SURFACE J817-2

REV.
MAR91
VEHICLE
400 Commonwealth Drive, Warrendale, PA 15096-0001
INFORMATION Issued 1962-04
REPORT Revised 1991-03

Superseding J817 JUL76

(R) ENGINEERING DESIGN SERVICEABILITY GUIDELINES—CONSTRUCTION AND INDUSTRIAL

MACHINERY—MAINTAINABILITY INDEX—OFF-ROAD WORK MACHINES

1. Scope—This SAE Information Report establishes a point system that encourages ease of maintenance
actions on off-road work machines. The point system minimizes subjectivity in evaluating maintainability as
defined in J817-1.

1.1 This document applies to machines defined in J1057 and categorized in J1116.

2. References

2.1 Applicable Publications—The following publications form a part of this specification to the extent specified
herein. The latest issue of SAE publications shall apply.

2.1.1 SAE PUBLICATIONS—Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.

SAE J753 MAY91—Lubrication Chart—Construction and Industrial Machinery

SAE J817/1 MAR91—Engineering Design Serviceability Guidelines—Construction and Industrial
Machinery—Serviceability Definitions—Off-Road Work Machines
SAE J920 SEP85—Technical Publications for Off-Road Work Machines
SAE J1057 SEP88—Identification Terminology of Earthmoving Machines
SAE J1116 JUN86—Categories of Off-Road Self-Propelled Work Machines

3. Maintainability Index—A system for establishing a number to rate an existing or new concept machine. With
this system, lubrication and 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 applied 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.

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 therefrom, 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.

QUESTIONS REGARDING THIS DOCUMENT: (724) 772-8512 FAX: (724) 776-0243

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SAE WEB ADDRESS http://www.sae.org

Copyright 1991 Society of Automotive Engineers, Inc.

All rights reserved. Printed in U.S.A.
 SAE J817-2 Revised MAR91

Frequency multipliers are numbers that represent various service intervals. The subtotal of each item is
multiplied by 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 to 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 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 SAE J1057 and J1116, as it is felt adherence 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
document 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), except for
those nearly identical or identical items to be covered by the quantity multiplier. The items to be listed will be
those defined in the Maintenance Instructions defined in J920, when such instructions are published. The
Maintenance Chart defined by 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 the scheduled interval and
retightening during the first 100 h. The actual machine(s) shall be used. It will be the 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.

Although not essential, it is desirable to list according to frequency, shortest frequency first, as suggested by
the format in Figure 1. Figure 1 will be used as a reference throughout this procedure.

Items that can be continuously monitored from the operator's station are exempt from point assessments.
Dipsticks or level indicators are still needed at fill points and will 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 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 of fittings in a common location remote from the joints being lubricated.

Search the list under the discussion of requirements—location, access, operation, and miscellaneous—for the
characteristics which most closely resemble those of the item being rated. Enter the corresponding point value
in the appropriate 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. 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.

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 SAE J817-2 Revised MAR91

3.3 Requirements—(See Tables 1 through 6.)

3.3.1 LOCATION—Location refers to the position 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 each.

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 operation 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 level—working upright, within normal reach 1
b. Ground level—bending or stretching outside normal reach 2
Ground level—squatting, kneeling, or lying (except under
c. the machine) 3
d. Mount machine—normal reach 10
e. Mount machine—bending, stretching, or squatting 15
Any position (other than upright) under or within the
f. confines of the machine 25
g. Requires climbing into position without handrails and/or steps/platforms being provided 50

Accessibility considerations along with their respective point values are shown in Table 2.

TABLE 2—ACCESSIBILITY CONSIDERATIONS AND THEIR RESPECTIVE POINT VALUES

Accessibility Consideration Points
a. Exposed 1
b. Exposed—through opening 2
c. Flip up cover or flap 3
d. Door or cover—hand operated 4
e. Door or cover—single fastener 10
f. Door or cover—multiple fasteners 15
g. Hood removal 35
h. Multiple covers—multiple fasteners 50
i. Radiator guard removal 50
j. Tilt cab 75
k. Crankcase/drivetrain guard removal—hinged and bolted 75
—bolted only 100

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 SAE J817-2 Revised MAR91

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 THEIR RESPECTIVE POINT VALUES

Operation Considerations Points
Compartment Checking (Liquid)
a. Visual check 1
b. Dipstick 3
c. Screw cap—hand removable 4
d. Multiple screw cap—hand removable 6
e. Screw cap or plug requiring tool 8
f. Multiple screw cap or plug requiring tool 10

Component Checking
a. Visual check 1
b. Hand check of belt tension 2
c. Nonprecision tool (includes tire pressure check or torque wrench) 5
d. Precision tool 10

Lubricating
a. Fitting (or bank of fittings) 1
b. Fitting requiring special adapter 3
c. Brush on lube 5
d. Oil can lube 5
e. Fitting requiring secondary action, such as hand rotating shaft to get fitting to accessible
location 5
f. Hand packing (each) 20

Draining
a. Drain valve—hand operable 1
b. Drain valve—tool required 3
c. Horizontal plug 6
d. Vertical plug 8
e. Cover plate 10
f. Multiple plugs or covers 15

Filling
a. Hand removed cap 1
b. Tool removed cap or plug—vertical 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 to fill (i.e., differential under machine) 10
f. Multiple caps or plugs 15

Cleaning
a. Blow with air 3
b. Single bath wash 5
c. Multiple bath wash or wash and oil 10
d. Clean reservoir by solvent spray or similar technique 10

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 SAE J817-2 Revised MAR91

TABLE 3—OPERATION CONSIDERATIONS AND THEIR RESPECTIVE POINT VALUES (CONTINUED)

Operation Considerations Points
Filter Replacement
a. Spin on (vertical base up) 1
b. Spin on (base up inclined more 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 2
b. Multiple step 4
c. Multiple location multiple step 10

3.3.4 MISCELLANEOUS—Items in this list cannot 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 for miscellaneous items are punitive points. The requirements for caution can be established by the
manufacturer's Maintenance Instructions, by Warnings and Cautions affixed to the machine or by the
judgment of the auditor.

The miscellaneous considerations are shown in Table 4.

TABLE 4—MISCELLANEOUS CONSIDERATIONS AND THEIR RESPECTIVE POINT VALUES

Consideration Points
a. Drainage indirectly collectible into container (requires hose or pipe) 2
b. Interval not in conformance with SAE Recommended Practice J753 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 engine 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 ladder separate from machine 50
r. Operation requiring caution 100
s. Position requiring caution 100

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 SAE J817-2 Revised MAR91

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 or
lubricant changes for new machines with less than 100 h 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

Frequency
Maintenance Interval Multiplier
a. 1000 h-Semi-annually, or greater 1
b. 500 h-Quarterly, or as required 2
c. 250 h-Monthly 4
d. 100 h-Semi-monthly 10
e. 50 h-Weekly 20
f. 10 h-Daily 50

The hour intervals listed conform to SAE Recommended Practice J753. If intervals other than those shown
are used, apply the frequency multiplier of the nearest SAE Recommended Practice interval plus a
miscellaneous penalty of two points.

Each lubrication and maintenance item is assigned a frequency multiplier once—the most frequent interval
performed. For example, a schedule that stipulates that the engine oil level must be checked daily would be
recorded on the form only once. This item would not enter the count again, even though it may be performed
during a monthly oil change.

TABLE 6—POINTS LIST

Points
Location
a. Ground level—working upright, within normal reach 1
b. Ground level—bending or stretching outside normal reach 2
c. Ground level—squatting, kneeling, or lying (except under the machine) 3
d. Mount machine—normal reach 10
e. Mount machine—bending, 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 being provided 50

Access
a. Exposed 1
b. Exposed—through opening 2
c. Flip up cover or flap 3
d. Door or cover—hand operated 4
e. Door or cover—single fastener 10
f. Door or cover—multiple fasteners 15
g. Hood removal 35
h. Multiple covers—multiple fasteners 50
i. Radiator guard removal 50
j. Tilt cab 75
k. Crankcase/drivetrain guard removal—hinged and bolted 75
—bolted only 100
Operation
Compartment Checking (Liquid)
a. Visual check 1

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 SAE J817-2 Revised MAR91

TABLE 6—POINTS LIST (CONTINUED)

Points
b. Dipstick 3
c. Screw cap—hand removable 4
d. Multiple screw cap—hand removable 6
e. Screw cap or plug requiring tool 8
f. Multiple screw cap or plug requiring tool 10

Component Checking
a. Visual check 1
b. Hand check of belt tension 2
c. Nonprecision tool (includes tire pressure check or
5
torque wrench)
d. Precision tool 10

Lubricating
a. Fitting (or bank of fittings) 1
b. Fitting requiring special adapter 3
c. Brush on lube 5
d. Oil can lube 5
e. Fitting requiring secondary action, such as hand
5
rotating shaft to get fitting to accessible location
f. Hand packing (each) 20

Draining
a. Drain valve (including removal of plug) 1
b. Horizontal plug 6
c. Vertical plug 8
d. Cover plate 10
e. Multiple plugs or covers 15

Filling
a. Hand removed cap 1
b. Tool removed cap or plug—vertical 3
c. Awkward access to filler because of interfering parts of excessive slope of filler tube 8
d. Tool removed plug—horizontal 10
e. Requires pump to fill (i.e., differential under machine) 10
f. Multiple caps or plugs 15

Cleaning
a. Blow with air 3
b. Single bath wash 5
c. Multiple bath wash or wash and oil 10
d. Clean reservoir by solvent spray or similar technique 10

Filter Replacement
a. Spin on (vertical base up) 1
b. Spin on (base up inclined more 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

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 SAE J817-2 Revised MAR91

TABLE 6—POINTS LIST (CONTINUED)

Points
Adjustment
a. Single step 2
b. Multiple step 4
c. Multiple location multiple step 10

Miscellaneous
a. Drainage indirectly collectible into container (requires hose or pipe) 2
b. Interval not in conformance with SAE Recommended Practice J753 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 engine 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 ladder separate from machine 50
r. Operation requiring caution 100
s. Position requiring caution 100

Frequency Multiplier Frequency

(Maintenance Interval) Multiplier
a. 1000 h—Semi-annually, or greater 1
b. 500 h—Quarterly, or as required 2
c. 250 h—Monthly 4
d. 100 h—Semi-monthly 10
e. 50 h—Weekly 20
f. 10 h—Daily 50

4. Summary—Any items which have a high point value must be carefully scrutinized. In addition to offering an
excellent opportunity for 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 in the point scores but still of value to the user.
Examples include:

a. Minimum number of liquid types,

b. Standardized filter elements,
c. Common location of maintenance items on a machine family.

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SAE J817-2 Revised MAR91

FIGURE 1—SAMPLE ENTRIES

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 SAE J817-2 Revised MAR91

FIGURE 2—MAINTENANCE INDEX DATA SHEET

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 SAE J817-2 Revised MAR91

5. Notes

5.1 Marginal Indicia—The change bar (l) located in the left margin is for the convenience of the user in locating
areas where technical revisions have been made to the previous issue of the report. An (R) symbol to the left
of the document title indicates a complete revision of the report.

PREPARED BY THE SAE OFF-ROAD MACHINERY TECHNICAL COMMITTEE SC16—

SERVICEABILITY

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 SAE J817-2 Revised MAR91

Rationale—

Introduction—The object is to completely revise the Information Report as directed under the five-year
review. The last update was July 1976.

Discussion—The document has been divided to provide a preliminary definitions section and separate
sections for each of the major design factors affecting serviceability.

The definitions were unchanged except for the addition of a Diagnostics category.

The Repair Index procedure was dropped with unanimous consent of ORMTC members polled.

The procedure was not being used as more practical repairability measurements exist, such as time
studies. The future development of systems for measuring diagnostics and repairability is possible.

This revision was validated on machines by the committee and found to meet these established
objectives:

a. More emphasis on penalizing difficult operations.

b. More emphasis on penalizing items with personal injury potential.
c. Recognition of design facilitation of periodic maintenance items, i.e.:

In seat checks
Banked fittings

d. Reduced emphasis on the frequency multiplier in order to have more difficult but infrequent items
significantly influence the total score.
e. Items have been added in various categories to clarify the scoring procedure.

The Data Sheet has had Subtotal and Quantity Multiplier columns added to facilitate the work of the
auditor. The same data sheet included emphasizes the use of auditor comments.

There will be no direct correlation between scores derived by the proposed revised procedure and the
former one. The new procedure scores will better reflect actual difficulty of maintenance work. This
remains a heuristic procedure.

Relationship of SAE Standard to ISO Standard—Not applicable.

Application—This SAE Information Report establishes a point system that encourages ease of maintenance
actions on off-road work machines. The point system minimizes subjectivity in evaluating maintainability
as defined in J817/1.
 SAE J817-2 Revised MAR91

Reference Section

SAE J753 MAY91—Lubrication Chart—Construction and Industrial Machinery

SAE J817/1 MAR91—Engineering Design Serviceability Guidelines—Construction and Industrial

Machinery—Serviceability Definitions—Off-Road Work Machines

SAE J920 SEP85—Technical Publications for Off-Road Work Machines

SAE J1057 SEP88—Identification Terminology of Earthmoving Machines

SAE J1116 JUN86—Categories of Off-Road Self-Propelled Work Machines

Developed by the SAE Off-Road Machinery Technical Committee SC16—Serviceability

Sponsored by the SAE Off-Road Machinery Technical Committee