Rubber Tyred Vehicles Technical Bulletin

Transcription

1 Rubber Tyred Vehicles Technical Bulletin Bulletin Number: TB0906 Date: 17/06/2009 Subject: TBS Design Registration 130 Purpose To inform the industry of the registration of the Transport Braking System for 130 LHD's. Applicable to Sandvik 130 LHD's Description New South Wales design registration has been granted for the Transport Braking System on 130 LHD's currently in service. Although the registration applies to vehicles operating in NSW coal workplaces, attachments to this technical bulletin are applicable to all End Users. Changes Required changes to existing vehicles are nominated in A2U (attached). Contact Contact your Sandvik representative for further information or any questions you may have. Attachments DOCUMENT NO. ISSUE DATE TITLE 1 MDR TBS 13/11/08 Notice of Registration of Plant Design (Braking System) 2 A2U A 3/02/09 Compliance Statement, Conditions Of Use, MDR TBS 3 A2U E 17/10/08 Registration Drawing, Braking System, Model 130 LHD 4 RA0021 A 31/10/08 Non-Conformance Risk Assessment for 130 Braking System against MDG39, including Amendment No.1 Sandvik Mining and Construction Tomago Pty ABN Old Punt Road Telephone Tomago NSW Australia Facsimile

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6 DOCUMENT No.: A2U Rev: A TECHNICAL STATEMENT DOCUMENT No.: A2U TITLE: COMPLIANCE STATEMENT, CONDITIONS OF USE, MDR TBS JOB No.: EN9105 PROJECT: PRODUCT LINE: RUBBER TYRED VEHICLES MACHINE MODEL(S): 130 SERIAL NO.(s): REFERENCE: MDR TBS Issued by: Mark Peristy Design Engineer Sandvik Mining and Construction Tomago Pty REV DATE DESCRIPTION AUTHOR A Initial Release Mark Peristy Sandvik Mining and Construction Tomago Pty Page 1 of 7 ABN Old Punt Road Telephone Tomago NSW Australia Facsimile

7 DOCUMENT No.: A2U Rev: A Table of Contents 1 Compliance Statement 2 2 Schedule of Partial and Non-Compliances 2 3 Document Schedule 2 4 Design Changes and End User Actions 3 5 General Recommendations for End Users Regarding Transport Braking Systems 4 6 Notes Regarding Braking Rates and Testing 5 7 Appendix A - Conditions of Use Compliance Details 6 1 Compliance Statement 1.1 The following compliance statement is applicable to 130 series Load Haul Dump vehicles (hereby referred to as loader(s)) designed, manufactured and supplied by Sandvik Mining and Construction Tomago Pty Limited (hereby referred to as Sandvik) into the New South Wales market. 1.2 The transport braking system design for this loader and any acceptable variation to it specified in documents listed in MDR TBS Section 2.1 complies with the following guideline, with the exceptions as listed in Section 2 of this document. MDG 39 February 2001 Handbook For Approval Assessment Of Transport Braking Systems On Free-Steered Vehicles In Underground Coal Mines incorporating Amendments No. 1 - MDG 39 December Schedule of Partial and Non-Compliances 2.1 Refer to Sandvik Risk Assessment RA0021 for listing of non-compliances and for recommended end user actions and residual risks arising from these noncompliances. 3 Document Schedule 3.1 The design of the 130 braking system has been examined and tested as recorded in MDR TBS Section 2.2. Sandvik Mining and Construction Tomago Pty Page 2 of 7 ABN Old Punt Road Telephone Tomago NSW Australia Facsimile

8 DOCUMENT No.: A2U Rev: A 4 Design Changes and End User Actions 4.1 This registration applies to existing loaders already in service. There are some changes from MDA DEV 51 including all supplementary approvals (but excluding Supplementary approvals MDA DEV 51/3 and 51/4 which will form part of an alternative design registration). 4.2 Loader Modifications Owners and operators of existing loaders are required to perform the modifications listed below in Table 1 in order to comply with the requirements of MDR TBS. Table 1 Required Loader Modifications Item Reference Design Change 1 MDR TBS Fit new compliance registration nameplate and remove existing TBS nameplate. 2 MDR TBS Ensure vehicles have separate hose runs for return lines for primary and secondary brake dump valves. 3 MDA DEV 51/2 Addition of secondary brake dump valve. 4 MDA DEV 51/2 Alterations to the transmission isolate valve and pilot line. 5 MDA DEV 51/2 Change to service brake valve, part No MDA DEV 51/2 Optional auto brake valve to apply the brakes when the engine safety circuit shut down the diesel engine. 7 MDA DEV 51 Issue M Automatic brake with door interlock. 8 MDA DEV 51 Initial design 4.3 Changes to Testing or Procedures Owners and operators of existing loaders are required to implement or change testing or procedures listed below in Table 2. Table 2 Required Changes to Testing or Procedures and End User Actions Change From Previous Design End User Action Required For Existing Loaders In-service testing requirements have been revised. Update mechanical engineering management plan in accordance with requirements in MDR Ensure Loader is routinely tested in service to the revised braking rates listed in the registration drawings. Sandvik Mining and Construction Tomago Pty Page 3 of 7 ABN Old Punt Road Telephone Tomago NSW Australia Facsimile

9 DOCUMENT No.: A2U Rev: A 5 General Requirements for End Users Regarding Transport Braking Systems 5.1 These recommendations are additional to those provided in the loader Operator and Service Manuals (including addendums), and relevant alerts and bulletins issued by Sandvik or the industry. 5.2 All vehicle operators to be suitably trained and qualified especially with regard to parking procedures and emergency braking procedures. 5.3 All vehicle operators to be made aware of roadway, vehicle and environment conditions that may significantly alter the vehicle s stopping distance and ability to hold on grade. 5.4 This MDR doesn t cover use of braked trailers. These must be assessed separately. 5.5 Sandvik FMEA's on vehicle systems may exclude generic faults from the analyses in accordance with AS Section 4. The generic faults that may be excluded and conditions for exclusion are in listed in AS Appendices A, B, C, and D. End Users should note that if the vehicle system is modified outside the scope of the registration or design intention, or has not been tested or maintained as specified, the conditions upon which a generic fault may have been excluded will no longer be valid, and the likelihood of this fault occurring will increase. 5.6 Sandvik FMEA's and risk assessments assume that the assessed design has not been modified and has been adequately maintained. End Users should note that modification or poor maintenance practices will invalidate assessment of some risks. 5.7 Mine Transport Rules should consider the following issues: Prevention of collisions with personnel, mobile plant, or fixed objects Rated grades for mobile plant are not exceeded Reduced loads and travelling speeds for some roadway conditions Sandvik Mining and Construction Tomago Pty Page 4 of 7 ABN Old Punt Road Telephone Tomago NSW Australia Facsimile

10 DOCUMENT No.: A2U Rev: A 6 Notes Regarding Braking Rates and Testing 6.1 The braking rate and pull force pass/fail criteria for in-service testing have been revised to comply with the requirements of MDG39 amendment No.1. The required braking rates are shown on the registration drawing and registration nameplate. 6.2 To provide flexibility in regards to testing, the braking rates are nominated for a loader without any QDS attachment fitted. 6.3 On some road surfaces the required braking rates and pull force may be difficult to achieve due to wheel slip. This may be addressed by changing the test location (road surface) and/or adding additional mass to the loader for testing purposes and using an adjusted pass/fail braking rate calculated as per MDG39 Amendment No.1 Amend. [18]. 6.4 Braking rates and holding forces for vehicles fitted with steel wheel chains are especially dependent on the type of road surface. It may be necessary to conduct routine brake testing of these vehicles on soft ground to ensure adequate braking effort is transferred between the tyres and the ground. Sandvik Mining and Construction Tomago Pty Page 5 of 7 ABN Old Punt Road Telephone Tomago NSW Australia Facsimile

11 DOCUMENT No.: A2U Rev: A 7 Appendix A - Conditions of Use Compliance Details 7.1 The following table details the compliance to conditions of use nominated in MDR TBS. 7.2 Note that Sandvik no longer manufacture this transport braking system. Table A1 Clause By Clause Conditions of Use Compliance Details Item Requirement End User Requirements 3 Conditions for Supply and Use 3.1 General Conditions for Supply 1. The plant design registration number must appear in a conspicuous place in a legible manner on each item of registered plant, unless specifically excluded. 2. The designer, manufacturer and/or supplier must provide any person who owns the plant, or who has control of the plant or the end use all information as required by clauses 96, 105, and 122 of the Regulation and all documents listed in section 2.1 of this registration. 3. A copy of the registration of plant design documentation must be supplied to any person who owns or who has control of the registered plant. The documentation must comprise the number of pages listed in the footer block together with all documentation and drawings as listed in the Schedule specifically nominated for the purposes of installation, inspection and maintenance of the plant design. 4. The manufacturer is to certify in writing that the particular plant design supplied is in accordance with the requirements of this design registration. 5. There must be no variation in the materials, design or construction of the plant associated with this registration. Unauthorised alteration or substitution of registered plant will render this registration void. 6. New plant must not be manufactured, (or supplied) to this design registration after the specified date of expiry. If no date is specified, after 10 years for the date of registration. This does not prevent ongoing use of existing plant manufactured prior to the specified date of expiry. Install nameplate to existing vehicles. Remove old approval nameplate. Ensure the required documentation is supplied when selling or hiring out the Loader. Ensure the required documentation is supplied when selling or hiring out the Loader. Ensure loader is maintained as per registration requirements. Not Applicable 3.2 General Conditions for Use Comply with requirements of Section 3.2 of MDR TBS. 3.3 Specific Conditions 1. The system identification number MDR TBS and the supplier s name or mark, the brake performance limits, the maximum operating grades, speed and masses must be inscribed on a durable plate fixed in a prominent position on the equipment. 2. The mine s Mechanical Engineering Management Plan under clause 20 of the Coal Mine Health and Safety Regulation 2006 must include provisions to regularly check, inspect and maintain the transport braking system to ensure it remains in a safe condition for use. 3. The Coal Operator must ensure that the underground Transport Management Plan (clause 31, Coal Mine Health and Safety Regulation 2006) incorporates provision to ensure site operational parameters do not exceed those stated in condition (4) below. Install nameplate BD Ensure MEMP complies with requirement. Ensure TMP complies with requirement. Sandvik Mining and Construction Tomago Pty Page 6 of 7 ABN Old Punt Road Telephone Tomago NSW Australia Facsimile

12 DOCUMENT No.: A2U Rev: A Item Requirement End User Requirements 4. The operating parameters for ideal conditions must not exceed: Ensure that the vehicle is a) Maximum gross vehicle 28,545 kg utilised within the mass nominated parameters, b) Tare mass (no QDS attach) 19,180 kg under ideal conditions. Tare mass (with QDS 21,545 kg attach) c) Maximum load 7,000 kg d) Maximum braked towing load Maximum un-braked towing load 7,000 kg f) Maximum combination of 28,545 kg payload and towing load g) Maximum operating speed 24 km/h h) Maximum grade 25% 1:4 Sandvik Mining and Construction Tomago Pty Page 7 of 7 ABN Old Punt Road Telephone Tomago NSW Australia Facsimile

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14 REPORT NO.: RA0021 JOB NO.: EN 9105 MACHINE: 130 PROJECT: Non-conformance Risk Assessment for 130 Braking System against MDG39, including Amendment No.1 ASSESSMENT DATE: 31/10/08 PREPARED FOR: NSW Department of Primary Industries REVISION DATE REVISIONS A 31/10/08 Initial Release... Mark Peristy Design Engineer Construction Tomago Pty Construction - Tomago Pty Limited page 1 of 14

15 TABLE OF CONTENTS 1 EXECUTIVE SUMMARY INTRODUCTION BACKGROUND REFERENCES DEFINITIONS RISK ASSESSMENT OBJECTIVE RISK ASSESSMENT SCOPE RISK ASSESSMENT TEAM MEMBERS METHODOLOGY RISK ASSESSMENT PROCEDURE RISK ASSESSMENT PROCESS RISK ASSESSMENT FLOWCHART SET ASSESSMENT OBJECTIVES DEVELOP OPERATIONAL PROCESS IDENTIFY HAZARDS NOMINATE EXISTING BARRIERS ESTIMATE FREQUENCY ESTIMATE SEVERITY ESTABLISH RISK FROM RISK MATRIX RECOMMEND POTENTIAL NEW BARRIERS IMPLEMENT NEW BARRIERS PREPARE REPORT RISK IDENTIFICATION AND HAZARD MANAGEMENT Construction - Tomago Pty Limited page 2 of 14

16 1 EXECUTIVE SUMMARY 1.1 In order to minimise risk due to partial and non-compliances to MDG39 incorporating Amendment No.1, Sandvik and End Users are required to perform the following actions. Refer to Section 4 for hazard identifications and specific actions required for each risk. 1.2 Sandvik Actions as an outcome of the Risk Assessment. These actions are nominally due for completion by November 2008: Design revised TBS nameplate Revise TBS drawing Engineer steering accumulator dump valve Issue Technical Bulletin on changes 1.3 End User Actions as an outcome of the Risk Assessment. These actions are nominally due for completion by June 2009: Install revised nameplate Ensure exisiting vehicles match TBS drawing Install steering accumulator dump valve if required. Construction - Tomago Pty Limited page 3 of 14

17 2 INTRODUCTION 2.1 BACKGROUND In order to apply for Design Registration for the 130 braking systems, a gap analysis and risk assessment are required to be performed and issued to the regulating authority. The gap analysis has been performed in Sandvik Compliance report CR0347. The partial and non-compliances identified by this compliance report have been risk assessed in this Risk Assessment Report to identify the criticality their non-compliances present to the use of the machine. 2.2 REFERENCES Australian / New Zealand Standard , Risk Management MDG Risk Management Handbook MDG Guide to Reviewing a Risk Assessment MDG39 - Handbook for the Design, Installation, Testing And Maintenance Of Braking Systems On Free-Steered Vehicles in Underground Coal Mines incorporating Amendment No. 1. CR Transport Braking System Compliance to MDG39 Including Amendment No DEFINITIONS Hazard Principle Hazard Likelihood Probability Consequence Risk Risk Analysis Risk Assessment Risk Management Risk Control Monitor FMEA A source of potential harm or a situation with a potential to cause loss. A source of potential harm or a situation with a potential to result in multiple fatalities. Used as a qualitative description of probability and frequency. The likelihood of a specific outcome, measured by the ratio of specific outcomes to the total number of possible outcomes. The outcome of an event or situation expressed qualitatively or quantitatively, being loss, injury disadvantage or gain. The chance of something happening that will have an impact upon objectives. It is measured in terms of consequences and likelihood. A systematic use of available information to determine how often specified events may occur and the magnitude of their likely consequences. The overall process of risk analysis and risk evaluation. The systematic application of management policies, procedures and practices to the tasks of identifying, analysing, evaluating, treating and monitoring risk. That part of risk management, which involves the provision of, polices, standards and procedures to eliminate, avoid or minimise adverse risks facing an enterprise. To check, supervise, observe critically, or record the progress of an activity, action or system on a regular basis in order to identify change. A procedure by which potential failures are analysed and each failure mode identified is ranked according to the combined influence of its likelihood of occurrence and the severity of its consequences. Construction - Tomago Pty Limited page 4 of 14

18 2.4 RISK ASSESSMENT OBJECTIVE The objective of the risk assessment is to identify and then resolve or minimise any hazards which could impact on the health or safety of workers operating the 130 LHD due to it s non-conformances with the current braking system guideline for Underground Coal Mines. The resolution or minimisation of risks may be achieved via design changes, additional signage, or modifications to operating and maintenance procedures. Engineering changes that eliminate the risk are preferred where practical. 2.5 RISK ASSESSMENT SCOPE The Risk Assessment scope is limited to the braking system on 130 LHD s. Risk areas have been identified as areas of non-conformance with the current braking system guideline, MDG39 incorporating Amendment No RISK ASSESSMENT TEAM MEMBERS NAME ORGANISATION POSITION Phil Nelthorpe Construction Engineering Manager - RTV Tomago Pty. Mark Peristy Construction Tomago Pty. Design Engineer Construction - Tomago Pty Limited page 5 of 14

19 3 METHODOLOGY 3.1 RISK ASSESSMENT PROCEDURE The risk assessment was carried out by following the following four defined stages: Stage 1 Determine an objective and a scope. The objective was to identify non-compliances with MDG39 incorporating Amendment No.1, and then perform a risk assessment on these non-compliances. The scope was limited to the braking systems on the 130 LHD, specifically the noncompliances to MDG39 incorporating Amendment No.1. Stage 2 Identification of non-conformances of the 130 LHD braking systems to MDG39 incorporating Amendment No.1. These have been recorded in Sandvik Compliance Report CR0347. Stage 3 The formal risk review was undertaken at, Hexham offices on 31/10/08. This risk review nominated the expected criticality of the risks and suggested new barriers where applicable Stage 4 Following the completion of the risk assessment, the report was written and a list of recommendations developed for implementation. Stage 5 Additional actions are required subsequent to the risk assessment and these are as follows: Engineering and Management review of Risk Assessment recommendations to determine suitability, requirements, practicality and approval of each suggested new barrier. Engineering of approved suggested new barriers and recommendations. Update of vehicle training, operating and maintenance documentation to reflect approved recommendations. Communication of new barriers to industry via Technical Bulletin. Ongoing audit of Risk Assessment actions until all items closed out. Re-assessment of risks in response to changes to requirements, or vehicle design for the life of the machines. 3.2 RISK ASSESSMENT PROCESS The risk assessment process utilised is outlined on the following flowchart 2.3 to clearly define each step. Construction - Tomago Pty Limited page 6 of 14

20 3.3 RISK ASSESSMENT FLOWCHART SET ASSESSMENT OBJECTIVES DEVELOP OPERATIONAL PROCESS IDENTIFY HAZARDS NOMINATE EXISTING BARRIERS ESTIMATE PROBABILITY ESTIMATE CONSEQUENCES ESTIMATE RISK USING MATRIX RECOMMEND POTENTIAL NEW BARRIERS IMPLEMENT NEW BARRIERS PREPARE REPORT 3.4 SET ASSESSMENT OBJECTIVES Set an objective to aim at throughout the process. It is important that all parties agree on the objective of the process and that it is strictly adhered to throughout the discussions. 3.5 DEVELOP OPERATIONAL PROCESS Analyse the operation of the equipment and to lay it out in a flow chart form so that a step by step approach to the use of the equipment can be evaluated. 3.6 IDENTIFY HAZARDS Examine each operation along the flow chart created in step 2 to identify hazards or loss scenarios associated with those operations. In line with the previously decided limitations of the exercise, only the operations relating to the objectives and scope were examined for possible hazards and loss scenarios. 3.7 NOMINATE EXISTING BARRIERS Nominate, where possible, any existing barriers presently in the design of the machine, system or procedure, which may prevent identified hazards from occurring. 3.8 ESTIMATE FREQUENCY Determine the probability of a hazard, as identified in step 3, occurring. The rating of the probability is decided by team consensus or statistics where available. The basis of the rating is shown on the table below for a WRAC SYSTEM TO MDG 1010 APPENDIX A7. A B C D E FREQUENCY OF THE EVENT Almost certain to happen, more once per month Likely to happen at some point, more than once per year Possible, it might happen, more than once per 5 years Not likely to happen, less than once per 5 years Practically impossible, unlikely to ever occur Construction - Tomago Pty Limited page 7 of 14

21 3.9 ESTIMATE SEVERITY Determine the severity of the identified failure should they occur. The consequence rating is determined by team consensus or statistical information where available. The basis of the severity rating is shown on the following table. SEVERITY OF THE EVENT PERSONNEL INJURY FINANCIAL COST LOSS OF PRODUCTION 1 FATALITY OR PERMANENT > $500K > 1 DAY DISABILITY 2 SERIOUS LOST TIME INJURY $100K - $500K > 1 SHIFT OR ILLNESS 3 MODERATE LOST TIME $50K - $100K > 1 HOUR INJURY OR ILLNESS 4 MINOR LOST TIME INJURY $5K - $50K 1 HOUR OR ILLNESS 5 NO LOST TIME (POSSIBLE FIRST AID) <$5K INSIGNIFICANT 3.10 ESTABLISH RISK FROM RISK MATRIX The risk ranking can be determined by checking the frequency and severity rating for each hazard against the Risk Matrix below. The Risk Matrix has been sourced from Sandvik s Sandvik Safety Take 5 Personal Risk Assessment Handbook. RISK MATRIX FREQUENCY SEVERITY A B C D E RECOMMEND POTENTIAL NEW BARRIERS Recommend through group discussion, drawing from the team members' experience, means of reducing or eliminating the risk through appropriate barriers or controls. Construction - Tomago Pty Limited page 8 of 14

22 3.12 IMPLEMENT NEW BARRIERS The implementation of the potential new barriers that have been selected by the manufacturer and/or end-user of the equipment or system of use A written explanation as to the reasoning behind selection or rejection of the suggested new barriers is required for each of the identified hazards As a guide to ensure each identified hazard is sufficiently addressed, the table below may be used as a guide for the minimum expected controls or barriers for each risk ranking. RISK LOW MEDIUM HIGH NECESSARY CONTROLS AND BARRIERS Risk may or may not have barriers set but in the interest of the manufacturer/end-user those barriers that are relatively easy or cost effective to implement should be implemented. Controls or barriers should be implemented. Identified risks in this category shall have barriers or controls in place Hard barriers or mechanical forms of protection should be used in preference to soft barriers (training and procedures) where practical. This is especially true when implementing barriers and controls for High risk ranked hazards PREPARE REPORT Step 10 is to prepare the report; this report should have included the following as a minimum A list of the risk assessment team including the person's name, company and position A list of the new or revised items being assessed on the equipment Clear drawings, diagrams and photos where available to validate the affected equipment Any available injury and safety statistics should be documented in the appendix All processes, hazards, probabilities, consequences, risks and barriers nominated in the exercise are to be listed A final recommendation list of selected barriers and the hazards they minimise or eliminate must be listed Statements as to the reasons why potential new barriers have not been implemented must be supplied by the manufacturer/end-user. Construction - Tomago Pty Limited page 9 of 14

23 4 RISK IDENTIFICATION AND HAZARD MANAGEMENT 4.1 The partial compliances and non-compliances to MDG39 Incorporating Amendment No.1 have been assessed for design risk in this section. The information is contained in the following 3 tables: Table 1 Listing of all hazards requiring Sandvik or End User Action, sorted highest risk to lowest risk Table 2 Listing of all hazards requiring Sandvik action and delegation of responsibilities. Table 3 Listing of all risks pertaining to gap analysis between 130 LHD and MDG39 incorporating Amendment No.1. Construction - Tomago Pty Limited page 10 of 14

24 Construction Tomago Pty Table 1 Listing of all hazards requiring Sandvik or End User Action, sorted highest risk to lowest risk Rev Clause No. Hazard & Effects A para 2 (MDG39 Amend 1) Unplanned Movement (Collision due to failed braking) A (a) No increased risk. item included here as there is a Sandvik action. A 2.2 No increased risk. item included here as there is a Sandvik action. Risk Rank Suggested new Barriers 17 TBS schematic shows single tank line. Actual vehicle schematics specify separate return lines for Primary and Secondary Brake Dumps. TBS drawing should be revised to reflect this (no change in risk) Risk Rank Sandvik Action Required to Implement New Barrier 17 Revise TBS drawing. Refer A2U Revision E. Fit bleed valve Sandvik to issue Technical Bulletin advising of option for older vehicles. Install compliance plate Sandvik shall revise the nameplate to list required braking rates. End User Action Required to Implement New Barrier Ensure separate tank lines as per TBS drawing for primary and secondary brake dump valves. Fit steering accumulator dump valve Fit new nameplate page 11 of 14

25 Construction Tomago Pty Table 2 Listing of all hazards requiring Sandvik action and delegation of responsibilities. Rev ITEM SUGGESTED CONTROLS ACTION RESPONSIBLE APPROVED 1 A para 2 (MDG39 Amend 1) A (a) TBS schematic shows single tank line. Actual vehicle schematics specify separate return lines for Primary and Secondary Brake Dumps. TBS drawing should be revised to reflect this (no change in risk) Fit bleed valve Revise TBS drawing. Refer A2U Revision E. Sandvik to issue Technical Bulletin advising of option for older vehicles. (YES/NO) DATE REQUIRED M Peristy Yes Complete M Peristy Yes Complete A 2.2 Install compliance plate Sandvik shall revise the nameplate to list required braking rates. M Peristy Yes Complete 1. Approval may be determined subsequent to initial issue of this Risk Assessment. page 12 of 14

26 Construction Tomago Pty Rev A A Clause No para 2 (MDG39 Amend 1) para 3 (MDG39 Amend 1) Clause Comply Comments/Justification Hazard & Effects Failure of a single component shall not prevent the mobile plant from being held stationary on the maximum operating grade. The secondary brake system shall be tested to simulate the performance condition when the service brake system has failed under the worst case failure as identified by the risk assessment, refer clause If the secondary brake system forms part of the service brake, then the service brake must be modified and separated from the secondary brake, so that secondary brake system can be operated alone for the test. Partial Do Not Comply Table 3 Listing of all risks pertaining to gap analysis between 130 LHD and MDG39 incorporating Amendment No.1. Braking will not achieve required performance if hose line to brakes is crushed and high pressure retained. The likelihood of this occurring to a high pressure hydraulic hose protected by the vehicle frame is expected to be so rare that the risk level is low. Note that blockage of this line is a precluded failure as the hose is in the power (pressure) circuit as per AS Table C8. TBS schematic shows single tank line. Actual vehicle schematics specify separate return lines for Primary and Secondary Brake Dumps. TBS drawing should be revised to reflect this. Testing for worst case failure not conducted as vehicle predates MDG39. Refer also para 2. Unplanned Movement (Collision due to failed braking) Unplanned Movement (Collision due to single line component ceasing system function) page 13 of 14 Existing Barriers Steer LHD into rib, Drop bucket/qds, Protected hose, Filtered fluid, Engine retardation Pre-start check Line to front brake passes through centre of articulation clear of pinch points and is clear of lift arms. Rear brake line passes clear of bolster pinch points. Proven brake reliability in service. Steer LHD into rib, Drop bucket/qds, Protected hose, Filtered fluid Engine retardation Pre-start check Line to front brake passes through centre of articulation clear of pinch points and is clear of lift arms. Rear brake line passes clear of bolster pinch points. Front and rear brake lines are separated. Consequence to Personnel, or Equipment Probability Consequence Risk Rank Suggested new Barriers Both D 3 17 TBS schematic shows single tank line. Actual vehicle schematics specify separate return lines for Primary and Secondary Brake Dumps. TBS drawing should be revised to reflect this (no change in risk) Both D 3 17 Probability Consequence Risk Rank Risk Notes D 3 17 Refer also Clause (ii) (MDG39 Amend 1) Sandvik Action Required to Implement New Barrier Revise TBS drawing. Refer A2U Revision E. End User Action Required to Implement New Barrier Ensure separate tank lines as per TBS drawing for primary and secondary brake dump valves.

27 Construction Tomago Pty Rev A Clause No (ii) (MDG39 Amend 1) Clause Comply Comments/Justification Hazard & Effects (ii) A failure of a single component of the braking system that provides the worst condition for braking as identified by the design risk assessment, and Partial Brake will not achieve required performance if hose line to brakes is crushed and high pressure retained. The likelihood of this occurring to a high pressure hydraulic hose protected by the vehicle frame is expected to be so rare that the risk level is low. Note that blockage is a precluded failure as the hose is in the power (pressure) circuit as per AS Table C8. Unplanned Movement (Collision due to single line component ceasing system function) Existing Barriers Proven brake reliability in service. Steer LHD into rib, Drop bucket/qds, Protected hose, Filtered fluid Engine retardation Pre-start check Line to front brake passes through centre of articulation clear of pinch points and is clear of lift arms. Consequence to Personnel, or Equipment Probability Consequence Risk Rank Both D 3 17 Suggested new Barriers Probability Consequence Risk Rank Risk Notes Sandvik Action Required to Implement New Barrier End User Action Required to Implement New Barrier Rear brake line passes clear of bolster pinch points. Front and rear brake lines are separated. A (a) Fluid Power Systems (a) Accumulators A manual bleed valve shall be fitted to allow pressure relief for maintenance. Fluid should return to tank. Partial No bleed valve fitted for steering accumulators (not part of brake circuit). Steering accumulator drained by activation of steering controls. Brake Dump valve removes pressure from accumulator when engine shut off. Can also empty accumulator by applying foot brake a number of times. Gauge in dash indicates accumulator pressure. No increased risk. item included here as there is a Sandvik action. Fit bleed valve Sandvik to issue Technical Bulletin advising of option for older vehicles. Fit steering accumulator dump valve A 2.2 COMPLIANCE PLATE Partial Maximum gross unbraked towing capacity not stated. Calculations show that this is dependent on payload carried by vehicle, rolling resistance of trailer and coefficient of friction between vehicle wheels and mine floor. A single number is too simplistic No increased risk. item included here as there is a Sandvik action. Install compliance plate Sandvik shall revise the nameplate to list required braking rates. Fit new nameplate Holding grade quoted as ratio rather than percentage as ratio is in common use. page 14 of 14