VUL-INS-20 Mobile crushing, sizing or stacking plant Inspection

Controls and Interlock Safety Devices

Where applicable, functionally test all controls and interlocks.

Height of Equipment

Label inside operators cabin / transportable building to indicate the maximum height of the equipment (both travel height and maximum working height if applicable).
Inspector must validate the height of the vehicle / equipment / transportable building to confirm the measurement indicated on the label.

Instrumentation, Metering and Gauges

Instrumentation, metering and gauges are clearly visible, adequate and operational.

Lights, Indicators and Lighting

lighting must be eﬀective for safe operation including emergency stops, access and controls. External lights (headlights, tail lights and indicators) must be clearly visible, adequate and operational.
Lenses must be clean and capable to perform their intended function.

Operating Manual

A copy of the equipment operating manual is available, this could be in the equipment or in the site office

Steering or Track control

Check for excessive play or abnormal feel/noise If fitted, check ancillary steering is functional. Ensure all controls have either a dead man or return to neutral control.

Warning Device

Mobile equipment must be fitted with manually or automatically operated audible warning device for movement, starting or boom control e.g. Horn, siren or buzzer. Equipment fitted with air-horns must also be fitted with a secondary horn (electric).
An automatically operating Tramming or reversing alarm must be fitted and operational.

Door Open Catches

Where applicable, Confirm the doors are fitted with catches or a means to secure the door in the open position.

Brackets, Pins & Hinge Points

Carry out a functional inspection to identify loose brackets, pins & hinge points and locking mechanisms
e.g. Dozer belly guards, bonnets, doors and tilt cabins.
Check that pin retainers are in place and that the pins are not slipping out. Check that all mounting bolts are secure by visual inspection.

Diesel Fuel Only

Petrol powered equipment is restricted on site. if electrical driven then N/A.

Emergency Stops and Pull Wires

Emergency stop devices must be clearly marked “EMERGENCY STOP” .

Emergency stops must have the following features: red button / switch, deliberate on/oﬀ activation, manual de-activation. Reactivation will not restart the plant.

Emergency stops and Pull wires are to be tested and verified as operational. Operational test is to be carried out for all Emergency Stops.
As a minimum, emergency stops are to be fitted so there is one in the reach of the operator from the control panel, within the zone of reach and located so as to minimise the risk of inadvertent operation and one accessible at ground level where the controls are accessed by stairs or ladder. Where belts or rollers are accessible from the ground without the assistance of a step or ladder, hard guarding must be used to protect the operators. where this is not possible a Emergency stop or pull wire must be located in reach of the operator to allow for the equipment to be shut down in the case of a emergency.

Emergency stops must not be located in front of out blowing fans or air flows.
Emergency stops must not be wired to cut out communications (site two-way radios) upon activation.

E-Stop operation

Must be a push-to-stop design, with a protective shroud to prevent unintended activation

Equipment Modifications

Compliance plate must be provided for all modified equipment. Registered Professional Engineer Queensland (RPEQ) certificates must be provided for structural modifications

Isolation & Lockout

A suitable lockout system is to be provided to enable physical isolation of the unit as per AS 4871.6. The isolation devices must be capable of being padlocked and clasped in the OFF position. ON and OFF positions should be clearly identified.
In circuits at Extra Low Voltage (ELV – below 50Vac or 120Vdc) potential, isolation may be achieved by switching the positive / negative conductor only. All circuits above ELV must achieve positive isolation by switching all active and neutral conductors.

Battery isolators are to be red in colour and disconnect power to all electrical loads. If fitted, Starter Motor Isolators must be yellow in colour.

Systems such as fire protection, communication (site two-way radios), GPS, or tyre monitoring systems are permitted to not be controlled by the battery isolation switch, provided they have separate isolator switches for their circuit(s)."
The isolation and lockout systems are to be tested and verified as safe and functional. Isolation process must include isolation of the jump-start receptacle.
Check that all exposed terminals are protected from arcing.

Isolation switches are not to be positioned in a potential crush zone (e.g. between position 1 or 2 wheels and chassis, or in articulation points).

High Visibility Call Sign

Identification must be clearly visible at all times. Identification numbers must be located on both sidesof the vehicle/equipment and must meet the following requirements:

• Reflective yellow coloured letters and numbers on a black background, as close as practicable to the format detailed below.
• A type face of Helvetica Narrow Bold, with standard spacing (no compression) and a letter down s
• Space between letters and numerals must be an ‘em’ space (relates to typography).
• All mobile equipment must be identifiable from 360 degrees in accordance with the table above.

Where applicable, If it is impractical for rear facing call signs to meet the size requirements, the largest allowable size shall be selected such that it is still readable from a 50m distance. When fitted on road registrable vehicles they must be made from non-reflective material.
Auxiliary equipment not requiring positive radio contact (complete list provided in Definitions section) only require plant identification numbers, and are not required to meet the sign size requirements listed in the above table.

Jump Start Receptacle

Mobile Equipment (and where fitted on medium vehicles) must have a jump start receptacle that can be an Anderson or CAT style plugs. These must not bypass the battery or starter motor isolator.
Standard configuration is:
• 12V must utilise a 175 A plug
• 24V must utilise a minimum of a 350 A plug
• These will be clearly labelled
This requirement is not applicable for:
• Light Vehicles
• Electric drive equipment
• Auxiliary equipment

Reflective Yellow Tape

The vehicle must have reflective yellow tape on both sides, minimum of 50mm width. Reflective tape must be positioned to indicate the overall length of machine

Signage

All machine controls and service points must be provided with clear signage to indicate function.

Check that the equipment is fitted with clearly visible permanent markings, signs, compliance and identification plates on safety devices and systems including, but not limited to: ROPs; FOPs; pressure vessels; fire suppression systems; emergency exits; electrical cubicles/enclosure panels; accumulator reliefs, tow, confined space; crush points; rotating and hot parts; E-stops; pressure reliefs; spring under compression chambers; limits of operation in cab; hearing protection in noisy environments; unique Hi-Vis plant ID.

Structural Damage Inspection

Visual check for cracks, deformation or excessive rust.

Access and Egress

For non-standard access systems, check for appropriate railing, step/grab handle combinations and boarding facilities to allow safe and eﬃcient access and egress of the equipment.

Check that the machine has two means of egress from the operators cabin with at least one means of egress (normal access), and 1 means of emergency egress.

Check that the bottom step of any fixed access system does not exceed 700 mm from ground level with equipment in normal stationary position. Where there are retractable access ladders, this value cannot exceed 400mm.
The maintenance step-down entry onto the tracks does not require a self-closing gate on the platform unless the distance exceeds 700mm.

Check that all personnel are able to carry out normal duties without leaving a designated walkway, access platform or the ground; and where this is not practicable and leaves the potential for a person to fall more than 1.8 metres, where fitted an engineered harness attachment point must be certified and indicated.

Top rails must be not less than 850mm nor more than 1100mm above standing level of a platform or walkway, and the intermediate rails must be parallel to the top rail with a maximum distance of 550mm between.

Platforms above 1.8 metres must have foot barriers (kick rail) installed on handrails, between 50mm and 100mm in height.

Where retractable access systems on Earth Moving Equipment are fitted:
• If the operator cabin is >2m above the ground, the operation of the retractable access system must be possible from the ground, or a secondary access system must be present.
• The movement of powered retractable access systems must stop when the control is released (constant positive action).
• Controls must not be mounted under the zone of the lowering step ladders.

Flashing Beacon

Flashing beacon must be fitted and operate when tramming at a minimum, the beacon must be visible from all angles of approach (360°). Colour requirements:
Green

Under Carriage

Where applicable for Track based equipment. Check the track frames, tracks, rollers and idlers for any signs of significant cracks and wear damage. Check that all bolts and fixings are in good condition and fit for purpose.

Tyres, Wheels and Tracks – Non-Road Going

Tyre wheel and track assemblies must be free of abnormal damage, deterioration or uneven wear. Check that rims and tyre are OEM approved for the equipment.
Check that rims and tyres 600mm (24 inch) or larger have a unique identification system in place. Equipment owners must provide evidence of current service hours and/or last rim inspection report compiling to the requirements of AS 4457.

Wear Plates and Belt Scrapers

Wear plates are not holed or torn. Belt scrapers and in correct operational order and not damaged or in poor condition.

Fire Extinguishers

Must have a 4.5 kg / hand-held, dry chemical powder.
• One located near the control panel (can be located on the platform end of the access point, if it cannot be mounted within reach of the ground).
Fire extinguishers must be inspected and tested in accordance with AS 1851

Battery System

Battery boxes where fitted must be ventilated, drained and of robust construction; terminals clean & bracket secure; leads properly secured and not showing signs of heat or abrasion; (+) terminal insulated (one battery fitted), or all terminals insulated (battery bank).
The location of batteries must be clear of all ignition sources.
Surface Mobile Equipment must have Valve Regulated Lead Acid (VRLA) batteries (also called ‘sealed’ or ‘maintenance free’ batteries) installed.

Engine / Drive Motor

Check engine / drive motor for no leaks. Check mounts, wiring, and piping are secure.
Check that the exhaust system is secure, free from damage / leaks and is fit for purpose.
Check that exposed rotating parts that are easily accessible (not behind a cover, under the machine, or under the bonnet in the case of Light Vehicles) have protection fitted to protect against inadvertent contact.

Extra Low Voltage (ELV) <50Volts AC or <120 Volts DC

Exposed copper wiring is prohibited. Single insulation at connection plugs is permitted up to 100mm provided that there is adequate support and protection against damage.
Electrical connections must be rated a minimum of IP2X.

Check that all exposed terminals are protected from arcing. Check that all operator interfaces are ELV.
Check that all connections are terminated so that they cannot loosen or overheat under normal conditions of service.
Check that disconnected cables have been removed or properly terminated.

If equipment is above ELV an Electrical Inspection must be completed.

Glands / Bushing of Cables

Check that where wiring is threaded through conduits, partition walls etc. should be adequately glanded or bushed so that wiring and cabling does not come in contact with any surfaces that may degrade the sheathing or insulation of any wiring.
All wiring should be positioned / secured such that the potential to rub onto vibrating or abrasive surfaces is minimised.

Radiator Pressure Relief System

The radiator must have a method for relieving pressure build-up prior to the removal of the radiator cap, such as a pressure relief cap, expansion tank, two stage caps or similar.
All venting must be away from personnel.

Safety Guards

When the machine is in the stationary position and the engine is running the guarding of rotating components and hot surfaces must not allow any person to touch these parts from the ground or access- way or platform.

All guards must require the use of a tool to remove and replace or be fitted with an interlock to stop motion. The tool can be an implement such as a key or wrench to operate a fastener, in accordance with AS/NZS 4024.1601.

Where inspection or cleaning covers are provided and their removal exposes dangerous parts of the machine which are within reach, such covers must be clearly labelled "DANGER – Isolate drive before removing cover".

Hot Surfaces, Exhaust Systems

Where personnel are exposed to hot surfaces (e.g. exhaust / turbo) while carrying out normal operations, heat shielding / lagging or barriers must also be fitted.
Check that warning signs are fitted to access points, warning personnel of hot surfaces.

Fuel System

Check for any degradation in the fuel system.
Check that all fuel pipes are routed in a manner which gives them maximum mechanical protection and away from hot engine surfaces.
Where required check removable caps is in place.

Where high flow / quick fill arrangements are present;
• Tank breather/vent overflow hoses must go to ground,
• Tank breathers/vents are fitted, serviceable, and functional,
• Quick fill couplings (tank receivers) are serviceable, free from damage and functional.

Hydraulic Hoses, Cylinders and Fittings

Check degradation of hoses, all hoses are suitably supported and segregated to prevent rubbing, all pins and clips for visual signs of wear or damage.

Inspect all hydraulic hoses / fitting / cylinders / control valves for visible cuts, signs of wear or damaged outer casings.
That suitable guarding has been installed for hydraulic hoses, located within 1.0 m of the operator control station(s).
Steel guarding or burst sleeving is adequate where no other component or structure performs this function however glass is not suﬃcient for this purpose.

For flexible hydraulic hoses in close proximity to hot engine components (turbo/exhaust) without suitable lagging, they must be fitted with thermal and/or burst protection. If burst sleeving has been installed, check that both ends of the hose are secured as per OEM recommendations.

Fire Suppression Systems

If a Fire Suppression is fitted, it must be meet the requirements of Fire Suppression Systems Site standard.

Maintenance and Inspection Records

Brake testing of wheeled equipment must be completed to the requirement of the Braking Systems Performance.
A copy of the ‘Brake Test Record Form’ as well as the test results (either inertia test and/or transducer test dockets) must be included.
Maintenance and Inspection Records
Equipment is to be routinely maintained and records kept to ensure that it remains “fit-for-purpose”.

Example copies of documentation must be provided as evidence that the equipment is part of an ongoing maintenance program and references the OEM maintenance recommendations, such as;
• Pre-start inspection sheet with defects identified,
• Completed service sheets with defects repaired,
• Evidence of service history within the previous 12 months.

Not applicable for brand new equipment or equipment that has been purchased without previous maintenance (a full equipment inspection must be completed prior to compliance) records undergoing an Initial inspection.