What enters?
Material size, condition, rate, energy and the upstream equipment handing it over.
Australian mining equipment library
Understand the machine.
See the system.
Four commodity systems and 27 connected equipment families across iron ore, coal, lithium and gold. Follow each machine's purpose, major systems, maintenance focus and material handover.
Choose a commodity
One equipment library. Four different systems.
Compare the machines used in iron ore, coal, lithium and gold—from extraction and processing to the final product handover.
How to use the library
Equipment makes more sense when you follow the handovers.
A crusher cannot deliver if its feeder starves or floods it. A reclaimer can be mechanically healthy and still stop because the outbound conveyor is unavailable. A shiploader depends on the stockyard, berth, vessel plan and upstream product supply. This iron ore guide treats equipment as one operating system; use the commodity selector above to open the coal, lithium and gold systems.
Start with purpose. Trace the material path. Then examine the assemblies, controls, condition and handover points.
Iron ore system map
Follow one stream of iron ore from pit to ship.
The pulse shows direction, not equipment speed or process timing. Real routes and bypasses vary by operation.
- 01PitMine & haul
- 02ProcessingSize & classify
- 03Rail load-outLoad the train
- 04RailHaul by rail
- 05Port receivalUnload the train
- 06StockyardBuild stockpiles
- 07ReclaimRecover stockpiles
- 08Every handoverMove the ore
- 09WharfLoad the vessel
Open full size ↗A practical reading model
Five questions unlock almost any machine.
What changes?
The machine may move, reduce, classify, store, reclaim, measure or position the material.
What carries the load?
Structure, shafts, bearings, belts, wheels, rails, hydraulics and other load paths.
What controls it?
Power, drives, PLC logic, instruments, communications, safeguards and operator decisions.
What leaves?
The material stream, condition, rate, location and information handed to the next stage.
Iron ore equipment index
Nine guides. Open the level you need.
01 · Pit
Back to system map ↑Drills, loading units and haul trucks
Fragment, excavate and move run-of-mine ore from the active mining area to the first fixed-plant handover.
Open full size ↗InputIn-situ orebody and mine plan
Machine purposeFragment, excavate and move run-of-mine ore from the active mining area to the first fixed-plant handover.
OutputRun-of-mine ore at the crusher or ROM pad
Open the detailed guide+
Operating principle
How the system works
Production drills create a controlled pattern of blast holes. After blasting, excavators or shovels load fragmented material into haul trucks. The haulage system then links the face to the crusher, stockpile or waste destination. Payload, road condition, dispatch, queueing and equipment availability all affect the rate delivered to the plant.
Major assemblies
Component-to-function map
Drill system
Mast, feed or pulldown, rotary head, drill string, air system, dust control and machine controls.
Loading unit
Boom, stick, bucket or dipper, swing system, crowd or hoist system, undercarriage and operator or automation controls.
Haul truck
Engine or electric drive, wheel motors or transmission, retarding and brakes, steering, suspension, tyres and dump body.
Fleet interface
Dispatch, positioning, communications, haul roads, loading areas, dumps, fuel or charging and ancillary equipment.
Maintenance disciplines
What teams manage
- Structural and undercarriage inspection
- Powertrain, braking, hydraulic and cooling health
- Tyres, payload data, lubrication and contamination control
- Drill consumables, air systems and dust-control performance
Common degradation
What can reduce condition
- Wear, fatigue and cracking from load cycles
- Heat, dust and contamination
- Tyre damage and haul-road interaction
- Hydraulic leaks, hose damage and component drift
People around the asset
Multiple disciplines, one machine.
DrillersExcavator and shovel operatorsHaul-truck operators or controllersHD fittersAuto electriciansTyre techniciansMine control
Configuration boundary: Truck payload, drive system, loading-tool match and drill method vary widely. Treat OEM figures as machine-specific, not a generic Pilbara standard.
02 · Processing
Back to system map ↑Feeders, crushers and screens
Control the feed, reduce rock size and separate material into the streams required by the process and product plan.
Open full size ↗InputRun-of-mine ore with variable size and condition
Machine purposeControl the feed, reduce rock size and separate material into the streams required by the process and product plan.
OutputControlled size fractions for conveying, further crushing or product stockpiles
Open the detailed guide+
Operating principle
How the system works
A ROM bin receives trucked or conveyed ore. A heavy-duty feeder meters the load into the primary crusher instead of allowing an uncontrolled surge. The crusher reduces top size. Screens then classify the stream: material that meets the target can move forward, while oversize may return for further crushing. The exact arrangement depends on ore characteristics and product requirements.
Major assemblies
Component-to-function map
ROM receival
Dump pocket or bin, rock-breaker interface, protective structure, level detection and dust management.
Feeder
Apron pans or belt, chains, rollers, sprockets, drive, tensioning and support frame that regulate the feed rate.
Crusher
Gyratory, jaw, cone or other reduction chamber, main shaft or rotor, drive, lubrication, hydraulic and wear components.
Screening
Decks and media, exciters or drive, springs, support structure, chutes and separate discharge streams.
Maintenance disciplines
What teams manage
- Wear-liner, crusher-chamber and feeder-pan condition
- Lubrication, hydraulic and drive-system health
- Screen media, exciters, springs and structural connections
- Chute flow, buildup, spillage and dust-control condition
Common degradation
What can reduce condition
- Abrasion and impact wear
- Blockage, buildup or poor feed distribution
- Bearing, drive and lubrication distress
- Screen-media damage and structural fatigue
People around the asset
Multiple disciplines, one machine.
Process operatorsMechanical fittersBoilermakersElectricians and E&I techniciansCondition-monitoring techniciansMetallurgists and reliability teams
Configuration boundary: Primary, secondary and tertiary stages are site-specific. Crusher type, closed- or open-circuit screening and recirculating load depend on the ore and process design.
03 · Rail load-out
Back to system map ↑Train load-out systems
Transfer saleable ore into each wagon at a controlled rate and mass before the train leaves the mine.
Open full size ↗InputProduct ore from a stockpile, bin or feed conveyor
Machine purposeTransfer saleable ore into each wagon at a controlled rate and mass before the train leaves the mine.
OutputA loaded, measured and documented ore train
Open the detailed guide+
Operating principle
How the system works
A surge or load-out bin decouples the upstream conveyor from individual wagon loading. Gates or feeders meter ore into each moving or indexed wagon. Weighing, level and train-position systems help control the load profile and avoid overloading or uneven distribution. Sampling and product tracking may operate alongside the loading sequence.
Major assemblies
Component-to-function map
Storage
Surge or load-out bin, structure, liners, level instruments and controlled discharge openings.
Loading
Gates, feeders, chutes and profile-control arrangements that place ore into the wagon.
Measurement
Weighing, sampling, train detection, position and speed feedback linked to the loading logic.
Control interface
PLC, field instruments, train communications, alarms, interlocks and production records.
Maintenance disciplines
What teams manage
- Gate, feeder and chute wear or buildup
- Scale and instrument verification under approved systems
- Hydraulic, pneumatic and actuator condition
- Structural, access and dust-control inspections
Common degradation
What can reduce condition
- Liner and chute abrasion
- Gate leakage, sticking or timing drift
- Instrument contamination or loss of calibration
- Impact and fatigue around load paths
People around the asset
Multiple disciplines, one machine.
Load-out operatorsTrain drivers or autonomous-train controllersMechanical fittersElectricians and E&I techniciansMetallurgy and quality teamsRail maintenance
Configuration boundary: Batch and continuous load-out arrangements differ. The acceptable wagon load and profile come from the railway, wagon, track and operating requirements—not a generic target.
04 · Rail
Back to system map ↑Locomotives, ore cars and heavy-haul rail
Move large quantities of iron ore from inland mining hubs to coastal stockyards and port terminals.
InputLoaded ore cars assembled into a train
Machine purposeMove large quantities of iron ore from inland mining hubs to coastal stockyards and port terminals.
OutputOre delivered to the port receival system
Open the detailed guide+
Operating principle
How the system works
Diesel-electric locomotives—and increasingly battery-electric units in trials or mixed consists—convert energy into tractive effort. Distributed power and train-control systems coordinate locomotives along the consist. Ore cars carry the load while couplers, bearings, braking equipment, track, signalling and communications work as one railway system.
Major assemblies
Component-to-function map
Locomotive
Prime mover or battery system, alternator, traction equipment, cooling, braking, controls and communications.
Ore cars
Body, doors or rotary-dumper compatibility, bogies, wheelsets, bearings, couplers and brake equipment.
Permanent way
Rail, sleepers, ballast, formation, points, crossings, drainage and trackside monitoring.
Train control
Signalling, communications, distributed power, train protection, wayside detection and network control.
Maintenance disciplines
What teams manage
- Wheel, rail and bearing condition
- Traction, cooling, braking and energy systems
- Couplers, wagon structure and brake equipment
- Track geometry, points, crossings and wayside systems
Common degradation
What can reduce condition
- Rolling-contact fatigue and wear
- Bearing heat and lubrication problems
- Brake, coupler or draft-gear faults
- Track geometry, ballast and drainage deterioration
People around the asset
Multiple disciplines, one machine.
Train drivers or autonomous-rail controllersLocomotive and wagon maintainersTrack crewsSignal techniciansRail engineersNetwork controllers
Configuration boundary: Train length, locomotive placement, braking system and axle load are network-specific. Public examples describe particular fleets, not a universal Pilbara configuration.
05 · Port receival
Back to system map ↑Railcar dumpers and train positioners
Index and empty ore cars into the port materials-handling stream while managing the train as a controlled sequence.
InputLoaded ore train arriving at the terminal
Machine purposeIndex and empty ore cars into the port materials-handling stream while managing the train as a controlled sequence.
OutputOre in the receival hopper and empty wagons released onward
Open the detailed guide+
Operating principle
How the system works
A positioner or indexer moves one or more wagons into the dumper. Clamps and support systems secure the cars in the designed position. The barrel rotates—or another unloading arrangement operates—so ore falls into a hopper below. Feeders then draw material out at a controlled rate for the downstream conveyor.
Major assemblies
Component-to-function map
Train positioning
Indexer or positioner arms, rail clamps, wheel grippers, drives and position feedback.
Dumper
Barrel or tippler structure, clamps, support rollers, drive, braking and locking systems.
Receival
Hopper, grizzly where fitted, liners, feeders, dust control and discharge conveyor.
Sequence control
Train detection, permissives, interlocks, communications and synchronised machine logic.
Maintenance disciplines
What teams manage
- Clamp, positioner and locking-system condition
- Barrel, trunnion, support-roller and drive health
- Hopper, feeder, liner and dust-system condition
- Position sensing, braking and sequence-control verification
Common degradation
What can reduce condition
- Impact and abrasion in the ore path
- Fatigue around rotating and load-bearing structures
- Misalignment, roller or drive deterioration
- Hydraulic leaks and position-sensor faults
People around the asset
Multiple disciplines, one machine.
Dumper operatorsRail controllersMechanical fittersElectricians and control techniciansStructural inspectorsBoilermakers and reliability teams
Configuration boundary: Single, tandem, rotary and side-unloading systems exist. Wagon design and terminal sequence determine how a train can be unloaded.
06 · Stockyard
Back to system map ↑Stackers, stockyards and blending
Place incoming product into controlled stockpiles so the operation can store, sequence and blend ore before shipment.
InputOre from rail receival or product conveyors
Machine purposePlace incoming product into controlled stockpiles so the operation can store, sequence and blend ore before shipment.
OutputDefined stockpiles available for later reclaiming
Open the detailed guide+
Operating principle
How the system works
A yard conveyor carries ore beside the stockyard. A tripper transfers the stream onto the stacker’s boom conveyor. Long travel selects the position along the yard; slew and luff movements place ore across the pile. Stacking patterns influence segregation, blending, reclaim access and the stockyard’s ability to respond to the shipping plan.
Major assemblies
Component-to-function map
Yard feed
Incoming conveyor, tripper car, transfer chute, cable systems and machine interface.
Boom conveyor
Belt, pulleys, idlers, drive, take-up, discharge chute and boom structure.
Machine motions
Long travel bogies, rail clamps, slew bearing and drives, luff system, brakes and storm restraints.
Stockyard control
Positioning, pile profile, collision avoidance, dust control, communications and sequence logic.
Maintenance disciplines
What teams manage
- Boom conveyor and transfer-point condition
- Long-travel wheels, rails, bogies and alignment
- Slew, luff, brakes and restraint systems
- Structure, cable management and position-control systems
Common degradation
What can reduce condition
- Conveyor wear, carryback and spillage
- Wheel, rail and bogie wear
- Fatigue at boom and machine connections
- Corrosion, dust ingress and cable damage
People around the asset
Multiple disciplines, one machine.
Stockyard operators or remote controllersMechanical fittersElectricians and control techniciansBoilermakers and structural inspectorsSurvey and product-quality teams
Configuration boundary: Chevron, windrow, cone-shell and other stacking patterns are process decisions. Stacker, combined stacker-reclaimer and fixed stacking arrangements differ by yard design.
07 · Reclaim
Back to system map ↑Bucket wheel reclaimers
Recover nominated product from a stockpile at a controlled rate and place it onto the outbound conveyor system.
InputPlanned stockpile and reclaim instruction
Machine purposeRecover nominated product from a stockpile at a controlled rate and place it onto the outbound conveyor system.
OutputControlled ore stream to the yard or wharf conveyor
Open the detailed guide+
Operating principle
How the system works
The bucket wheel cuts into the stockpile face. Buckets lift the ore and discharge it through a chute onto the boom conveyor. Slewing sweeps the wheel across the face, luffing adjusts boom elevation and long travel advances the machine along the stockpile. The reclaim method is coordinated with stockpile geometry, material condition and downstream demand.
Major assemblies
Component-to-function map
Bucket wheel
Wheel body, buckets and teeth, liners, hub, shaft, bearings, drive and discharge chute.
Boom conveyor
Belt, pulleys, idlers, drive, take-up, cleaners, skirts and boom support structure.
Machine motions
Slew bearing and drives, luff winch or cylinders, long-travel bogies, rails, brakes and clamps.
Machine services
Power distribution, cable reel or festoon, PLC, instruments, communications, lubrication and dust control.
Maintenance disciplines
What teams manage
- Bucket, tooth, wheel and chute wear
- Boom conveyor alignment, cleaners, pulleys and drives
- Slew, luff, long-travel and braking systems
- Primary structure, lubrication, power and control condition
Common degradation
What can reduce condition
- Abrasive wear and impact damage
- Fatigue at wheel, boom and portal structures
- Bearing, gearbox and lubrication distress
- Rail alignment, bogie, cable and sensor deterioration
People around the asset
Multiple disciplines, one machine.
Reclaimer operators or remote controllersMechanical fittersElectricians and E&I techniciansBoilermakers and structural inspectorsCondition-monitoring techniciansPlanners and reliability engineers
Configuration boundary: Wheel diameter, number of buckets, reclaim rate, boom length and machine motions are design-specific. Always use the current machine drawings and OEM data.
08 · Every handover
Back to system map ↑Conveyors and transfer stations
Move bulk material continuously between equipment and process stages, often over long distances and through multiple transfers.
InputOre discharged from upstream plant or another conveyor
Machine purposeMove bulk material continuously between equipment and process stages, often over long distances and through multiple transfers.
OutputA stable material stream delivered to the next machine or destination
Open the detailed guide+
Operating principle
How the system works
A drive pulley transfers torque into the belt. Carry idlers support the loaded belt and return idlers support the empty side. The take-up maintains the designed tension regime. At a transfer point, the outgoing trajectory, chute geometry, liners, skirting and receiving belt work together to control loading, impact, wear, spillage and dust.
Major assemblies
Component-to-function map
Belt system
Belt carcass and covers, splices, cleaners, skirting, tracking devices and condition monitoring.
Drive station
Drive pulley, motor, gearbox or gearless drive, coupling, brakes, holdbacks and guarding.
Support & tension
Idlers, frames, stringers, pulleys, bearings, gravity or winch take-up and supporting structure.
Transfer station
Head chute, wear liners, impact zone, receiving belt, sealing, dust control and blocked-chute or belt-protection instruments.
Maintenance disciplines
What teams manage
- Belt, splice, tracking and cleaner condition
- Pulley, bearing, idler and drive health
- Take-up travel, tension-system and structural condition
- Chute wear, buildup, skirting, spillage and protection devices
Common degradation
What can reduce condition
- Cover wear, cuts, splice damage and longitudinal rip
- Carryback, buildup and mistracking
- Seized idlers, pulley-lagging or bearing distress
- Chute abrasion, impact damage and structural fatigue
People around the asset
Multiple disciplines, one machine.
Operators and controllersMechanical fittersBelt splicersElectricians and control techniciansBoilermakersCondition-monitoring and reliability teams
Configuration boundary: Belt width, speed, tension, drive arrangement, idler spacing and transfer geometry are engineered for a particular duty. Generic numbers are unsafe substitutes for the approved design.
09 · Wharf
Back to system map ↑Shiploaders and berth systems
Transfer ore from the wharf conveyor into nominated vessel holds according to the terminal and vessel loading plan.
InputProduct ore from the outbound stockyard and wharf conveyors
Machine purposeTransfer ore from the wharf conveyor into nominated vessel holds according to the terminal and vessel loading plan.
OutputOre placed into the vessel’s cargo holds
Open the detailed guide+
Operating principle
How the system works
The wharf conveyor feeds the shiploader boom. Long travel positions the machine along the berth; luffing, slewing or shuttling places the discharge over the nominated hold. A telescopic chute or spoon controls the final drop. Loading is coordinated with the vessel plan, berth limits, marine conditions and upstream stockyard supply.
Major assemblies
Component-to-function map
Wharf interface
Approach conveyor, tripper or transfer, machine feed chute, cable management and communications.
Boom conveyor
Belt, pulleys, idlers, drive, shuttle where fitted, supporting structure and discharge end.
Machine motions
Long travel, luff, slew or shuttle systems, brakes, rails, bogies, storm restraints and collision protection.
Loading chute
Telescopic sections, spoon or trimming arrangement, wear components, dust control and position feedback.
Maintenance disciplines
What teams manage
- Boom and shuttle conveyor condition
- Long-travel, luff, slew, brakes and restraints
- Loading chute, liners and wear components
- Structure, cable management, controls and wharf interfaces
Common degradation
What can reduce condition
- Abrasive wear in chutes and transfers
- Fatigue, corrosion and marine exposure
- Wheel, rail, drive and braking deterioration
- Cable, instrument and communication faults
People around the asset
Multiple disciplines, one machine.
Shiploader operators or remote controllersMarine and berth coordinatorsMechanical fittersElectricians and control techniciansStructural inspectors and boilermakersPlanners and reliability teams
Configuration boundary: Travelling, radial, quadrant and other shiploader arrangements exist. Published Port Hedland loading rates are berth-specific and should not be generalised across terminals.
Maintenance matrix
Who sees which part of the system?
The strongest maintenance decisions combine field observations, condition data, technical authority, work history and operating context.
DisciplinePrimary lensTypical evidence
OperationsMaterial flow, machine behaviour and abnormal conditionsInspections, alarms, trends, handovers and operating observations
MechanicalLoad paths, wear, alignment, lubrication and component conditionMeasurements, inspection findings, repair records and test outcomes
Electrical & E&IPower, drives, instruments, protection and control interfacesTesting, fault records, calibration, change control and verification
StructuralCracking, corrosion, deformation, connections and load-bearing integrityInspection records, NDT results, engineering assessment and repair history
Condition monitoringDeveloping faults and change over timeVibration, thermography, ultrasound, oil analysis and confirmed defect feedback
Planning & reliabilityExecutable work, failure history and maintenance strategyWork orders, defects, backlog, failure analysis, tactics and close-out quality
Plain-language glossary
Ten terms used across the equipment chain.
- ROM
- Run-of-mine material before the main processing stages.
- Comminution
- The controlled reduction of rock or ore size through crushing and grinding.
- Recirculating load
- Material returned within a crushing or screening circuit for more processing.
- Slew
- Rotation of a machine or boom around a vertical axis.
- Luff
- Raising or lowering a boom to change its operating angle or height.
- Long travel
- Movement of a large mobile machine along its rails or travel path.
- Take-up
- The conveyor system that manages belt tension and accommodates belt stretch.
- Carryback
- Material that remains attached to the return side of a conveyor belt after discharge.
- Indexer
- Equipment that positions rail wagons through an unloading or loading sequence.
- Interlock
- A control condition that prevents or permits an action based on defined system states.
Authoritative starting points
Iron ore equipment sources.
Source-checked 30 August 2026. Confirm details against current OEM and site-controlled documents.
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BHP Western Australia Iron Ore
Official overview of the integrated Pilbara mines, processing hubs, rail and port system.
Caterpillar mining trucks
OEM overview of large mechanical- and electric-drive mining truck systems.
Epiroc surface blasthole drills
OEM range and configuration context for rotary and down-the-hole production drills.
Metso crushing and screening
OEM explanation of size reduction, classification and circuit interaction.
Metso feeders
OEM overview of apron, belt and other feeding equipment used to control material flow.
Wabtec heavy-haul rail
OEM context for distributed power, locomotive technology and Pilbara iron ore rail applications.
TAKRAF wagon unloading
OEM overview of rotary, crescent and side-unloading railcar-dumper systems and train positioners.
TAKRAF handling equipment
OEM library covering stackers, reclaimers, conveyors and shiploaders.
Continental conveying solutions
OEM material on conveyor belts, belt monitoring and specialist conveying configurations.
Pilbara Ports facilities
Current berth, wharf and published Port Hedland shiploader information.
Scope: This independent library explains equipment purpose, interfaces and maintenance disciplines. It is not a maintenance instruction, inspection standard, isolation plan or substitute for competency, supervision, engineering authority, OEM manuals, drawings and approved site procedures.