therequirementsforcautioncanbeestablishedbythemanufacturer'sMaintenanceInstructions,byWarningsandCautionsaffixedtothemachineorbythejudgmentoftheauditor.ThemiscellaneousconsiderationsareshowninTable4.FilterReplacementa.Spinon(verticalbaseup)1b.Spinon(baseupinclinedmorethan15degrees)3c.Singlefastenernotrequiringtool4d.Singlefastenerrequiringtool5e.Multiplefastenernotrequiringtool6f.Multiplefastenerrequiringtool7Adjustmenta.Singlestep2b.Multiplestep4c.Multiplelocationmultiplestep10TABLE4—MISCELLANEOUSCONSIDERATIONSANDTHEIRRESPECTIVEPOINTVALUESConsiderationPointsa.Drainageindirectlycollectibleintocontainer(requireshoseorpipe)2b.IntervalnotinconformancewithSAERecommendedPracticeJ7532c.Bleedingrequired3d.Primingrequired3e.Specialtool4f.Inadequatelyidentified4g.Fillersizeinadequate5h.Vulnerabletocontamination5i.Needtostartengine5j.Torquingrequired(perfastener)5k.Drainandwashfilterhousing8l.Needforspecialinstruction10m.Needtooperateorpositionmachine(includeswarm-up)10n.Unabletocollectfluid20o.Inadequateclearanceforrequiredoperation20p.Twopersonsrequired40q.Requiresuseofladderseparatefrommachine50r.Operationrequiringcaution100s.Positionrequiringcaution100TABLE3—OPERATIONCONSIDERATIONSANDTHEIRRESPECTIVEPOINTVALUES(CONTINUED)OperationConsiderationsPointsSAEJ817-2RevisedMAR91-6-3.3.5FREQUENCYMULTIPLIER(MAINTENANCEINTERVAL)—Maintenanceintervalreferstothefrequencyofperformingalubricationormaintenanceitem.Requirementsforone-time-only,scheduledretighteningorlubricantchangesfornewmachineswithlessthan100honthemwillnotbeconsideredindeterminingmaintenanceindexpoints.ThefrequencymultipliersareassignedasshowninTable5.ThehourintervalslistedconformtoSAERecommendedPracticeJ753.Ifintervalsotherthanthoseshownareused,applythefrequencymultiplierofthenearestSAERecommendedPracticeintervalplusamiscellaneouspenaltyoftwopoints.Eachlubricationandmaintenanceitemisassignedafrequencymultiplieronce—themostfrequentintervalperformed.Forexample,aschedulethatstipulatesthattheengineoillevelmustbecheckeddailywouldberecordedontheformonlyonce.Thisitemwouldnotenterthecountagain,eventhoughitmaybeperformedduringamonthlyoilchange.TABLE5—FREQUENCYMULTIPLIERSMaintenanceIntervalFrequencyMultipliera.1000h-Semi-annually,orgreater1b.500h-Quarterly,orasrequired2c.250h-Monthly4d.100h-Semi-monthly10e.50h-Weekly20f.10h-Daily50TABLE6—POINTSLISTPointsLocationa.Groundlevel—workingupright,withinnormalreach1b.Groundlevel—bendingorstretchingoutsidenormalreach2c.Groundlevel—squatting,kneeling,orlying(exceptunderthemachine)3d.Mountmachine—normalreach10e.Mountmachine—bending,stretching,orsquatting15f.Anyposition(otherthanupright)underorwithintheconfinesofthemachine25g.Requiresclimbingintopositionwithouthandrailsand/orsteps/platformsbeingprovided50Accessa.Exposed1b.Exposed—throughopening2c.Flipupcoverorflap3d.Doororcover—handoperated4e.Doororcover—singlefastener10f.Doororcover—multiplefasteners15g.Hoodremoval35h.Multiplecovers—multiplefasteners50i.Radiatorguardremoval50j.Tiltcab75k.Crankcase/drivetrainguardremoval—hingedandbolted75—boltedonly100OperationCompartmentChecking(Liquid)a.Visualcheck1SAEJ817-2RevisedMAR91-7-b.Dipstick3c.Screwcap—handremovable4d.Multiplescrewcap—handremovable6e.Screwcaporplugrequiringtool8f.Multiplescrewcaporplugrequiringtool10ComponentCheckinga.Visualcheck1b.Handcheckofbelttension2c.Nonprecisiontool(includestirepressurecheckortorquewrench)5d.Precisiontool10Lubricatinga.Fitting(orbankoffittings)1b.Fittingrequiringspecialadapter3c.Brushonlube5d.Oilcanlube5e.Fittingrequiringsecondaryaction,suchashandrotatingshafttogetfittingtoaccessiblelocation5f.Handpacking(each)20Draininga.Drainvalve(includingremovalofplug)1b.Horizontalplug6c.Verticalplug8d.Coverplate10e.Multipleplugsorcovers15Fillinga.Handremovedcap1b.Toolremovedcaporplug—vertical3c.Awkwardaccesstofillerbecauseofinterferingpartsofexcessiveslopeoffillertube8d.Toolremovedplug—horizontal10e.Requirespumptofill(i.e.,differentialundermachine)10f.Multiplecapsorplugs15Cleaninga.Blowwithair3b.Singlebathwash5c.Multiplebathwashorwashandoil10d.Cleanreservoirbysolventsprayorsimilartechnique10FilterReplacementa.Spinon(verticalbaseup)1b.Spinon(baseupinclinedmorethan15degrees)3c.Singlefastenernotrequiringtool4d.Singlefastenerrequiringtool5e.Multiplefastenernotrequiringtool6f.Multiplefastenerrequiringtool7TABLE6—POINTSLIST(CONTINUED)PointsSAEJ817-2RevisedMAR91-8-4.Summary—Anyitemswhichhaveahighpointvaluemustbecarefullyscrutinized.Inadditiontoofferinganexcellentopportunityforareductioninthemaintenanceindex,itemswithahighpointvalueemphasizemaintenanceareaswhicharelikelytobeskippedbytheservicemanbecauseofthedifficultyinvolved.Improvementintheseareascanreducetheriskofmachineorcomponentfailurebecauseofneglect,aswellasreducecriticalmachinedowntimeforperiodicmaintenance.Therearemaintenancereductionpossibilitiesnotincludedinthepointscoresbutstillofvaluetotheuser.Examplesinclude:a.Minimumnumberofliquidtypes,b.Standardizedfilterelements,c.Commonlocationofmaintenanceitemsonamachinefamily.Adjustmenta.Singlestep2b.Multiplestep4c.Multiplelocationmultiplestep10Miscellaneousa.Drainageindirectlycollectibleintocontainer(requireshoseorpipe)2b.IntervalnotinconformancewithSAERecommendedPracticeJ7532c.Bleedingrequired3d.Primingrequired3e.Specialtool4f.Inadequatelyidentified4g.Fillersizeinadequate5h.Vulnerabletocontamination5i.Needtostartengine5j.Torquingrequired(perfastener)5k.Drainandwashfilterhousing8l.Needforspecialinstruction10m.Needtooperateorpositionmachine(includeswarm-up)10n.Unabletocollectfluid20o.Inadequateclearanceforrequiredoperation20p.Twopersonsrequired40q.Requiresuseofladderseparatefrommachine50r.Operationrequiringcaution100s.Positionrequiringcaution100FrequencyMultiplierFrequency(MaintenanceInterval)Multipliera.1000h—Semi-annually,orgreater1b.500h—Quarterly,orasrequired2c.250h—Monthly4d.100h—Semi-monthly10e.50h—Weekly20f.10h—Daily50TABLE6—POINTSLIST(CONTINUED)PointsSAEJ817-2RevisedMAR91-9-FIGURE1—SAMPLEENTRIESSAEJ817-2RevisedMAR91-10-FIGURE2—MAINTENANCEINDEXDATASHEETSAEJ817-2RevisedMAR91-11-5.Notes5.1MarginalIndicia—Thechangebar(l)locatedintheleftmarginisfortheconvenienceoftheuserinlocatingareaswheretechnicalrevisionshavebeenmadetothepreviousissueofthereport.An(R)symboltotheleftofthedocumenttitleindicatesacompleterevisionofthereport.PREPAREDBYTHESAEOFF-ROADMACHINERYTECHNICALCOMMITTEESC16—SERVICEABILITYSAEJ817-2RevisedMAR91Rationale—Introduction—TheobjectistocompletelyrevisetheInformationReportasdirectedunderthefive-yearreview.ThelastupdatewasJuly1976.Discussion—Thedocumenthasbeendividedtoprovideapreliminarydefinitionssectionandseparatesectionsforeachofthemajordesignfactorsaffectingserviceability.ThedefinitionswereunchangedexceptfortheadditionofaDiagnosticscategory.TheRepairIndexprocedurewasdroppedwithunanimousconsentofORMTCmemberspolled.Theprocedurewasnotbeingusedasmorepracticalrepairabilitymeasurementsexist,suchastimestudies.Thefuturedevelopmentofsystemsformeasuringdiagnosticsandrepairabilityispossible.Thisrevisionwasvalidatedonmachinesbythecommitteeandfoundtomeettheseestablishedobjectives:a.Moreemphasisonpenalizingdifficultoperations.b.Moreemphasisonpenalizingitemswithpersonalinjurypotential.c.Recognitionofdesignfacilitationofperiodicmaintenanceitems,i.e.:InseatchecksBankedfittingsd.Reducedemphasisonthefrequencymultiplierinordertohavemoredifficultbutinfrequentitemssignificantlyinfluencethetotalscore.e.Itemshavebeenaddedinvariouscategoriestoclarifythescoringprocedure.TheDataSheethashadSubtotalandQuantityMultipliercolumnsaddedtofacilitatetheworkoftheauditor.Thesamedatasheetincludedemphasizestheuseofauditorcomments.Therewillbenodirectcorrelationbetweenscoresderivedbytheproposedrevisedprocedureandtheformerone.Thenewprocedurescoreswillbetterreflectactualdifficultyofmaintenancework.Thisremainsaheuristicprocedure.RelationshipofSAEStandardtoISOStandard—Notapplicable.Application—ThisSAEInformationReportestablishesapointsystemthatencourageseaseofmaintenanceactionsonoff-roadworkmachines.ThepointsystemminimizessubjectivityinevaluatingmaintainabilityasdefinedinJ817/1.SAEJ817-2RevisedMAR91ReferenceSectionSAEJ753MAY91—LubricationChart—ConstructionandIndustrialMachinerySAEJ817/1MAR91—EngineeringDesignServiceabilityGuidelines—ConstructionandIndustrialMachinery—ServiceabilityDefinitions—Off-RoadWorkMachinesSAEJ920SEP85—TechnicalPublicationsforOff-RoadWorkMachinesSAEJ1057SEP88—IdentificationTerminologyofEarthmovingMachinesSAEJ1116JUN86—CategoriesofOff-RoadSelf-PropelledWorkMachinesDevelopedbytheSAEOff-RoadMachineryTechnicalCommitteeSC16—ServiceabilitySponsoredbytheSAEOff-RoadMachineryTechnicalCommittee