INTRODUCTION

The KAMCO working unit is subdivided into 5 departments viz. HR,

assembly, QA, machine shop, finance dpt. The five day internship program was
mainly focused on assembly department in which 2 types of engine models are being
assembled. (i) ER 90 (ii) DI 120.
The ER 90 model is a 4 stroke, 9HP engine. Its performance is low since the
fuel is not injected directly. The DI engine consumes lesser amount of fuel as the fuel
is injected directly into the chamber in the piston and has 12HP power.
KAMCO aims at improving the production rate with minimised man power.
ISO certified tiller parts are imported to the company, machined to the accurate
dimensions in the machine shop and assembled.

Assembly line consists of engine line and transmission line. The movement of engine
and transmission systems throughout the unit is shown in the following flow chart.
ASSEMBLY LINE
Engine Line

Transmission Line

E1

T1

E2

T2

Engine testing

T3

Pre-treatment & painting

KMB 1

EF

Pre-treatment & painting

KMB 2
KMB 3
KMB 4

TF
QA
Rectifier
Packing

The internship gave us an idea about the different assembling parts, steps
in assembling and overall working of the tiller.

A brief explanation of the various assembling parts in different

assembling lines is given:
ENGINE LINE
E 1: Following parts are being assembled in E1

Liner: for the smooth motion of cylinder

Oil filter: absorbs dirt, dust and filters the engine oil
Tappets: to control the inlet and outlet valves via rocker arms
Bushes & bearings: to reduce friction between metals in contact
Cam shaft: consisting of cams to regulate inlet & outlet valves
Balance shaft: to reduce vibration due to unbalance
RPM regulating shaft: to vary the rpm by controlling flow of fuel
using governor shaft
Radiator: for cooling action of engine
Crank shaft: to drive power from the piston
Piston with rings: to compress air & produce strokes
Connecting rod: connects piston with crank

E 2: Following parts are added onto the engine case in E2

Side cover: To cover the idle gears & other gears

Fuel governor: adjust the flow of fuel
Fuel filter: cleans or filters the fuel from fuel tank
Cylinder head: covers the end of cylinder
Fuel injector: inject fuel in the end of compression stroke
Rocker case: sets up the inlet outlet valve
Dynamo: cooling engine, to provide power to the headlight
Flywheel: stores energy & gives starting torque
Oil pump: to pump the oil back to the engine case

Engine Testing:
The engine from E2 after assembly enters engine testing unit
where various tests like performance test, leakage test, shim test etc are
conducted. Small adjustments of valves are done in this unit.
Conventional testing methods are used in engine testing unit.
Preheating & Painting:
This section mainly includes 4 blocks including washing. The
finished engine parts & transmission parts are washed first and then
painted. Spray painting technique is used. Different colours are used for
ER(silver) & DI(green) engines to identify. Since same transmission
system is used with both engines, same colour is given.
Engine Finishing:
The auxiliary parts are fitted onto the painted engines..

Intake air filter: filters the air sucked into the cylinder
Exhaust: fumes allowed out & reduces noise
FLO body: to limit fuel supply
Engine pulley: to transmit power to the transmission system
Pulley covers: protects pulley
Fuel tank: stores fuel
Inlet & outlet pipes/tubes from fuel filter

TRANSMISSION LINE
T1: The gear axle & 4th gear is assembled to the main gear case
T2: The whole gear system is assembled in this section.
Third gear: onto which dog clutches or steering clutches are
attached
Second AC: onto which brake is attached
First AC: high & low gears are mounted on it
Second gear shaft
First gear shaft
Reverse gear
Idle gear: for driving the tiller blades
T3: The outlet from the gear system is attached in this section
Main clutch: to cut power from engine to the transmission gears
Cover plate: with shifters to change gears
Checking metal: with shifters to shift high & low gears of tiller
blades
Gear & axle of tiller
Testing of transmission box

KMB 1: Tiller parts are assembled in KMB1 section

Tiller supports: to support the tiller shaft
Tiller shaft: with projections to bolt tiller blades
Chain & chain cover: Since the tiller blade is single drive only one chain
drive is used
Wheel cap: onto which tyre is assembled
Pre-treatment & Painting:
Same procedures of engine is done in this unit
KMB 2: Auxiliary parts is assembled to the transmission system

Mud guard
Side plate
Tiller plate
Support wheel on inner pipe
Outer pipe: contains screw to adjust the support wheel
Bracket: onto which outer pipe is fixed
Rear cover & apron

KMB 3: Further parts are added onto the transmission system

Tension pulley: to provide additional tightness to the engine pulley
Wheel distance piece: to allow the distance of wheel or tyre from the
transmission system
Auxiliary wheel hub: separation between wheel & transmission
Tyre
Front stand & protector
Engine frame: to place the engine onto the transmission system
KMB 4: the output levers from transmission gears is pulled out

RR unit: electrical regulator to the headlight

Clutch lever & brake lever
Gear lever
Main handle cover

Tiller Finish (TF): The engine & transmission line assembles here.

Engine mounted onto engine frame using crane

Accelerator rod: to adjust rpm
Support wheel
Belt & belt cover
Bleeding test: to detect the presence of air in filter tubes

Quality Assurance(QA): Engines are tested for any loose parts, missing
parts, leakage etc. by running them for 3-4 hrs.
Rectifier: Tillers from QA are examined according to the report and
rectified. Headlights are fixed onto the tiller. They are again send to the
QA for retest & if they approve the engine, it is finally send to the
packing section.
Machine Shop: In machine shop parts such as cam shaft, bores in engine
block and main transmission case, governer sleeve, are machined and
then sent for heat treatment, from where the hardened parts are then
distributed the assembly section.