GUIDELINES

MDG 15
Guideline for mobile and
transportable plant for use at
mines – Draft for comment

Produced by Mine Safety Operations Branch

NSW Trade & Investment
August 2012
COMMENTS
Comments on this document can be sent via email to lyndon.hughes@industry.nsw.gov.au.
Alternatively comments can be mailed to Lyndon Hughes,Mine Safety Operations, 516 High St,
Maitland NSW 2320.
Comments must be received by close of business on 31 August 2012.

PUBLICATION HISTORY
– First published June 1992
– 1st Revision Date: March 2002
– DRAFT 2nd Revision Date: August 2012

DISCLAIMER
The compilation of information contained in this document relies upon material and data derived
from a number of third party sources and is intended as a guide only in devising risk and safety
management systems for the working of mines and is not designed to replace or be used
instead of an appropriately designed safety management plan for each individual mine. Users
should rely on their own advice, skills and experience in applying risk and safety management
systems in individual workplaces.
Use of this document does not relieve the user (or a person on whose behalf it is used) of any
obligation or duty that might arise under any legislation (including the Work Health and Safety
(WHS) Act 2011, any other act containing requirements relating to mine safety and any
regulations and rules under those acts) covering the activities to which this document has been
or is to be applied.
The information in this document is provided voluntarily and for information purposes only. The
New South Wales Government does not guarantee that the information is complete, current or
correct and accepts no responsibility for unsuitable or inaccurate material that may be
encountered.
Unless otherwise stated, the authorised version of all reports, guides, data and other information
should be sourced from official printed versions of the agency directly. Neither Trade &
Investment, the New South Wales Government, nor any employee or agent of the Department,
nor any author of or contributor to this document produced by the Department, shall be
responsible or liable for any loss, damage, personal injury or death howsoever caused. A
reference in this document to "the Department" or "Trade and Investment" is taken to be a
reference to the NSW Department of Trade and Investment, Regional Infrastructure and
Services.
Users should always verify historical material by making and relying upon their own separate
enquiries prior to making any important decisions or taking any action on the basis of this
information.
This publication contains information regarding occupational health, safety, injury management
and workers compensation. It includes some obligations under the various workers
compensation and occupational health and safety legislation that Trade & Investment
administers. To ensure compliance with legal obligations, refer to the appropriate legislation.
In the event of inconsistency with a provision of any relevant Act or Regulation the provision
prevails over the guideline.
This publication may refer to NSW legislation that has been amended or repealed. When
reading this publication, refer to the latest laws. Information on the latest laws can be checked
at:
www.legislation.nsw.gov.au
Alternatively, phone (02) 4931 6666.
FOREWORD
This Guideline (MDG 15), Guideline for Mobile and Transportable Plant for Use at Mines, has
been compiled to assist persons conducting a business or undertaking (PCBUs) in meeting work
health and safety obligations when involved in the management, control, design, Manufacturer,
import, Supply, Purchase, installation, construction, commissioning or Operation of mobile and
transportable plant. This MDG also assists the Mine Safety Operations branch of the N.S.W.
Department of Trade and investment, Regional Infrastructure and Services when assessing
safety aspects of mobile and transportable plant used at Mines, Surface of Underground Coal
Mines and Product Processing Plants.
This is a ‘Published Guideline’. Further information on the status of Guidelines in the range of
supporting WHS documents is available through the N.S.W. Department of Trade and
Investment Legislation Update Number 2/2001. The range of supporting WHS documents

• Acts of Parliament
includes:

• Regulations made under the Acts

• Standards (AS, ISO, IEC)
• Approved Codes of Practice (under the WHS Act 2011)
• Published Guidelines
• Guidance Notes
• Technical Reference documents
• Safety Alerts
• Gazettal notices
The principles stated in this document are intended as a general guideline, for the assistance of
Owners, Managers, Manufacturers, Suppliers, Importers and Designers in devising safety
standards for the design, operation and maintenance of Mobile and Transportable Plant.
Persons in Control Business Undertaking’s (PCBUs) should rely upon the application of risk
management and risk assessment techniques in applying practices to be observed in individual
workplaces.
The Work Health and Safety Act and Regulation 2011 can be accessed from the following
website:
http://www.workcover.nsw.gov.au/lawpolicy/Regulations/Pages/default.aspx

MAJOR CHANGES
Major changes in this version of MDG 15 include:
(a) Standards Australia have withdrawn nearly all Australian earth-moving machinery standards.
ISO earth-moving machinery standards have instead been referenced.
(b) Electrical section has been expanded.
(c) Information on road-registrable vehicles is included.

MDG 15 – Guideline for mobile and transportable plant for use at mines - Draft for comment iii
CONTENTS
1 SCOPE AND PURPOSE ............................................................................................................6
1.1 SCOPE .................................................................................................................................6
1.2 OBJECTIVE ..........................................................................................................................6
1.3 ACT AND REGULATION ......................................................................................................6
1.4 APPLICATION ......................................................................................................................6
1.5 MANAGEMENT OF RISKS ..................................................................................................7
1.6 RELATED AND REFERENCE DOCUMENTS .....................................................................8
1.7 DEFINITIONS .......................................................................................................................8
2 GENERAL REQUIREMENTS ...................................................................................................13
2.1 RECOGNISED PUBLISHED STANDARDS - GENERAL ...................................................13
2.2 COMPLIANCE STATEMENT .............................................................................................13
2.3 DOCUMENTATION ............................................................................................................13
2.4 SAFETY REQUIREMENTS ................................................................................................17
2.5 MAINTENANCE ..................................................................................................................19
2.6 ACCIDENT REVIEW ..........................................................................................................20
2.7 LIMITS OF PLANT APPLICATION .....................................................................................20
2.8 OPERATIONAL REQUIREMENTS ....................................................................................21
3 REQUIREMENTS FOR DESIGN AND MANUFACTURE ........................................................23
3.1 ACCESS TO PLANT...........................................................................................................23
3.2 BRAKES .............................................................................................................................24
3.3 BRAKE PERFORMANCE ...................................................................................................25
3.4 CONTROL FUNCTIONS ....................................................................................................26
3.5 ENGINE COMPARTMENT .................................................................................................27
3.6 ERGONOMICS ...................................................................................................................28
3.7 FIRE CONTROL SYSTEMS ...............................................................................................29
3.8 FLUID SYSTEMS ...............................................................................................................31
3.9 GUARDS AND SHIELDS....................................................................................................33
3.10 MARKING, SIGNS AND IDENTIFICATION ......................................................................34
3.11 LIGHTING AND ALARMS.................................................................................................36
3.12 NOISE ...............................................................................................................................37
3.13 OPERATOR'S CABIN AND PROTECTION......................................................................38
3.14 PRESSURE VESSELS .....................................................................................................41
3.15 STEERING........................................................................................................................42
3.16 TOWING, JACKING & SUPPORTING .............................................................................42
3.17 WHEELS AND RIMS ........................................................................................................43
 3.18 TYRES ..............................................................................................................................44
3.19 PROXIMITY DETECTION AND COLLISION AVOIDANCE .............................................44
4 REQUIREMENTS FOR SPECIFIC TYPES OF PLANT ...........................................................45
4.1 DUMP TRUCKS..................................................................................................................45
4.2 CONVEYORS .....................................................................................................................46
4.3 CRUSHERS ........................................................................................................................46
5 ELECTRICAL REQUIREMENTS .............................................................................................47
5.1 GENERAL ...........................................................................................................................47
5.2 MECHANICAL PROTECTION OF CABLES, CONDUCTORS AND WIRING LOOMS ......48
5.3 EMERGENCY STOP DEVICE SYSTEM ............................................................................50
5.4 GENERAL ARRANGEMENT OF EXTRA LOW VOLTAGE CONTROL & PROTECTION .51
6 APPENDICES ...........................................................................................................................55
6.1 APPENDIX A – ASSOCIATED STANDARDS AND CODES ..............................................55
6.2 APPENDIX B – ELECTRICAL WIRING DIAGRAMS..........................................................69
6.3 APPENDIX C – LEGISLATION...........................................................................................76
6.4 APPENDIX D – HUMAN ERROR .......................................................................................79
6.5 Appendix E – GENERIC HAZARD CHECKLIST FOR PLANT ...........................................80
6.6 Appendix f - PUBLIC ROAD REGISTRABLE PLANT .........................................................84
6.7 APPENDIX g – FEEDBACK SHEET ..................................................................................85

MDG 15 – Guideline for mobile and transportable plant for use at mines - Draft for comment v
1 SCOPE AND PURPOSE

1.1 SCOPE
This guideline is an informative guide for anyone who has a duty of care relating to mobile
and transportable plant used in mines.
This Guideline sets out safety information for the design, manufacture, operation and
maintenance of Mobile and Transportable Plant and associated plant for Use at Mines.
This Guideline covers both Electric and Diesel Powered plant unless otherwise specifically
mentioned. It includes many of those items that have been identified as requiring specific
attention in order to provide safe mobile or transportable plant, but it by no means covers all
possible details that should be reviewed by a person conducting a business or undertaking
(PCBU) involved in design, manufacture, import, supply, purchase, ownership, operation and
site contracting.
This Guideline does not generally give quantitative information as it is not intended to restrict
innovative design. Where specific values or test procedures are required, advice should be
sought from the relevant regulatory body or those with a duty to provide that information.
NOTE: Information for plant used on mine sites that is capable of being registered for use on
public roads is given in Appendix F.

1.2 OBJECTIVE
The objective of this Guideline is to assist PCBU’s and associated duty holders in meeting
their duty when involved in plant life cycle and activities including design, manufacture,
importation, supply, purchase, ownership, operation, maintenance, and site contracting.

1.3 ACT AND REGULATION

The reader, when applying any part of this Guideline, is required to be aware of duty of care
under the Work Health and Safety Act 2011 (WHS) and Work Health and Safety Regulation
2011.
This Guideline does not in any way negate or replace legislative requirements.

1.4 APPLICATION
This Guideline is intended to cover the safety aspects of mobile and transportable plant used
at mines and Product Processing Plants.
This Guideline does not apply to underground coal mining plant.
It should be used and considered when;
(a) Plant is designed or purchased,
(b) Plant is overhauled or modified,
(c) Used plant is purchased,
(d) Plant is used on site.
1.5 MANAGEMENT OF RISKS

An extract from WHS Regulation 2011, Clause 35 and Clause 36:

35 Managing risks to health and safety
A duty holder, in managing risks to health and safety, must:
(a) eliminate risks to health and safety so far as is reasonably practicable, and
(b) if it is not reasonably practicable to eliminate risks to health and safety—
minimise those risks so far as is reasonably practicable.
36 Hierarchy of control measures
(1) This clause applies if it is not reasonably practicable for a duty holder to eliminate
risks to health and safety.
(2) A duty holder, in minimising risks to health and safety, must implement risk control
measures in accordance with this clause.
(3) The duty holder must minimise risks, so far as is reasonably practicable, by doing 1
or more of the following:
(a) substituting (wholly or partly) the hazard giving rise to the risk with something
that gives rise to a lesser risk,
(b) isolating the hazard from any person exposed to it,
(c) implementing engineering controls.
(4) If a risk then remains, the duty holder must minimise the remaining risk, so far as is
reasonably practicable, by implementing administrative controls.
(5) If a risk then remains, the duty holder must minimise the remaining risk, so far as is
reasonably practicable, by ensuring the provision and use of suitable personal
protective equipment.
Note. A combination of the controls set out in this clause may be used to minimise risks, so far
as is reasonably practicable, if a single control is not sufficient for the purpose.

It is intended for this Guideline to highlight areas that may have prevented incidents in
relation to this type of plant in the past. It is not intended for this Guideline to be mandatory,
except as required by legislation.

1.5.1 Alternatives
Alternative methods of providing safety based on risk assessment may be used provided that
the level of safety offered by alternatives is at least equal to or better than that provided by
the methods given in this Guideline.
At time of drafting this Guideline, Safe Work Australia was drafting a Code of Practise;
“Managing Risks of Plant in the Workplace”. The reader should check the following website
to see whether it has been published at time of using this Guideline:
http://www.safeworkaustralia.gov.au/sites/swa/legislation/model-cop/pages/model-cop.aspx

MDG 15 – Guideline for mobile and transportable plant for use at mines - Draft for comment Page 7 of 85
1.6 RELATED AND REFERENCE DOCUMENTS
A list of the documents referred to in this Guideline and other documents that are considered
relevant are given in Appendix A.

1.7 DEFINITIONS
For the purpose of this document the definitions below apply.

1.7.1 Modifications (Alterations)

Change in the design of, add to or take away from the mobile plant, where the change may
affect health or safety, but does not include routine maintenance, repair or replacement.

1.7.2 Check
Compare with a predetermined standard or normal condition of operation: E.g. Check oil
level – by dip stick or level gauge, Or check for security, hold down bolts. Etc

1.7.3 Competent Person

A person who has acquired through training, qualification or experience the knowledge and
skills to carry out the task.

1.7.4 Earth-moving machinery

Means an operator controlled item of plant used to excavate, load, transport, compact or
spread earth, overburden, rubble, aggregate or similar material but does not include a tractor
or industrial lift truck.

1.7.5 Emergency Brakes

A system used to stop the plant in the event of a brake failure. This system may incorporate
the secondary brake system.

1.7.6 Examine
Verify by manual or manual operation and by measurement and gauging of working and
loaded components and surfaces that the machinery or equipment is in a safe and
satisfactory condition to do its job. Strip dismantle and clean as necessary to carry out the
examination.

1.7.7 Fail Safe

The principles of failure to safety, which is any failure of the machinery, its associated
safeguards, control circuits or its power supply that leaves the machinery in a safe condition
and allows an operator to maintain control.

1.7.8 Firewall
A non flammable device to separate a heat source from a fuel source.

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1.7.9 Fire Suppression System
A system that will deliver extinguishant from a bulk container through pipes or tubes to a
number of key areas on the plant.

1.7.10 FOPS (Falling Object Protective Structure)

Means a system of structural members arranged to reduce the possibility of the crushing of
the Operator in case a rock or other object falls on the cabin, or in the case of passengers,
protection for those people.

1.7.11 Hazard
A source of potentially damaging energy or a situation that may give rise to a personal injury
or disease.

1.7.12 Inspect/inspection
Inspect by using the sense of sight, hearing, smell and touch, to verify that the machinery or
equipment (which should be cleaned as necessary to permit inspection) is in working order in
so far as can be judged by the senses, for example prior to operation or during maintenance
activities.

1.7.13 Major repairs

Means repairs to plant which is damaged to the extent that its operation or condition is
impaired and the risk to health or safety is increased.

1.7.14 Mobile Plant

A machine capable of being readily moved while in service. For example trucks, loaders,
graders, bulldozers, tractors, excavators, drills, draglines and the like.
NOTE: Not intended to include personnel transporters, light vehicles, trucks less than 12t (gross
vehicle mass), delivery or pick-up vehicles, freight of mined product predominantly on public
roads.

1.7.15 Must
Indicates a legal requirement exists.

1.7.16 OEM
Original Equipment Manufacturer.

1.7.17 Operator
The person or persons given the task of installing, operating, adjusting, cleaning, or
transporting the plant.

1.7.18 Operator Protective Device

Includes, roll over protective structures, tip over protective structures, falling object protective
structures, operator restraining devices and seat belts.

MDG 15 – Guideline for mobile and transportable plant for use at mines - Draft for comment Page 9 of 85
1.7.19 Owner
The person or organisation that owns the legal rights to a particular piece of plant.
Where the plant is leased or financed such that the legal rights to the plant is maintained by
the finance company and the finance company has no interest in the operation of the plant
then the Owner is the person or organisation that pays the finance company and/or has
option to purchase the plant at the end of the lease or finance period.
May refer to a person conducting a business or undertaking (PCBU) in relation to mobile
plant as defined in the Work Health and Safety Act 2011, Part 1, Division 3, Subdivision 2,
Section 5, for example a person with management or control of plant at a workplace.

1.7.20 Park Brake

A system used to hold a stopped machine stationary.

1.7.21 Plant
Any machinery, equipment, appliance, container, implement and tool, including any
components and attachments.

1.7.22 Potential Fire Source

A potential source of fuel that will sustain a fire.

1.7.23 Reasonably practicable

That which is, or was at a particular time, reasonably able to be done in relation to ensuring
health and safety, taking into account and weighing up all relevant matters including:
(a) the likelihood of the hazard or the risk concerned occurring, and
(b) the degree of harm that might result from the hazard or the risk, and
(c) what the person concerned knows, or ought reasonably to know, about:
(i) the hazard or the risk, and
(ii) ways of eliminating or minimising the risk, and
(d) the availability and suitability of ways to eliminate or minimise the risk, and
(e) after assessing the extent of the risk and the available ways of eliminating or
minimising the risk, the cost associated with available ways of eliminating or
minimising the risk, including whether the cost is grossly disproportionate to the
risk.
NOTE: Taken from the Work Health and Safety Act 2011, Section 18.

1.7.24 Repair
Restoration of mobile plant to an operational condition. Excludes routine maintenance,
replacement or modifications.’

1.7.25 Reversing
Movement of the plant where the operator’s seat is facing the opposite direction to the
movement.

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1.7.26 Risk
The combination of the probability and degree of possible injury or damage to health arising
from exposure to any danger zone.

1.7.27 ROPS (Roll Over Protective Structure)

A system of structural members arranged to reduce the possibility of crushing the Operator in
case the plant overturns.

1.7.28 Safety Device

A device that eliminates or reduces danger.

1.7.29 Safety Critical Systems

Those parts of control systems which are critical to the safe operation of the mobile plant.
Includes, for example, propulsion, braking, steering, warning systems and interlocks .

1.7.30 Secondary Brake

A system used to stop a machine in the event of any failure in the service brake system.

1.7.31 Service Brake

A system used to stop and momentarily hold a machine.

1.7.32 Shall
Indicates a statement is ‘strongly recommended’.

1.7.33 Should
Indicates a statement is ‘recommended’.

1.7.34 Supply/Supplier
(a) A supply of a thing includes a supply and a resupply of the thing by way of sale,
exchange, lease, hire or hire-purchase, whether as principal or agent.
(b) A supply of a thing occurs on the passing of possession of the thing to the person
or an agent of the person to be supplied.
NOTE: For a full definition of “supply”, see Work Health and Safety Act 2011, Section 6.

1.7.35 Test
Carry out a procedure including, where appropriate, operation of the machinery or
equipment, but not dismantling, as necessary to determine that it is correctly assembled,
functioning properly and likely to continue to do so.

1.7.36 TKPH
Tonnes Kilometres Per Hour (see AS 4457). The measure by which a tyre’s maximum duty
cycle is rated.

MDG 15 – Guideline for mobile and transportable plant for use at mines - Draft for comment Page 11 of 85
1.7.37 TOPS (Tip Over Protective Structure)
A system of structural members arranged to reduce the possibility of crushing the Operator in
case the plant tips over.

1.7.38 Transportable Plant

Plant that, from the nature of its use, requires to be moved to a new position regularly, from
time to time between periods of operation. It includes pumps, generators, lighting towers,
drills, highwall auger, mobile crushing plants and the like but excluding transformers.

1.7.39 Worker
A person is a worker if the person carries out work in any capacity for a person conducting a
business or undertaking, including work as:
(a) an employee, or
(b) a contractor or subcontractor, or
(c) an employee of a contractor or subcontractor, or
(d) an employee of a labour hire company who has been assigned to work in the
person’s business or undertaking, or
(e) an outworker, or
(f) an apprentice or trainee, or
(g) a student gaining work experience, or
(h) a volunteer, or
(i) a person of a prescribed class.
NOTE: This comes from Section 7 of the WHS Act 2011.

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2 GENERAL REQUIREMENTS

2.1 RECOGNISED PUBLISHED STANDARDS - GENERAL

A list of recognised relevant Standards is included in Appendix A. Additional Standards may
be relevant.

2.1.1 Standard of Risk Assessment

Where a Risk Assessment is required under this Guideline, additional guidance may be
sought from AS/NZS ISO/IEC 31000, ISO/IEC 31010, ISO 12100, ISO Guide 73.

2.2 COMPLIANCE STATEMENT

The Supplier should provide to the PCBU the following:-
(a) A statement of compliance to this document including;
(i) A list of variations/improvements or reason for non compliance with each
item mentioned. A marked up and signed copy of these guide-lines may be
used.
(ii) A Risk Assessment identifying equivalent levels of safety for all variations
and recommendations that have not been adopted.
(b) Any further information requested within these guide-lines or considered to be
appropriate to ensure the safe operation and maintenance of the plant.
(c) Any information as required by legislation.
(d) Results of test reports and a statement of compliance with all requirements in
accordance with Australian or other relevant Standards.

2.3 DOCUMENTATION
Documentation shall be supplied by the Manufacturer and Supplier and maintained by the
person with management or control of the plant.
All documentation provided by the Manufacturer / Supplier shall be for the ‘as built/supplied’
plant.
‘As built/supplied’ manuals and drawings shall be supplied where non-OEM components are
installed.
The manuals shall include the relevant ‘as built/supplied’ electrical, hydraulic, pneumatic
schematic diagrams, parts lists, major components ratings and a section on recommended
maintenance periods and procedures, including safety precautions to be taken.
All hydraulic and pneumatic symbols shall be in accordance with AS 1101.1 or ISO 1219.1
Graphic symbols for general engineering - Hydraulic and pneumatic systems
When modifications are being made to the system, diagrams shall be updated as soon as
reasonably practicable by the appropriate personnel and details distributed to ensure
hazards are not created by the use of incorrect information.
Access to electronic copies of the information specified in this Clause (and subclauses) shall
be provided.

MDG 15 – Guideline for mobile and transportable plant for use at mines - Draft for comment Page 13 of 85
As a minimum the documentation shall also include the information specified in
Clauses 2.3.1 to 2.3.7 .

2.3.1 Installation, Testing, commissioning and Dismantling Manuals

Installation, testing, commissioning and dismantling procedures and results shall be provided
and shall contain the following information as a minimum but be not limited to:
(a) Identification of hazards and appropriate controls associated with the installation,
testing and dismantling of the plant.
(b) Procedures associated with the installation, testing, commissioning and
dismantling of the plant. The limits of travel of all moving elements should be
shown.
(c) A copy of all results and procedures in regards to testing, setup and
commissioning of the Plant should be maintained.
(d) Transport and lifting requirements for the plant and its major components
including;
(i) Component weights and dimensions.
(ii) Jacking weights.
(iii) Lifting, jacking and support stand locations.

2.3.2 Operation, Maintenance and Parts Manuals

Operation and maintenance manuals shall be provided. These manuals shall contain the
following information categorised in appropriate sections as a minimum but be not limited to:
(a) Recommended preventative maintenance requirements to maintain the plant in a
safe operating condition, including lubrication, ongoing adjustments, tests, setting
of controls, etc.
(b) Recommended schemes and procedures to check whether the plant is fit for
purpose, for example inspection, examination and testing.
(c) Identification of any hazards involved in maintaining and operating the plant,
including fire risk, confined spaces, etc.
(d) Energy isolation and control.
(e) Procedures to carry out routine maintenance on the plant, including setting of
controls.
(f) Trouble shooting guide
Parts manuals shall be provided.

2.3.3 Synopsis of Plant

The Manufacturer and Supplier shall provide the following information on the plant being
supplied:
(a) Plant operating limits and capacities as detailed in Clause 2.7 .
(b) Detailed General Arrangement drawings showing the physical dimensions of the
plant including all extremities and all limits of application.
(c) Hydraulic and pneumatic drawings and schematics.

2.3.4 Towing Instructions

As a minimum, towing instructions shall be provided for each of the following:

14
(a) For towing the plant where inoperable.
(b) For towing a load.
(c) Maximum load to be towed, including tow point ratings.
(d) Direction of pull.

2.3.5 Modifications to ‘As Built/Supplied’ Plant

Any plant modification that is to be carried out on original plant should be carried out in
consultation with the OEM. Modifications to Plant shall be designed and implemented under
the direction of a competent person.
Modifications shall be approved by the PCBU.
Details of any modifications that have been carried out to ‘as built/supplied’ plant shall be
listed in the plant safety file.
All modifications shall have change management and implementation documentation.

2.3.6 Safety critical systems and safety devices

A comprehensive list of all safety critical systems and safety devices and their functions shall
be provided by the supplier to the PCBU. The list shall be split into;
(a) Those provided with the plant, and
(b) Those which are not provided with the plant, but which are available as an option
with the plant.
This list shall also include:
(i) The systematic and periodic checking and testing of all safety critical systems and
safety devices.
(ii) Reasonably practicable maintenance instructions that will ensure all safety critical
systems and safety devices remain functional over the life of the mobile plant, if
followed.
The PCBU shall assess and document all safety critical systems and safety devices. The
PCBU shall ensure all safety critical systems that are installed on plant are maintained and
recorded in the plant safety file.

2.3.7 Plant Safety File

2.3.7.1 Introduction to site
Prior to use at a mine, plant shall have a plant safety file. A documented plant safety file
should be prepared by the manufacturer/supplier and provided to the PCBU. Plant safety
files should contain all information relating to:-
(a) Hazard identification, risk assessments, risk control methods and any other
information that is required by the PCBU for the safe operation and maintenance
of the plant;
(b) Consultation records;
(c) The purpose for which the plant was designed (safe operating envelope);
(d) The identification of all safety critical systems and their functions
(e) The systematic examination, inspection, checking and testing to be carried out;

MDG 15 – Guideline for mobile and transportable plant for use at mines - Draft for comment Page 15 of 85
(f) Procedures for; installation, commissioning, operation, maintenance, inspection,
cleaning, transport, storage and dismantling.
(g) Training/competency requirements for operators, supervisors and maintenance
personnel
(h) Systems of work necessary for the safe use of the plant
(i) Emergency procedures

2.3.7.2 Maintenance of the safety file

The plant safety file should be maintained throughout the life of the plant by the PCBU and
should contain all information relating to:-
(a) Any information provided by the manufacturer/supplier;
(b) Training/competency records for operators, supervisors, persons undertaking
maintenance;
(c) Inspection, examination, checking, testing and maintenance of safety critical
systems;
(d) Daily prestart safety checks;
(e) Defect notification and rectification;
(f) Records of inspections ;
(g) Modifications and repairs;
(h) Preventative maintenance activities;
(i) Results of actions from periodic audits and reviews; and
(j) Accidents/incidents and reviews.

2.3.8 Records
The following apply to records:
(a) The records should be kept in a form that can be directly imported into a
published electronic format without any modification, and
(b) The records shall contain the following fields:
(i) Name of PCBU using the plant.
(ii) Plant type, (‘mobile plant’, ‘remote controlled plant’)
(iii) Legal name of the plant manufacturer
(iv) Model number of plant
(v) Serial number of plant
(vi) Legal name of owner of plant
(vii) Date plant was put to use by the PCBU or arrived at the mine site
(viii) Name of a competent person who has inspected the plant and who has
confirmed that the plant is safe to operate at the mine
(ix) Date of such inspection referred to in (viii) above
(x) Date plant was removed from use by the PCBU or removed from the mine
site, where applicable
(c) In the case of mobile plant, the records shall contain the following additional
fields:
(i) Description of the mobile plant, as described by the mobile plant
manufacturer (for example; rear dump truck, six wheel drive articulated
truck, load haul dump, wheeled loader, etc.)

16
 (ii) Unladen mass of the mobile plant
(iii) Maximum payload of the mobile plant
(iv) Maximum number of people the mobile plant is designed to transport
(d) In the case of remotely controlled plant, the records shall contain the following
additional fields:
(i) Legal name of the remote control system manufacturer
(ii) Type of remote control system (radio, umbilical cord, infra red etc)
(iii) Model number of the remote control system
(iv) Serial number of the remote control system receiver and ALL associated
transmitters
(v) Legal name of owner of the remote control system
(vi) Date the remote control system was put to use by the PCBU or arrived at the
mine site

2.4 SAFETY REQUIREMENTS

2.4.1 Identification of Hazards

WHS Regulation 2011, Clause 34:

34 Duty to identify hazards

A duty holder, in managing risks to health and safety, must identify reasonably
foreseeable hazards that could give rise to risks to health and safety.

Manufacturers/suppliers shall provide hazard identification information to the person with

management or control of the plant when supplied.

2.4.2 Operational and Maintenance Risk Assessment(s)

On the introduction of any plant to a mine site, Risk Assessment(s) shall be conducted to
identify risks associated with that plant. Part of such risk assessment(s) should include:
(a) hazards to the operator;
(b) hazards to the maintainer;
(c) hazards associated with operating that plant in the overall context of the site;
Risk assessments should include learnings from accident reviews (see Clause 2.6 ) and
consider human error (see APPENDIX D – HUMAN ERROR).

2.4.3 Isolation and Energy Dissipation

Procedures shall be supplied by the Manufacturer/Supplier and maintained and developed
by the person with management or control of the plant for the safe isolation and / or energy
dissipation. They should be available for all activities associated with the installation,
operation and maintenance of the plant.
A person shall not carry out repairs to plant unless the energy source is isolated and cannot
be reconnected accidentally before it is safe to do so.

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The system of isolation adopted should incorporate a tagging system, a locking system or
permit system and in any case shall also include a method of verification that isolation and /
or energy dissipation is effectively established.
Isolation and energy dissipation should be carried out in accordance with AS 4024.1603.
Where energy is unable to be isolated, procedures shall be developed to ensure the safety of
workers involved.

2.4.4 Safework Procedures

Safework procedures should be developed and maintained by the person with management
or control of the plant taking consideration of procedures supplied by the
manufacturer/supplier.

2.4.5 Training
All relevant workers shall be formally trained.
Training shall include as a minimum but be not limited to the following:
(a) Knowledge and understanding of hazards and the required controls.
(b) Plant safety procedures, including emergency procedures.
(c) The correct and safe way of operating and maintaining the plant.
(d) Understanding the purpose and function of safeguards which protect personnel.
(e) Reporting of faults and defects.
(f) Use of protective plant.
(g) Statutory requirements.
(h) Automatic and manual fire systems

2.4.6 Safety Critical Systems

2.4.6.1 Integrity of Safety Critical Systems
The integrity of all safety critical systems shall be subject to a design risk assessment.
This design risk assessment shall be in the form which systematically analyses the failure
modes and integrity of each safety critical system, associated warning devices and any
relevant safety related instructions. This shall be carried out by the plant
manufacturer/Supplier.
The appropriate integrity level or category level shall be applied to safety critical systems in
accordance with AS 4024:1501, AS 4024:1502, AS/IEC 62061, AS/IEC 61508 or other
similar standards.
NOTES:
1) Guidance can be found in AS 4024.1301, AS 4024.1302 and ISO 31010
2) Other relevant standards are available for guidance on performance level / category
level / safety integrity level. For example, see; ISO 15998, ISO 13849, AS/IEC 61508,
AS/IEC 62061, AS 4024.1501, AS 4024.1502.

2.4.6.2 Monitoring of Safety Critical Systems

The failure of any safety critical system should give rise to a means of indicating the safety
critical system failure to the operator, such as a warning light and/or alarm.

18
A system indicator should provide the operator notification of a failure of a safety critical
alarm or warning device, where reasonably practicable.
NOTE: A self diagnostic validation test on start-up is considered to meet this requirement.

2.5 MAINTENANCE

Extracts from WHS Regulation 2011, Clause 213:

213 Maintenance and inspection of plant

(1) The person with management or control of plant at a workplace must ensure that
the maintenance, inspection and, if necessary, testing of the plant is carried out by a
competent person.
(2) The maintenance, inspection and testing must be carried out:
(a) in accordance with the manufacturer’s recommendations, if any, or
(b) if there are no manufacturer’s recommendations, in accordance with the
recommendations of a competent person, or
(c) in relation to inspection, if it is not reasonably practicable to comply with
paragraph (a) or (b), annually.

The PCBU must ensure that all plant is maintained fit for purpose, is appropriately guarded
and protected and is provided with adequate access for operation, maintenance and
inspection.
Maintenance management systems for mobile plant shall:-
(a) Identify and document all safety critical systems.
(b) Maintain, periodically check, test and verify all safety critical systems and warning
devices to confirm functionality.
NOTE: Safety critical systems need to be maintained to be effective.
(c) Confirm relevant workers involved with plant are familiar with all safety critical
systems, trained, unimpaired and competent for the task at hand.
(d) Ensure a competent person inspects plant periodically and verifies it is safe to
operate.
(e) Ensure a competent person inspects plant that has safety related defects or
damaged prior to the mobile plant being placed back into service.
(f) Ensure major repairs or modifications are carried out in consultation with the plant
manufacturers or verified by a competent person as safe.
(g) Ensure operator/passenger restraint systems are supplied, correctly installed and
maintained.
(h) Ensure site maintenance practices are periodically audited against the
documented mine safety management plan (MSMP).
(i) Ensure any changes to the manufacturer’s safety features or devices are
assessed and documented by a competent person. The competent person shall
assess that the change in use does not present an increased risk to health or
safety.
NOTE: The competent person should contact the plant manufacturer when making
assessment on the safety features.

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2.5.2 Structural Repairs
Structural repairs to equipment must be designed and implemented under the direction of the
OEM or a competent Structural or Mechanical Engineer.
The repairer shall ensure all repairs meet or exceed the OEM’s safety requirements.
Details of any repairs that have been carried out to ‘as built/supplied’ plant shall be listed in
the plant safety file.

2.6 ACCIDENT REVIEW

To minimise the risk of repetitive accidents the Manufacturers and PCBUs should maintain a
comprehensive list of all incident statistics and relevant details, including root cause, for the
same or comparable equipment. These statistics should be reviewed and corrective action
taken, as far as is practical, to avoid further accidents.
The person with management or control of plant should provide to the manufacturer details
of all incidents in relation to the plant.
The manufacturer should notify all PCBUs of any safety related incidents that they become
aware of from time to time and their recommendation to rectify such defect. (e.g. Safety
Alerts, Technical Bulletins, etc.)
The statistics covering reportable significant accidents and occurrences by statute may be
obtained from the individual mine or from the Department of Trade and Investment, Regional
Infrastructure and Services (Mine Safety Operations) Chief Inspector's Annual Report.
For further information on accident reviews, see:
(a) Coal Mines Insurance, NSW;
(b) Various State minerals websites for safety alerts and bulletins;
(c) EMESRT design philosophies on their website:
www.emesrt.org/
(d) information from the manufacturer.
(e) Safety alerts http://www.resources.nsw.gov.au/safety/safety-alerts

2.7 LIMITS OF PLANT APPLICATION

The Manufacturer/Supplier SHALL provide to the PCBU all the necessary limits of operation
for the plant supplied. Such limits SHALL be in accordance with applicable Standards.
Site conditions can affect performance and limits specified for the plant and need to be
considered in a risk assessment.
Examples of such limits are as follows:
(a) Maximum Working Grade (%)
(i) Loaded at maximum gross vehicle mass (GVM). (As built).
(ii) Unloaded.
(iii) Tipping.
(iv) Fully loaded with park brake applied.
(v) Other variables where applicable.
(b) Maximum Cross Grade(%)
(i) Loaded at maximum GVM. (As built).
(ii) Unloaded.

20
 (iii) Tipping.
(iv) Other variables where applicable.
(c) Maximum Load (tonnes)
(i) Level conditions.
(ii) On range of grades.
(iii) Other variables where applicable.
(d) Maximum Speed (km/h)
(i) On level conditions.
(ii) On range of grades.
(iii) Other variables where applicable.

2.8 OPERATIONAL REQUIREMENTS

An extract from WHS Regulation 2011, Clause 204:

204 Control of risks arising from installation or commissioning

(1) A person with management or control of plant at a workplace must not

commission the plant unless the person has established that the plant is, so far as
is reasonably practicable, without risks to the health and safety of any person.

PCBUs in control of plant must ensure:

(a) Plant is used only for the purpose for which it was designed.
(b) Operators are trained in the safe operation of the plant. For example
(i) the safety critical systems,
(ii) the emergency systems,
(iii) the correct gear, speed and use of retarder to descend a grade whether
empty or fully loaded; and
(iv) Other factors such as road conditions, visibility, traffic and weather may
need to be considered.
(c) Operator/passenger restraint systems are used.
(d) Where safety features or warning devices are incorporated into plant, the features
or devices are used as intended.
(e) Daily prestart safety checks are carried out with all identified defects which affect
the safe operation of the machine assessed by a competent person before the
plant is used.
(f) Mobile plant is not overloaded or operated outside the operational limits as
specified by the manufacturer.
(g) Haulage roads are designed to grades of 10% or less wherever reasonably
practicable.
Review site haulage routes and identify all plant travelling on grades in excess of 10%
and verify with the plant manufacturer or a competent person that the plant can safely
operate on that grade.
(h) Appropriate control measures are put in place where descending grades exceed
10%. For example, a sign placed at the top of the ramp stating
(i) The grade;
(ii) The gear to be preselected; and

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 (iii) The maximum descending speed.
NOTE: The mine safety management plan (MSMP) should assess the maximum safe
operating grade of all mobile plant and prohibit the use of mobile plant without
adequate braking capacity on grades greater that 10%.
(i) The design of mine haul roads consider the mine safety management systems
and transport management plans.
Further guidance is given in the following documents:
(i) Code of Practice title ‘Roads & Other Vehicle Operating Areas’, by Safe
Work Australia;
(ii) At time of drafting this Guideline, Safe Work Australia was drafting a Code of
Practise; “Roads & Other Vehicle Operating Areas”. The reader should
check the following website to see whether it has been published at time of
using this Guideline:
http://www.safeworkaustralia.gov.au/sites/swa/legislation/model-
cop/pages/model-cop.aspx.
(j) All foreseeable hazards associated with potential out of control plant have been
addressed, including, but not limited to hazards associated with:-
(i) The potential failure of any safety critical systems, or other safety related
components and the safe operation of the plant;
(ii) Condition of roads including; line of sight for the operator, potential for
impaired vision from dust, fog, rain or other factors, signage and fit for
purpose bunding or windrows;
(iii) Site environmental conditions that may lead to loss of traction between the
wheels/tracks and ground or skidding;
(iv) Operator error (see APPENDIX D – HUMAN ERROR);
(v) Operator actions in an emergency.

22
3 REQUIREMENTS FOR DESIGN AND MANUFACTURE

3.1 ACCESS TO PLANT

3.1.1 General
Access systems shall as a minimum be in accordance with either
(a) ISO 2867 and ISO 14122 Parts 1 - 4; or
(b) AS 1657 and AS 3868.
Plant Operators and maintenance personnel should be able to carry out normal duties
without leaving a designated walkway, access platform, or the ground. Where this is not
reasonably practicable and there is a potential that a person could fall, a risk assessment
shall be conducted and, where required, suitable controls put in place.

3.1.2 Ladders and Stairs

The following requirements apply:
(a) Vertical ladders should be avoided where ever possible.
(b) Stairs shall be provided where ever practical.
(c) Retractable stairs or ladders shall be considered where reasonably practicable.
(d) Flexible bottom steps shall be avoided unless there is no reasonably practicable
alternative.
(e) The bottom step of the primary access should not be more than 400 mm from
ground level as measured on flat ground.

3.1.3 Walkways and Handrails

The following requirements apply:
(a) Handrails should be in a continuous length without sudden changes of direction to
facilitate evacuation with minimal visibility.
(b) Walkway surfaces shall be self cleaning and non slip.
(c) Openings in guardrails for the purpose of access to ladders shall be fitted with a
hinged or sliding guardrail gate where reasonably practicable. Chains are not
considered acceptable. Where practical, hinged gates shall open onto the platform
and be self-closing.

3.1.4 Egress
3.1.4.1 Cabin
Two means of egress shall be provided from the Operator’s cabin to the ground including;
(a) At least 1 means of easy egress (normal access e.g. cabin door); and
(b) At least 1 means of emergency egress. This shall be suitably marked and may be
achieved by, for example, a second door or a push out window.
At least one means of exit shall be useable in the event of a roll over of any type of plant.
At least 1 of these means of egress shall not be in the vicinity of a potential fire source.

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3.1.4.2 Deck / platform
The location of the two means of egress shall take into consideration the possibility of a fire
or plant roll-over. Except for escape chutes, all means of egress shall have provision for
three points of contact (e.g. handrails on both sides of escape ladders).

3.2 BRAKES

3.2.1 General
This section is intended to apply to plant suppliers and manufacturers of new plant.
For wheeled and high speed rubber-tracked earth moving plant, braking systems shall be in
accordance with ISO 3450, as a minimum.
For all other crawler earth moving plant with maximum speed less than 20 km/h braking
systems shall be in accordance with ISO 10265, as a minimum.
General requirements for brakes include:
(a) All mechanical braking systems shall be fail safe.
(b) Consideration should be given to eliminate, or minimise so far as reasonably
practicable, locking of the wheels.
(c) An effective interlock should be provided to protect against the plant being driven
with any brake applied. This interlock can be overridden for maintenance which is
being carried out in accordance with the Manufacturers’ instructions.
(d) Brake lining material must not contain asbestos.
The manufacturer/supplier shall calculate and stipulate the brake slope capability in
accordance with ISO 3450-2011 Annexure B. Adequate information shall be provided on the
performance of braking systems (service, secondary and park brake), including:
(i) The maximum longitudinal grade and speed the service and secondary brakes
are able to stop and hold a machine at gross vehicle mass (GVM).
(ii) The maximum longitudinal grade the park brake can hold a machine stationary on
at gross vehicle mass (GVM).
(iii) Operator information for descending and ascending a grade.

3.2.2 Brake system periodic verification

Information on brakes shall be provided in manuals to enable periodic verification tests for
brake systems. The information shall include
(a) operator brake check method instructions, which include:
(i) a method of verifying the functionality of the service and parking brakes; and
(ii) Provisions for verifying the functionality of the secondary brakes if the
service and/or parking brake check method does not verify functionality of
the secondary brakes;
(b) in-service/periodic or post-maintenance brake verification instructions, which
include:
(i) a method for verifying the functionality of the service and parking brakes
including acceptance criteria;
(ii) a means of verifying the functionality of the secondary brakes;
(iii) for testing, all brake systems performances; and
(iv) deceleration limits and stopping distances for all braking systems;

24
 NOTES:
1) For existing plant in use at mines, a gap analysis should be carried out. The gap
analysis should identify the hazards, assess the risk and implement appropriate risk
controls.
2) These requirements are in addition to safety alerts SA06-12, SA06-13 and SA06-14
see www.resources.nsw.gov.au/safety/safety-alerts .

3.3 BRAKE PERFORMANCE

3.3.1 Park Brake System

All plant shall be equipped with a park brake system capable of being applied and released
from the Operator’s position.
The park brake system shall have the capability of holding the plant stationary on a 15%
grade in both forward and reverse directions.
This shall apply with the plant at its gross vehicle mass as specified by the Manufacturer.
Safety chocks should also be available in the event of the plant being immobilised.
Once applied the park brake system shall not rely on any exhaustible energy source.

3.3.2 Brake Pressures

A warning light easily visible from the Operators’ seat and/or an audible alarm should be
used to monitor the state of all pressurised braking systems.

3.3.2.1 Line Pressures

Suitable connecting points for checking pressures of all braking systems shall be provided.

3.3.2.2 Brake Drag Indication

A suitable brake warning device should be provided to monitor brake drag where required.
e.g. residual brake pressure.

3.3.3 Brake Wear Indication

A clearly identifiable means of monitoring brake wear and the required adjustment range
shall be supplied by the Manufacturer.

3.3.4 Energy Storage

Air or hydraulic energy storage for service brake applications should be independent from the
requirements of other systems.

3.3.5 Multiple Circuit Braking Systems

Braking systems shall be designed as a minimum as dual circuit systems.
The use of single circuit brake systems should only be considered where all risk scenarios
have been considered and measures taken to effectively eliminate or minimise risk.
All split brake systems should be supplied with a means of readily identifying when excessive
differential pressure between the two sections occurs.

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This may be achieved by use of an indicator light readily visible to the operator.

3.3.6 Oil Immersed Braking Systems

Oil immersed braking systems shall be so designed that the temperature never reaches the
flash point for the oil. The oil used in braking systems shall be as specified by the plant
Manufacturer.
The use of fire resistant brake fluid should be considered for all non-oil immersed hydraulic
brake systems.

3.3.6.1 Monitoring
(a) The temperature of any oil immersed braking system should be monitored.
(b) Monitoring should be visible from the Operator’s seated position.

3.3.7 Brake Testing

A means of using measurement for maintenance checking (or at least indication) of vehicle
deceleration shall be provided where practical for rubber tyred plant.
Part of the maintenance plan shall include onboard brake and electrical retard brake tests.
The results shall be recorded in the Mine maintenance records.
The Manufacture shall provide to the PCBU the accepted deceleration limits for all braking
systems (electrical retard and mechanical) as designed for the plant.
A portable means of recording brake application frequency and length of application is
considered satisfactory. This should be suitable for easy installation on the plant when
required for checking purposes.
NOTE: This is particularly useful for:
1. Operator training.
2. Identifying effectiveness/ deterioration of the braking system rather than relying on
"Operator feel".
3. Could give pre-warning of possible brake failure.
4. Complementing periodic inspections.

3.3.8 Automatic Operation of Brakes

Automatic operation of brakes may in some circumstances correct for operator error and
prevent serious accidents. Hence consideration be given to the following controls:
(a) Where the service brake system fails, then the emergency brakes shall be
automatically applied.
(b) A warning device that effectively indicates to the Operator that the braking system
is about to apply automatically shall be provided (ref. ISO 3450). Operators shall
be trained in the operation of the automatic brakes.

3.4 CONTROL FUNCTIONS

3.4.1 General
Instrumentation and Operator controls shall comply with appropriate International Standards.

26
For example, see:
(a) ISO 10968 Earth-moving machinery - Operator's controls
(b) EN ISO 6682, Earth-moving Machinery - Zones of Comfort and Reach for Controls
(c) ISO 6405-1 Earth-moving machinery - Symbols for operator controls and other
displays - Part 1: Common symbols
The operating controls shall be clearly marked to show their function and mode of operation
in accordance with ISO 6405.2.

3.4.2 Warning Device

An audible warning device (eg. horn) shall be provided for use as a manually initiated
warning device.

3.4.2.1 Air Device

Where an audible warning device is air operated, a secondary warning device shall be
provided (eg. for electric start trucks where air is not available until the engine is operating,
then an electric horn is required.)

3.4.2.2 Pre-Start Warning

An automatically initiated pre-start warning device shall be provided where a hazard exists if
people may be near the plant and it is started or moved. This applies particularly to draglines,
large shovels, reclaimers, loaders and other large plant where it is difficult for the Operator to
ensure that no one is exposed to a hazard when the plant is started.

3.4.2.3 Reversing
An automatic reversing warning system shall be provided on all plant except bi-directional
plant.
Audible alarms may be replaced by alternative methods provided they give an equivalent
level of safety and consideration is given to environmental noise impacts.

3.5 ENGINE COMPARTMENT

3.5.1 Location of Services

The following apply to the location of services:
(a) The location of services including fuel, hydraulic oil and electric power within the
engine compartment shall be avoided wherever possible.
(b) Any services required to be in the engine compartment shall be effectively
shielded from hot spots and suitably protected from wear and tear.
(c) The potential for physical damage to services during maintenance work shall be
considered

3.5.2 Fuel and Hydraulic Circuits

The following apply to all fuel and hydraulic circuits within the engine compartment:
(a) Where possible hydraulic components should not be located where main
ventilating air will cause leaking oil to be spread over the engine compartment.

MDG 15 – Guideline for mobile and transportable plant for use at mines - Draft for comment Page 27 of 85
(b) Hydraulically driven fans should not be used where potential exists for an oil leak
from the fan hydraulics to contact hot surfaces (e.g. resistor bank cooling). Where
there is no alternative to using hydraulic driven fans then the fan hydraulics shall
be suitably guarded to ensure that oil does not come in contact with ignition
sources.
(c) All fuel tanks shall be fitted with non leaking caps which are effective irrespective
of the angle of the plant.
(d) All fuel filters shall be of metal construction or alternatively installed within a metal
container.

3.5.2.2 Pipes & Hoses

The following apply to pipes, lines and hoses:
(a) All fuel lines shall be in accordance with applicable Standards. For example, see
the following:
(i) ISO 13775-2:2000 Thermoplastic tubing and hoses for automotive use -
Part 2: Petroleum-based-fuel applications
(ii) ISO 19013-1:2005 Rubber hoses and tubing for fuel circuits for internal
combustion engines - Specification - Part 1: Diesel fuels
(iii) ISO 8535-1:2011 Diesel engines - Steel tubes for high-pressure fuel
injection pipes - Part 1: Requirements for seamless cold-drawn single-wall
tubes
(iv) ISO 8535-2:2003 Compression-ignition engines - Steel tubes for high-
pressure fuel injection pipes - Part 2: Requirements for composite tubes
(v) SAE J2405 - 2007/07/02: Low-Permeation Fuel Fill and Vent Tube
(vi) SAE J30 - 2012/02/17: Fuel and Oil Hoses
(b) All pipes/hoses shall be constructed of fire resistant material and shall be routed
away from hot engine surfaces. Appendix A lists standards that will act as a guide.
(c) should the requirements of a) above prove to be impractical then an effective
shield is required between the pipe/hose and any adjacent components, etc.
which have operating surface temperatures in excess of 150 degrees Celsius.
(d) All pipes/hoses shall be routed in a manner which will give them maximum
mechanical protection against wear and damage
(e) All connections shall be in accordance with relevant Standards (See Appendix A).

3.5.3 Radiator Caps

Radiator caps for cooling systems shall not be able to be opened while there is pressure in
the cooling system. Cooling systems should be fitted with a means of safely relieving
pressure to prevent burning personnel and shall be able to be accessed safely.
A means to check coolant level without the removal of the radiator cap shall be provided.
A means of filling the radiator without removing the radiator cap should be provided.

3.6 ERGONOMICS
All relevant ergonomic aspects of the plant should be addressed by the Manufacturer in the
design and manufacture of the plant.
The PCBU should assess the ergonomic aspects of the plant to minimise risks to health and
safety of personnel (e.g. see AS 4024.1401).

28
3.6.1 Controls
The controls shall be located within the "zones of comfort and reach" as detailed in
ISO 6682.

3.6.2 Vibration
Adequate preventative measures shall be taken to prevent excessive vibration being
transmitted to the Operator during the operation of any equipment. The transmitted vibration
during operations shall not exceed the limit levels specified by the European Directive
2002/44/EC, which involves measurement to ISO 2631-1. a standard identical to AS 2670.1,
‘Evaluation of human exposure to whole-body vibration - General requirements’.
The evaluation of human exposure to whole-body vibration should be conducted in
conjunction with Clause 3.12.2 Operator Noise to ensure occupational health at the
Operators’ position. The frequency distribution of the noise at the Operator’s position should
be analysed as described in the AS/NZS 1269 series to distinguish between structural and
airborne noise entering the Operator’s cabin.
Further guidance is given in ISO 7096 for laboratory evaluation of operator seat vibration.

3.7 FIRE CONTROL SYSTEMS

Fire control systems shall be designed, installed and maintained in accordance with the
appropriate standards. (See AS 5062, AS 1851, AS 1850, AS 1841 (series), AS 2444.)
The manufacturer/supplier shall identify all potential fuel sources and provide a full
assessment of fire risk associated with the plant being supplied.
A fire risk assessment shall be carried out on all mobile plant in accordance with AS 5062,
‘Fire protection of mobile and transportable equipment’.
When required by the risk assessment, fire protection (detection and suppression) systems
shall be designed, manufactured, tested, commissioned and maintained in accordance with
AS 5062.

3.7.1 Fire Extinguisher(s)

Portable fire extinguisher(s) should have a minimum rating of 80 ABE and capacity in
accordance with the fire risk assessment. Extinguishers should be located on the plant in a
readily accessible location where access would not present a hazard to the user. The
location should be in an area that is least likely to be affected by fire. Extinguishers should be
easily detached by a person from their mountings and have gauges that are easily readable.
All fire extinguishers should be maintained in accordance with AS 1851.

3.7.2 Fire Suppression

A fire suppression system shall be provided on all plant unless deemed unnecessary by a
fire risk assessment. Any fire suppression system installed shall be in accordance with the
outcomes of a fire risk assessment.
NOTE: Where there is more than one item of plant with the same specifications, only one risk
assessment is required. A risk assessment needs to be done for each variation from
the collective specification.
All fire suppression systems shall comply with AS 5062.

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Risk management techniques shall be used to determine the method of operation of the fire
suppression system, (manually operated fire suppression system or an automatically
operated fire suppression system).
Where a fire suppression system is installed, activation of the system shall automatically stop
the fuel supply and stop the engine. This may be applied by an engine management system,
fire suppression system or emergency stops.

3.7.2.1 Design
The fire suppression system shall be designed to provide protection to personnel from fires
that may be initiated from any heat source. The considerations for the design of a fire
suppression system should include but be not limited to:
(a) Fail to safe.
(b) The volume of the area to be covered.
(c) The ventilation of the area to be covered.
(d) The quantity of fuel, including diesel fuel, oil or other combustible material that
may be available to feed the fire.
(e) The areas where ignition is more easily initiated (eg. Turbo chargers, exhaust
manifolds, exhaust tubing and mufflers.).
(f) The storage, type and application of the extinguishing agent shall be shown to be
non-injurious to all personnel likely to come into contact with the system in either
the stored or discharged condition.
(g) Pressurised carbon dioxide systems are not preferred (because of the danger of
asphyxiating personnel).
(h) A system for the charging / filing of fire fighting systems shall be provided.
(i) Fire fighting system extinguishants shall comply with the requirements of the
Ozone Protection Act, 1989 and any Regulations pertaining to this Act.
(j) All pressurised systems shall be protected by a relief system to prevent over
pressurisation.
(k) All pressurised systems adjacent to heat sources should have hydraulic hose
diffuser sleeves fitted.
(l) A review of previous catastrophic plant fires.

3.7.2.2 Firewalls
Firewalls shall be suitably rated in accordance with the risk assessment. Firewalls should
be:
(a) installed for all diesel powered plant.
(b) considered for all electric powered plant,
(c) designed to separate the engine (heat source) from the any fuel source (e.g.
diesel fuel, hydraulic fluid).
(d) designed to not interfere with the engine ventilation.
(e) located to isolate and separate high volume pressurised hydraulic fuel sources
(e.g. this applies to hydraulic pump locations).

3.7.2.3 Activation of System

Clear indication of the selected mode of operation (automatic or manual) should be visible
from the operator’s normal driving position.
Manually operated controls to trigger the system shall be provided:

30
(a) Within the Operator’s cabin and located within reach of the operator’s normal
operating position; and
(b) At ground level as determined by risk assessment.
Visual indication shall be provided for the plant Operator to show whether the system is
ready for operation or has been discharged.

3.7.2.4 Electrical Control

Each component of an electrical installation that supplies a fire protection system shall be
separately controlled by a switch which is additional to the main switch used to control other
components of the equipment.
This switch shall be clearly marked, “Fire Suppression System”.
All electrical controls shall fail to safety unless a back up power supply system is provided.
Loss of electric power shall not prevent the operation of the fire extinguishing system by
manual initiation.
Wiring systems on fire suppression equipment should have a 2 hour fire rating.

3.7.3 Automatic Fire Suppression

Where fitted, automatic fire suppression systems should, where appropriate, be interlocked
to automatically shut down all power so that the plant cannot be operated if the fire
suppression system is disabled or faulty.
Where interlocking occurs, the system should allow for manual override to allow control by
the Operator when required.
Where automatic fire suppression systems are fitted or installed a visible and audible
warning must be given to the Operator when a fire is detected.

3.7.3.1 Shutdown Delay

For automatic fire suppression systems the shut off valve should operate in a sequence that
allows the operator to evacuate the plant. The following should be considered:
(a) The engine should shut down as soon as possible.
(b) The fire suppression system should be activated by the operator prior to
evacuating the plant. A time delay may be considered to allow the operator safe
egress.

3.8 FLUID SYSTEMS

3.8.1 General
Hydraulic and pneumatic systems shall comply with AS 2671 and should comply with
ISO 4413, ISO 4414 and ISO 3457.
Fluid systems should comply with MDG 41, ‘Guideline for fluid power system safety at mines’
as applicable.

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3.8.2 Emergency Shutdown
It shall be possible to relieve the pressure from hydraulic systems, steering systems,
accumulators and pressurised fuel tanks from the vicinity of all of the emergency stop points
at ground level to relieve pressure which may be fuelling a fire.

3.8.3 Hoses
The following apply to hoses:
(a) Hydraulic hose shall comply with the provisions of AS 3791 and MDG 41.
(b) Flexible hoses and fittings shall be suitable for the fluid used and the maximum
system pressure and temperature.
(c) The hose assembly factor of safety shall be a minimum of 4 to 1 based on hose or
fitting burst pressure to maximum working pressure for the maximum operating
temperature. Refer AS 3791 and ISO 7751.
(d) Elastomeric (rubber type) hose shall not be used on a delivery line between an air
compressor and air receiver. Fit for purpose Teflon with steel braid is satisfactory.
All delivery hoses shall be heat resistant. All other hosing shall be suitable for the
application.
(e) All air, hydraulic, fuel, refrigerant and fire suppression hoses shall be routed
separately and suitably clamped (to prevent vibration and pulsation causing
fretting between services leading to hose and cable failure.)
(f) Hoses should be labelled with information or identification to enable the following
to be identified;
(i) Date of installation.
(ii) Working pressure.
(iii) Code of construction.
(iv) Length, end fittings and date of fitment.
(v) Fluid medium being transported.
Further guidance on hoses for hydraulics is given in international standards listed in
Appendix A.

3.8.3.2 Fire Resistant Hose

All hydraulic hose shall be fire resistant unless the hose is located in an area with a low risk
of fire.
The requirements for flame resistance should be in accordance with;
(a) Testing to AS 1180-10b and acceptance to AS 2660, or

(b) Satisfy the flame test requirements of the U.S.A. Code of Federal Regulations
Title 30 Part 18 Section 18.65 (see www.msha.gov/30cfr/18.65.htm); or
(c) Comply with type 1 or type 3 hose specifications as listed in ISO 6805, or an
equivalent level of fire resistance provided.

3.8.3.3 Fire Proof Hose

All brake, turbo lube hoses and fire suppression system hoses should be fire proof but as a
minimum shall be fire resistant. The requirements for flame resistance should be in
accordance with;

32
(a) SAE Aerospace standard SAE AS1339, Hose Assembly, Polytetrafluoroethylene,
Metallic Reinforced, 3000 psi, 400°F, Lightweight, Hydraulic and Pneumatic. The
operating limit for this hose is -540 C to +2320 C, or
(b) An equivalent level of fire resistance provided.

3.9 GUARDS AND SHIELDS

When a hazard cannot be eliminated or avoided by design, then the provision of safeguards
shall be considered.
Guards and shields shall comply with AS 4024.1 and ISO 3457.

3.9.1 Shields
Shields should be fitted to protect any hydraulic hoses that may be damaged by impact. (e.g.
in wheel arch areas, under body, etc.)
Consideration of hydraulic and engine oil coming into contact with hot engine parts (e.g. the
forced induction, exhaust manifold) shall be part of the fire risk assessment as required in
Clause 3.7 .
Hydraulic and engine oil shall, as far as reasonably practicable, be shielded from the such
components. Such shielding shall not trap fuel or oil around hot engine parts.

3.9.2 Guards

From WHS Regulation 2011, Clause 194:

194 Guarding

(1) A manufacturer of plant must ensure that guarding used as a control measure is of
solid construction and securely mounted so as to resist impact or shock.
...
(2) A manufacturer of plant must ensure:
(a) that any guarding used as a control measure in relation to plant is of a kind
that can be removed to allow maintenance and cleaning of the plant at any
time that the plant is not in normal operation, and
(b) if the guarding is removed—that, so far as is reasonably practicable, the plant
cannot be restarted unless the guarding is replaced.
...

Guards shall be fitted as follows:-

(a) On every fan to prevent contact.
(b) In the vicinity of every moving component that is readily accessible and can result
in injury.
(c) In the vicinity of any access way where a person may contact moving equipment.
(d) Where failure of pressurised components of plant that may release fluids or cause
a part to be ejected that may adversely affect the health and safety of the operator
or maintainer in the normal process of their duties.
(e) Any other areas required to be guarded by regulations listed above.

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(f) Any other areas as identified from accident statistics or risk assessments such as
drivelines.

3.9.3 Fire Resistant Guards

Fire resistant guards are to be provided as follows:
(a) Any covers, shields or guards not constructed from steel shall be constructed from
fire resistant material where the failure of the material is likely to place an operator
at risk if a fire occurs.
(b) The degree of fire resistance should suit the size of the fire that may eventuate
and should provide protection for at least 2 hours.
(c) Comparative fire resistance may be obtained by testing to ASTM E1354,
ISO 5660 (series) or AS 1530.
(d) This specifically applies to engine covers of large rear dump trucks as well as
most other large plant.
(e) The engine compartment should be effectively shielded from the Operator's
compartment in the event of a fire.
(f) The means of egress shall be effectively shielded in the event of a fire to provide
safe egress for the Operator.

3.10 MARKING, SIGNS AND IDENTIFICATION

3.10.1 General
Where appropriate, permanent markings, signs and identification plates shall be in
accordance with AS 1318 and AS 1319.
Where a hazard could exist from the misinterpretation of a symbol the meaning of the symbol
shall be clarified in writing.

3.10.1.1 Construction & Location

Markings, signs and labels shall be of durable construction and be permanently attached. It
is preferable for signs and labels to be constructed of engraved brass, stainless steel,
‘Traffolyte’ or similar.
Markings, signs and labels shall be installed or positioned and maintained so that they are
clearly visible.

3.10.2 Labelling
Labelling shall include individual labels displayed in a suitable position covering the following
areas where applicable:-

3.10.2.1 Compliance Plate

Compliance plates where required by relevant Australian and International Standard shall be
displayed in a prominent position. For example, the compliance plate of a rubber tyred
vehicle might show the following:
(a) The date of manufacture and serial number.
(b) The tare and gross weight of the plant.
(c) The axle loads.

34
(d) The maximum number of personnel for which seating is provided.
(e) Other appropriate plant details.

3.10.2.2 Limits of Application

In the Operator’s cabin information should be provided regarding all limits of application of
the plant as identified in Clause 2.7 .
On board indication of grade (cross and fore/aft) with the safe limits identified shall be
provided where appropriate. This applies particularly to cranes, rubber tyred vehicles and
overburden drills but should also be considered for other plant.

3.10.2.3 Warning and Danger Signs

Labelling shall include as a minimum but be not limited to:
(a) A warning sign adjacent to all accessible rotating fans.
(b) A warning at all accumulators that pressure shall be safely released before work
commences.
(c) A warning on any spring applied brake chamber that it contains a spring under
compression.
(d) A warning that "hearing protection shall be worn” is to be placed on the plant at
relevant locations where the noise exceeds regulatory levels and personnel are
required to carry out operational or maintenance activities.
(e) A warning that the park brake shall be applied and implements lowered before
leaving the plant.
(f) For analogue gauges, minimum safe operating limits should be indicated by green
and red zones. For digital displays, a clear visual or audible indication should
indicate whether the pressure is outside the safe operating range.
(g) Any automatic/self starting plant or plant started remotely shall be identified as
such.
Danger/hazard signs and other signs as considered necessary by the Manufacturer/supplier
should be placed in appropriate positions on the plant.

3.10.2.4 Controls & Pre-Operational Checklist

Labelling shall include as a minimum but be not limited to:
(a) Identification of all controls including direction of movement where applicable in
accordance with ISO 6405-1 and ISO 6405-2, as applicable.
(b) Emergency stops. (See Clause 5.2.6.3 .)
(c) Location of isolation points.
(d) Location of emergency egress points.

3.10.2.5 Action in Event of Fire

The required Operator action in event of a fire occurring shall be provided within the Operator
compartment visible from the normal operating position, similar to the following;

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 IN CASE OF FIRE

(a) Safely Stop Machine

(b) Shut Down All Power and Apply Park Brake
(c) Activate Fire Suppression System (If fitted)
(d) Initiate Mine Emergency Response

Do not endanger yourself by attempting to get

down from moving equipment

It is important that Operators are trained in the actions required in the event of a fire for each
type of plant.

3.10.3 Towing, Jacking and Supporting

The designated locations for towing, lifting, jacking and supporting the plant shall be
identified (e.g. painted a different colour) and should be labelled.

3.11 LIGHTING AND ALARMS

3.11.1 General
The following are applicable to all lighting and alarms:
(a) Suitable permanent or mobile lighting SHALL be provided for mobile and
transportable plant appropriate to their location in accordance with the appropriate
standard.
(b) Lighting and marking SHALL comply with ISO 12509 unless otherwise specified.
(c) The main access SHALL be adequately lit without interfering with operator
visibility.

3.11.1.2 Emergency Lighting

Emergency lighting shall be provided to allow for safe egress in the absence of normal
power, unless the Operator can leave the plant safely without exposure to hazards or risk of
injury. (eg. smaller plant that does not normally have their access way lit when operating at
night or day).

3.11.1.3 Reversing Lights

Reversing lights shall be provided on all plant.
The lights should provide the Operator with adequate visibility when reversing at night.

3.11.2 Brakes and Direction Indicators

All plant that exceeds 8 km/hr shall be provided with the following:

36
(a) Dual globe or Multiple LED direction indication blinker lights at the front, rear and
side of the plant.
(b) Dual globe or Multiple LED service brake indication lights readily visible from the
rear of the plant, (front location should be considered).
(c) Dual globe or Multiple LED retard brake indication lights readily visible from the
rear of the plant, (front location should be considered).This is applicable for
electrical and mechanical retarding systems.

3.11.3 Reflectors / Lights

Adequate reflectors, reflective tape and/or lights shall be provided on all plant to make it
readily visible from any direction and hence reduce the likelihood of a collision. (e.g. broken
down plant) This includes but is not limited to:
(a) Lights or reflectors visible from the side arranged in strips to assist in identifying
the length of the plant.
This applies in particular to diesel powered overburden drills and dump trucks but
should also be considered for other plant.
(b) The front head board or highest extremity of all trackless plant to provide visibility
in undulating terrain.

3.12 NOISE

3.12.1 Noise Assessment

The Manufacturer/supplier SHALL provide a full and comprehensive sound level analysis of
the supplied plant with respect to operator and/or bystander noise exposure.
This analysis SHALL be carried out in accordance with the AS/NZS 1269 (series), ISO 6394
and ISO 6396.

3.12.2 Operator/Bystander Noise Exposure

Management of noise must be in accordance with WHS Regulation 2011, Chapter 4, Part 4.1
Noise, Clauses 56 to 59.
A bystander is any person in the noise affected area of the truck, for example, anyone
involved with safety inspections, operator changeovers, maintenance refuelling and similar.

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 WHS Regulation 2011, Chapter 4, Part 4.1 Noise, Clause 56:

56 Meaning of “exposure standard for noise”

(1) In this Regulation, exposure standard for noise, in relation to a person, means:
(a) LAeq,8h of 85 dB(A), or
(b) LC,peak of 140 dB(C).
(2) In this clause:
LAeq,8h means the eight-hour equivalent continuous A-weighted sound pressure
level in decibels (dB(A)) referenced to 20 micropascals, determined in accordance
with AS/NZS 1269.1:2005 (Occupational noise management—Measurement and
assessment of noise immission and exposure).

LC,peak means the C-weighted peak sound pressure level in decibels (dB(C))
referenced to 20 micropascals, determined in accordance with AS/NZS
1269.1:2005 (Occupational noise management—Measurement and assessment of
noise immission and exposure).

NOTE: ISO 6394 and ISO 6396 specifies the method for determining the emission sound
pressure level of the plant at the Operator position. AS/NZS 1269 provides guidance on
the measurement and assessment of noise immission and exposure to a Bystander of
the plant.

3.13 OPERATOR'S CABIN AND PROTECTION

3.13.1 OPERATOR PROTECTIVE STRUCTURES

3.13.1.1 General

An extract from WHS Regulation 2011, Clause 217:

217 Protective structures on earth-moving machinery

(1) The person with management or control of earth-moving machinery at a

workplace must ensure that the machinery is not used unless it is securely fitted
with a protective structure.

Operator protective structures must be provided, used and maintained where there is a risk
of:
(a) mobile plant overturning; or
(b) an object falling on or coming into contact with the operator, or
(c) an operator being ejected from the seat; or
(d) the plant colliding with anything.

38
For all mobile plant, a risk assessment must be carried out to determine;
(i) the risk of unintended overturning, an object hitting the operator or a falling object
coming into contact with the operator, and
(ii) the required operator protective devices
For example, overburden drills operating near high walls, should be provided with a falling
object protective structure.
All passengers must be provided with the same zone of protection as that afforded to the
operator.

3.13.1.2 ROPS
ROPS shall be fitted to plant where the operator is seated in accordance with ISO 3471. This
includes plant such as:
(a) Wheeled prime-movers,
(b) Wheeled off-highway dump trucks,
(c) Rubber-tyred and crawler mounted dozers,
(d) Scrapers,
(e) Graders,
(f) Rollers,
(g) Loaders,
(h) Tractors (with or without attachments) used mainly on the surface working at any
mine.
(i) Excavators, which shall be in accordance with ISO 12117 or ISO 12117-2 as
applicable.

3.13.1.3 FOPS
FOPS shall be fitted to plant where the operator is seated in accordance with ISO 3449. This
includes plant such as:
(a) Loaders,
(b) Graders,
(c) Dump trucks,
(d) Rollers,
(e) Dozers,
(f) Drilling rigs – rubber-tyred or track mounted,
(g) Blast-hole drills on the surface of mines

3.13.1.4 TOPS – Excavators

TOPS shall be installed on excavators and shall be in accordance with ISO 12117 or
AS 4987, as applicable.

3.13.1.5 Operator Protective Guard (OPG) – Excavators

OPGs shall be installed on excavators and shall be in accordance with ISO 10262, as
applicable.

3.13.2 Cabins
The following apply to operator cabins:

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(a) Operator Cabins should be totally enclosed and soundproofed (see Clause 3.12.2
).
(b) Maximum visibility shall be provided to the Operator (see Appendix A2,
ISO 5006).
(c) All windows shall be fitted with safety glass or equivalent.
(d) Windscreen washing and wiping facilities should be provided.
(e) Storage for tools and similar should be outside the cabin. Where cabins have
storage space, this shall be secure to prevent projectiles in any accident.
(f) The Operator’s working space, passenger carrying space, cabin or working
platforms should be designed to minimise as far as reasonably practicable any
protrudences or sharp edges which could cause injury in the event of an accident
or sudden movement.
International Standards applicable to mobile plant operators cabins are listed in Clause A1,
Appendix A.

3.13.3 Heating, Demisting and Fresh Air Supply

Heating, demisting and fresh air supply should be provided as follows:-
(a) Be capable of adequately demisting the Operator's cabin window.
(b) Supply filtered external makeup air sufficient to maintain a positive pressure
inside the Operator's cabin with windows and doors closed.
The air supply system should make adequate allowance for deterioration of door and
window seals.
(c) The heater should have isolating valves fitted to both supply and return lines
adjacent to the engine to allow changing of heater hoses and/or core without
disturbance to the engine cooling system.
Guidance on the operator enclosure environment is given in ISO 10263 Parts 1 to 6.

3.13.4 Seats and Personal Restraint Systems

Seats and personal restraint systems (e.g. seat belts) as a minimum shall be in accordance
with the following:
(a) The Operator's seat should be a high backed type where suitable (may not be for
dozers), fully suspended and adjustable. For further guidance, see ISO 11112.
(b) Seat belts shall be provided for all seats on any rubber tyred plant.
(c) Seat belts should be installed on any plant that travels at more than 8 km per
hour.
(d) All seat belts and anchorages shall comply with SAE J386 or ISO 6683.
(e) Personal restraining mechanisms should be designed and installed under the
plant Manufacturer/supplier’s instructions and wherever possible factory fitted to
the plant.
(f) Passenger seats should be fitted with a restraining device to provide the same
level of protection to any occupants within the machinery or vehicles.
(g) These seats and devices should be used exclusively for safely carrying and
securing persons. On no account should these seats be used to carry goods or
ancillary equipment.

40
3.13.5 Air Conditioning
Air Conditioning should be provided. Where provided, it shall be in accordance with the
following:
(a) The system shall comply with the requirements of the "Ozone Protection Act
1989" - No 208 and the "Ozone Protection Regulation 1991" No 134, NSW.
(b) The mounting of the air conditioner and accessories should not interfere with
operator visibility or cabin headroom within the applicable ergonomics standard.
(c) The air conditioner’s mountings shall not interfere with the structural integrity of
ROPS or FOPS.
(d) The air conditioner intake location shall be located to avoid:-
(i) Exhaust emissions.
(ii) Areas where significant fuel and heat sources are present or where fumes
from a fire may be expected to concentrate.

3.14 PRESSURE VESSELS

An extract from WHS Regulation 2011, Clause 224:

224 Pressure equipment

(1) The person with management or control of pressure equipment at a workplace must
ensure that:
(a) the equipment is inspected on a regular basis by a competent person, and
(b) any gas cylinder that is inspected is marked with a current inspection mark
showing the date of the most recent inspection.

Designs and items that must be registered are listed in Appendix C, Section 6.3.2 ,
Appendix C2 Design and item registration.

3.14.1 Standards
All pressure vessels at a mine or plant shall be designed, inspected, maintained and
operated in accordance with the following standards;
(a) AS 1200, ‘Pressure Equipment’
(b) AS 1210, ‘Pressure Vessels’
(c) AS 3788, ‘Pressure Equipment – In Service Inspection’
(d) AS 3873, ‘Pressure Equipment – Operation and Maintenance’
(e) AS 3892, ‘Pressure Equipment – Installation’
(f) AS 4343, ‘Pressure equipment – Hazard levels’
(g) AS 2030.1, ‘Gas cylinders – General requirements’
(h) AS 2030.5, ‘Gas cylinders – Filling, inspection and testing of refillable cylinders’
(i) Any other relevant Australian Standard
The supplier shall provide a current ‘Certificate of Inspection’ with the delivery of plant in
accordance with applicable legislation.

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3.14.2 Accumulators
The following apply to accumulators:
(a) All hydraulic accumulators shall be designed, manufactured, certified, installed,
labelled, maintained and inspected in accordance with the relevant Australian
Standard or equivalent Standard, refer Clause 3.14 ‘Pressure vessels’.
(b) Accumulators shall be securely installed.
(c) Where a hydraulic system incorporates an accumulator the attachments to the
accumulator shall be by means of a minimal length adapter and flexible hose.
(d) Fittings shall be located or otherwise guarded to provide mechanical protection
against operational and maintenance damage, for example rock damage, stepping
onto components during maintenance and similar.
(e) A manual bleed valve should be fitted to allow pressure relief for maintenance
purposes. This should preferably be accessible from ground level and fluid should
return to tank, as per Clause 3.8.2 ‘Emergency Shutdown’.
(f) A safety relief valve should be included in the manual gas charging circuit where
gas charging accumulators are installed.

3.14.3 PVC Piping

The use of nylon or PVC piping for pneumatic safety control systems shall not be used
unless the loss of pressure within these systems cause the system to fail to safety. All such
piping shall be adequately protected and shielded from contact with hot and/or sharp
surfaces.

3.15 STEERING

3.15.1 Power Steering

All plant fitted with power steering, shall be capable of safe operation in the event of engine
or power failure to enable the plant to be brought safely to rest.
Power assisted and fully powered steering systems should preferably be separate from other
systems and circuits. Where this is not the case the power assisted and fully powered
steering systems shall have priority over other systems or circuits except for an emergency
steering system.
Further guidance is given in ISO 5010 Earth-moving machinery – rubber tyred machines –
steering requirements

3.15.2 Emergency Steering

Emergency steering shall be provided on all tractor scrapers, articulated trucks and dumpers.
Where fitted, emergency steering should comply with ISO 5010.

3.16 TOWING, JACKING & SUPPORTING

3.16.1 Towing of Plant Which is Inoperable.

NOTE: This is not intended to cover recovery of plant. (e.g. bogged plant)

42
A fit for purpose means of towing shall be recommended by the Manufacturer/supplier and
included in the operating manual.
Designed towing attachments and connectors shall be located at the front and rear of the
vehicle, with the maximum design load and direction of load specified.
Chains shall not be used for towing or recovery.
The following apply to towing:
(a) A risk assessment shall be carried out to determine the towing method.
(b) Any towing connector used shall not recoil if loaded beyond their breaking force.
For example, slings may be made of Kevlar.
(c) The maximum towable weight (gross load) for towed plant should be as per the
towing plant manufacturer/supplier's recommendation.
(d) A means of releasing fail safe brakes should be provided.
(e) A means of steering or guiding the towed plant should be provided.
(f) A means of adequately braking the plant system should be provided.
Where towing or being towed is not viable, this should be stated by the
Manufacturer/supplier.

3.16.2 Jacking and Supporting Equipment

Designated positions for the independent jacking and supporting of the plant shall be
provided. Labelling and documentation shall be provided in the maintenance manual. For
labelling of jacking and supporting points, see Clause 3.10.3 .

3.17 WHEELS AND RIMS

The principles of Australian Standard AS 4457.1 ‘Earth-moving Machinery – Off the Road
Wheels, Rims and Tyres – Maintenance and Repair Part 1: Wheel Assemblies and Rim
Assemblies' shall apply.
Changing a wheel or rim is considered high risk.
The supplier of any wheel or rim shall provide adequate information to ensure that the plant
is without risks to health and safety when used for a purpose for which it was designed or
manufactured.
A standard of engineering practice shall be developed for all wheel/rim assemblies on site.
The standard shall cover the life cycle of maintenance for wheel and rim assemblies and
shall be determined in consultation with the OEM/supplier for each group of rubber tyred
mobile plant on site. The standard should identify and detail the following:-
(a) the brand;
(b) the type/model;
(c) the part numbers for each component of the assembly;
(d) the initial periodic examination in operating hours or months,
(e) the ongoing periodic examination of the components.
(f) The maximum duty cycle that the components will be subjected to on the various
plant at the mine. eg. Graders, Loaders and Trucks
(g) All components of wheel/rim assemblies shall be uniquely marked for identification
to ensure incorrect matching is avoided.

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(h) A register shall be established for life cycle maintenance tracking of all
components.

3.18 TYRES
The tyre manufacturer shall recommend the maximum permissible duty cycle (TKPH) and
tyre pressure.
Tyres shall be maintained in accordance with the OEM’s recommendations and AS 4457.2.
The OEM shall be consulted to ensure the TKPH rating of the tyre matches the duty cycle of
the plant.

3.19 PROXIMITY DETECTION AND COLLISION AVOIDANCE

3.19.1 Visibility
The following apply to operator visibility:
(a) Operator visibility shall be maximised e.g. auxiliary plant should be located where
it will not interfere with visibility.
(b) The Manufacturer/supplier shall provide a drawing identifying the Operators field
of vision and a suitable diagram shall be available in the Operators cabin.
(c) Reference shall be made to ISO 5006 in the review of visibility.
(d) Guidance on rear view mirrors is given in ISO 14401 Parts 1 and 2.
(e) Closed circuit television system / reversing cameras may be considered for large
plant blind spots.

3.19.2 System operation

Proximity detection systems and collision avoidance systems should be considered when
introducing plant to a mine.
Proximity detection systems should alert persons to the imminent interaction between
equipment to persons, equipment to infrastructure and equipment to equipment. In addition,
collision avoidance systems should also intervene and take a form of control to prevent
impact between equipment to persons, equipment to infrastructure and equipment to
equipment.
NOTE: At time of writing, a new MDG was being considered, titled: “Guideline for Proximity
Detection and Anti Collision Systems for Mining”.

44
4 REQUIREMENTS FOR SPECIFIC TYPES OF PLANT

4.1 DUMP TRUCKS

Mine sites shall consider and manage the risk of the tail from one vehicle entering the cab of
another vehicle. Proximity detection should be considered. This shall not be achieved by any
means which restricts the Operators visibility. e.g. moving the Operators cabin further back.

4.1.1 Dump Body Warning Device

An audible and visual warning device shall be provided in the Operators cabin, to indicate
when the rear dump tray is elevated when forward motion is selected.
The device shall be visual and/or audible, and located such that it is readily noticed by the
Operator.

4.1.2 Dump Body Interlocks

When the rear dump tray is elevated, propulsion in the FORWARD and REVERSE direction
shall be inhibited unless the conditions specified below apply.

4.1.2.1 Mechanical Drive Truck

Where mechanical drive dump trucks are to move forward with the tray in the raised position,
an interlock shall be used which limits forward direction to first gear only, and reverse
direction is inhibited. The interlock remains active until the dump tray has fully lowered.

4.1.2.2 Electric Drive Truck

Where electric drive dump trucks are to move forward with the tray in the raised position,
switch shall be provided to restrict propulsion in the FORWARD direction only and shall
contain the following features;
(a) When operated and held in position, forward propulsion is possible at low speed
only.
(b) When released the switch shall automatically return to a position where ALL
propulsion is inhibited while the rear dump tray raised.
(c) The switch shall not prevent the operation of the rear dump tray raised warning
device.

4.1.3 Dump Body Restraint

To avoid crush injuries to personnel involved in maintenance and inspection beneath a dump
body, the following apply to dump body restraints:
(a) Rear dump truck shall be provided with a “means” of restraining the dump body
when in the raised position for inspection or maintenance.
(b) Power down controls shall be isolated.
(c) This “means of restraint” should consist of pins or slings or similar and shall have
a minimum safety factor of 2 to 1 when applied to the maximum possible down
load which can be exerted on the dump body when the dump body is in the raised
position.

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4.2 CONVEYORS
Conveyors on mobile and transportable plant shall comply with AS 1755.
NOTE: At the time of drafting this MDG, a revision of AS 1744 was underway. The revision will
re-designate the AS 1755 conveyor standard as a number of Standards under the
safety of machinery series, intended to be: AS 4024.3610 to AS 4024.3616.

4.3 CRUSHERS
Mobile crushers are usually associated with multiple integrated plant such as conveyors,
screens, hydraulics, electrics etc. There are significant risks associated with the operation
and maintenance of this type of plant.
In order to manage the risks associated with this complex array of plant a systematic process
should be adopted to:
(a) Identify hazards
(b) assess the risks associated with the hazards
(c) implement and maintain risk control measures
(d) review the risk control measures.
Assistance can be obtained from ISO 21873.2 Building construction machinery and
equipment – Mobile crushers Part 2 Safety requirements.

46
5 ELECTRICAL REQUIREMENTS

5.1 GENERAL
The electrical wiring of all Mobile and Transportable plant shall comply with the requirement
of this section. This section supplements the requirements of AS 4242, AS 4871.6 and
AS 60204.1.
Where requirements are not covered by the above standards, then all electrical wiring shall
comply with the requirements of AS 3000 and the AS 3007 series, as applicable.

5.1.1 Segregation of different voltage levels

All extra-low voltage circuits shall be segregated from low voltage and high voltage circuits.

5.1.2 Safe and Sound Practice.

Equipment shall be installed in accordance with the appropriate requirements of this
document and the generally accepted principles of safe, sound and good electrical
engineering practice.

5.1.3 Fixing and Supports.

All fixings, fastenings and supports shall be of adequate strength and arranged to protect the
wiring and associated electrical equipment from mechanical damage and failure.

5.1.4 General Protection Against Damage

All electrical parts of plant shall be protected against damage due to:
(a) mechanical failure,
(b) rock damage,
(c) stepping onto components during maintenance,
(d) exposure to weather,
(e) water,
(f) excessive dampness,
(g) corrosive fumes,
(h) accumulation of dust/debris,
(i) steam,
(j) oil,
(k) grease & fuel,
(l) high temperature,
(m) or any other circumstances which may damage electrical

5.1.5 Protection of Live Parts.

All live parts shall be arranged so that a short circuit or arcing, either between other live parts
or between live parts and other conductive materials, will not take place under the normal
conditions of service.

MDG 15 – Guideline for mobile and transportable plant for use at mines - Draft for comment Page 47 of 85
All connections shall be made so that they can not loosen or overheat under normal
conditions of service.

5.1.6 Extra Low Voltage

All extra-low voltage wiring shall comply with AS 4242, "Earth-moving machinery and
ancillary equipment for use in mines - Electrical wiring systems at extra-low voltage”.

5.1.7 Trailing Cable Supplied Plant

Trailing cable supplied plant (eg. draglines, drills and electric shovels) shall be wired in
accordance with AS 3000 and the AS 3007 series (as applicable) where there is no conflict
with the regulations. Electrical components on such plant shall comply with the relevant
Australian Standards. Trailing Cables should be constructed in accordance with AS 1802 or
AS 2802. This type of plant (eg. electric draglines, drills and shovels) is not covered by this
guideline. Reference should be made to the AS 3007 series, AS 60204.1 and AS 60204.11.

5.1.8 Lithium Batteries

Lithium battery packs shall be adequately protected against vibration and fretting which may
result in a short circuit occurring. The risk of lithium batteries should be assessed for each
installation.
NOTE: They can explode if a short circuit occurs.

5.2 MECHANICAL PROTECTION OF CABLES, CONDUCTORS

AND WIRING LOOMS

5.2.1 Wiring - General

In addition to the requirements of AS 4242, all wiring reticulated about the plant shall be;
(a) Enclosed in suitable mechanical protection (ie flexible conduit, rigid conduit, or
any other suitable means), and
(b) Arranged and located so as to facilitate regular visual inspections, and
(c) Arranged so it is not in contact with any hot surfaces or harnessed with, fuel lines,
brake lines, oil lines, pneumatic lines, hydraulic lines, etc.
Open ended, split conduit or spiral wrap is not a suitable protection at locations where the
ingress of contaminants is possible or mechanical protection is necessary.
Refer Appendix B for typical diagrams showing examples of compliance and non-compliance
with this clause.

5.2.1.2 Materials In Contact With Wiring

All materials in contact with or adjacent to any cable, conductor, or its covering shall be
shaped so that it will not cause abrasion of the cable, conductor or its covering that could
lead to its failure.

5.2.1.3 Maintenance
Electrical wiring should not be located where it can be damaged during maintenance or
repair. (e.g. being struck by falling objects, being walked upon, etc.)

48
5.2.1.4 Enclosed Wiring
Wiring enclosed within cabinets, components, junction boxes etc., shall be suitably loomed,
harnessed and supported.

5.2.1.5 Wiring through Walls

Where wiring is to be threaded through conduits, partition walls or similar the wiring shall be
adequately glanded or bushed, and where wiring protective covering terminates at a partition
wall (that is, an electrical cabinet or similar) it shall be adequately fixed to the point of
termination.
NOTE: Refer Appendix B for typical diagrams showing examples of compliance and non-
compliance with this clause.

5.2.2 Segregation of Wiring Systems

Segregation of wiring shall be as follows:
(a) Wiring of fire protection systems shall not be enclosed with wiring of any other
system, except for the purpose of termination at the point of supply.
(b) Circuits that are not provided with electrical protection shall be segregated from all
other circuits by barriers, conduits etc.

5.2.3 Prohibited Connections.

Unserviceable plant which is in an unsafe condition shall be isolated and shall not remain
connected to the point of supply.

5.2.4 Unused Equipment and Cables.

All redundant parts of electrical equipment and cables shall be completely disconnected from
the source of supply and marked, stating the location of the opposite end of the circuit and
the status of the interconnecting cable (ie. open circuit, healthy, short circuit etc.).
Disconnected wiring which remains in association with wiring that is in use shall be
terminated or insulated and means taken at both ends to prevent inadvertent reconnection.

5.2.5 Circuit Diagrams and Manuals.

Each item of plant shall be supplied with an accurate electrical schematic diagram, showing
all components and conductor markings. Where plug and socket arrangements are used
their location shall be noted on the schematic diagram. Diagrams should include aftermarket
components fitted by the Local Supplier.
Manuals shall be supplied with each item of plant. The manuals should include the relevant
electrical diagrams, parts list, cable schedule, component ratings and a section on
recommended maintenance periods and procedures, including safety precautions to be
taken.
When any circuit modifications are made the electrical schematic and wiring diagrams shall
be updated immediately including unused equipment and cables. (refer Clause 5.2.4 .)

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5.2.6 Labelling
5.2.6.1 Circuit Identification.
At each protective device there shall be placed a label of durable material, securely fastened,
indicating the circuit or sub circuit being supplied by that protective device and the rating of
that device.
Where this is not reasonably practicable, each protective device may be identified by a code.
A legend plate relating the code to the relevant circuit and the rating of the device shall be
placed in a conspicuous position and be made of a durable material. Any such coding
system shall be clearly shown on the electrical schematic and wiring diagrams.
It is recommended labels, legend plates etc. are suitably fastened by reliable methods (eg,
screws, pop rivets, or similar).

5.2.6.2 Cable Marking

Each conductor shall be marked at every point of termination in accordance with the plant
electrical schematic diagram. The marking shall be of a durable material that is easily
cleaned.

5.2.6.3 Component Identification

The following components shall be identified:
(a) Isolators;
(b) The on/off position of isolators;
(c) Jump-start receptacle;
(d) Electrical components, e.g. solenoids, relays, fuses, circuit-breakers;
(e) Emergency stops;
(f) Cables (should be labelled at terminations)

5.3 EMERGENCY STOP DEVICE SYSTEM

5.3.1 General
Emergency stops are safety critical systems and a functional safety approach shall be taken
in their design.
Emergency stop facilities should be provided in accordance with AS 4024.1604.
Emergency stop controls shall be provided and shall include the following features:
(a) An emergency stop shall be initiated by pushing a large red button.
(b) Be of the manually operated, automatic lock-off manual reset type.
(c) On activating the emergency stop device, the device shall latch either electrically
or mechanically, such that the actuation can only be reversed by a deliberate
action; the plant shall not restart automatically.
(d) The circuit shall be designed fail safe (i.e. not need power to shut down the
engine), and otherwise protected from faults that may defeat the operation of the
facility.
(e) Be capable of being operated with minimal effort without danger to the Operator
(f) Be designed such that the operation of the emergency stop is a deliberate action.
(g) The control voltage shall be Extra Low Voltage

50
5.3.2 Identification
Emergency stops shall be clearly marked "EMERGENCY STOP" and signage shall be in
accordance with AS 1318 and AS 1319.

5.3.3 Location
Emergency stops shall be located as follows:
(a) In the Operators cabin, and located ergonomically within the zone of reach and
located so as to minimise the risk of inadvertent operation.
(b) In the vicinity of the normal boarding point onto the plant, and located such that
both large and small Operators can reach the device from a position on the
ground at the boarding point.
These stops shall not be located in front of outblowing fans or airflows. (may direct fire
to control point).
NOTE: Consideration should be given to the location of the emergency stops so as to avoid
inadvertent operation when travelling on a public road. Refer to road authority rules.

5.3.4 Emergency Circuits

Circuits installed to supply devices that are to be used in an emergency shall be dedicated
for that purpose. Electrical protection devices such as fuses, circuit breakers or similar may
be undesirable in such circuits. Fire protection systems shall be in accordance with
Clause 3.7.2.4 .
Where no electrical protection is provided, alternative precautions to minimise the risk of a
fault occurring in the circuit shall be taken. Such alternatives should include but be not limited
to:
(a) Total segregation,
(b) Additional physical protection,
(c) Oversizing of cables and components,
(d) Increased creepage and clearance distances,
(e) Increased thermal withstand, etc.

5.4 GENERAL ARRANGEMENT OF EXTRA LOW VOLTAGE

CONTROL & PROTECTION

5.4.1 General
The general arrangement, control and protection of circuits and equipment shall be such that
the installation safely operates with regard to the following:
(a) Selection of cables.
(b) Arrangement and functionality of circuits.
(c) Control of circuits by suitable switching arrangements.
(d) Protection of circuits from overload and short circuit conditions.
(e) Selection, design and location of switches and ancillary equipment normally used
on plant.

MDG 15 – Guideline for mobile and transportable plant for use at mines - Draft for comment Page 51 of 85
(f) Operation and arrangement of switches, push buttons or other devices shall be
such that their inadvertent operation shall not cause any danger to plant operators
or plant.
(g) Where electrical protective devices or circuits are required not to disconnect the
electrical supply in order to prevent loss of control of the plant, a warning device
shall be located in the Operator’s cabin to warn the Operator of a malfunction.

5.4.2 Circuit Protection

Where it is not reasonably practicable to protect certain circuits with electrical protective
devices, additional precautions shall be taken to minimise the risk of the circuit failing.
These additional precautions shall include but be not limited to:
(a) Additional mechanical protection.
(b) Suitable location.
(c) Adequate harnessing and support.
(d) Segregation from other circuits, energy sources, fuels, etc.
(e) Oversizing of cables and components.
In summary use the increased safety philosophy.

5.4.3 Size & Type of Cables & Conductors

5.4.3.1 General
Cables shall be selected having due regard to the following criteria.
(a) The current-carrying capacity as determined from the cable insulant, and
installation methods.
(b) Voltage drop.
(c) Short circuit performance as determined from the characteristics of the protective
device .
(d) Mechanical strength.
All cables that reticulate about the plant shall be enclosed in conduit or other protective
measures of adequate strength which is oil, water and fuel resistant.

5.4.3.2 Current Carrying Capacity

Every cable shall have a current carrying capacity not less than the maximum load current to
be carried by it, and shall be capable of carrying the expected currents under both normal
and abnormal conditions. Normal conditions may include increased ambient temperature.
(eg. Inside engine bays cables may need to be derated.)

5.4.4 Current Rating of Control Devices

Every switch, fuse, push button, circuit breaker (and similar) shall have a current rating not
less than the maximum demand of the circuit it controls.

5.4.5 Voltage Rating of Components

Every switch, fuse, push button, circuit breaker etc., shall have a voltage rating not less than
the maximum voltage of the circuit.

52
5.4.6 Current Rating of Protective Devices
Protective devices shall be arranged so as to automatically disconnect the active conductors
of a circuit in the event of an overload or a short circuit or both. These devices shall be
provided to interrupt any over-current flowing in the circuit before any damage is caused by
thermal effects. Circuit breakers shall not be automatic reset devices.
Current rating of the protective device shall be not more than current carrying capacity of
connected cable.

5.4.7 Requirements for Specific Types of Plant

Rear Dump Trucks only shall in addition to the above comply with the following:
(a) SAE J1317 - ‘Electric Propulsion Rotating Equipment - Off Road Dumpers’
(b) SAE J1299 - ‘Electric Propulsion Control - Off Road Dumpers’
(c) Enclosures containing electrical components and electrical components shall
comply with the relevant Australian Standards.
(d) The minimum degree of protection against access to live parts shall be IP2X as
defined in AS 60529, ‘Degree of Protection Provided by Enclosures for Electrical
Equipment (IP Code)’.
It should be realised that for maintainability and ease of cleaning, enclosures and devices
may need to be rated as high as IP57. The customer/user should take this into consideration
when specifying their requirements.

5.4.8 Warnings / Indications in the Operators Cabin.

Indication shall be provided to the Operator of any malfunction on the plant that may cause
loss of control or serious damage to the plant, so as to allow the plant to be brought safely to
rest. i.e. Ground fault alarm, overspeed, or similar.

5.4.9 Electric Drive Loaders Only – Propulsion Systems

The system shall provide adequate control and safety features to ensure that, when operated
as designed, the risk of malfunction is minimised and that the risk of injury to Operators or
damage to the plant is minimised.

5.4.10 Batteries
No fuses or switching devices to be installed in battery enclosure

5.4.11 Jump start Facilities

Jump start receptacles shall be connected to the line side of the battery isolator to prevent
inadvertent starting of the machine while the battery isolator is in the OFF position.
Inadvertent connection of jumpstart supplies of incorrect voltage or polarity shall be
prevented. Refer AS 4871.6, if or when published.

5.4.12 Battery isolator

Battery isolators shall open both the positive and negative battery supply.

MDG 15 – Guideline for mobile and transportable plant for use at mines - Draft for comment Page 53 of 85
Only fire protection, communication and safety systems need not be controlled by the battery
isolating switch. Consideration shall be given to the use of double pole over-current
protection for circuits not controlled by the battery isolator, e.g. two-way radio systems.

5.4.13 Starter isolator

Where a starter or auxiliary isolator is fitted for maintenance purposes, the isolator must open
the positive battery supply and, where possible, open the negative battery supply.

5.4.14 Remote control

All remote control plant other than those excluded in the scope of the AS/NZS 4240 series
should comply with the AS/NZS 4240 series, as applicable.

54
6 APPENDICES

6.1 APPENDIX A – ASSOCIATED STANDARDS AND CODES

The reader should check the latest version of a Standard at time of use.
Australian and ISO standards are available through Standards Australia;
standards.org.au
infostore.saiglobal.com/store/

6.1.1 Appendix A1 – Australian Standards

The following Australian Standards have been referenced in this Guideline. Some equivalent
ISO standards are noted.

Australian Title Equivalent ISO Standard

Standard
1101.1-2007 Graphic symbols for general engineering - ISO 1219.1
Hydraulic and pneumatic systems
1180-(Series) Methods of test for hose made from elastomeric 1402
materials
1817
6802
6803
8030
8032
10619-1
10619-2
10619-3
13774
28702
1200-2000 Pressure equipment
1210-2010 Pressure Vessels
1318-1985 Use of colour for the marking of physical hazards
and the identification of certain equipment in
industry (known as the SAA Industrial Safety
Colour Code)
1319-1994 Safety signs for the occupational environment
1418-(Series) Cranes, hoists and winches
1530-(Series) Methods for fire tests on building materials, 5657
components and structures

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Australian Title Equivalent ISO Standard
Standard
1530.1-1994 Methods for fire tests on building materials, modified 1182
components and structures - Combustibility test
for materials
1530.2-1993 Methods for fire tests on building materials,
components and structures - Test for
flammability of materials
1530.3-1999 Methods for fire tests on building materials,
components and structures - Simultaneous
determination of ignitability, flame propagation,
heat release and smoke release
1530.4-2005 Methods for fire tests on building materials, 834
components and structures - Fire-resistance test
of elements of construction
1530.7-2007 Methods for fire tests on building materials,
components and structures - Smoke control
assemblies - Ambient and medium temperature
leakage test procedure
1636-(Series) Tractors, roll over protective structures – Criteria 3463
and tests
5700
Part 1: Conventional tractors
Part 2: Rear mounted tractors
Part 3: Mid-mounted for narrow track tractors
1657-1992 Fixed, platforms, walkways, stairways and 2867
ladders
1755-2000 Conveyors – Safety requirements
1802-2003 Electric cables - Reeling and trailing - For
underground coal mining purposes
1841-(series) Portable fire extinguishers
1841.1-2007 Portable fire extinguishers - General
requirements
1841.2-2007 Portable fire extinguishers - Specific
requirements for water type extinguishers
1841.3-2007 Portable fire extinguishers - Specific
requirements for wet chemical type extinguishers
1841.4-2007 Portable fire extinguishers - Specific
requirements for foam type extinguishers
1841.5-2007 Portable fire extinguishers - Specific
requirements for powder type extinguishers
1841.6-2007 Portable fire extinguishers - Specific
requirements for carbon dioxide type
extinguishers

56
Australian Title Equivalent ISO Standard
Standard
1841.7-2007 Portable fire extinguishers - Specific
requirements for vaporizing liquid type
extinguishers
1841.8-2007 Portable fire extinguishers - Specific
requirements for non-rechargeable type
extinguishers
1850-2009 Portable fire extinguishers - Classification, rating
and performance testing
1851-2005 Maintenance of fire protection equipment
2012.2-1990 Operators Position equivalent 6394
2030.1-2009 Gas cylinders - General requirements
2030.5-2009 Gas cylinders - Filling, inspection and testing of
refillable cylinders
2187.2 Explosives - Storage and use – Part 2: Use of
explosives
2294.1 Earth-moving machinery—Protective NA
structures—Part 1: General
2444-2001 Portable fire extinguishers and fire blankets -
Selection and location
2550.10-2006 Cranes, hoists and winches - Safe use - Mobile
elevating work platforms
2550.1-2011 Cranes - Safe use - General requirements
2550.5-2002 Cranes, hoists and winches - Safe use - Mobile
cranes
2550.9-1996 Cranes - Safe use - Vehicle hoists
2660-1991 Hose and hose assemblies - Air/water - For
underground coal mines
2670.1-2001 Evaluation of human exposure to whole-body 2631-1
vibration - General requirements
2671-2002 Fluid power, hydraulic systems and components modified 4413
2802-2000 Electric cables - Reeling and trailing for mining
and general use (other than underground coal
mining)
2958.1-1995 Earth-moving machinery - Safety - Wheeled
machines - Brakes
2958.1-1995 Wheeled machines—Brakes based on 3450
2958.3-1992 Earth-moving machinery - Safety - Roller
compactors - Brake systems
2958.3-1992 Roller compactors—Brake systems 20474-1

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Australian Title Equivalent ISO Standard
Standard
3000-2007 Electrical installations (known as the
Australian/New Zealand Wiring Rules)
3007.1-2004 Electrical installations - Surface mines and
associated processing plant - Scope and
definitions
3007.2-2004 Electrical installations - Surface mines and
associated processing plant - General protection
requirements
3007.3-2004 Electrical installations - Surface mines and
associated processing plant - General
requirements for equipment and ancillaries
3007.4-2004 Electrical installations - Surface mines and
associated processing plant - Additional
requirements for specific applications
3007.5-2004 Electrical installations - Surface mines and
associated processing plant - Operating
requirements
31000-2009 Risk management - Principles and guidelines
3788-2006 Pressure equipment - In-service inspection
3791-1991 Hydraulic hose 1436
3862
3949
4079
6805
11237
TR 11340
18752
23297
3868-1991 Earth-moving machinery—Design guide for based on 2867
access systems
3873-2001 Pressure equipment - Operation and
maintenance
3892-2001 Pressure equipment - Installation
4024.1-(series) Safety of machinery
4024.1301-2006 Risk assessment - Principles of risk assessment
4024.1302-2006 Risk assessment - Reduction of risks to health
and safety from hazardous substances emitted
by machinery - Principles and specification for
machinery manufacturers

58
Australian Title Equivalent ISO Standard
Standard
4024.1401-2006 Ergonomic principles - Design principles -
Terminology and general principles
4024.1501-2006 Design of safety related parts of control systems
- General principles
4024.1502-2006 Design of safety related parts of control systems
– Validation
4024.1603-2006 Safety of machinery - Design of controls,
interlocks and guarding - Prevention of
unexpected start-up
4024.1604-2006 Safety of machinery - Design of controls,
interlocks and guarding - Emergency stop -
Principles for design
4024.2801-2008 Safety of machinery - Safety distances and
safety gaps - Positioning of protective equipment
with respect to the approach speed of parts of
the human body
4240.1-2009 Remote control systems for mining equipment -
Design, construction, testing, installation and
commissioning
4240.2-2009 Remote control systems for mining equipment -
Operation and maintenance for underground
metalliferous mining
4242-1994 Earth-moving machinery and ancillary equipment NA
for use in mines—Electrical wiring systems at
extra-low voltage
4343-2005 Pressure equipment - Hazard levels
4457.1-2007 Earth-moving machinery—Off-highway rims and NA
wheels—Maintenance and repair—Part 1: Wheel
assemblies and rim assemblies
4457.2-2008 Earth-moving machinery—Off-highway rims and
wheels—Maintenance and repair—Part 2: Tyres
4871.6-2007 Electrical equipment for coal mines, for use
underground - Part 2: Diesel powered machinery
and ancillary equipment
4987-2002 Earth –moving machinery – Tip-over protective ISO 12117
structure (TOPS) for compact excavators –
Laboratory tests and performance requirements
5062-2006 Fire protection for mobile and transportable
equipment
60204.11-2006 Safety of machinery - Electrical equipment of Equivalent IEC 60204.11
machines - Requirements for HV equipment for
voltages above 1000 V a.c. or 1500 V d.c and
not exceeding 36 kV

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Australian Title Equivalent ISO Standard
Standard
60204.1-2005 Safety of machinery - Electrical equipment of Modified IEC 60204.1
machines - General requirements

60529-2004 Degrees of protection provided by enclosures (IP

Code)
61508-(series) Functional safety of electrical / electronic /
programmable electronic safety-related systems
- General requirements
62061-2006 Safety of machinery - Functional safety of safety-
related electrical, electronic and programmable
electronic control systems
NOTE: The letters NA in the ISO No and Year column indicate that there is no ISO Standard.
ie the Australian Standard was developed here.

6.1.2 Appendix A2 – ISO Standards for cabins

The following ISO Standards applicable to mobile plant operators cabins were referenced in
this Guideline:
Number Title Subject

ISO 5006:2006 Earth-moving machinery -- Operator's field of view -- Test Cabins

method and performance criteria

ISO 6394:2008 Earth-moving machinery -- Determination of emission Cabins

sound pressure level at operator's position -- Stationary
test conditions

ISO 6396:2008 Earth-moving machinery -- Determination of emission Cabins

sound pressure level at operator's position -- Dynamic
test conditions

ISO 6405-1:2004 Earth-moving machinery -- Symbols for operator controls Cabins

and other displays -- Part 1: Common symbols

ISO 6405-2:1993 Earth-moving machinery -- Symbols for operator controls Cabins

and other displays -- Part 2: Specific symbols for
machines, equipment and accessories

ISO 10263-1:2009 Earth-moving machinery -- Operator enclosure Cabins

environment -- Part 1: Terms and definitions

ISO 10263-2:2009 Earth-moving machinery -- Operator enclosure Cabins

environment -- Part 2: Air filter element test method

ISO 10263-3:2009 Earth-moving machinery -- Operator enclosure Cabins

environment -- Part 3: Pressurization test method

60
 Number Title Subject

ISO 10263-4:2009 Earth-moving machinery -- Operator enclosure Cabins

environment -- Part 4: Heating, ventilating and air
conditioning (HVAC) test method and performance

ISO 10263-5:2009 Earth-moving machinery -- Operator enclosure Cabins

environment -- Part 5: Windscreen defrosting system test
method

ISO 10263-6:2009 Earth-moving machinery -- Operator enclosure Cabins

environment -- Part 6: Determination of effect of solar
heating

ISO 10968:2004 Earth-moving machinery -- Operator's controls Cabins

ISO 11112:1995 Earth-moving machinery -- Operator's seat -- Dimensions Cabins

and requirements

ISO 14401-1:2009 Earth-moving machinery -- Field of vision of surveillance Cabins

and rear-view mirrors -- Part 1: Test methods

ISO 14401-2:2009 Earth-moving machinery -- Field of vision of surveillance Cabins

and rear-view mirrors -- Part 2: Performance criteria

6.1.3 Appendix A3 – International Standards for earthmoving

equipment
The following international standards applicable to earthmoving equipment were referenced
in this Guideline:
Number Title Subject

ISO Guide 73 Risk management - Vocabulary Risk

ISO 834-1:1999 Fire-resistance tests - Elements of building construction fire resistance

- Part 1: General requirements

ISO/TR 834-2:2009 Fire-resistance tests - Elements of building construction fire resistance

- Part 2: Guidance on measuring uniformity of furnace
exposure on test samples

ISO/TR 834-3:2012 Fire-resistance tests - Elements of building construction fire resistance

- Part 3: Commentary on test method and guide to the
application of the outputs from the fire-resistance test

ISO 2631-1:1997 Mechanical vibration and shock - Evaluation of human Ergonomics

exposure to whole-body vibration - Part 1: General
requirements

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Number Title Subject

ISO 2631-2:2003 Mechanical vibration and shock - Evaluation of human Ergonomics

exposure to whole-body vibration - Part 2: Vibration in
buildings (1 Hz to 80 Hz)

ISO 2631-5:2004 Mechanical vibration and shock - Evaluation of human Ergonomics

exposure to whole-body vibration - Part 5: Method for
evaluation of vibration containing multiple shocks

ISO 2867:2011 Earth-moving machinery - Access systems Access

ISO 31010 Risk management - Risk assessment techniques Risk

ISO 3450:2011 Earth-moving machinery - Wheeled or high-speed Braking

rubber-tracked machines - Performance requirements
and test procedures for brake systems

ISO 3457:2003 Earth-moving machinery - Guards - Definitions and Definitions

requirements

ISO 3471:2008 Earth-moving machinery - Roll-over protective Protective

structures - Laboratory tests and performance structure
requirements

ISO 5010:2007 Earth-moving machinery - Rubber-tyred machines - Mechanical

Steering requirements

ISO 5657:1997 Reaction to fire tests - Ignitability of building products Testing

using a radiant heat source

ISO 5660-1: 2002 Reaction-to-fire tests - Heat release, smoke production fire resistance
and mass loss rate - Part 1: Heat release rate (cone
calorimeter method)

ISO 5660-2:2002 Reaction-to-fire tests - Heat release, smoke production fire resistance
and mass loss rate - Part 2: Smoke production rate
(dynamic measurement)

ISO 6682:1986 Earth-moving machinery - Zones of comfort and reach Ergonomics

for controls

ISO 6683:2005 Earth-moving machinery - Seat belts and seat belt Testing
anchorages - Performance requirements and tests

ISO 7096:2000 Earth-moving machinery - Laboratory evaluation of Ergonomics

operator seat vibration

ISO 8535-1:2011 Diesel engines - Steel tubes for high-pressure fuel Engines
injection pipes - Part 1: Requirements for seamless
cold-drawn single-wall tubes

62
 Number Title Subject

ISO 8535-2:2003 Compression-ignition engines - Steel tubes for high- Engines

pressure fuel injection pipes - Part 2: Requirements for
composite tubes

ISO 10262:1998 Earth-moving machinery - Hydraulic excavators - Testing

Laboratory tests and performance requirements for
operator protective guards

ISO 10265:2008 Earth-moving machinery - Crawler machines - Braking

Performance requirements and test procedures for
braking systems

ISO 1182:2010 Reaction to fire tests for products - Non-combustibility fire resistance
test

ISO 12100 Safety of machinery - General principles for design - Risk

Risk assessment and risk reduction

ISO 12117:1997 Earth-moving machinery - Tip-over protection structure Protective

(TOPS) for compact excavators - Laboratory tests and structure
performance requirements

ISO 12117-2:2008 Earth-moving machinery - Laboratory tests and Protective

performance requirements for protective structures of structure
excavators - Part 2: Roll-over protective structures
(ROPS) for excavators of over 6 t

ISO 12509:2004 Earth-moving machinery - Lighting, signalling and

marking lights, and reflex-reflector devices

ISO 14122-1:2001 Safety of machinery - Permanent means of access to Safety of

machinery - Part 1: Choice of fixed means of access Machinery
between two levels

ISO 14122-2:2001 Safety of machinery - Permanent means of access to Safety of

machinery - Part 2: Working platforms and walkways Machinery

ISO 14122-3:2001 Safety of machinery - Permanent means of access to Safety of

machinery - Part 3: Stairs, stepladders and guard-rails Machinery

ISO 14122-4:2004 Safety of machinery - Permanent means of access to Safety of

machinery - Part 4: Fixed ladders Machinery

ISO 15998:2008 Earth-moving machinery - Machine-control systems Control &

(MCS) using electronic components - Performance display
criteria and tests for functional safety

ISO 21873-1 Building construction machinery and equipment - Mobile

crushers - Part 1: Terminology and commercial
specifications

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 Number Title Subject

ISO 21873-2 Building construction machinery and equipment - Mobile

crushers - Part 2: Safety requirements

ISO 13849-1:2006 Safety of machinery - Safety-related parts of control Safety of

systems - Part 1: General principles for design Machinery

ISO 13849-2:2003 Safety of machinery - Safety-related parts of control Safety of

systems - Part 2: Validation Machinery

ISO/TR 5660-3:2003 Reaction-to-fire tests - Heat release, smoke production fire resistance
and mass loss rate - Part 3: Guidance on measurement

IEC 60204-1 2009 Safety of machinery - Electrical equipment of machines Electrical

- Part 1: General requirements

IEC 60204-11 2000 Safety of machinery - Electrical equipment of machines Electrical

- Part 11: Requirements for HV equipment for voltages
above 1 000 V a.c. or 1 500 V d.c. and not exceeding
36 kV

6.1.4 Appendix A4 – ISO Standards for fluid power systems

The following Standards applicable to hydraulic power systems are referenced in this
Guideline:
Number Title Subject

ISO 1219-1:2012 Fluid power systems and components - Graphical Fluid power
symbols and circuit diagrams - Part 1: Graphical
symbols for conventional use and data-processing
applications

ISO 1219-2:1995 Fluid power systems and components - Graphic symbols Fluid power
and circuit diagrams - Part 2: Circuit diagrams

ISO 4413:2010 Hydraulic fluid power - General rules and safety Fluid power
requirements for systems and their components

ISO 4414:2010 Pneumatic fluid power - General rules and safety Fluid power
requirements for systems and their components

6.1.5 Appendix A5 – ISO Standards for hydraulic and pneumatic

hoses
The following Standards applicable to hoses for hydraulics are referenced in this Guideline:
Number Title Subject

64
 Number Title Subject

ISO 1402:2009 Rubber and plastics hoses and hose assemblies -- Hoses
Hydrostatic testing

ISO 1436 Rubber hoses and hose assemblies -- Wire-braid- Hoses

reinforced hydraulic types for oil-based or water-based
fluids -- Specification

ISO 1817:2011 Rubber, vulcanized or thermoplastic - Determination of Hoses

the effect of liquids

ISO 3862 Rubber hoses and hose assemblies -- Rubber-covered Hoses

spiral-wire-reinforced hydraulic types for oil-based or
water-based fluids -- Specification

ISO 3949 Plastics hoses and hose assemblies -- Textile-reinforced Hoses

types for hydraulic applications -- Specification

ISO 4079 Rubber hoses and hose assemblies -- Textile-reinforced Hoses

hydraulic types for oil-based or water-based fluids --
Specification

ISO 6802:2005 Rubber and plastics hoses and hose assemblies with Hoses
wire reinforcements - Hydraulic impulse test with flexing

ISO 6803:2008 Rubber or plastics hoses and hose assemblies - Hoses

Hydraulic-pressure impulse test without flexing

ISO 6805:1994 Rubber hoses and hose assemblies for underground Hoses
mining - Wire-reinforced hydraulic types for coal mining -
Specification

ISO 7751:1991 Rubber and plastics hoses and hose assemblies -- Hoses
Ratios of proof and burst pressure to maximum working
pressure

ISO 8030:1995 Rubber and plastics hoses -- Method of test for Hoses
flammability

ISO 8032:1997 Rubber and plastics hose assemblies - Flexing Hoses

combined with hydraulic impulse test (half-omega test)

ISO 10619-1:2011 Rubber and plastics hoses and tubing - Measurement of Hoses
flexibility and stiffness - Part 1: Bending tests at ambient
temperature

ISO 10619-2:2011 Rubber and plastics hoses and tubing - Measurement of Hoses
flexibility and stiffness - Part 2: Bending tests at sub-
ambient temperatures

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 Number Title Subject

ISO 10619-3:2011 Rubber and plastics hoses and tubing - Measurement of Hoses
flexibility and stiffness - Part 3: Bending tests at high and
low temperatures

ISO 11237:2010 Rubber hoses and hose assemblies -- Compact wire- Hoses
braid-reinforced hydraulic types for oil-based or water-
based fluids -- Specification

ISO/TR 11340:1994 Rubber and rubber products -- Hydraulic hose Hoses

assemblies -- External leakage classification for
hydraulic systems

ISO 13774:1998 Rubber and plastics hoses for fuels for internal- Hoses
combustion engines -- Method of test for flammability

ISO 13775-2:2000 Thermoplastic tubing and hoses for automotive use -- Hoses
Part 2: Petroleum-based-fuel applications

ISO 18752:2006 Rubber hoses and hose assemblies -- Wire- or textile- Hoses
reinforced single-pressure types for hydraulic
applications -- Specification

ISO 19013-1:2005 Rubber hoses and tubing for fuel circuits for internal Hoses
combustion engines -- Specification -- Part 1: Diesel
fuels

ISO 23297:2008 Thermoplastics hoses and hose assemblies -- Wire or Hoses

synthetic yarn reinforced single-pressure types for
hydraulic applications -- Specification

ISO 28702:2008 Rubber and plastics hoses and tubing - Textile- Hoses
reinforced types - Sub-ambient temperature crush test

6.1.6 Appendix A6 - SAE Standards

SAE Automotive Standards
The following SAE standards are referenced in this Guideline:

SAE No. Title

Electrical
J1299 Electrical Propulsion Control—Off-Road Dumpers
J1317 Electrical Propulsion Rotating Equipment—Off-Road Dumper

Non-hydraulic hoses
J30-2012 Fuel and Oil Hoses
J2405-2007 Low-Permeation Fuel Fill and Vent Tube

66
 SAE No. Title

Aerospace Standards
SAE AS1339 Hose Assembly, Polytetrafluoroethylene, Metallic Reinforced,
3000 psi, 400 °F, Lightweight, Hydraulic and Pneumatic

NOTE: SAE standards are available through Standards Australia, (www.standards.com.au) or

directly through Society of Automotive Engineers U.S.A. on (www.sae.org)

6.1.7 Appendix A7 - ASTM Standards

ASTM Automotive Standards
The following ASTM standard is referenced in this Guideline:

ASTM No. Title

E1354 – 11b Standard Test Method for Heat and Visible Smoke Release Rates
for Materials and Products Using an Oxygen Consumption
Calorimeter
NOTE: How to read the ASTM designation number:
o E = miscellaneous subjects;
o 1354 = assigned sequential number
o 11 = year of original adoption (or, in the case of revision, the year of last revision)
o b = indicates subsequent revision in same year

6.1.8 Appendix A8 – European Directives

The following European Directive is referenced in this Guideline:
Directive 2002/44/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of
25 June 2002 on the minimum health and safety requirements regarding the exposure of
workers to the risks arising from physical agents (vibration) (sixteenth individual Directive
within the meaning of Article 16(1) of Directive 89/391/EEC)

6.1.9 Appendix A9 – Codes of Practice

The following published codes of practice are referenced in this Guideline:
o Managing the risk of falls at workplaces
o Managing noise and preventing hearing loss at work

The following draft code of practice is referenced in this Guideline:

o Roads & Other Vehicle Operating Areas

Codes of Practice may be found at:

www.workcover.nsw.gov.au/lawpolicy/codesofPractice/Pages/default.aspx

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www.safeworkaustralia.gov.au/sites/swa/legislation/model-cop/pages/model-cop.aspx

6.1.10 Appendix A10 – Design and Re-design

The following information applies to design and re-design, and is referenced in this
Guideline:
o EMESRT Design Philosophies, see: www.emesrt.org/design-philosophies/
o ANSI/ASSE Z590.3 - 2011 Prevention through Design - Guidelines for Addressing
Occupational Hazards and Risks in Design and Redesign Processes

68
6.2 APPENDIX B – ELECTRICAL WIRING DIAGRAMS

6.2.1 Appendix B1 Examples of Compliance – General Wiring

Cable clamp base

Physical protection of cable/insulated conductor.

Machine frame, engine Cable/insulated conductor/s

etc.

Physical protection of cable/insulated conductor.

This separation distance should be sufficient to

maintain separation with regard to to sag, pulsation etc.

Hydraulic hose, fuel line etc

Figure 6.1 – Example of Compliance With ‘Wiring – General’

6.2.2 Appendix B2 Examples of Compliance (With Qualification) – General Wiring

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 With electrical wiring and hoses located in this position the
inspections are more difficult to do and combustible
materials may collect around wiring and hoses.
Where there is intimate contact with hot surfaces,
hoses, electrical wiring and its protection needs to
have the appropriate thermal rating.

Physical protection of cable/insulated conductor.

Machine frame, engine Cable/insulated conductor/s

etc.

Physical protection of cable/insulated conductor.

This separation distance should be sufficient to

maintain separation with regard to to sag, pulsation etc.

Hydraulic hose, fuel line etc.

Figure 6.2 – Example of Compliance (With Qualification) With ‘Wiring – General’

70
 With electrical wiring and hoses located in this position the
inspections are more difficult to do and combustible
materials may collect around wiring and hoses.
Where there is intimate contact with hot surfaces,
hoses, electrical wiring and its protection needs to
have the appropriate thermal rating.

Hydraulic hose, fuel line etc.

Physical protection of cable/insulated conductor.

Hose clamp base.

Hose clamp.

Cable/insulated conductor/s

Physical protection of cable/insulated conductor.

This separation distance should be sufficient to

maintain separation with regard to to sag, pulsation etc.

Figure 6.3 – Example of Compliance (With Qualification) With ‘Wiring – General’

MDG 15 – Guideline for mobile and transportable plant for use at mines - Draft for comment Page 71 of 85
6.2.3 Appendix B3 Does Not Comply With General Wiring

Physical protection of cable/insulated conductor.

Machine frame, engine Cable/insulated conductor/s

etc.

Physical protection of cable/insulated conductor.

Hydraulic hose, fuel line etc. in contact with physical protection

of electrical wiring does not comply

Hydraulic hose, fuel line etc

Figure 6.4 – Example of Does Not Comply With ‘Wiring – General’

72
 Hydraulic hose, fuel line etc. in contact with Hydraulic hose, fuel line etc
does not comply.

Hydraulic hose, fuel line etc.

Physical protection of cable/insulated conductor.

Cable/insulated conductor/s

Hydraulic hose, fuel line etc. in contact with physical protection

of electrical wiring does not comply

Physical protection of cable/insulated conductor.

Figure 6.5 – Example of Does Not Comply With, ‘Wiring – General’

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6.2.4 Appendix B4 Example of Compliance and Non-Compliance With ‘Wiring Through Walls’

COMPLIES

Gland/clamp arrangement
Insulated conductors Physical protection of electrical wiring

Exposed insulated conductors

DOES NOT COMPLY

Interior of an electrical
enclosure Exterior of an electrical
enclosure

Figure 6.6 – Example of Compliance and Non-Compliance ‘Wiring Through Walls’

74
 Plug fitting

DOES NOT COMPLY

(Insulated wires
exposed)

Wiring harness/conduit Wiring harness/conduit

Exposed insulated wires

Plug fitting

COMPLIES

Wiring harness/conduit Wiring harness/conduit

Note: Plug joint seals should be an Covering that gives adequate physical protection, prevents
appropriate IP rating. ie if the plug fittings ingress of dust and moisture, and does not deteriorate due
may be exposed to a water cannon then to the effects of fuel, oil etc., that it is likely to come into
the rating should be IP56 contact with.

Figure 6.7 – Example of Compliance and Non-Compliance With ‘Wiring Through Walls’

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6.3 APPENDIX C – LEGISLATION

6.3.1 Appendix C1 Framework

For NSW mining the following legislative framework applies:

For N.S.W. mining the following legislation applies:

(a) Work Health and Safety Act, 2011,
(b) Work, Health and Safety Regulation 2011
(c) Mine Health and Safety Act 2004
(d) Mine Health and Safety Regulation 2007
(e) Coal Mines Health and Safety Act 2002
(f) Coal mines Health and Safety Regulations 2006,

All electrical and mechanical apparatus must comply with the requirements of these regulations.
NOTE: The Chief Inspector may from time to time vary the legislative requirements of the above
regulations. These are published in the N.S.W. Government Gazette.
Duty holders under the WHS Act involved in Designing, Manufacturing, Supplying, Importing,
Owning, Operating and Site Contracts should ensure Gazette Notices are complied with where
applicable.

76
6.3.2 Appendix C2 Design and item registration

From WHS Regulation 2011, Clause 243:

243 Plant design to be registered

The design of an item of plant specified in Part 1 of Schedule 5 must be registered under
this Part.
Note. See section 42 of the Act.

From WHS Regulation 2011, Schedule 5:

Schedule 5 Registration of plant and plant designs

Part 1 Plant requiring registration of design

1 Items of plant requiring registration of design

1.1 Pressure equipment, other than pressure piping, and categorised as hazard
level A, B, C or D according to the criteria in Section 2.1 of AS 4343:2005
(Pressure equipment—hazard levels).
1.2 Gas cylinders covered by Section 1.1 of AS 2030.1:2009 (Gas cylinders—
General Requirements).
1.3 Tower cranes including self-erecting tower cranes.
1.4 Lifts, including escalators and moving walkways.
1.5 Building maintenance units.
1.6 Hoists with a platform movement exceeding 2.4 metres, designed to lift people.
1.7 Work boxes designed to be suspended from cranes.
1.8 Amusement devices covered by Section 2.1 of AS 3533.1:2009 (Amusement
rides and devices—Design and construction), except devices specified in
clause 2 (2).
1.9 Concrete placement units with delivery booms.
1.10 Prefabricated scaffolding and prefabricated formwork.
1.11 Boom-type elevating work platforms.
1.12 Gantry cranes with a safe working load greater than 5 tonnes or bridge
cranes with a safe working load of greater than 10 tonnes, and any gantry crane
or bridge crane which is designed to handle molten metal or Schedule 11
hazardous chemicals.
1.13 Vehicle hoists.
1.14 Mast climbing work platforms.
1.15 Mobile cranes with a rated capacity of greater than 10 tonnes.

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From WHS Regulation 2011, Clause 246:

246 Items of plant to be registered

(1) An item of plant specified in Part 2 of Schedule 5 must be registered under this
Part.
Note. See section 42 of the Act.
(2) The purpose of registering an item of plant is to ensure that it is inspected by a
competent person and is safe to operate.

From WHS Regulation 2011, Schedule 5:

Schedule 5 Registration of plant and plant designs

Part 2 Items of plant requiring registration

3 Items of plant requiring registration

3.1 Boilers categorised as hazard level A, B or C according to criteria in Section

2.1 of AS 4343:2005 (Pressure equipment—Hazard levels).
3.2 Pressure vessels categorised as hazard level A, B or C according to the
criteria in Section 2.1 of AS 4343:2005 (Pressure equipment—Hazard levels),
except:
(a) gas cylinders, and
(b) LP Gas fuel vessels for automotive use, and
(c) serially produced vessels.
3.3 Tower cranes including self-erecting tower cranes.
3.4 Lifts, including escalators and moving walkways.
3.5 Building maintenance units.
3.6 Amusement devices covered by Section 2.1 of AS 3533.1:2009 (Amusement
rides and devices—Design and construction), except devices specified in
clause 4 (2).
3.7 Concrete placement units with delivery booms.
3.8 Mobile cranes with a rated capacity of greater than 10 tonnes.

78
6.4 APPENDIX D – HUMAN ERROR
Prior to introducing plant onsite, PCBU’s should consider human error.
Designers need to consider changes in design that may affect human interactions with the plant
and result in foreseeable human errors.
Manufacturers, suppliers and importers need to consider whether the plant they intend to sell is
different to existing plant in use and whether this difference is may result in foreseeable human
error and issue documentation with the item of plant addressing this.
Examples of types of human errors include:
(a) Slip – frequently performed action goes wrong.
(b) Lapse – of attention or memory.
(c) Mistake – selecting the wrong action and not understanding the outcome.
Competence may be an issue.
(d) Violation – deliberate decision to not follow requirements/rules.
(e) A combination of the above.
Some human failings that can lead to error include:
(i) Being bored
(ii) Being careless
(iii) Being complacent
(iv) Being fatigued
(v) Being overconfident
(vi) Being stubborn
(vii) Being disinterested
(viii) Being drug or alcohol affected
(ix) Being distracted
(x) To misinterpret
(xi) To misread
(xii) To underestimate

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6.5 APPENDIX E – GENERIC HAZARD CHECKLIST FOR PLANT

This generic hazard checklist comes from model the WHS Code of Practice titled MANAGING
RISKS OF PLANT IN THE WORKPLACE produced by Safe Work Australia

HAZARD CHECKLIST YES NO

Entanglement

Can a person’s hair, clothing, gloves, necktie, jewellery, cleaning

brush or rag become entangled with moving parts of the plant?

Crushing

Can anyone be crushed due to:

• material falling off the plant?
• uncontrolled or unexpected movement of the plant?
• lack of capacity for the plant to be slowed, stopped or
immobilised?
• the plant tipping or rolling over?
• parts of the plant collapsing?
• coming into contact with moving parts of the plant during
testing, inspection, operation, maintenance, cleaning or repair?
• being thrown off or under plant?
• being trapped between the plant and materials or fixed
structures?
• other factors not mentioned?

Cutting, Stabbing or Puncturing

Can anyone be stabbed or punctured due to:

• coming in contact with sharp or flying objects?
• coming in contact with moving parts during testing, inspection,
operation, maintenance, cleaning or repair?
• the plant, parts of the plant or work pieces disintegrating?
• work pieces being ejected?
• the mobility of the plant?
• uncontrolled or unexpected movement of the plant?
• other factors not mentioned?

80
 Shearing

Can anyone’s body parts be sheared between two parts of the

plant, or between a part of the plant and a work piece or structure?

Striking

Can anyone be struck by moving objects due to:

• uncontrolled or unexpected movement of the plant or material
handled by the plant?
• the plant, parts of the plant or work pieces disintegrating?
• work pieces being ejected?
• mobility of the plant?
• other factors not mentioned?

High Pressure Fluid

Can anyone come into contact with fluids under high pressure, due
to plant failure or misuse of the plant?

Electrical

Can anyone be injured by electrical shock or burnt due to:

• the plant contacting live electrical conductors?
• the plant working in close proximity to electrical conductors?
• overload of electrical circuits?
• damaged or poorly maintained electrical leads and cables?
• damaged electrical switches?
• water near electrical equipment?
• lack of isolation procedures?
• other factors not mentioned?

Explosion

Can anyone be injured by explosion of gases, vapours, liquids,

dusts or other substances, triggered by the operation of the plant or
by material handled by the plant?

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Slipping, Tripping and Falling

Can anyone using the plant, or in the vicinity of the plant, slip, trip
or fall due to:
• uneven or slippery work surfaces?
• poor housekeeping, e.g. offcuts, cables, hoses obstructing
walkways, spills not cleaned up?
• obstacles being placed in the vicinity of the plant?
• other factors not mentioned?
Can anyone fall from a height due to:
• lack of a proper work platform?
• lack of proper stairs or ladders?
• lack of guardrails or other suitable edge protection?
• unprotected holes, penetrations or gaps?
• poor floor or walking surfaces, such as the lack of a slip-
resistant surface?
• steep walking surfaces?
• collapse of the supporting structure?
• other factors not mentioned?

Ergonomic

Can anyone be injured due to:

• poorly designed seating
• poorly designed operator controls?
• high forces?
• repetitive movements?
• awkward body posture or the need for excessive effort?
• vibration?
• other factors not mentioned?

Combination of hazards

Can anyone be injured due to unexpected start-up, unexpected

over-run/over-speed (or similar malfunction) from:
• failure/disorder of the control system, for example, a hydraulic
system?
• restoration of energy supply after an interruption?
• external influences on electrical equipment?
• other environmental factors (gravity, wind, etc.)?
• errors in the software?
• errors made by the operator ?

82
 Other hazards

Can anyone be injured due to:

• noise?
• inadequate or poorly placed lighting?
• entry into any confined spaces of the plant?
• failure to select plant that is suitable for its intended use?
• contact with hot or cold parts of plant?
• exposure to hazardous chemicals, radiation or other emissions
released by the plant?
• lack of operator competency?
• other factors not mentioned?

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6.6 APPENDIX F - PUBLIC ROAD REGISTRABLE PLANT
NOTES:
1) Some items of plant used at mines, such as backhoes, water trucks, tractors, and similar,
may be registered or registrable for use on public roads. The registration regime for such
plant does not require regular authorised maintenance inspections like other commercial
trucks. As such there have been several incidents with this type of plant on mines, where
the safety critical systems on the plant have not been maintained in a satisfactory
condition.
2) A process shall be developed to ensure, as far as reasonably practicable, that the plant is
safe and without risks to the health and safety of any person prior to approving it for use
on a mine site.
This Appendix does not apply to vehicles that do not participate directly in the mining or any
earth-moving activity for the winning of a product and are not predominately based on a mine
site (e.g. personnel transporters, light vehicles, trucks less than 10t, delivery or pick-up vehicles,
freight of mined product predominantly on public roads).
All public road registrable ‘plant’ that is used for mining or earth-moving activities (e.g. water
trucks, haul trucks, service trucks, explosives trucks, truck-mounted exploration drill rigs) shall
be subject to an inspection by a competent person prior to the mobile plant operated on a mine
site. As a minimum the competent person shall inspect for the following:
(a) Mobile plant has been maintained and is in a fit for purpose condition to enter the
mine site.
(b) All safety critical systems are functional.
(c) A structural inspection is carried out of the undercarriage, body, suspension, brakes
and all other structural areas.
(d) The tyres on the mobile plant are in a good condition.
An in service performance brake test should be carried out to verify the (mobile plant) is capable
of stopping on the maximum grades for use.
Explosive manufacturing plant shall comply with AS 2187.2.

84
6.7 APPENDIX G – FEEDBACK SHEET
FEEDBACK SHEET – MDG15 2012
Your comment on this Guideline will be very helpful in reviewing and improving the document.
Please copy and complete the Feedback Sheet and return it to:
The Senior Inspector of Mechanical Engineering
Mine Safety
NSW Trade & Investment
PO Box 344
Hunter Region MC NSW 2310
Ph: 02 4931 6666
Fax: (02) 4931 6790

How did you use, or intend to use, this Guideline?

What do you find most useful about the Guideline?

What do you find least useful?

Do you have any suggested changes to the Guideline?

Thank you for completing and returning this Feedback Sheet

MDG 15 – Guideline for mobile and transportable plant for use at mines - Draft for comment Page 85 of 85