Fleet Strategy & Delivery - Purchasing Specification

Fleet 6 Haul Truck

High Performance Dump Body
XEMC for 830E AC

HME-PSPE-117

© 2013, Held within Rio Tinto

For Internal Use Only

Document Owner: Fleet Strategy & Delivery

Version History
Version Description Prepared by Reviewer: Approver: Date

0 Steve Lihou Shane Dinsdale Caroline Healy

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Document Attributes
As a Purchasing Specification, this document has the following attributes (refer to RTIO-IT-
0002760 for document type definitions):

Authoriser: Superintendent

Reviewer: Supervisor

Document Controller: Department Administrator

Audience: Department

Document Type: Purchasing Specification

References

Reference No. FDMS Reference Title

1 RTIO-IT-0002760 Document Management Standards and Guidelines

Document Enquiries
For any enquiries please email the specification team at: (Mobile Plant Specification
Enquiries) or [email protected]

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 Contents

Section 1 -General...............................................................................5

Section 2 -Scope of Work.....................................................................6

2.1 Design Features.............................................................................................................. 6

2.2 XEMC Body Worksheet (BW) approval..........................................................................6

2.3 Actual Design weight...................................................................................................... 6

2.4 High Performance Dump Body (HPDB)..........................................................................6

2.5 Blast, Prime, and Final Top Coat....................................................................................6

2.6 Canopy Side Rock Deflectors......................................................................................... 7

2.7 Pipe Spill Rail on Headboard..........................................................................................7

2.8 Body Restraint Strap....................................................................................................... 7

2.9 Chain Rock Ejectors....................................................................................................... 7

2.10 Body Centring Device..................................................................................................... 7

2.11 Small Parts Kit................................................................................................................ 8

2.12 Headboard Fixtures........................................................................................................ 8

2.13 Rear-Sidewall Light Fixtures...........................................................................................8

2.14 Rubber Mud-Flaps.......................................................................................................... 9

2.15 Load Centring Indicator................................................................................................... 9

2.16 Full Maintenance Manual................................................................................................ 9

2.17 Documentation................................................................................................................ 9

2.18 Identification Numbers.................................................................................................... 9

2.19 High Performance Dump Body Tray Pads......................................................................9

2.20 Maintenance Tooling..................................................................................................... 10

2.21 Manufacturing and Supply Schedule............................................................................10

2.22 Risk Assessments and Job Hazard Analysis (JHA)......................................................10

Section 3 -Reliability, Availability, Maintainability, Build-ability and

Operability 11

Section 4 -Work Not Included..............................................................12

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Section 5 -High Performance Dump Body Capabilities (HPDB)..............13

Section 6 -Electrical Requirements......................................................14

Section 7 -General Requirements........................................................15

Section 8 -Risk Assessment and Installations......................................16

Section 9 -Quality Management..........................................................17

Section 10 - Shipping Arrangement.....................................................18

Appendix A -Photographic Reference..................................................19

Introduction
This Specification applies to Iron Ore Operations in the Pilbara operating under the Rio Tinto
(RTIO) banner, including Pilbara Iron, Hamersley Iron, Robe River Mining and Hamersley
HMS.

This HME Purchasing specification describes the modifications, from the manufacturer’s
standard machine, to be made to every electrical-drive haul truck dump body that is to be
purchased by Rio Tinto for its Western Australian iron ore sites.

This document is an output from the HME specification development process. Changes to this
document can only be made through that process.

The modifications to the Dump Body may be carried out by the manufacturer (OEM) or the
local dealer. The modifications are described in detail in the body of the document

A HME Purchasing specification issued to a supplier (an OEM or a local dealer) for quoting
must be accompanied by an HME Scope of supply.

Note: If there is any conflict between this purchasing specification and the HME Standard for
this type of HME, this purchasing specification has precedence.

Rio Tinto is committed to the health, safety and environment of its workers and the
community. As part of this commitment, all HME must comply with Rio Tinto's requirements,
and the laws and regulations that apply in Western Australia. Also, the design, manufacture
and modification of this HME must follow the fundamentals of:

Recognised standards, such as Australian Standards (AS), International Organization for

Standardization (ISO),

Australian codes of practice.

Rio Tinto’s requirements are listed below.

Specific HME requirements are described in HME-PSUP-001 Attachments for HME

Standards and purchasing specifications

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Supporting Documents

Title

XEMC Visual Inspection

RTIO_VIS_SPEC_Re
v01.pptx

HME-PSUP-001 HME Purchasing Specification

RTIO-AM-0073841
Supplement

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General
This specification, details the requirements for the supply of High Performance Dump Bodies
(HPDB) for the Relevant Companies.

The works detailed in this specification will take into consideration the sustainable
development in the areas of social, environment and economics.

HPDB build and assembly must comply with all regulations, standards and specifications as
listed in this document and attached appendices to this document.

Where these specifications contain omissions or requirements that contradict sound operating
practice in the mining Industry then the Supplier must raise these issues with the Rio Tinto
Representative for clarification and must not proceed without obtaining express and written
approval of the Rio Tinto Representative.

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Scope of Work
This specification is for the design, manufacture, and supply of HPDB to Pilbara Iron Sites.
High Performance Dump Bodies (HPDB) will be primarily used to transport iron ore in the
loading and hauling operations. Design, manufacture and supply of HPDB compatible with
830E AC trucks according to the following requirements that can be updated by the Relevant
Company any time but before the start of manufacturing of the quantities on order at any time.

Design Features 设计特性

The Design must be able to achieve a nominal payload of 230 tonnes at a loose

material density of 1.7t/m3 设计必须满足的装载负荷为 230 吨，松散物料密度为

1.7t/m3

Load capacity shall be calculated as (SAE 2:1 Volume) * (87%). 根据 SAE2:1 计

算，装载容积率为 87%。

XEMC Body Worksheet (BW) approval 车斗工作单确认

The Supplier must provide all required details in the document (Body Application

Worksheet Update 2004.doc) within 4 weeks prior to the start of manufacturing

HPDB and must not start manufacture of HPDB without express written approval

from the Rio Tinto Representative regarding the BW approval process by XEMC.

Supplier shall modify the Design if required to obtain BW approval from XEMC.

The Rio Tinto Representative shall submit for approval to XEMC. 供应商必须在

开工前 4 周按要求提供详细文件（车斗配置工作单 2004 更新版），没有获得力拓

书面认可之前不得开工。如湘电需要修改车斗工作单，需要提交力拓代表批准通过。

Actual Design weight 实际设计重量

Actual design weight shall not exceed 33,600 kilograms, designed for a minimum

of 18,000 hour Design Life and must meet the following specifications 实际设计重量不能
超过 33600kg，车斗寿命需要满足 18000 小时并符合以下要求

Design Life may exceed the minimum requirement 设计寿命需要满足最低要求

Approximate annual operation hours are 6000 hrs/year, which equates

to a Design Life of 3 years. 年工作小时为 6000 小时/年，等同于 3 年。
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 Design weight will be inclusive of weld allowance and inclusive of small
parts requirements 设计重量包括焊接材料和要求安装的小部件。

A plate will need to be affixed to the dump body to

indicate weight of tray, and model number and

year and month of manufacturer.车斗加装一块板，上面

标明车斗的重量、型号及生产年月。

High Performance Dump Body (HPDB)车斗

The HPDB must be fully manufactured and assembled in China by the Supplier
according to the quality assurance and documentation requirements set
out in document “Quality Assurance Requirements for HPDB
Manufacturing”.车斗需要完全在中国境内由供应商生产和组装，生产和组装需要遵守车斗制造质保要求中的质保
和文件要求。

Blast, Prime, and Final Top Coat 抛丸，底漆和面漆

Blast, prime, and final top coat shall be:抛丸、底漆和面漆需要满足：

Primer 底漆 – Interseal 670HS

Top Coat 面漆- Interfine 979

Colour 颜色 - Komatsu Dozer Yellow

Lead, Beryllium, Isocyanate, any other volatile organic compounds

(VOC’s) and toxic free paint as described in the Purchasing
Specification Supplement document 不含铅、铍、异氰酸盐和其他采购规范文件中的
标明的易挥发物质和有毒物质。

The paint finish shall be to a professional standard. The use of body

fillers is not acceptable.面漆喷涂需要达到专业水准，不允许使用腻子。

Canopy Side Rock Deflectors 保护板侧防砸装置

Canopy side rock deflectors, both left-hand-side and right-hand-side, to cover

from side mirror to rear of deck and must meet the following
requirements:保护板左、右两侧的防砸装置覆盖区域从侧镜到甲板后面，必须满足以下要求：

300mm width 宽 300mm

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 Rock deflectors to extend 500mm down the front-wall transition 防砸装置需要
延伸至前板通道前方 500mm

Overall width shall no exceed maximum of 8092mm 总的宽度最大不能超过

8092mm

Pipe Spill Rail on Headboard 顶板防倾管状栏杆

Pipe spill rail on headboard to negate risk of material spillage must meet the
following specifications:顶板上的防倾管状栏杆用于防止物料倾覆，必须满足以下规格

350mm height 高 350mm

Pipe rail size NB 40mm 管状栏杆尺寸 NB 40mm

Overall height shall not exceed maximum of 7501mm 最大总高度不能超过

7501mm

Body Restraint Strap 车斗限位带

Mounting brackets to allow fitment and storage of “Body Up” sling as per
SF33901 Dump Body "up" dimension and must comply with the following
specifications:根据 SF33901 车斗“上升”尺寸安装支架用于安装和存放“升斗”绳，尺寸如下：

Brackets shall be designed for a minimum 60 tonnes static load rating 安

装支架设计静态额定载重为 60 吨

Rio Tinto Representative shall provide detail on location and dimension

of bracket components prior to the start of manufacturing 力拓代表

将在生产前提供支架的详细尺寸和位置。

Supply a 35T rated Dyneema Sling.提供一根 35 吨的迪尼玛吊索。

Chain Rock Ejectors 排石链

Supply and install chain rock ejectors, complete with chain, "D" shackles and
hammerlocks to each HPDB in accordance to the following specifications:
提供和安装防石链，每台车斗需要安装链条、D 型卸扣和锁，尺寸如下：

Rock ejectors fitted, shall be as per supplied ‘visual specification’ in

document (RTIO_VIS_SPEC_Rev01.ppt)排石链需要符合文件
RTIO_VIS_SPEC_Rev01.ppt 中外观尺寸要求

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 24mm Chain including shackles, pins and Hammer-locks 24mm 链条包括卸扣、
销子和锁

Body Centring Device 车斗防摆支座

Supply and install body centring device (bolt on & inclusive of) according to the
following specifications;提供和安装车斗铰支座（包括安装螺栓），尺寸如下：

A designed body centring device to suit 830E AC chassis. 设计的车斗铰支座需要

与 830E 交流车车架相匹配

The bolt on option shall allow for the lower section of the centring device
to be removed and refitted if the body needs to be transported 如车
斗需要运输，铰支架低处的螺栓需要可拆卸和重装

The bolt pattern shall consist of 6 x 20mm bolts. (Refer to Photographic

Reference Bolt pattern - Picture 1) 安装 6 个 20mm 的螺栓（参见后图 1 的照
片）

The price shall include welding of the base section of the centring device
and excludes the site bolt up of the lower section, to be installed
during commissioning of the haul truck on site 价格应该包括铰支架底部焊接，
不包括螺栓从低处拆除和在矿山的安装。

Small Parts Kit 小部件包

Supply a small parts kit as follows:提供小部件包，如下：

8 x Chassis bump pads 8 个车架防砸垫（缓冲垫）

8 x 10mm plate compatible to chassis pad 8 个

10mm 的垫片与车架垫板相容（出资料增加）

80 x 1mm plate 80 个 1mm 的垫片

Associated hardware for fixing plates to chassis 安装车架调整垫片的所需的五金工具

Tray pivot gasket 8 x 1mm, 8 x 3mm and 8 x 5mm

(Refer to item 24 and 25 drawing number

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 SF8A-8500000) 车斗铰链座垫片 8 个 1mm， 8 个 3mm，

8 个 5mm（参考第图纸 SF8A-8500000 第 24 和 25 项）

A visual tray down indicator hose shall be supplied 提供车斗可视下落指示器

软管

Headboard Fixtures 前板附件安装

Affix tray down bracket (operator visual tray down indicator)加装车斗下落支架（驾驶

员可视车斗下落指示器）

Supply and installation of headboard light fixtures, inclusive of;提供和安装前灯，包括

Pressed steel mountings for HPDB Pilbara Iron standard lights 压制钢件支架用
于安装皮尔巴拉铁矿标准用灯

Installation of wiring to junction box as specified prior to manufacture 根据

说明，在制造之前将电缆接入接线盒

Installation of electrical harness and cabling to meet IP66 安装的线束和电缆必须满

足 IP66

Installation of LED lights as specified prior to manufacture 制造之前，根据说明安

装 LED 灯

Rear-Sidewall Light Fixtures 加装尾灯

Supply and installation of rear-sidewall light fixtures as per Rio Tinto design,
inclusive of;根据加力拓设计提供和安装尾灯，包括：

Steel mountings for LED light brackets for HPDB to suit Komatsu /
Pilbara Iron standard lights (Komatsu Part#: PC1913 flange
mount red) 根据小松/力拓皮尔巴拉铁矿标准用灯，为车斗安装钢制 LED 灯安装支架（小
松零件号： PC1913 红色凸缘架）

Installation of wiring to junction box as specified prior to manufacture 根据

说明，在制造之前将电缆接入接线盒

Installation of electrical harness and cabling to meet IP66 安装的线束和电缆必须满

足 IP66

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 Installation of LED lights as specified prior to manufacture 制造之前，根据说明安
装 LED 灯

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 Rubber Mud-Flaps 挡泥板

The HPDB fixtures to enable installation of rubber mud-flaps as per XEMC

design drawings and approved by RTIO and according to the following
specifications; 加装由湘电设计并通过力拓批准的车斗挡泥板，尺寸规格如下：

As per visual Specification (RTIO_VIS_SPEC_Rev01.ppt) 参照

RTIO_VIS_SPEC_Rev01.ppt 中外观尺寸

Inclusive of front-wall fixtures 包括前板夹具

Load Centring Indicator 装载中心指示器

Centre dump loading identification plates shall be welded to both sides of the
tray. (Reflective material) 车斗两侧均需要焊装装载中心指示板（反光材料）

Full Maintenance Manual 完整的维护手册

Development and supply of a full maintenance manual according to the following

requirements: 提供完整的维护手册，要求如下：

As set out in Appendix I of HME Purchasing Specification Supplement

Inspection sheets and required inspection intervals; and

Identification of likely failure modes and required actions 如附件 1 HME 采购规
范附件检测表格和抽检要求，可能发生的故障及解决方案。

Documentation 文件

Supply documentation and manufacturing drawings as set out in clause 3 and

clause 4 of document “Quality Assurance Requirements for HPDB
Manufacturing”. Manufacturing drawings and all documents must be in
English and compatible with Relevant Company CAD/CAM software
package.如文件“车斗生产质量保证要求”条款 3 和 4 要求，提供文件和制造图纸。

Identification Numbers 号码指示牌

Supply and installation of truck identification numbers:提供并安装车辆号码指示牌

As per visual specification document (RTIO_VIS_SPEC_Rev01. ppt)

attached in the supporting documents table of this document.如附上
的(RTIO_VIS_SPEC_Rev01. ppt)文件上的外观尺寸

Relevant Company to supply numbering and specifications prior to

manufacturing 力拓讲在生产前提供号码和规格

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 Reflective signage as per specifications supplied by Rio Tinto
Representative prior to start of manufacturing. 生产开始前力拓代表根据规范提
供反光标示。

Fleet number plates to be welded on the left and right hand sides of the
tray (size to be confirmed) 车辆编码牌需要焊接在车斗的左、右侧（尺寸待定）

High Performance Dump Body Tray Pads 车斗垫片

Supply of eight (8) HPDB tray pads for the interface points between the HPDB
and the truck chassis according to the following specifications; 提供 8 快车斗垫
片用于调整车斗和车架之间的空隙，规范如下：

Design of tray pads must be compliant with the XEMC design drawings
and approved by RTIO which was supplied by the Relevant
Company as an electronic document and 根据力拓认可的湘电车斗图纸设计车斗垫
片。

Maintenance Tooling 维护工具

The supplier shall supply any essential maintenance tooling as mutually agreed
between the Supplier and Relevant RTIO Company Representative.湘电必须
提供双方认可的，所有的维护必备工具。

Manufacturing and Supply Schedule 生产和交货计划

Supply of a Manufacturing and Supply Schedule, as set out in clause 3.1.3 of the
document “Quality Assurance Requirements for HPDB Manufacturing”
within 21 days of issue of each Purchase Order.根据文件《车斗质量保证要求》3.1.3 条，
在订单下达 21 内提供生产和交货计划

Risk Assessments and Job Hazard Analysis (JHA)危险评估和职业危害分析

Supply risk assessment and JHA’s for onsite assembly in the format specified by
the Rio Tinto Representative. This document must be submitted to Rio
Tinto Representative within 14 days.按照力拓提供的格式提供危险评估和职业危害分析报告。此文
件必须在 14 日提交力拓代表。

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General Requirements 大致要求
The High Performance Dump Body shall comply with all relevant Standards and
Rio Tinto safety regulations and codes before commissioning, whether or
not listed in this specification.车斗必须满足力拓已列出或未列的相关标准和安全条例。

Install 4 x welded tapped buttons at 600 centres for securing of grease lines to

the hoist cylinder bores. 在中心 600 处焊装 4 套管夹，用于固定进到举升缸孔

的油管

Tray lifting points must be constructed as per XEMC S33901 trays. Refer to
Appendix A Photographic Reference, Tray Lifting Points - Pictures 2, 3
and 4 起吊点请参考 SF33901 整车车斗，及附上的图片，吊点请参考图片 2，3,4

There shall be 1 set of removable handrails (as per Appendix A, Photographic

Reference, Removable Safety Handrails – Picture 5) supplied per 9 trays

ordered.如附上的图片 5，每九个车斗需要配置一套可移动扶栏。

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Shipping Arrangement 运输
Trays are to be shipped upright with steel fabricated transport frames as shown
in Appendix A, Photographic Reference, Transport Frames – Picture 6
and 7.车斗需要使用支架，直立运输，请见附件的照片，支架请参考图 6 和 7

XEMC shall adhere to the following requirements:需要满足以下要求

Mark lifting points 标示起吊点

One set of certified lifting pins and shackles for each cargo shipment 每批
发运都需要一整套合格的起吊斗销和卸扣

Approved transport stands to evenly distribute the load 运输时均匀的分配重量

All timber/package is to be fumigated and treated and stamped 所有木质包装

需要熏蒸处理和标示。

All tie down points to be clearly marked 所有紧固点需要明晰标示

One set of fall restraint safety rails per batch and shipped with first batch
第一批交货时需要附上防坠落安全扶梯。（此条款待 6 月初与力拓确认）

The trays should be cleaned and free from all contaminates i.e. dirt and
insects 车斗需要清洁，无污染，如污渍和昆虫

The trays should be fitted out with all hardware i.e. mud flaps, rock
ejector chains, lighting and decals 车斗需要安装完整的附件，如挡泥板，排石链，车灯
和警示贴纸

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 Photographic Reference 参考照片

Bolt Pattern - Picture 1

Tray Lifting Points - Picture 2

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 Tray Lifting Points - Picture 3

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 Tray Lifting Points Picture - 4

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 Removable Safety Handrails – Picture 5

Transport Stands – Picture 6

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 Transport Stands – Picture 7

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