TRAINING REPORT

K A M C O , A T H A N I

0 1 / 0 8 / 2 0 1 4

Hameeda Bindu Vahab

2013 -18-112

KCAET , TAVANUR

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Introduction

Kerala Agro Machineries Corporation limited, KAMCO which is the one of the large

farm machinery manufacturer having a successful history of more than 35 years, especially for

the production of power tiller under the control of government of Kerala. KAMCO was

established in the year 1973 as a Wholly owned subsidiary of Kerala Agro Industries corporation

limited, Thiruvanathapuram for manufacture of agricultural machinery specifically Power Tiller.

Subsequently KAMCO becomes a separate Government of Kerala

undertaking in 1986.Assembly unit was established in 1970 at Athani by Kerala Agro Industries

Corporation for the assembly of KUBOTA Power Tillers in technical collaboration with

KUBOTA Ltd Japan, The world’s leading manufacturers of Tillers and Other

Agricultural machinery. On the expiry of collaboration KAMCO manufactured Power

Tillers with their own facilities.

KAMCO manufacturing facilities include special purpose machines and imported

machines. The company was incorporated with the intention of manufacturing and

marketing agricultural machines useful for small and marginal farmers. Company

products are Power tiller, Power reaper, Garden tiller and Tera track(Tractor).

Power tiller

Here mainly two types of power tillers are producing those are only differ in their engine

specification. The two types are ER-90 and DI, later one is having a cavity on the top of the

piston which works as combustion chamber. This will reduce the power losses and increases

efficiency.

ER-90

No load rpm - 2100

Rated hp - 9

Stroke volume - 744cc

SFC - 190 to 210 g/hp/hr

2

DI

No load rpm - 2180

Rated hp - 12

Stroke volume - 744cc

SFC - 175 to 190 g/hp/hr

The three main sections in the production of power tiller are

i) Machine shop

ii) Assembly shop

iii) Quality assurance

i) Machine shop

C om pan y h a s a m od e r n m ach in e sh op w i t h s p ec i a l pu r pos e m ach i n es

w h ich ensures conformity with prescribed quality standards. The materials purchased by the

purchase department, then sent to the stores from their materials to the QA department, it sent to

the Machine shop. In the machine shop the process like milling, drilling, boring etc

are doing on material to get the product which is used in the assembly. From the

machine shop the finished products are directly sent to the assembly only for the inspection

in QA. From the QA it will be sent to the stores

Following machines are used in the machine shop

1. Vertical and Horizontal milling machine : Used for milling of engine block, main

gear casing & side cover

2. Taping machine: To make thread for screw. Tool is HSS Carbide.

3. Radial Drilling machine: For keeping holes

4. Vertical and Horizontal drilling machine: Otherwise known as Multi spindle drilling

machine

5. Boring machine: Multi spindle boring machine also is there.

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6. Cylindrical grinding machine: To grind and smooth the material in highly accurate

portions. Smoothening and grinding of internal and external diameter can be done

according to the work.

7. Cam grinding machine: Grinding of cam corresponding to desired cam profile.

8. Capstain lathe

ii) Assembly shop

The process of complete assembling of power tiller takes place here. The completion of

the assembling is done through three lines. Those are engine line, transmission line and tiller

line. Engine assembly completed via four steps. Those are engine 1, Engine 2, Engine testing and

Engine finishing. Transmission assembly is completed via three steps. Those are Transmission 1,

transmission 2 and transmission 3. Then it goes to tiller section .This section is completed

through four stages K1, K2, K3 and K4. After the completion of these three lines the engine from

finishing section and K4 undergoes tiller finishing. Then inspection of the products will takes

place.

Flow diagram of the assembling section is given below

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T1 E1

Inspection

E2

TF

Tiller finishing

Finishing

K4

K3

ET

EF

T3

T2

K2

K1

Painting

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The assembling is done according to the procedure given by ISO. The assembling

procedure is described below

Engine 1

Assembly of Cylinder and Piston , Crank shaft and balancing shaft , Fuel cam and Cam shaft

and Radiator is in this section

Clean cylinder frame and punch engine number. Apply oil to O ring and cylinder liner.

Then fix ring in the cylinder liner. Then drive that to cylinder frame. Fix head studs to cylinder

frame. Screw and tight the plugs in position with copper packing. Place the wooden base on the

conveyer and mount it on. Apply oil on tappets and insert in position. Drive and fix cylinder pin

in the location on the cylinder frame. Drive and fix the ball bearing 5205 into idle gear for cam

shaft. Insert Key, Drive and fix cam gear and fix fuel cam to the cam shaft with washer and nut.

Fix balance idle shaft to the cylinder frame. Fix the idle shaft in the cylinder frame using proper

driving tool. Insert idle gear for cam shaft assembly to idle shaft and put shaft circlip in the

groove. Insert cam shaft assembly in position. Fix the radiator base by using stud. Clean crank

shaft and fix parallel key. Drive and fix main bearing case assembly to crank shaft sub assembly.

Drive and fix the crankshaft assembly in position to cylinder frame with screw and spring lock

washer. Dip the piston assembly in the heated kerosene tank. Take the piston sub assembly from

the heated kerosene tank and immediately fit in the connecting rod with piston and piston pin.

Insert and fix 2 halves of crank pin bearing into the big end of the connecting rod. Align and

insert the connecting rod assembly through the cylinder liner. Connect the big end to the crank

shaft with crank pin bearing set by using lock washer. Set the timing mark on gears. Fix key

drive and fix ball bearing. Drive and fix balance shaft upper assembly. Drive ball bearing with

snap ring at the opposite end of the shaft. Then lock with Shaft Circlip. Drive and fix the oil

supply ring assembly in the MBC cover. Put circlip in the groove and fix the MBC cover

assembly and crank case upper cover. Then fix the balance shaft cover and breath valve

assembly to the rear cover. Put O ring in the groove of Oil feed cup. Check the level of Oil in the

sump. Then insert balance idle gear assembly in the location and set the timing mark. Rivet the

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governor ball guide to the starting gear. Rivet the governor sleeve cup to the governor sleeve

body.

Insert the governor sleeve body assembly in the starting shaft in position. Insert starting gear

assembly in position and driving partial to the starting shaft. Put 8 nos of large balls between ball

guide and governor sleeve body. Drive against starting gear assembly in the required depth.

Insert the governor sleeve body, starting shaft assembly and finally set the timing mark.

Engine 2

Assembly of these parts will takes place in this section Cylinder Head, Inlet and outlet

valves, Rocker for valves and rocker case , Oil and Fuel pump, Fuel filter , Fan Bracket and

dynamo and Fly wheel

Clean the DI cylinder and walls. Lap the wall seats on DI cylinder head and confirm the

seating. DI clean parts and assemble the DI cylinder head in partial. Fix the DI pin to DI cylinder

frame. Fix oil seat in the spring retainer. Insert the spring retainer and then indicator mark into

the wall shaft assembly. Locate the DI inlet and exhaust rocker arms and DI collar in position.

Drive the DI rocker shaft in the hole on DI rocker case through rocker arms, DI collar and lock

with screw and nut.

Insert the indicator wall assembly. Fix DI dowel, DI cylinder head gasket and DI cylinder

head assembly to the DI cylinder frame. Fix DI rocker assembly with DI packing to the cylinder

head assembly using screw and washer. Fix the side cover through appropriate position. Fix the

governor level seat with GI pin. Fix GL seat governor lever assembly with side cover using

governor spindle. Before inserting steal ball is to be put in the hole. Assemble speed change level

assembly with governor lever side cover assembly. Fix the guide plate. Fix the side cover

assembly on the DI cylinder using spring washer and bolt

Ensure that the fuel cam on position in BDC. Fix the fuel pump on side cover using spring

and screw. Fix the AC flange along with FI pipe supporter and release setting metal to the

cylinder head with screws. Fix the bracket for fuel filter and screw the fuel filter assembly to the

bracket. Fix Oil pump assembly to the DI cylinder frame. Clean the pipes with Diesel and Air.

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Screw and tight the oil inlet pipe, DI Oil Supply pipe in position with corresponding pipe, bolts

and copper packing. Insert push rod through DI rocker arms to the wall tappets. Rotate crank

shaft to ensure compression at TDC. Set the wall clearance by adjusting the screw in between

rocker arms and valves. Turn the adjusting screw freely on the compression shaft.

Insert the compression shaft along the adjusting screw to the DI rocker cover and fix DI

rocker assembly with screw. Then test the nozzle pressure 250 – 288. Fix DI overflow pipe

joined to nozzle holder in position. Insert DI nozzle holder, DI pipe joint assembly to cylinder

head. Fix both ends to DI fuel pump and DI nozzle. Fix the supporter to DI FIP. Drive and fix

the ball bearing also crank shaft from inner side of the fan bracket. Take the leads of dynamo coil

outside the fan bracket through the holes provided for fixing fan bracket dynamo assembly. Then

fix the fan drying pulley with D8 Flywheel. Then drive and fix the DI flywheel. Drive and fix

ball bearing in the FT pulley keeping the seat of bearing comes in position. Fix the FT pulley

assembly with the fan bracket using Nut and sprocket lock washer. Drive and fix spring through

Oil Seal curve hold.

Engine Testing

Mount engine on the bed. Connect fuel line to diesel filter and bleed. Fill water in the

radiator, couple prony brake dynamometer to engine flywheel using couple. Fix brake shoes and

water pipes. Start engine, set speed change lever to maximum. Idle run the engine to observe oil

pressure, oil leak and sound. In case of abnormal sound, detect and correct. If al are normal, run

engine at 1600 rpm for 45 minutes. Then set the rpm to 2100. Load engine gradually and again

run at 2000 rpm. Then adjust load corresponding to 9HP @2000 rpm. Observe and record time

for 42 gm consumption of fuel at 9HP. Calculate and record SFC corresponding to 9HP in

engine test record format. Load the engine for maximum load. Calculate and record maximum

HP. In case of variation, report to superior for verification. Check Cylinder head nut torque and

valve clearance. Smoke test of the engine should be conducted as per the quality plan. Remove

from test bed and send engine for painting.

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Engine Finishing

Check the tested engine and insert fan belt to fan driving pulley and fan tension pulley.

Then check the necessary tension on belt. Drive and fix stud to engine pulley. Fix engine pulley

with flywheel, keeping seating face in contact. Fix plunger knob with spring and dust cap to FLA

body. Screw and fix the grip for SPE-C lever with washer. Fix silencer flange to cylinder head.

Screw and lock the silencer to silencer to silencer flange. Remove the radiator cap assembly and

eye bolt with washer. Fix radiator cover using screw. Fix fan pulley cover to fan bracket woth

spring lock. Fix radiator grill to radiator cover in position with spring lock washer. Fix overflow

pipe in fuel tank and lock with pipe holder. Also put the packing of filter screen and insert it to

the fuel port on fuel tank and push it forward so as to keep the holes in fuel tank and radiator

covering on axis.

Fix the clamp for head lamp and then keep the other end of overflow pipe freely in

convenience so as to connect with nozzle end. Fix the diesel level pipe and lock it at two ends

with locking wire. Screw and fix the fuel lock with copper packing and fiber packing. Insert

protecting spring to fuel pipe. Fix it to the fuel lock cock locking with pipe holder, keeping the

other end to the filter freely. Insert the pipe holder to the other end of the fuel pipe and fix the

pipe joint also. Fix the pipe joint to the filter using joint bolt and lock with pipe holder. Fix one

end of braided hose to the filter. Fix the other end of braided hose to fuel pump assembly with

parts supplied along with fuel pump assembly.

Connect the other end of copper pipe to the nozzle with packing and bolt supplied along

with nozzle holder assembly. Screw the bracket engine model label in position with multi tooth

lock washer. Dismantle the air cleaner assembly and thoroughly clean the parts like pan, filter

etc. Fill the oil SAE 40 up to the mark level. Assemble it again and fix to the air cleaner flange

with screws and nuts. Fix the head lamp assemblies on clamp for head lamps. Fix the front end

of the head light cover to the fuel tank with plain washer. Fix the guard to the mask for head

lamp. Fix side plate L and R to leg of fuel tank and clamp of head lamp using screw. Stick all

caution and instruction labels. Fix the flywheel cover by using water fan pulley cover and screw

of balancer shaft cover.

The production procedure for DI and ER-90 is same. But in the case of ER90 some extra

parts will be there on the head portion .

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Transmission 1

Dip main gear case in Kerosene an clean by compressed air, punch number on MGC.

Drive and fix arm shaft gear to MGC. Insert arm shaft for shift forks for auxiliary speed change.

Drive ball bearing to axle shaft and fourth shaft and put circlip. Apply Oil to Oil seal, then drive

and fix the oil seal to outside axle cover. Clean AGC and parts. Hold it and locate 53 T gear

through the lower side of axle box and drive the axle shaft assembly to the 53 T gear. Also drive

sub assembly of 4th

Shaft to the AGC, meshing with 53T gear on axle shaft. Fix the outside axle

cover assembly with M8 screws and insert collar in position and drive ball bearing to axle shaft

and fourth shaft. Fix the inside axle cover with washer and screw and tight plug with packing to

the cover. Fix the cover at bottom of AGC with washer and screw. Then do the same for left side

also. Then assemble the sub assembly 2T 105, 106 and 107 to the AGCL partial assembly. Fix

the axle key to the axle. Same ot the right also. Hold the MGC in assembly fixture. Set the AGC

sub assembly with packing and also aligning with base. And nock pin of AGC with respect to

bore and nock hole in MGC.

Transmission 2

Freely slide 42T gear to fourth shaft and put shaft circlip in the groove of the shaft. Set

and lock the 44 T gear in 3rd

shaft on position with the screw and locking wire. Insert 16T gear

with pawl in the 3rd

shaft 44 T gear assembly in position and locate it in the corresponding bore.

Drive the ball bearing on both end of 3rd

shaft and covered along with shim if necessary. Check

the gap between pawls of 44T and 16T gears. Drive ball bearing in the ASC second shaft. Check

the free sliding movement of 16-31 T gear in the 2nd

ASC shaft. Locate the gear in position and

insert the ASC second shaft bearing assembly from left side by driving with ball bearing into the

MGC. Fix the bearing cover in left end of ASC second shaft with packing and screw.

Drive the oil seal into the second shaft cover. Drive the guide pin to the brake case &

insert O ring to the brake cam. Push the brake cam in position through the lock in the brake case.

Plate the pressure plate & brake case in face to face & guide in the pin. Paste the packing with

shellac to the brake case & grease with opposite side of packing. Drive the ball bearing. Place the

ASC second shaft cover assembly with steel washer & bolt. Clean the shift fork using kerosene

and air. Apply oil inside the spring and lock it with split pin. Set the shaft fork with help of guide

pin. Put O ring top the shaft rod, drive the shaft rod partially to the MGC. Set the ASC shaft fork

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assembly in position through shift rod by driving fully to MGC. Remove the gate pin used for

sub assembly of shift fork. Remove the arm shaft guide from guide and put the O ring to the arm

shaft guide. Relocate the arm shaft linking with shift fork ASC. Check the sliding of shift fork

through shift rod and this by the sliding of 16-31T gear in the 2nd

ASC shifter. Lock the shaft rod

with locate-plate, washer and screw. Drive the ball bearing in the ASC 1st shaft. Check the free

sliding movement of gears through the shaft. Locate the gear and collar in corresponding bow in

the order and drive the shaft through the bore as well as through gear and collar. Fix the bearing

cover using packing using seal washer and screw. Drive the ball bearing to the opposite side of

ASC final shaft.

Fix the bearing cover with packing using screw an d washer. Drive and fix cylindrical

spring to the reverse shaft. Apply Oil to the gear and bush. Drive and fix the bush to the gear by

locating the oil holes on bush coincide with hole on gear. Locate and insert the reverse shaft

assembly partial to corresponding bore in the MGCL and insert the collar reverse gear assembly

and the collar to reverse shaft assembly in position. Drive the collar and bearing at one end of

second shaft. Check the sliding of gear in the shaft. Locate and partially insert the 2nd

shaft sum

assembly in MGC from right side. Insert the gears and collars in the order. Drive the shaft in

position to the bore in the MGC. Drive and fix the distance piece small and ball bearing in the

corresponding end of BSC shaft in position.

Check the sliding of gears in the shaft. Locate the BSC shaft corresponding to the right

side bore in the MGC and insert partially so as to drive the gears and distance pieces in the order

to the shaft. Drive the shaft fully to the MGC. Check the sliding of gears in the shaft .insert the

gears and collars in chronological order. Drive and fix the ball bearing at the end. Place the

fourth shaft assembly in the corresponding bore on the MGC. Add necessary shim if necessary to

the MGC cover. Paste the other side. Drive the cover to the MGC locating the piston to the even

shaft. Fix the cover with the spacing washer & screw. Insert the 16t gear in position to the first

from the left side through the corresponding bore on the MGC. Insert bore circlip to the Idle

gear.

Drive and fix ball bearing in the gear from both side. Locate the idle gear sub assembly

in position in AGC &drive the Idle gear shaft sub assembly trough the bore in auxiliary gear case

in position and fix the bore circlip. Insert collar to the second shaft. Drive & fix the ball bearing

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in the shaft & the corresponding bore on MGC. Drive and fix the ball bearing on the BSC shaft

and corresponding bore in the MGC. Add shim if necessary. Insert GI slinger collar for the first

shaft in order to & position. Drive ball bearing in first shaft fixing it to the auxiliary gear case.

Paste the packing with shellac on the auxiliary gear case cover. Add necessary shim if require to

the cover for bearing in the first shaft. Fix the cover in position with spring washer & screw.

Transmission 3

Check the rotation plan and filament of components assembled up to T2. Screw and tight

the plugs in MGC cover, Auxiliary Cover and 2 numbers of 3rd

shaft cover. Also drive plug PLC

18 in the counter hole for the shaft rod ASC. Drive and press ball bearing to the mains haft.

Drive sub assembly of the main shaft with bearing to the AGC. Drive ball bearing at other end of

mains haft. Check any abnormal in idle gear. Assemble spring and steel ball in BSC shifter using

proper guide pins and using spring in between the end of the supporter for BSC shift rod and

shifter for BSC. Locate the sub assembly in the hole for BSC shift rode and drive it in position.

Lock the shift rod with Set plant and M6 washer and screw.

Drive the shaft and insert checking plate in position in the haft. Fix the checking plate

with plain washer and split plain. Check the mechanism. Drive and fix 2 cylindrical pin on

MGC. Screw and tight 5 numbers of stud to MGC. Sub assemble the shaft and st-C arm seat to

st-C shift fork R with split pin assembly and then L. Load the spring in position on both of st-C

shift fork and locate in between the wall of MGC together in position. Keeping ends enter in 16T

gear with pawl in 3rd

shaft. Add shim if required to adjust the travel of shift fork. Drive the arm

shaft gate to the upper cover., Insert O ring to steering clutch arm shaft in position and insert it

from inner sides through the guide.

Fix the st-C shaft lever to the steering clutch arm shaft with spring lock washer and nut.

Check full movement of the speed change rod in the hole of the MTC upper cover before

assembling. Assemble the shaft arm on speed change rod using fixture. Lock the shift arm with

washer and screw. Tight the shift rod oil cover with spring lock washer and screw. Load the

spring and steel ball to shifter by suing guide pin. Load the spring and steel ball to shifter A

using guide pin. Locate the shifter B sub assembly and shifter A subassembly to the

corresponding holes on MGC upper cover and drive shift rod B and shaft Rod A in position. Fix

the load plate in between the groove of shifter A and B. Locate into lock spring in the MGC

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cover considering with the hole on lock plate. Tight the inter lock spring and lock palate with

plain washer. Check the function of interlock spring and free movement of the shifter A and B

through the shift rods by actuating speed change rods.

Set the MGC upper cover on the MGC with the reamer bolt so as to connect shifter A and

B with 22-26T gear and tight the upper cover and set the bolt. Check the movement of shifter A

and B by twisting the sliding of gear on speed change rod and there by the sliding of gears on

first shaft. Also check the free rotation of main shaft manually. Screw and tight pin for brake

intermediate level with spring lock washer. Relocate the hole on st-C shift fork R and L

coinciding with holes on MGC upper cover. Drive the shaft cover st-C through st-C shift fork L

and R so as to come out on the opposite side of MGC upper cover. Lock the shift rod with

washer in M6 screw and spring lock washer.

Check free movement and function of st-C fork L and R by actuating steering clutch shaft

lever with spanner. Fix the lower window cover with its packing by applying shellac and grease

on opposite sides using spring lock washer and screw. Screw the oil gauge to the cover. Fix the

cover with 2 screw using plain washer and spring lock washer and other 2 spring with spring

lock washer alone. Also screw the spring lock washer. Fix AGC cover with its packing using

spring lock washer and screw. Fix the cover using one screw with seal washer and 3 screws with

spring lock washer. Ix lever C with arm shaft for shift fork suing spring lock washer and nut.

Insert collar A to ASC level shaft and put through the holes on main MGC cover big. Insert

collar B also in the shaft.

Fix ASSC level B at end of the shaft in position and tight with the punch washer. Insert

MC road short with yoke B and yoke LHT and lock the yokes with the corresponding nuts LHT

and RHT. Connect lever and ASC lever B respectively with yoke B and yoke LHT of MC rod

short assembly using Clevis Pin. Check the link connection and function of auxiliary speed

change lever shaft. Sub assembly clutch lever bush and oil seal with main shaft using fixture and

driving lock. Care should be taken when driving the bush to keep the position of Oil seal surface

up. Fix the main shaft cover sub assembly in position using washer and screw to the AGC. Drive

the Cam lever to the bearing using the fixture and driving tool. Insert Cam lever sub assembly in

position to the clutch lever bush on main shaft cover subassembly. Remove the clutch assembly

unit from the pulley. Drive bearing to the MC pulley end. Fix the water proof seal top the MC

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cover with araldite. MC cover packing is to be fixed on MC cover with shellac. Insert clutch

assembly in position to the sub assembly. Insert clutch assembly in position to the MC pulley

bearing sub assembly. Fix the MC cover water proof seal sub assembly in position to MC pulley

with spring lock washer & screw.

Insert &drive the MC pulley main clutch sub assembly through the main shaft &seated in

position. Insert the MC collar & drive bearing. Lock the assembly with lock washer main shaft

washer using screw. Cover the bearing with clutch bearing cover and its supporter bearing retain

plate with both side packing using screw &spring. Insert the brake intermediate lever to pin for

brake intermediate lever & lock it with punched washer and split pin. Fix the brake lever with

split pin in position at ASC second shaft end and hook the spring at both ends of brake lever and

brake intermediate level.

Drive and fix ball bearing to rotary driving shaft. Check the free movement of

intermediately rod in central gear case. Insert the intermediate rod in position to the central gear

case and fix parallel key. Drive the BSC shaft arm B to intermediate rod for BSC and fix it with

plain washer and nut. Fix the gear bush to gear keeping holes on bush & gear coincide with each

other. Partly insert the RD shaft bearing sub assembly to the CGC intermediate rod sub assembly

in position so as to insert all the internal components in the chronological order as specified and

drive the shaft fully to CGC. Locate the sub assembly and its parts with knock pin and

corresponding holes as well as link the intermediate rod for BSC with the supporter for shift rod.

Fix the CGC cover with its packing .Sub assemble the universal joint A & B using screw. Link

other end of the joint with speed change rod .

Kubota machine Batch 1

Locate and fix supporting arm L with its packing to CGC using spring lock washer and

supporting arm bolt and same for right also. Check the gap between the pawls on either side of

dog clutch in CGC cover. Sub assemble oil seals, distance pieces etc. at the of side frame. Fix the

side frame R sub assembly with its packing to the supporting arm using spring lock washer and

supporting arm bolts. Fix two side frame L to supporting arm L using spring lock washers

&Bolts. Fix the blade shaft L and blade shaft R using properly mixed araldite and corresponding

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blade shaft bushes. Use special cup washers, lock and for fastening the bush after positioning the

blade shaft plates in touch with blade socket. Insert oil seal protector guide with right end of belt

shaft and locate the end along with protected guide at the bottomed end of the side frame.

Release the bolt bottom half portion of side frames so to dislocate its position.

Drive ball bearing to the blade shaft supporting bush ion the side frame. Tight the ring

nut fully and lock the set washer. Fix the blade shaft cover with packing using spring lock

washer and screw. Pour the oil SAE and screw the plug PLA 10 with fiber packing PA 10 on

blade shaft cover. Fix the chain case cover with its packing keeping the chain spring tightened.

Drive ball bearing through the blade shaft side through chain case cover hole at bottom. Tight the

bearing with blade shaft washer using bolt LHT. Lock the claw washer. Fix the CCU cover with

packing using M6 screw and spring lock washer. Fix the peep hole cover with packing using seal

washer and screw. Fix the CCL cover with packing using seal washer and screw. Pour Oil SAE

90 to the side frames, screw, plug PLA. Check free movement of the blade shaft. Drive the wheel

hub in position through axle shaft L and R, locking with nut and washer.

Kubota machine Batch 2

Fix the side plate L & R to the side frame using screw. Fix mud protecting cloth between

mud guard and plate &holder. Fix one end of MG plate sub assembly to side frame through side

plate. Fix rear wheel bracket to the side plate wth one end of mud guard plate assembly and

fitting plate .Tight the side plate. Fix rear apron to rear cover for tilling part with fitting plate for

rear apron. Fix rea cover for tilling part sub assembly with rear cover joining bar .Fix front cover

for filling part. Fix thrust bearing to screw rod and insert the same through rear wheel outer pipe

sub assembly to rear wheel bracket using fitting metal & rear wheel clamping handle easy. Fix

rear wheel handle on rear wheel outer pipe. Fix grip to rear wheel. Fix polymer tail wheel to tail

wheel inner pipe using tail wheel bolt. Fix the tail wheel assembly to the rear wheel outer pipe

fitting in the rear wheel bracket.

Kubota machine Batch 3

Fix front to axle gear case L & R using screw & washer. Fix supporter A to front frame

using screw & washer Fix supporter B. Insert bearing &collars to tension pulley shat. Insert

above assembly to the tension pulley. Fix TT pulley assembly to supporter B .Fix front stand to

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the front frame. Fix lever for stand lock with spring to front stand. Connect spring from front

stand to front frame. Fix protector to frame. Inset wheel rim & tube to the tyre & apply chalk

powder. Fix pin for hub to wheel hub. Insert wheel distance piece ad tyre assembly. Fix packing

A & auxiliary wheel hub using fitting nut with washer. Fix fitting bar B on front frame and

fitting bar A for wheel cover L on MGC cover small. And same for R. Fi x main handle to MGC

upper cover. Sub assemble handle stay A & B. Adjust the height of main handle & lock the nut.

Kubota machine Batch 4

Insert the st C wire through the main handle. Connect the yoke end to St C shaft lever

using plane washer. Connect the st C rod assy to the st C lever using clevis pin. Insert

intermediate lever shaft through MCI shaft bearing & MCI lever R. Stick the label for ASC and

label for L&H guide plate. Insert name plate arm to the guide plate then insert spring and lock

with split pin Fix and align supporter A on main handle. Insert MSC rod to BSC pipe. Insert the

yoke end of shift pipe to shift arm. Flat end to universal joint B. Subassemble the guide plate

.Insert the spring and washer to on BSC pipe. Sub assemble the MC rod with yokes and nut

Connect the yoke A end to the MC rod short sub assembly to the lever. Same for long MC rod.

Connect the yoke LHT for brake rod to brake intermediate lever. Insert return spring and washer

on ASC rod. Insert grip end of ASC rod subassembly through guide plates. Fix auxiliary handle

to main handle

Tiller finishing

Fix engine stand to front frame. Fix engine to engine stand. Fix and align V

belt. Fix front bracket o front frame and rear bracket on main shaft cover .Rivet

name plate for tiller on main handle. Insert spring A&B on set pin. Fix the other

end of handle to the main handle. Fix upper cover and auxiliary side plate and label

for MC to guide plate on main handle. Insert grip on handle. Connect release wire

assy to release lever assy. Fix oil cover plug to chain case cover. Fix tilling blade

wiring harness.

Then the Engine goes to QA section to test or assure the tiller quality.

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iii) Quality assurance

Assurance of quality of the material is takes place under three divisions.

1. Brought out QA

The materials brought from the vendors are checked here as per pre drawn designs of

each component

2. Implant QA

Components which are machined in the machine shop are checked here as per company

requirements

3. Sample inspection

Sample checking of assembling parts from new vendors to assure the quality and design.

Different equipments used in these QA’s are

1. Trimose

2. Plug gauge

3. Magnetic B block

4. Screw pitch gauge

5. Radius gauge

6. Profile projector

7. Height gauge

8. Air gauge

9. Brinell’s hardness tester and rock well hardness tester

In QA testing of engine also is to be done by using eddy current dynamometer. This is accurate

than the previous one