Liebherr T264 FPO&DPO checklist

Information

Inspection date
Asset Number
Serial number

Factory Provided Options

2.0 Functional Requirement

The Liebherr OHT must be supplied Autonomous ready 2.1

3.1 Machine Access

The primary access must remain as the OEM diagonal staircase 3.10
Exit to ground from the primary access staircase is on LHS of machine 3.11
Hydraulic stairs control switch [upper deck] cannot be activated by a person whilst on the machine in a way that places the person activating the Switch in the line of fire 3.12
Hydraulic stairs control switch ground level cannot be activated by a person whilst on the machine in a way that puts the person activating the switch in the line of fire or crush zone 3.13
An Interlock/Warning system must be fitted to prevent driving through the park brake 3.14
An Interlock to prevent driving with the hydraulic ladder in the down position must be fitted, with a corresponding in-dash warning light to alert the operator that the ladder is down 3.15
Mirror provided to enable vision of the base of the ladder while in the normal operating position 3.16
Emergency egress system is on the LHS and RHS of the machine 3.17

3.2 Access Ways & Walkways

Access to all monitoring and servicing points e.g., filters, dipsticks, etc must be adequate to allow easy servicing of the equipment 3.21
Walkway to access rear of operators cab with handrails that clear the body in the down position 3.22

3.2.2 Handrails

All handrails must be a contrasting colour to the machines as per AS5327:2022 3.2.20
Liebherr factory standard handrails must be fitted on the haul truck 3.2.21
All handrails must meet the requirements as set out in AS 5327-2022 Earth Moving Machinery – Access Systems. The Supplier must be responsible for checking Australian Standards for the latest information. 3.2.22
All walkways must be fitted with handrails & all handrails must have a mid-rail & kick rail 3.2.23

3.3 Guarding

Rotating equipment, e.g., engine fan pulleys & associated belts, trip hazards, etc must be guarded 3.31
Where necessary to prevent accidental contact by personnel, hot surfaces must be guarded, shrouded, or lined with insulating material from the manifold, turbo to the muffler (including muffler and pipes in engine bay) 3.32
Rhino Skins must be installed to protect the fuel tank 3.33
Rhino skins installed to protect the hydraulic tank. 3.34

4 Operator Cabin

Operator seat must be OEM standard, which can be changed to an ISRI air ride suspension base seat onsite on the first scheduled seat changeout. 4.1
Trainer (companion) seat will be an air ride suspension base seat 4.2
An inertia reel 3-point retractable seat belt must be fitted to the operator’s seat. The seat belt and anchorage must be fitted to the seat and the shoulder anchorage point for the sash must be fitted to the pillar side of the seat to ensure proper support of the operator in the event of a roll over 4.3

5.1 Cabin Electrical

An Audible Alarm and warning on HMI screen indicating the cab door is open, when the park brake is not applied must be installed 5.11

5.2.1 Battery

OEM Standard batteries must be supplied and installed. 5.2.11
CAT Battery Jump Start Receptacle must be located near the isolation box 5.2.12

5.2.2 Isolation

Lock safe isolation points will be provided to isolate the negative circuit of the battery (red) and the starter motor (yellow), these must be lockable. 5.2.21

5.2.3 Emergency Stops

Two E-Stops must be provided, one in the operator cabin, within easy reach of the driver, and one at ground level at the base of the access stairs 5.2.31
The ground level E-Stop must be fitted within easy reach of a person standing at ground level with the ladder in the raised or lowered position clear of the operating ladder. 5.2.32
E-Stops must be wired to shut down the engine immediately 5.2.33
E-Stops wired to shut down everything except all driving lights and the auxiliary circuit, to ensure the lights and two way radio retain function 5.2.34

5.2.4 Horn

An air horn system will be supplied and fitted 5.2.41

5.3 Air Conditioning System

OEM standard air conditioning system 5.31

7.1 External Lighting

All external work lighting must be LED Lighting. This includes the 8 front headlights: 7.11
An additional LED light is to be fitted to the left-hand front corner of the top deck platform to illuminate windrows off the left-hand side of the truck. The amp must be mounted so that it is not visible from the operator’s position in the cabin. This windrow light is to be activated by a switch mounted adjacent to the head light switch on the dash 7.12
The machine must be fitted with one LED boarding light. 7.12
The machine must be fitted with two LED engine bay lights 7.13

7.2 Reversing Lights & Alarm

Two LED lamps, one each on the RHS & LHS, at the top deck platform level adjacent to both rear-view mirrors. These are positioned to enable access for cleaning & maintenance from the top deck platform and activate when reverse gear is selected 7.21
The Two Reverse lights must be guarded from falling objects, mud & dust thrown up by the front wheels 7.22
Two LED lamps at the rear on the axle lighting array to come on when reverse is selected 7.23
Reverse alarm to sound when reverse is selected 7.24

7.3 Brake Lights & Indicators

A rear lighting array fitted at the rear of the truck must include: Red LED brake lights activated by service brake and retarder operation; Red LED taillight. 7.31
Amber LED turn indicating lamps are to be fitted to the front and side of the upper platform kick rails, to ensure they are visible from oncoming and side on traffic. These lights will also act as clearance lights. 7.32

8 Engine

Liebherr (latest tier) engine must be used, with an engine oil capacity sufficient for 500 Hour oil drain interval 8.1
Automatic engine shutdown timer with an override switch on dash must be fitted 8.2
OEM standard engine starter motors 8.3

9 Radiator & Cooling System

All standard radiator caps must be replaced with Pressure Release Valve (PRV) type 9.1

11 Service & Lubrication System

Refuel points will be pressure less fast fill cut off systems with fill points on both sides of the truck 11.11
The Fuel Tank breather must remain OEM 11.12
An inline check valve must be fitted to both fuel tanks, with a fast fill crossover hose to the fast fill station to enable refueling from both sides of the Truck 11.13
A 5000L capacity fuel tank must be fitted 11.14

11.2 Grease System

Timer with an audible failure alarm. switched by the grease pressure at the furthest most point 11.21
A manual test switch 11.22

12 Braking System

OEM standard braking systems 12.1
Machine braking systems must include both Service and Dynamic braking systems. These systems when activated are to be illustrated by Red LED lighting on the rear of the machine only 12.2

13 Payload / Weigh System

Payload/weigh system must be fitted with the following features: The payload total displayed via a load display on the dash of the operators’ cabin. An audible alarm will be sounded when the load exceeds 120% of the rated capacity. Payload system data must be able to be downloaded to a portable computer for remote analysis. Factory payload indicating LED scoreboards are to be fitted to the LH side on the operator’s cab and the RH platform at the outer most point. 13.1

14 Rims & Tyres

Rims must be supplied loose by FMG with the rim ID number already stamped
46/90R57 or 50/80R57 tyres must be supplied loose by FMG & to be fitted by OEM

15 Machine Body

The supplier must provide the tray body mounting kit, including: - Tray & hoist pins - Eight rubber body pads & shims - Tray pin shims 15.1

Sign off

Fortescue Representative
OEM Representative

Dealer Provided Options

3.1 Machine Access

Hydraulic stairs emergency release to be located in a position where it can be activated from ground level without placing the person activating it in the line of fire from the hydraulic ladder lowering into position 3.12
Access to emergency egress system is via a self-closing, inward opening hinged gate 3.13
Access to the rear chassis must be from behind the cab via a diagonal staircase with a WAH decal on the gate 3.14

3.2 Access Ways & Walkways

Yellow and black stripes to highlight changes in deck height 3.21
Gas charged support struts and locking stays must be fitted to all top deck hatches and cabinets 3.22
Engine bay access ladder platforms to be extended with removable dropdown platforms to prevent falling whilst carrying out maintenance tasks 3.23
Walkway to access the rear of the HV cabinet with handrails that clear the body in the down position 3.24
Non-slip Material to nosing and Walkways must be fitted (Colour – Yellow) 3.25

3.2.2 Handrails

Inward opening, self-closing gates required at the top of both (LHS & RHS) engine bay access ladders 3.2.21
A handrail must be fitted to the engine bay access ladders rear handrail to close the gap between machine pedestal and access ladders 3.2.22
Handrails must be fitted on the top of the grid box and be accessible via an inward opening, self-closing gate 3.2.23
The handrail at the top of the main access stairs must be raised to the height of the top deck handrails 3.2.24
Main access ladder bottom landing handrail must have infill panels fitted to prevent pinch points whilst ladder is being raised 3.2.25
NB: Handrails will be fitted on the truck wherever required to prevent any Working at heights potential breaches and be in line with the FMG working at heights 2 x 2 guidelines

3.3 Guarding

Turbo oil feed and drain hoses are to have high temperature and flame-resistant sleeves 3.31
All worm drive hose clamps larger then 3/8 must be replaced with T Bolt clamps 3.32
The AHS cabinet must be supplied with hinges and locking stays 3.33
The CEB cabinet must be supplied with hinges and locking stays 3.34
Hydraulic cooler hoses must be suitably covered so that in the event of failure atomised oil will not enter the coolers or spray on to exhaust manifolds 3.35

4 Operators Cabin

Grey canvas seat covers must be supplied and installed on both operator and trainer seats and must also cover the headrests 4.1
Fully adjustable and robust roller blind must be supplied and fitted to the front window it must be 100% block out solid blind 4.2
All windows will be XIR or equivalent, shatterproof laminate and incorporate built in heat and UV reducing properties. 4.3
Operator cabin must be fitted with a pressuriser to create positive cabin pressure of at least 20 Pascals, to assist with prevention of dust ingress. For Eliwana & Flying Fish deliveries a Breath-safe HEPA Cab filtration system must be fitted 4.4
The pressuriser must be wired to operate with machine ignition switch 4.5
Cab pressurisation test required for the first machine of each new model and if there has been any changes or modifications made to the cabin System test documentation is to be supplied with commissioning documents 4.6
Noise and vibration tests (by approved NATA registered company) required for the first machine of each new model and if there has been any changes or modifications made to the cabin. System test documentation is to be supplied with commissioning documents. 4.7

5.1 Cabin Electrical

Site specific two-way must be supplied and fitted 5.11
A minimum 10-amp OEM power convertor must be supplied and installed 5.12
An AM/FM Radio with MP3 Jacking capabilities 5.13
All lights must be removed from the top of the operator’s cabin 5.14
The cab AHS mode change switch must be located in the roof lining switch panel and be a toggle switch 5.15
The ground level AHS mode change switch must be located at the front bumper 5.16

5.2.1 Battery

Nonconductive insulation must be installed on the inside of the battery cover 5.2.11

5.2.2 Isolation

The Battery isolator, Starter isolator, Propulsion isolator and Jump start receptacle must be relocated to the front bumper and housed in a control station, clear of any crush zones 5.2.21
The Ladder control box must be relocated to the front bumper, clear of any crush zones 5.2.22
The battery and starter motor isolator power indicator lights must be removed. 5.2.23
Both isolator switches (Red & Yellow) must be fitted with magnetic points to hold lever shut 5.2.24

5.2.4 Horn

An Additional electrically operated workshop horn with a switch in the cab 5.2.41

5.2.5 Caterpillar Product Link Elite

Caterpillar Product Link Elite must be installed with satellite network connectivity to transmit location, utilization and condition data. This is to enable remote review of data via Product Link Remote monitoring web interface. 5.2.51

5.4 Technology

All technology components must be installed, these include; 5.41
2x Radio WIFI Antenna & cables 5.41
G407 - Display screen and mounting bracket 5.41
GNSS (Global Navigation System) 5.41
Medium precision GPS & Mount 5.41
Cisco/AVI Radio 5.41
High precision receiver 5.41
CAN signal input from LMD box 5.41
Autonomous switch’s (Cab & Isolation box) 5.41
The OEM will supply and install everything else required for the fitment and commissioning of the system 5.42

6 High Voltage

The grid box must have mesh screens fitted underneath to stop build-up of debris 6.1
High Voltage electrical cabinets must be lockable 6.2
Grid box top access panels must have additional handles fitted and designed for ease of lifting. 6.3
Grid box louvres must be supplied and fitted 6.4
The HV Cabinet air filter cap must be accessible from the front deck 6.5

7.1 External Lighting

Manned Trucks Only: A green flashing LED light must be fitted to the front of the machine 7.12

7.3 Brake Light & Indicators

Red LED brake lights activated by the Dynamic Brake operation 7.31
Amber LED turn / hazard lights 7.32

8 Engine

Engine oil sight glass must be fitted 8.1
Fuel Filter must be relocated to an easy to access position from ground level 8.2

9 Radiator & Cooling System

Coolant will be PGXL 9.1
OEM standard coolant other than coolant that is site specific (PGXL coolant) must be drained. If the site-specific coolant is not OEM standard coolant, the cooling system is to be thoroughly flushed and refilled with site specific coolant. 9.2

10.1 FFF Fire Suppression System

A Fluorine Free Foam Water Spray fire suppression system must be mounted in a suitable location where it is easily accessible for servicing. Fire Suppression system must comply with 100-01000-SP-SA-0001 Heavy Mobile Equipment Fire Suppression System Specification. 10.11
Fire suppression bottles must be mounted on the LH and RH chassis rail behind the radiator 10.12
Three actuation points will be provided: > One in the operator cab > One accessible from ground, RHS of front bumper > One accessible from the ground, LHS, adjacent to boarding stairs 10.13

10.2 Fire Extinguishers

Two Fire Extinguishers must be provided and located at the following locations: 1 x 9kg dry powder fire extinguisher must be mounted to the front bumper 1 x 9kg dry powder fire extinguisher must be mounted near the operator’s cabin 10.21

11.1 Service & Lubrication

A fast fill station must be provided and readily accessible from ground level. This will be located under the RHS Fuel tank and will include: ▪ All Lubricant Fill & Evacuation Points with Banlaw Fitting Covers & Labels. ▪ All Live SOS Sampling Points (engine, transmission, hydraulics & steering) with Fitting Covers & Labels. 11.11
The fill nipples will be Banlaw electronic tab type fitting and will include an Auto ID chip to suit the Banlaw Fuel Track system 11.12

11.2 Grease System

Grease/Lubrication system must be supplied and installed with a Bulk Fill Tank fitted with Pressure Gauges and Test Points 11.21
V96 vent and overfill cut-off system 11.22
Grease fill point is to be from the fast fill service centre, adjacent to the fuel fill point 11.23
Banlaw grease fill fitting must be installed 11.24
Grease injector banks must be fitted with decals detailing each injector and its associated component 11.25
A remote Grease line must be fitted to the HV Alternator with a decal to identify grease type required 11.26

14 Rims & Tyres

Bridgestone I-Track must be supplied and fitted 14.1
Tyre saver liquid will be included in each tyre at the recommended volume 14.2
Rims must be stamped with a unique ID number 14.3
OEM to organise tyres to be fitted to rims 14.4

15 Machine Body

If a third-party tray is to be fitted, OEM to add boilermaker allowance to carry out any required works to fit tray 15.1
NB: The dump tray body will be determined through negotiations between the OEM and FMG. FMG will supply fitment document

16 Miscellaneous

Wheel chocks and holders to be removed. 16.1
Jacking plates must be welded into the axle box housing 16.2
The front access door to the axle box must open laterally 16.3
A cover must be fitted to the rear axle box opening 16.4
All Historical Campaigns, Product Advisories and Service Bulletins must be included in all machine builds 16.5

17 Signs & Warning Labels

All labels and signs must be anodised aluminium and be affixed by rivets (where practicable) or key ring, avoid gluing where possible 17.1
A sign reading NO UNAUTHORISED PARKING WITHIN 50 METRES on front LHS & RHS. Letters red on white background. 17.2
Machine/fleet numbers (black numbering on yellow reflective) must be provided on four (4) sides (1 on the Front, 1 on the LHS and RHS and 1 on the Rear). Fleet numbers to have clear coat installed to protect from high pressure water wash cannons 17.3
Fortescue logos must be provided on three (3) sides (LHS, RHS and Front). Fortescue logos are to be manufactured to current official branding standard. For most recent designs please contact FMG representative. 17.4
Reflective stripes to be placed on the sides and front. Edge sealed high visibility tapes reflective stripes to be placed on the front, sides and rear. Edge sealant to be 3M’s Safety-Walk Edge Sealing Compound. 17.5
Stored Energy Stickers must be placed on all Pressure Vessels/Accumulators. 17.6
HV Arc flash decals and CPR decals must be installed in the correct locations 17.7

18.1 Training

With each machine the supplier will provide mutually agreed training courses for either: (DPO 18.11) ▪ FMG either FMG maintenance staff covering Systems Operation, Testing and Adjusting, Trouble shooting, PC software use and download file management and interpretation ▪ Operator Training courses on machine understanding and operation Supplier must keep a register of available training & training used by FMG. All material must represent the Liebherr OHT as built including all non-standard additions or modifications. 18.11

18.2 Manuals & Literature

Two [2] sets of paper books Operator’s manuals and Service manuals to be supplied with the first unit to each site. 18.21
Copies of relevant certificates to be supplied before machine commissioning include. ▪ Fire Suppression ▪ Grease system ▪ Cab pressurization testing ▪ Noise and Vibration testing ▪ Tyre saver liquid ▪ XIR Glass ▪ OEM Commissioning Documentation NB: Testing certificates are only required for one of each type of machine unless significant design changes have occurred. 18.22
All dealer provided modifications must be included in the as-built documentation and all additional circuits clearly labelled on the machine. 18.23

18.3 Maintenance Strategies & Tactics

A comprehensive maintenance strategy is to be supplied outlining major & minor component change outs, supporting detail as to how these are achieved, and including ▪ PM Servicing Intervals ▪ Major Component Change Out Intervals ▪ PM Kit Listings in FMG Format ▪ Bill of Materials (BOMs) ▪ Emergency Spares to be held at Mine Site Warehouse ▪ Spares holding to be held at Mine Site Warehouse ▪ PM Service Sheets in FMG Format ▪ Safe Work Instruction/Scopes of Work in FMG Format ▪ List of Service Exchange Components & Spare Parts available at the local supplier warehouse 18.31

Sign off

Fortescue Representative
OEM Representative

Liebherr T264 FPO&DPO checklist

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2.0 Functional Requirement

3.1 Machine Access

3.2 Access Ways & Walkways

3.2.2 Handrails

3.3 Guarding

4 Operator Cabin

5.1 Cabin Electrical

5.2.1 Battery

5.2.2 Isolation

5.2.3 Emergency Stops

5.2.4 Horn

5.3 Air Conditioning System

7.1 External Lighting

7.2 Reversing Lights & Alarm

7.3 Brake Lights & Indicators

8 Engine

9 Radiator & Cooling System

11 Service & Lubrication System

11.2 Grease System

12 Braking System

13 Payload / Weigh System

14 Rims & Tyres

15 Machine Body

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3.1 Machine Access

3.2 Access Ways & Walkways

3.2.2 Handrails

3.3 Guarding

4 Operators Cabin

5.1 Cabin Electrical

5.2.1 Battery

5.2.2 Isolation

5.2.4 Horn

5.2.5 Caterpillar Product Link Elite

5.4 Technology

6 High Voltage

7.1 External Lighting

7.3 Brake Light & Indicators

8 Engine

9 Radiator & Cooling System

10.1 FFF Fire Suppression System

10.2 Fire Extinguishers

11.1 Service & Lubrication

11.2 Grease System

14 Rims & Tyres

15 Machine Body

16 Miscellaneous

17 Signs & Warning Labels

18.1 Training

18.2 Manuals & Literature

18.3 Maintenance Strategies & Tactics

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