KAMBOTO MODEL BATCH – Assembly Line

KMB1

The KMB assembly line is basically the tiller line.

The first stage of KMB assembly line carries out blade shaft assembly and
chain case assembly.

The left and right side frame to which the blade shaft is to be attached is
assembled first. Oil Seals, Cir clips and fulcrum shafts are used.

Oil seals are nothing but a rotary shaft seal which excludes dust, dirt, water or
any other contaminant whilst retaining lubricant in rotary shaft equipment.
Generally, it used as a means of protecting the bearings of rotating shafts.

Cir clips or C clip is a type of fastener or retaining ring consisting of a semi-

flexible metal ring with open ends which can be snapped into place, into
a machined groove on a dowel pin or other part to permit rotation but to
prevent lateral movement. They are stamped out of sheet metal and thus
have a smooth side and a rough side. It is installed in such a manner that the
smooth side face he part and the rough side face outward.

The chain case assembly consists of the chain case cover, ball bearing 6205
and the wheel hub.

The 6205-2RS ball bearing has two contact rubber seals one on each side of
the ball bearing. The 6205-ZZ ball bearing has two non-contact metal shields
one on each side of the ball bearing. RS provides a better seal but more
rolling friction than 2Z.

The code 6205 of the ball bearing has a specific meaning in which the first
digit relates to the bearing type. 6 represents for deep groove. This second
number relates the bearing series, which reflects the robustness of the
bearing. 2 thus indicates light load. The 3rd and 4th digits of the bearing
number relate to the bore size of the bearing, numbers 00 to 03 have a
designated bore size depending on the number. Numbers over 03 simply
have a bore size which is 5 times that of the 3rd and 4th digit.

The required time for 1 unit production is about 3.5 hours.

The products from KMB1 are then taken to painting.

KMB2

After painting is done the painted products are brought into KMB2 where the
wheel assembly, cover assembly and plate fitting is done.

KMB3

The main sub-assemblies that come under KMB3 are

Tyre assembly

Engine frame assembly

Pulley assembly
Painting

The basic principle of operation for standard type water wash spray booths is
a water curtain maintained by a pump providing continuous circulation of
water. A water curtain is maintained by a pump providing a 40 psi head
pressure and a 10 to 12 psi pressure at the nozzles along a manifold which
sprays against a deflector plate producing the water curtain. There are two
methods of washing the paint pigment out of the exhausted air stream. First,
by drawing the air through a continuous curtain of moving water, suspended
paint particles in the air are flushed out. The second type is, when the air
caning the paint particles makes a sudden change in direction of flow.
Centrifugal force (volute action) flings the solid particles off the curtain into
collecting pan.

Depending on booth design the air will travel through a number of wash
chambers. The upper centrifugal wash chamber is the point where most of
the pigment is separated from the exhausted air and flushed down the front
water curtain into the collecting pan. In the lower wash chamber the exhaust
air must pass through another unbroken water curtain. Again, scrubbing the
air and the violent change in the direction of the air removes the remaining
paint pigment before the air passes into the exhaust chamber. Through these
two actions the air being exhausted is now virtually free of all airborne
pigment. The water is treated (compounded). This causes the paint particles
to coagulate and float on the surface.

In the standard pump type booths, the particles are skimmed off the top from
time to time. In the non-pump booths, the water is compounded so that the
particles sink to the bottom of the booth. Properly engineered water wash
spray booths are the most acceptable means of removal of paint pigments
from the exhausted air regardless of the type of paint, its viscosity, drying
speed or production rates. Solvent vapours or fumes will not be removed in
any water wash spray booth. However, water wash spray booths are the
most acceptable types of spray booths to all health, fie, and building codes.

Container pressure 1.5kg/cm to 2kg/cm

Gun pressure 3kg/sq.cm to 3.5 kg/sq.cm

Pre-treatment Process
Engine Finishing - EF

Engine finishing is done in the later part of the engine assembly line where
once the process flow is completed through E1, E2 and engine testing.

Some of the major components used in engine finishing include:

The engine case assembly comprised the major components under the
case/housing such as

 Fan Belt AV10/1016

 Engine Pulley
 V Pulley Stud

The indicator cap was screwed to the DI rocker case.

Spindle spring, Plain Washer PWAM6 and Split pin 2x16 are other components
used.

Engine case assembly is followed by the silencer assembly with mainly the DI
silencer flange and DI packing for silencer flange. The DI silencer flange is
fixed to the DI Cylinder head. The DI Silencer is screwed and locked to the DI
silencer flange.

Since these tillers are used out in the field it is necessary to prevent harmful
debris, dirt and contaminants from entering the engine. Thus air filters are
used. The air cleaner assembly is assembled along with this production line.

The radiator grill assembly and headlight assembly are followed and consists
mainly of the following parts

 Radiator Cover
 Fan Pulley cover
 Radiator Grill
 Fuel Tank
 Filter Screen
 Clamp for head lamp

Packing is put on filter screen and inserted into fuel port on fuel tank.

Fuel cock is screwed and fixed with copper packing PA30 and Fibre packing
PA30