Assemble, install and test a hydraulic tipping kit
You are a technical operator in the chassis and frame assembly hall.
What has happened
Tipper body WO-26-0412 for Bellhaven Bulk Haulage is on the assembly line waiting for its front mount hydraulic tipping kit. The first set of hoses was returned to the supplier because the manufacture date was outside the limit, and the replacement hoses arrived this morning. The Assembly Supervisor wants the kit assembled and installed to the drawing, the no load and pressure tests completed to the procedure, and every reading recorded on the work order before he witnesses the final cycle on Thursday. Because the body will be raised during the pressure test, a Job Safety Analysis must be completed and signed on by the crew before the test starts. The build is due on 25 September.
Deliverables
- Component and hose check list
- Stock issue record
- Completed Job Safety Analysis Form
- Hydraulic test record with pass or fail decisions
- Updated work order and any non-conformance raised
Documents to use
Systems to use
Work Orders and Build Tracker
Tracks every body, trailer and bus build from planned release through fabrication, assembly, fit-out, paint and final inspection to delivery.
Materials and Components Stock
Stores register of steel, sheet, fasteners, hydraulic, electrical and paint stock with quantities on hand, reorder points and supplier.
Non-Conformance Register
Records every product, material or process non-conformance found at stage gates, in the field or at supplier receival, with disposition and corrective action status.
Units of competency
Current on training.gov.au for the Automotive Manufacturing as at 10 September 2026.
AUMGTM006Assemble, install and test hydraulic system kitsAUMGTM002Assemble vehicle frames and axlesAUMGTM005Read and interpret engineering drawings and determine requirementsAUMGTB011Assemble, install and test braking system kitsAUMATK002Prepare and operate tools, equipment and machineryQualifications
AUM30226Certificate III in Automotive Manufacturing Technical Operations - Bus, Truck and TrailerWhat to look for
Evidence guide
The Job Safety Analysis must identify the raised body as a crush hazard with a prop and exclusion zone as controls, and must show crew sign on. Test readings must be compared with the specification and any failure must stop the release. Look for correct hose date checks, routing and torque marking knowledge, and records that are complete enough for the gate inspector to verify without asking questions.