Free mining equipment maintenance checklist

• The MapTrack mining equipment maintenance checklist contains 27 checks across 8 sections. Sections covered: Fire and machine protection, ROPS, FOPS and operator station, Engine and driveline, Hydraulics, Brakes and steering, Tyres, tracks and ground engaging tools, Dust suppression, isolation and electrical, Warning devices and lighting.
• A mining checklist adds fire suppression, ROPS, FOPS, dust control, braking and isolation to the standard heavy plant inspection.
• It reflects the harsh mining duty cycle and the mines regulation that sits over general WHS duties.
• Fire suppression and brake checks are weighted heavily because the consequences in a pit are severe.
• Tracking tyre, track and GET wear controls some of the largest costs on mining plant.
• A dated inspection trail is evidence of a controlled process for the mining regulation, WHS and ISO 55001.

Learn more about maintenance and work orders in MapTrack.

• Safer machines: dedicated ROPS, FOPS, brake, fire and isolation checks keep the controls that protect operators and fitters proven and current.
• Less unplanned downtime: catching wear early on driveline, hydraulics and GET avoids failures that strand a machine in the pit mid shift.
• Fire risk control: routine inspection of suppression and the engine bay reduces the machine fire risk that mining heat and debris create.
• Lower running cost: tracking tyre, track and component condition supports replacement on real wear rather than premature or overdue change outs.
• Complete asset history: each dated inspection builds the record behind planned maintenance, criticality decisions and budget on high value plant.
• Audit evidence: a consistent inspection trail demonstrates a controlled maintenance process for the mining regulation, WHS duties and ISO 55001.

• Machine details: type, fleet number, serial, hour meter, site or pit, shift and inspection date
• Engine and driveline: oil and coolant levels, leaks, belts, exhaust and transmission condition
• Hydraulics: fluid level and condition, hoses, cylinders, leaks and ram operation
• Brakes: service brake, park brake, retarder or emergency brake test and response
• ROPS and FOPS: structure, mounts, glass and falling object protection condition
• Fire suppression: charge or pressure, nozzles, actuators, manual stations and engine bay cleanliness
• Dust suppression: water cart, sprays, cab pressurisation and filtration where fitted
• Isolation and lockout: battery isolator, isolation points, stored energy and lockout provisions
• Ground engaging tools: bucket teeth, edges, blades, ripper and wear plate condition
• Lighting, beacons, reversing alarm, emergency stops and operator restraint
• Sign off: defects raised, fit for service decision, fitter and supervisor names and dates

1. Isolate the machine before service

   Park on stable level ground, ground all attachments, apply the park brake and chock the wheels or tracks. Isolate the machine, dissipate stored hydraulic and electrical energy and apply personal locks before any service work begins, then record the hour meter and machine details.

2. Inspect the mining safety systems

   Check the fire suppression charge, nozzles, actuators and manual stations, and clear the engine bay of the debris and oil that feed a machine fire. Confirm ROPS and FOPS structures and mounts are sound, the dust suppression and cab filtration work, and the emergency stops, reversing alarm and beacons all function.

3. Check driveline, hydraulics and brakes

   Work through engine oil and coolant, transmission, belts and visible leaks, then assess hydraulic fluid, hoses and cylinders for damage and weeping. Test the service brake, park brake and any retarder or emergency brake against specification, because brake performance on a loaded machine on a grade is not negotiable.

4. Assess tyres, tracks and ground engaging tools

   Inspect tyres for cuts, pressure and tread or undercarriage components for wear and tension, since these are major cost and safety items on mining plant. Check ground engaging tools such as bucket teeth, cutting edges, blades and wear plates, and note any that are near or past their replacement point.

5. Record defects and decide fit for service

   Mark every line pass, fail or not applicable with the reading where one applies, and raise a work order for each failed item. Make a clear fit for service or hold decision, list the parts required, then have the fitter and supervisor sign and file the sheet against the asset history.

Practical answers about the form, record keeping and using MapTrack.

This form is a starting point. Check the current requirements that apply to your equipment, work and location. The form alone does not establish compliance.

• Work Health and Safety Act 2011 and primary duty of care (s19)
• Work Health and Safety (Mines and Petroleum Sites) Regulation, mining plant duties
• ISO 3471 ROPS and ISO 3449 FOPS performance for earthmoving machinery
• ISO 55001:2024 Asset management (controlled maintenance records)

• Model Work Health and Safety Act (Safe Work Australia)
• ISO 55001:2024, Asset management system requirements (ISO catalogue)

MapTrack publishes this template. The linked authorities publish their own guidance; they haven't endorsed this form.

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