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Management of mobile equipment maintenance audit– guideApproved: 27 January 20161 Adelaide Terrace, East Perth WA 6004Postal address: Mineral House, 100 Plain Street, East Perth WA 6004Telephone: (08) 9358 v.au

Table of contentsIntroduction . 2Glossary 21 Register of equipment . 42 Maintenance program . 43 Maintenance of key systems and components . 84 Maintenance of ancillary systems and components . 135 Maintenance facilities . 16Management of mobile equipment maintenance audit - guidePage 1 of 19

IntroductionThis document was reformatted in November 2015. At this time no material changes were made to thecontent of the guide, which was originally published in October 2014 under the title Guide to mobileequipment on mines high impact function (HIF) audit 2014 Part 4 – Management of mobile equipmentmaintenance.Note: The Safety Regulation System (SRS) has replaced the AXTAT system and all reporting is doneonline through SRS.This audit document is designed to include standards associated with the management of mobileequipment maintenance in mining operations.The four ‘mobile equipment’ audit documents cover: traffic management (Part 1), mining operations and equipment selection (Part 2), surface and underground operations with site deliveries (Part 3), and management of mobile equipment maintenance (Part 4).This document (Part 4) covers management of mobile equipment maintenance. This part has fiveelements and a total of 52 individual standards.This audit includes reference to a wide range of powered mobile equipment including haul trucks, watertankers, industrial lift trucks (forklifts), integrated tool carriers, elevating work platforms, mobile cranes,earthmoving machinery, surface miners, aircraft tugs, light vehicles and other vehicles fitting the title. Itincludes anything that can be driven or ridden on or in and excludes rail mounted equipment andequipment such as bridge & gantry cranes, stackers, reclaimers, ship loaders, locomotives and rollingstock and tethered mobile equipment (e.g. electric shovels, rope driven equipment).This audit should be read and utilised in conjunction with the Safe Work Australia’s model code ofpractice for roads and other vehicle operator areas.This part contains a number of standards that may not be applicable to all mines. Standards that are notapplicable should be left out and will not influence audit outcomes.Where the term “verify” is used in the guideline intent, it implies there is a regulatory requirement forcompliance with the standard. Where the term “ensure” is used, there is no mandatory requirement forcompliance but the standard sets out a recommended practice, which, if followed, should minimise therisk of incidents.Mobile equipment guidance material is available from the Department of Mines and Petroleum web site,www.dmp.wa.gov.au.Further traffic guidance material is provided at: lications/Index.htm n/Safe movement vehicl.pdf http://www.dme.qld.gov.au http://dpi.nsw.gov.au Personnel access to heavy mining machinery – guidelineGlossaryMSIAMSIRMSBSIRNSW SANSW SBWalesQLD SAMines Safety and Inspection Act 1994Mines Safety and Inspection Regulations 1995DMP Mines Safety BulletinDMP Mines Safety Significant Incident ReportSafety alerts issued by the Department of Trade and Investment, New South WalesSafety bulletins issued by the Department of Trade and Investment, New SouthSafety alerts issued by the Department of Natural Resources and Mines, QueenslandManagement of mobile equipment maintenance audit – guidePage 2 of 19

Management of mobile equipment maintenance audit – guidePage 3 of 19

1Register of equipmentRegister of equipmentPointStandardGuideline1.1There is a register of mobileequipment, includingpermanent contractor’sequipment and a system tomanage the condition andmaintenance of itinerantmobile equipment on the minesite.Intent:To ensure that all the relevant equipment details arereadily available.The register is current.Intent:To ensure that the register contains up to date records.1.2Personnel:Maintenance Manager.Method:View the register of mobile equipment. Check thatclassified mobile plant is included.Personnel:Maintenance Manager.Method:View the register of mobile equipment and correlateagainst recent purchases and disposals.1.3Each item of equipment isclearly identified with theappropriate register number, inlettering sufficiently largeenough to be easily read froma distance.Intent:To ensure that items of equipment can easily beidentified for requirements such as seeking permissionby radio for overtaking, passing behind etc.Personnel:N/AMethod:View various items of mobile equipment such asloaders, dozers, excavators, haul trucks, lightvehicles etc.2Maintenance programMaintenance programPointStandardGuidelineManagement of mobile equipment maintenance audit - guidePage 4 of 19

2.1A competent person isappointed to be in charge ofthe maintenance program.Intent:To ensure that maintenance will be under the directionof a suitable competent person.Personnel:Maintenance Supervisor.Method:Sight appointment documentation, interviewmaintenance supervisor.2.2There is an effective routinepreventative maintenanceprogram for mobile equipmentwhich is carried out atpredetermined intervals of timeor distance.Intent:To verify that mobile equipment is maintained in a safeoperating condition.Personnel:Maintenance personnel.Method:View written program and interview maintenancepersonnel.Refer to MSIR rr. 6.2, 10.37 and 13.2.2.3The maintenance program isdeveloped in accordance withthe recommendations of theequipment manufacturer.Intent:To verify that the maintenance program is specific tothe equipment.Personnel:Maintenance personnel.Method:Compare OEM maintenance manuals andrecommendations with the site maintenanceprocedures.Refer to MSIR r. 6.2.2.4The maintenance programcovers all the operatingfunctions of the mobileequipment.Intent:To verify that the vehicle operating functions aremaintained in a safe operable conditionPersonnel:Maintenance personnelMethod:View maintenance documents and interviewmaintenance personnel.Refer to MSIR r. 6.2.Management of mobile equipment maintenance audit – guidePage 5 of 19

2.5The maintenance programcovers all ancillary systemsand components fitted to themobile equipment.Intent:To verify that the vehicle ancillary systems andcomponents are maintained in a safe operableconditionPersonnel:Maintenance personnel.Method:View maintenance documents and interviewmaintenance personnel.Refer to MSIR r. 6.2.2.6The maintenance program isupdated when new equipmentis placed into operation.Intent:To ensure that all new equipment is included in themaintenance program.Personnel:Maintenance personnel.Method:Sight document records, interview maintenancepersonnel.2.7Replacement parts andcomponents are selected inaccordance with the mobileequipment manufacturer’sspecifications.Intent:To ensure that the replacement parts and componentsare compatible with the equipment.Personnel:Maintenance personnelMethod:View maintenance documents and interviewmaintenance personnel.2.8The defect reporting procedureprovides information andaccountability for therectification of faults found onmobile equipment.Intent:To ensure that there is clear accountability for therectification of faults found on mobile equipment.Personnel:Maintenance personnel.Method:Observe documentation and interview maintenancepersonnel.2.9Mobile equipment defectreports are attended to in atimely manner.Intent:To ensure that defects are rectified in a timely andsystematic manner.Personnel:Maintenance supervisor.Method:Inspect a sample of equipment defect reports. Confirmthat defects reported have been rectified in areasonable time frame. Confirm if the company has apriority escalation process based on timing.Management of mobile equipment maintenance audit – guidePage 6 of 19

2.10Results of mobile equipmentinspections are monitored toidentify common defects orpatterns of defects with a viewof preventing recurrences.Intent:To ensure that trends are identified in order to preventa recurrence.Personnel:Maintenance plannerMethod:Review prevention program.Management of mobile equipment maintenance audit – guidePage 7 of 19

3Maintenance of key systems and componentsMaintenance of key systems and componentsPointStandardGuideline3.1ROPS/FOPS and theirmountings are inspected andwhere damage is identified themobile equipment is removedfrom service.Intent:To verify that appropriate systems are in place andmeasures are taken to identify significant damage andmake necessary arrangements for repair orreplacement.Personnel:Maintenance personnel.Method:Review maintenance procedures, inspect samples ofROPS/FOPS placarding.Refer to MSIR r. 4.15(2)(c), AS 2294 Earth-movingmachinery— Protective structures Part 1: General, AS1636 Tractors – Roll-over protective structures –Criteria and tests and AS 2359.9 Powered industrialtrucks – Overhead guards – Specification and testing(ISO 6055:2004, MOD).3.2Where a ROPS/FOPS repair isrequired it is carried out inaccordance with themanufacturer’s specifications.Intent:To verify that if repairs are performed, theROPS/FOPS will function as designed.Personnel:Maintenance personnel.Method:Interview maintenance personnel and viewmanufacturer’s documents.Refer to MSIR r. 4.15(2)(c), AS 2294 Earth-movingmachinery— Protective structures Part 1: General, AS1636 Tractors – Roll-over protective structures –Criteria and tests and AS 2359.9 Powered industrialtrucks – Overhead guards – Specification and testing(ISO 6055:2004, MOD).3.3Mobile equipment brakecomponents are inspected,repaired or replaced inaccordance with themanufacturer’srecommendations.Intent:To verify that mobile equipment brakes will function asdesigned.Personnel:Maintenance personnel.Method:View manufacturer’s service documents andequipment service records.Refer to MSIR rr. 10.38 and 13.2.Management of mobile equipment maintenance audit – guidePage 8 of 19

3.4Any braking system installedon a trailer is maintained in anoperational condition.Intent:To ensure that any trailer fitted with a braking system isprovided with effective brakes capable to bring theequipment to a safe halt and hold it in allcircumstances.Personnel:Maintenance personnel.Method:Inspect maintenance records, the pre-start booklet anda sample of trailer equipment to ensure that the brakesare being checked and maintained on the equipmentprior to use.3.5Mobile equipment steeringcomponents are inspected,maintained, repaired orreplaced in accordance withthe manufacturer’srecommendations.Intent:To verify that the steering components will function asdesigned.Personnel:Maintenance personnel.Method:View manufacturer’s service documents andequipment service records to verify that componentsare checked and maintained on mobile equipmentservice sheet records.Refer to MSIR r. 10.37 and 13.3(4), Mines SafetyBulletin No. 84 and Mines Safety Significant IncidentReport No. 128.3.6Emergency braking andsteering systems, where fitted,are inspected and the resultsof these inspections arerecorded.Intent:To verify that mobile equipment emergency systemsare checked to ensure functionality.Personnel:Maintenance personnel.Method:View equipment records and interview maintenancepersonnel and service records.Refer to MSIR rr. 10.38(8) and 13.3(4).3.7Mobile equipment lighting isinspected and repaired orreplaced when found to bedefective.Intent:To verify that mobile equipment lighting will function asdesigned.Personnel:Maintenance personnel and operators.Method:View equipment service records and interviewmaintenance personnel and operators of equipment.Confirm that driving, marker, reversing, instrument, tail,indicator and brake lights are checked. Check in-situ.Refer to MSIR r. 13.3(4).Management of mobile equipment maintenance audit – guidePage 9 of 19