Hydraulic and Pneumatic Kit Assembly and Test Procedure

Purpose. Sets out how hydraulic tipping kits and pneumatic brake and air kits are assembled, installed, tested and recorded before a build leaves the assembly hall.

1.Scope

This procedure applies to the assembly and installation of hydraulic tipping kits, power take off pumps, hoist cylinders and control valves, and to air brake kits including reservoirs, valves, chambers and lines on trucks and trailers built or modified by Nexus.

2.Preparation

Confirm the kit part numbers against the work order and the drawing. Check that all hoses, fittings and components are the specified pressure rating and that hoses carry a current manufacture date. Draw components from stores against the work order so that stock is issued and traceable.

3.Assembly

Assemble components in a clean area with capped ports until connection. Route hoses and lines clear of moving parts, heat and sharp edges with the specified bend radius and secure them at the specified intervals. Torque all fittings and mounting fasteners to the specification and mark them with torque paint.

• Ports capped until connection
• Hoses routed and secured to the drawing
• Fasteners torqued and marked
• Fluid type and grade as specified

4.Hydraulic test

Fill and bleed the system, then run the hoist through its full stroke with no load and check for leaks, smooth operation and correct control valve function. Conduct the pressure test at the specified relief setting with the body restrained and all persons clear of the body and the cylinder. Record pressures, cycle times and any leak or defect on the work order.

5.Pneumatic test

Charge the air system and check build-up time, governor cut in and cut out, reservoir drain valves and low pressure warning. Conduct a leak down test and check chamber stroke at each wheel. Confirm brake application and release at each axle and record the results on the work order. Any leak or slow release must be corrected and the test repeated.

6.Release

The assembly gate inspector must review the test records, witness a final cycle of the hoist or a final brake application, and sign the work order before the build moves to fit-out. Any test failure must be recorded in the non-conformance register.