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 reaffirmed, revised, or cancelled. SAE invites your written comments and suggestions. Copyright 2009 SAE International All rights reserved. No part of this publication ma
3、y 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: 724-776-4970 (outside USA)
4、Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.orgSURFACEVEHICLEINFORMATIONREPORTJ817 DEC2009 Issued 1962-04 Reissued 2009-12 Superseding J817-2 MAR1991 Engineering Design Serviceability GuidelinesConstruction and Industrial Machinery Maintainability IndexOff-Road Wor
5、k Machines RATIONALEThis document has been reissued to bring it into alignment with the latest SAE format and update the references. SAEJ817-1 has been cancelled as the terms and definitions contained within are defined in ISO 8927, “Earth-moving machineryMachine availabilityVocabulary”. SAE J817-2
6、is being cancelled and will become SAE J817.1. SCOPE This SAE Information Report establishes a point system that encourages ease of maintenance actions on off-road machines. The point system minimizes subjectivity in evaluating maintainability as defined in ISO 8927. 1.1 This document applies to mac
7、hines defined and categorized in SAE J1116 and ISO 6165. 2. REFERENCES 2.1 Applicable Publications The following publications form a part of this report to the extent specified herein. Unless otherwise indicated, the latest issue of SAE and ISO publications shall apply. 2.1.1 SAE Publications Availa
8、ble from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel: 877-606-7323 (inside USA and Canada) or 724-776-4970 (outside USA), www.sae.org.SAE J753 Maintenance Interval Chart SAE J920 Technical Publications for Off-Road Work Machines SAE J1116 Categories of Off-Road Self-Pro
9、pelled Work Machines SAE J817 Reissued DEC2009 Page 2 of 92.1.2 ISO Publications Available from ANSI, 25 West 43rd Street, New York, NY 10036-8002, Tel: 212-642-4900, www.ansi.org.ISO 6165 Earth-moving machineryBasic typesVocabulary ISO 6750 Earth-moving machineryOperation and maintenanceFormat and
10、content of manuals ISO 8927 Earth-moving machineryMachine availabilityVocabulary ISO 12510 Earth-moving machineryOperation and maintenanceMaintainability guidelines 3. MAINTAINABILITY INDEX A system for establishing a number to rate an existing or new concept machine. With this system, lubrication a
11、nd maintenance items are assigned a point value based on certain requirements. These requirements include: location, access, operation, and miscellaneous. The requirements are defined and a procedure with a simple data sheet shows how to develop the point subtotals. A quantity multiplier may be appl
12、ied to the subtotal where repetitious, nearly identical items make it appropriate. The product of the subtotal times the quantity multiplier (when used) is multiplied by the frequency multiplier. Frequency multipliers are numbers that represent various service intervals. The subtotal of each item is
13、 multiplied the appropriate frequency multiplier to obtain the point total for each item. The point total of all items is the maintainability index for a machine. A low maintainability index is desirable. 3.1 System The system to fill out the data sheet requires judgment factors and assigns points t
14、o approximate the values used to judge machines in the field. The limits of application are: a. The maintainability index is not expressed in time or cost. b. The maintainability index is best used to compare early and late versions of a particular machine, various sized machines in a model line, or
15、 similar machines of other manufacturers. It is suggested that the maintainability index not be used to compare vastly dissimilar machines. c. This is a design guideline and general practice for use by designers of off-road work machines as categorized in ISO 6165 and SAE J1116, as it is felt adhere
16、nce to this guideline will facilitate machine maintenance. The best consistency of results in comparing more than one machine will be obtained by using the same auditor for comparison audits. d. Maintenance innovation and technology are constantly improving. The parameters which make up this documen
17、t may not be the latest. e. Detailed commentary is essential, especially in high point areas, to fully explain the acceptability or unacceptability of the maintenance item. 3.2 Procedure List all lubrication and/or maintenance items on the maintenance index data sheet(s), see Figure 1, except for th
18、ose nearly identical or identical items to be covered by the quantity multiplier. A completed maintenance index data sheet is shown in Figure 2. The items to be listed will be those in the Maintenance Instructions defined in SAE J920 and ISO 6750, which such instructions are published. The Maintenan
19、ce Charts defined by SAE J753 may be used in the absence of Maintenance Instructions, but it will probably be less inclusive. Excluded items are the first oil changes at less than thescheduled interval and retightening during the first 100 hours. The actual machine (s) shall be used. It will be the
20、responsibility of the auditor to identify obvious errors or omissions in the Maintenance Instructions when preparing maintenance index data sheets. Refueling the machine should be included. SAE J817 Reissued DEC2009 Page 3 of 9Although not essential, it is desirable to list according to frequency, s
21、hortest frequency first, as suggested by the format inFigure 2. Figure 2 will be used as a reference throughout this procedure. Items that can be continuously monitored from the operators station are exempt from point assessments. Dipsticks or level indicators are still needed at fill points and wil
22、l be assessed points at the change interval. Each phase of a multiple-step operation should be listed and points assessed. For example, an oil change requires draining the crankcase as one operation and filling the crankcase as another operation, so each should be listed. Each item should be listed
23、separately, or combined if nearly identical, through use of the quantity multiplier to give full credit when the number of items is reduced, except when “banking” is used. Banked fittings (two or more of the same interval) shall receive one point for each bank. Banked fittings are defined as a group
24、 of fittings in a common location remote from the joints being lubricated. Search the list under the discussion of requirementslocation, access, operation, and miscellaneousfor the characteristics which most closely resemble those of the item being rated. Enter the corresponding point value in the a
25、ppropriate column. Select the frequency multiplier for the proper interval and enter it in the column for each of the maintenance items listed. Add the points across the chart for each item and enter this in the subtotal column. Multiply by the quantity multiplier, if used, to determine subtotal 2.
26、Multiply subtotal 2 by the frequency multiplier to find the total for each item. When the totals have been found for all maintenance items, add them down to find the maintainability index for the entire machine. 3.3 Requirements (See Tables 1 through 5.) 3.3.1 Location Location refers to the positio
27、n in which an individual must locate himself in order to do the job. If more than one operation can be accomplished from the same location at the same service interval or multiple thereof, the first operation is assessed points applicable to that location, and the remainder are assessed one point ea
28、ch. Table 1 shows the positions considered and their respective point values. 3.3.2 Access Access refers to the ease of reaching a lubrication or maintenance point. If more than one operation can be accomplished through the same access at the same service interval or multiple thereof, the first oper
29、ation is assessed points applicable to that access and the remainder are assessed one point each. TABLE 1 - LOCATIONS AND RESPECTIVE POINT VALUES Positions Points a. Ground levelworking upright, within normal reach 1 b. Ground levelbending or stretching outside normal reach 2 c. Ground levelsquattin
30、g, kneeling, or lying (except under the machine) 3 d. Mount machinenormal reach 10 e. Mount machinebending, stretching, or squatting 15 f. Any position (other than upright) under or within the confines of the machine 25 g. Requires climbing into position without handrails and/or steps/platforms bein
31、g provided 50 Accessibility considerations along with their respective point values are shown in Table 1. SAE J817 Reissued DEC2009 Page 4 of 9TABLE 2 - ACCESSIBILITY CONSIDERATIONS AND THEIR RESPECTIVE POINT VALUES Accessibility Consideration Points a. Exposed 1 b. Exposedthrough opening 2 c. Flip
32、up cover or flap 3 d. Door or coverhand operated 4 e. Door or coversingle fastener 10 f. Door or covermultiple fasteners 15 g. Hood removal 35 h. Multiple coversmultiple fasteners 50 i. Radiator guard removal 50 j. Tilt Cab 75 k. Crankcase/drivetrain guard removalhinged and bolted 75 bolted only 100
33、 3.3.3 Operation Operation refers to the action required to perform the servicing of the listed items. The operation considerations and their respective point values are grouped into categories of similar actions for easy reference. They are shown in Table 3. TABLE 3 - OPERATION CONSIDERATIONS AND T
34、HEIR RESPECTIVE POINT VALUES Operation Considerations Points Compartment Checking (Liquid) a. Visual check 1b. Dipstick 3c. Screw caphand removable 4 d. Multiple screw caphand removable 6 e. Screw cap or plug requiring tool 8 f. Multiple screw cap or plug requiring tool 10 Component Checking a. Visu
35、al check 1b. Hand check of belt tension 2 c. Non-precision tool (includes tire pressure check or torque wrench) 5 d. Precision tool 10Lubricatinga. Fitting (or bank of fittings) 1 b. Fitting requiring special adapter 3 c. Brush on lube 5d. Oil can lube 5e. Fitting requiring secondary action, such as
36、 hand rotating shaft to get fitting to accessible location 5f. Hand packing (each) 20SAE J817 Reissued DEC2009 Page 5 of 9TABLE 3 - OPERATION CONSIDERATIONS AND THEIR RESPECTIVE POINT VALUES (CONTINUED) Operation Considerations Points Draininga. Drain valvehand operable 1 b. Drain valvetool required
37、 3 c. Horizontal plug 6d. Vertical plug 8e. Cover plate 10f. Multiple plugs or covers 15 Fillinga. Hand removed cap 1b. Tool removed cap or plugvertical 3 c. Awkward access to filler because of interfering parts or excessive slope of filler tube 8 d. Tool removed plug-horizontal 10 e. Requires pump
38、to fill (i.e., differential under machine) 10 f. Multiple caps or plugs 15Cleaninga. Blow with air 3b. Single bath wash 5c. Multiple bath wash or wash and oil 10 d. Clean reservoir by solvent or similar technique 10 Filter Replacement a. Spin on (vertical base up) 1 b. Spin on (base up inclined more
39、 than 15 degrees) 3 c. Single fastener not requiring tool 4 d. Single fastener requiring tool 5 e. Multiple fastener not requiring tool 6 f. Multiple fastener requiring tool 7 Adjustment a. Single step 2b. Multiple step 4c. Multiple location multiple step 10 3.3.4 Miscellaneous Items in this list ca
40、nnot be categorized under the headings in Table 3. These requirements are generally considered undesirable and as such should be avoided if possible. In effect, the point values listed or miscellaneous items are punitive points. The requirements for caution can be established by the manufacturers Ma
41、intenance Instructions, by Warning and Cautions affixed to the machine or by the judgment of the auditor. The miscellaneous considerations are shown in Table 4. SAE J817 Reissued DEC2009 Page 6 of 9TABLE 4 - MISCELLANEOUS CONSIDERATIONS AND THEIR RESPECTIVE POINT VALUES Consideration Points a. Drain
42、age indirectly collectible into container (requires hose or pipe) 2 b. Interval not in conformance with SAE J753 or ISO 6750 2 c. Bleeding required 3 d. Priming required 3 e. Special tool 4 f. Inadequately identified 4 g. Filler size inadequate 5 h. Vulnerable to contamination 5 i. Need to start eng
43、ine 5 j. Torquing required (per fastener) 5 k. Drain and wash filter housing 8 l. Need for special instruction 10 m. Need to operate or position machine (includes warm-up) 10 n. Unable to collect fluid 20 o. Inadequate clearance for required operation 20 p. Two persons required 40 q. Requires use of
44、 ladder separate from machine 50 r. Operation requiring caution 100 s. Position requiring caution 100 3.3.5 Frequency Multiplier (Maintenance Interval) Maintenance interval refers to the frequency of performing a lubrication or maintenance item. Requirements for one-time only, scheduled retightening
45、 or lubricant changes for new machines with less than 100 hours on them will not be considered in determining maintenance index points. The frequency multipliers are assigned as shown in Table 5. TABLE 5 - FREQUENCY MULTIPLIERS Maintenance Interval FrequencyMultipliera. 1000 hoursSemi-annually, or g
46、reater 1 b. 500 hoursQuarterly, or as required 2 c. 250 hoursMonthly 4 d. 100 hoursSemi-monthly 10 e. 50 hoursWeekly 20 f. 10 hoursDaily 50 The hour intervals listed conform to Annex B of ISO 6750 and SAE J753. If intervals other than those shown are used, apply the frequency multiplier of the neare
47、st SAE Recommended Practice interval plus a miscellaneous penalty of two points.Each lubrication and maintenance item is assigned a frequency multiplier oncethe most frequent interval performed. For example, a schedule that stipulates that the engine oil level must be checked daily would be recorded
48、 on the form only once. This item would not enter the count again, even though it may be performed during a monthly oil change. SAE J817 Reissued DEC2009 Page 7 of 94. SUMMARY Any items which have a high point value must be carefully scrutinized. In addition to offering an excellent opportunity for
49、a reduction in the maintenance index, items with a high point value emphasize maintenance areas which are likely to be skipped by the serviceman because of the difficulty involved. Improvement in these areas can reduce the risk of machine or component failure because of neglect, as well as reduce critical machine downtime for periodic maintenance. There are maintenance reduction possibilities not included
