Maintenance Catalog Example¶

This example shows a maintenance catalog based on operating hours for an Industrial Material Handler.

It illustrates a typical setup including maintenance intervals, activities, spare parts, and external links.

Functional Description¶

The maintenance catalog is based on operating hours as the maintenance trigger.

Maintenance tasks are created based on the signal
value.common.machine.hours.operation.total
An advance warning of 50 hours is configured before a task becomes due
A service counter (value.common.machine.service.count) is used to track completed maintenance

Maintenance Intervals¶

The following maintenance intervals are defined:

50h (one-time)
Initial service including checks, replacements, and lubrication
250h (recurring)
Regular service including oil change, inspections, and Kit A
500h (recurring)
Extended service including filter replacements, adjustments, and Kit B
1000h (recurring) Major service including full fluid changes, inspections, and Kit C
2000h (recurring)
Annual inspection including structural checks and major component inspection

Activities and Resources¶

Each interval defines:

A set of activities (e.g. Check, Replace, Inspect, Test)
Required spare parts grouped into kits
Links to external ordering systems and parts catalogs

YAML Configuration Example¶

The following YAML configuration represents the maintenance catalog described above.

YAML Configuration Example (click to view)

---
task:
  name:
    en: "Maintenance at $target hours"
  description:
    en: "Maintenance task for Industrial Material Handler."
  source: "industrial_material_handler.maintenance"

settings:
  base: "hours"
  advance: 50
  set_checklist_activities: False
  set_description_activities: True
  sort_description_activities_by_text: False
  sort_description_activities_by_cycle: True
  group_root_activities: True
  set_activity_cycle: False

signals:
  operating_hours:
    key: "value.common.machine.hours.operation.total"
    mandatory: true
  service_counter:
    key: "value.common.machine.service.count"
    mandatory: true

models:
  Industrial Material Handler:
    links:
      en:
        Order Kit-A: "https://shop.equipment-oem.com/parts-portal#Kit-A"
        Parts catalog: "https://parts.equipment-oem.com/catalog/handler-series"
        Order Kit-B: "https://shop.equipment-oem.com/parts-portal#Kit-B"
        Order Kit-C: "https://shop.equipment-oem.com/parts-portal#Kit-C"

    unique_activities:
      50:
        en:
          Check:
            - Battery connections/electrolyte
            - hydraulic oil level
            - all fluids
            - tire pressure/condition
            - safety systems
          Replace:
            - Engine oil filter (first service)
            - hydraulic pressure filter cartridges
          Lubricate:
            - Pivot points
            - bearings
            - steering linkages

    cycle_activities:
      250:
        en:
          Change:
            - Engine oil (15W-40)
            - engine oil filter
            - fuel filter
          Check:
            - Air filter
            - drive belts
            - brakes
            - hydraulic hoses
          Inspect:
            - Structural welds
            - mounting bolts
            - electrical connections
          Kit A (250h):
            - Engine oil filter ×1
            - fuel filter ×1
            - O-rings ×4
            - drain plug washers ×2

      500:
        en:
          Replace:
            - Primary air filter
            - fuel pre-filter
            - fuel main filter
            - hydraulic return filter
            - cabin air filter
          Change:
            - Transmission oil (if equipped)
          Check/Adjust:
            - Valve clearance
            - parking brake
            - steering alignment
          Test:
            - Hydraulic cylinders load test
            - hydraulic pressure (target ~210 bar)
          Kit B (500h):
            - Primary air filter ×1
            - fuel pre-filter ×1
            - fuel main filter ×1
            - hydraulic return filter ×1
            - cabin air filter ×1
            - transmission oil filter ×1

      1000:
        en:
          Replace:
            - Secondary air filter
            - all hydraulic filters + seals
            - breather filters
            - AdBlue/DEF filter (if equipped)
          Change:
            - Hydraulic oil (full system)
            - axle differential oil
          Inspect:
            - Turbocharger
            - exhaust system
            - engine mounts/dampeners
          Service:
            - Clean radiator/oil cooler
            - flush cooling system and replace coolant
          Kit C (1000h):
            - Hydraulic pressure filters ×3
            - hydraulic return filters ×2
            - breather filters ×2
            - secondary air filter ×1
            - AdBlue filter ×1
            - complete seal kit
            - filter housing O-rings ×12

      2000:
        en:
          Replace:
            - Drive belts (alt/fan/AC)
            - coolant (flush)
            - brake fluid
          Major inspection:
            - Load-test structure
            - NDT of critical welds (if needed)
            - calibrate load sensors/safety systems
          Check:
            - Wheel bearings
            - final drive planetaries
            - hydraulic pump wear/efficiency

Mapping to YAML Configuration¶

The following table maps the functional elements of this example to their corresponding YAML configuration fields.

Functional Concept	YAML Configuration
Machine type	`models: Industrial Material Handler`
Maintenance base (operating hours)	`settings.base: "hours"`
Primary signal (operating hours)	`signals.operating_hours.key`
Service counter	`signals.service_counter.key`
Advance warning (50h)	`settings.advance: 50`
One-time maintenance (50h)	`models.<model>.unique_activities.50`
Recurring maintenance (250h, 500h, etc.)	`models.<model>.cycle_activities.<interval>`
Activities (Check, Replace, etc.)	Nested under `unique_activities` or `cycle_activities`
Spare parts kits	Represented as grouped activity entries
External links	`models.<model>.links`