TITLE:- CONTENTS CL : 8.5.1 - Force Motors

FORCE MOTORS LTD. DOC NO:-MNT/III/D/01 PUNE REV. NO:- 01 MAINTENANCE ISSUE NO/ DT :-01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 2 TITLE:- CONTENTS CL : 8.5.1.2

DOC.NO DESCRIPTION REV NO MNT/III/D/01 CONTENTS 00 MNT/III/D/02 ISSUE AND REVISION SHEET 00 MNT/III/WI/01 WORK INSTRUCTION FOR ATTENDING BREAKDOWN 00 MNT/III/WI/02 WORK INSTRUCTION FOR PREVENTIVE MAINTENANCE 00 MNT/III/WI/03 WORK INSTRUCTION FOR CALIBRATION OF ABRO BALANCING 00 MACHINE MNT/III/WI/04 WORK INSTRUCTION FOR SMOKE METER CALIBRATION 00 MNT/III/WI/05 WORK INSTRUCTION FOR CALIBRATION OF TEMPERATURE 00 CONTROLLERS MNT/III/WI/06 WORK INSTRUCTION FOR WELD CURRENT MEASUREMENT AND 00 ELECTRODE FORCE MNT/III/WI/07 WORK INSTRUCTION TO START BOILER 00 MNT/III/WI/08 WORK INSTRUCTION FOR CALIBRATION OF LOAD CELL 00 MNT/III/WI/09 WORK INSTRUCTION FOR CARRING OUT RECONDITIONING 00 MNT/III/WI/10 WORK INSTRUCTION FOR DG SET AND COMPRESSOR 00 ATTENDENT MNT/III/WI/11 WORK INSTRUCTION FOR UNLOADING THE DIESEL FROM 00

TANKER MNT/III/WI/12 WORK INSTRUCTION FOR SHIFTING / MOVING THE MACHINE / 00 WEIGHT MNT/III/WI/13 WORK INSTRUCTION FOR WORKING ON CAPACITOR BANK 00 MNT/III/WI/14 WORK INSTRUCTION FOR WORKING ON LOW-TENSION PANEL 00 MNT/III/WI/15 WORK INSTRUCTION WHILE WORKING ON HIGH-TENSION YARD 00 MNT/III/WI/16 WORK INSTRUCTION FOR WORKING ON AIR-CONDITIONING / 00 REFRIGERATION SYSTEM MNT/III/WI/17 WORK INSTRUCTION FOR POWER HOUSE ATTENDENT 00 MNT/III/WI/18 WORK INSTRUCTION FOR STARTING / OPERATING / STOPPING 00 DG SETS MNT/III/WI/19 WORK INSTRUCTION FOR STARTING / OPERATING / STOPPING 00 COMPRESSOR MNT/III/WI/20 WORK INSTRUCTION FOR CALIBRATION OF PRESSURE GAUGE 00 / RPM METER / CURRENT METER / VOLTMETER/ MV CONTROLLER MNT/III/WI/21 WORK INSTRUCTION FOR CALIBRATION OF TRACTOR ROLLER 00 BRAKE TESTER BT-4783 MNT/III/WI/22 WORK INSTRUCTION FOR ELECTRICALLY HEATED OVEN IN 00 WINDING DEPARTMENT

APPD BY STAMP REVIEW / ISSUED BY :- REV. DATE:- 08.04.2022

FORCE MOTORS LTD. DOC NO:-MNT/III/D/01 PUNE REV. NO:- 01 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 2 OF 2 TITLE:- CONTENTS DOC NO. DESCRIPTION REV NO MNT/III/WI/23 WORK INSTRUCTION FOR REWINDING MOTOR 00 MNT/III/WI/24 WORK INSTRUCTION FOR REWINDING CONTROL 00 TRANSFORMER MNT/III/WI/25 WORK INSTRUCTION FOR REWINDING CLUTCH COILS AND 00 OTHER COILS MNT/III/WI/26 WORK INSTRUCTION FOR OVERHAULING OF MOTORS 00 MNT/III/WI/27 WORK INSTRUCTION FOR GEOMETRICAL ACCURACY TEST 00 MNT/III/WI/28 WORK INSTRUCTION FOR DISPOSAL OF NC PRODUCTS 00 MNT/III/WI/29 WORK INSTRUCTION FOR SENDING MATERIAL TO OUTSIDE 00 PARTY MNT/III/WI/30 WORK INSTRUCTIONS TO ISSUE MATERIAL FROM STORES 00 MNT/III/WI/31 WORK INSTRUCTIONS FOR PREDECTIVE MAINTENANCE 00 MNT/III/WI/32 WORK INSTRUCTIONS TO ATTEND UPS BREAKDOWN 00 MNT/III/WI/33 WORK INSTRUCTIONS FOR PREVENTIVE MAINT OF UPS 00 MNT/III/WI/34 WORK INSTRUCTIONS FOR WORK ON HEIGHT 00 MNT/III/WI/35 WORK INSTRUCTIONS FOR WORK IN PIT AREA 00 MNT/III/WI/36 WORK INSTRUCTIONS FOR HYD OIL SAMPLE CHECKING 00 MNT/III/WI/37 WORK INSTRUCTIONS FOR COOLANT CONCENTRATION CHECK 00 MNT/III/WI/38 WORK INSTRUCTIONS FOR PM OF HOIST 00 MNT/III/WI/39 WORK INSTRUCTIONS FOR PRESERVATION OF MACHINE 00 MNT/III/WI/40 WORK INSTRUCTIONS FOR CASH PURCHASE OF SPARES 00 MNT/III/WI/41 WORK INSTRUCTIONS FOR TOTAL PRODUCTIVE MAINTENANCE 00 MNT/III/WI/42 WORK INSTRUCTION FOR REWORK / LESSON LEARNT 00 MNT/III/WI/43 WI FOR REVIEW & VALIDATION OF CONTINGENCY PLAN 00 MNT/III/WI/44 WI FOR SERVICE LEVEL AGREEMENT WITH INTERNAL CUSTOMER 00 MNT/III/WI/45 WI FOR CALIBRATION OF SAJ BED TORQUEMETER 00 MNT/III/WI/46 WI FOR CALIBRATION OF SAJ BED THROTTLE UNIT 00 MNT/III/WI/47 WI FOR CALIBRATION OF SAJ BED DIESEL FLOW METER 00 APPD BY STAMP REVIEW / ISSUED BY :- REV. DATE:- 08.04.2022

FORCE MOTORS LTD. DOC NO:-MNT/III/D/02 PUNE REV. NO:- 01 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- ISSUE AND REVISION SHEET

Sr No DCN No Date Change Doc. Ref

1 MNT/DCN/01 09.12.2020 MNT/III/D/01 2 MNT/DCN/02 08.04.2022 MNT/III/D/01

STAMP REV ISSUED BY :- REV. DATE:- 08.04.2022

FORCE MOTORS LTD. DOC NO:-MNT/III/WI/01 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR ATTENDING BREAKDOWN OF MACHINES

DETAILS:- 1 Report to working table at the beginning of the shift. 2 Check for breakdown requisition, take instructions for repair as necessary. 3 Take safety precautions as per MNT/SOP/01, before start of work. 4 Study symptom,carry out diagnosis,Reach the root cause & take corrective action. 5 If required take the help from outside agencies like stores, tool room, winding etc. 6 After technician carries out the work, take trials in presence of user LIC/SIC, and hand

over the machine for production. 7 Clean the area you worked if made dirty and fix the covers etc. in its proper place

before living the machine. 8 Prepare indent for the parts required for storing of spares in stores. 9 Prepare monthly % breakdown analysis bar chart using the formula of respective section Lost Hours X 100 = % B/D No of Machines X No of Days X Working Hrs / day STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/WI/02 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR ATTENDING PREVENTIVE MAINTENANCE OF MACHINES

DETAILS:- 1 Report to working area at the beginning of the shift. 2 Take the machine which is scheduled for preventive maintenance Ref (MNT/00/53) 3 Take safety precautions as per MNT/SOP/01, before start of work. 4 Carry out preventive maintenance as per check list (MNT/00/54). 5 If any spares required or replaced inform maintenance LIC/SIC/DH during PM activity. 6 Take trials of machine along user LIC/SIC after PM is completed. 7 Take conformance of user LIC/SIC on check list (MNT/00/54) 8 After PM is completed hand over the machine to user. 9 Clean the surrounding and keep the scrap if removed in maintenance scrap bin before leaving the

machine.


FORCE MOTORS LTD. DOC NO:-MNT/III/WI/03 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR CALIBRATION OF ABRO BALANCING MACHINE BT-3610 & 4661 PROPELLER SHAFT

DETAILS:- A. LHS CALIBRATION 1. Set all pots (2RL, 2RM, 2RR) on 180 2. Keep other pots (A,B,C,L,ML,MR,R) on zero. 3. Put EREC switch to off condition and ED/SBD switch to ED for check calibration and to SBD for right chuck calibration. 4. Keep SK / LR switch on LR and 2P/3P switch on 2P for 2 plane job and on 3P for 3 plane job. 5. Keep sensitivity switch P1 on HS. 6. Note all the meter readings to zero (mechanical zero) when machine is in off condition. 7. Chuck run out should be less than 30 micron. If not get it rectified by production engineer. 8. Take TEST /ZREO switch on TEST and start the chuck at 3000 RPM, and check initial imbalance of chuck. It should be balance less then 1 % of scale. At 3000 RPM if imbalance is more then 1% of scale Put required weight on that angle and take their readings 9. At 3000 RPM put TEST / ZERO switch on ZERO and check amount meter for electrical zero. If electrical zero is not proper adjust through preset on card No. 503 for respective amount meter to bring pointer to zero 10. For chuck balance checking put known weight at any angle and rotate the chuck at 3000 rpm and take the reading. When set angle is less than 180 degree then observed angle should be set angle +180 degrees. If set angle is greater than 180 degrees but less than 360 degrees then observed angle should be set angle –180 degrees. 11. If observed weight is not equal to known weight then adjust the same through preset on card No.207 accordingly. B. MIDDLE METER CHECKING

1. Ensure electrical and mechanical zero of middle meter. Use reference as left chuck and left pickup for middle meter plug. PU(L) probe into PU(M) socket and put 2P /3P switch on 3P and rotate LHS chuck at 3000 RPM. Reading on middle meter should be same as that of left meter. C. RHS CALIBRATION

1. Put ED/SBD switch on SBD and other pots on original position. 2. Put Silver/Black foil on shaft chuck such that 0 to 180 degree portion covered by silver and 180 to 360 degrees portion covered by black foil. 3. Check & confirm run-out of RHS chuck to be less than 30 micron. 4. Fix belt on pulley properly & clamp the assembly and start the motor. 5. Check initial imbalance of the chuck. It should be less than 1% of full-scale reading. If chuck imbalance found more than 1% of full scale deflection of amount meter than balance the chuck with use of standard weights. After chuck balancing add known weight at any angle & start the motor at 3000 rpm. Note the readings of amount and angle meter. 6. Shift the known weight exactly 180 degrees opposite to the previous angle and observe the readings. 7. Known weight readings and corresponding angle should appear on amount meter and angle meter respectively. STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/04 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR SMOKE METER CALIBRATION A GENERAL INSTRUCTIONS

1. Switch OFF the main supply and remove test smoke probe from support handle. 2. Remove tube covers (right & left) and clean the machine with dry air. 3. Clean both the tubes (air tube & smoke tube) 4. Ensure mechanical Zero of meter. If not, then set zero with use of screw given on meter. 5. Connect the machine back to the supply & put the heaters on. B. WITHOUT USING GLASS

1. Ensure zero setting of HSU meter. 2. Take lever on ZERO. Reading should remain zero. If not, adjust through zero set pot on

panel. 3. For voltage checking, take SMOKE / VOLTAGE switch on VOLTAGE mode. Display should be

within 11.5 volts to 12.5 volts as indicated by blank band on meter. C. WITH USING GLASS (50 HSU)

1. Put glass on SMOKE side. Take lever on ZERO and ensure zero reading of the meter. If not,

adjust through pot provided on front panel. 2. Take lever on SMOKE. Reading should be 50+/- 2 HSU.

3. If reading is found OK calibration is conformed. If not OK then refer smoke meter manual STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/05 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 3 TITLE:- WORK INSTRUCTION FOR CALIBRATION OF TEMPERATURE CONTROLLERS

DETAILS:- A FOR INSTRUMENTS CALIBRATION OF RTD /PT-100 1. Use the milivolt calibrator unit, which is calibrated every year by certified NABL lab. 2. Switch off the main supply of instrument, which is to be calibrated. 3. Disconnect the sensor wire from temperature controller / indicator as well as relay contacts which

are used for controlling temperature. 4. Connect the mV calibrator unit to temperature controller / indicator which is to be calibrated. 5. Keep the switch selector on RTD 6. Switch on the calibrator as well as the instrument. 7. First take min. to max readings before calibration and note down all the readings from min to max 8. Feed minimum resistance to temperature controller / indicator from calibrator, accordingly it

should show the temperature (see table 4) otherwise adjust it by zero pot. 9. Feed maximum resistance to temperature controller / indicator from calibrator, accordingly it

should show the temperature (see table 4) otherwise adjust it by span pot. 10. Repeat 8

th and 9

th step for minimum & maximum readings until the results are within the

minimum error of zero and span (see table 4) 11. Then feed minimum to maximum resistance in steps and note down all readings in table (like

table 3) 12. Switch off the supply of temperature controller / indicator which is calibrated. 13. Disconnect the mV calibrator and reconnect thermocouple / sensor wires at sensor inputs. 14. Switch on the supply. 15. Measure the resistance of thermocouple at shown temperature it should match as per (table 3) 16. Tolerance is +/- 5 degrees . 17. Record all the readings as per table 4 in register (R-07) B. FOR INSTRUMENTS CALIBRATION OF Cr-Al/Fe-Ko/Pt Pt Rh 13 1. Use the mV calibrator unit which is calibrated every year by certified NABL Lab. 2. Switch off the main supply of instrument, which is to be calibrated. 3. Disconnect the sensor wire from temperature controller / indicator as well as relay contacts which

are used for controlling temperature. 4. Connect the mV calibrator unit to temperature controller / indicator at sensor input (check the

polarities of wire) Keep the selector switch on mV source. 5. Switch on the supply of instrument to calibrate and also of calibrator unit. 6. First take min. to max. readings before calibration and note down all readings. 7. Give minimum mV to temperature controller / indicator from calibrator, accordingly it should show

the temperature (see table 1) otherwise adjust it by zero pot. 8. Give maximum mV to temperature controller / indicator from calibrator, accordingly it should show

the temperature (see table 1) otherwise adjust it by span pot 9. Repeat 6

th and 7

th steps till minimum to maximum readings, until the results are within min. error

of zero and span. CONT.


FORCE MOTORS LTD. DOC NO:-MNT/III/WI/05 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 2 OF 3 cont.

10. Then give minimum and maximum mV in steps and note down all readings in table 2 11. Switch off the supply of temperature controller which is calibrated. 13. Disconnect the mV calibrator and connect temperature sensor wires and the relay wires 14. Switch on the supply. 15. Measure the mV coming from thermocouple / sensor and shown temperature should match as

per (table 1) 16. Permissible error is 1% FSD. 17. Record all the readings as per table 2 in register (R-07) TABLE 1: Standard Readings at Ambient Temperature 20 degree centigrade

Standard Temperature (degree Centigrade)

Milli Volt Feed

Cr-Al Pt-Pt-Rh 13 % FeKo

100 3.30 0.64 1.61

200 7.33 1.46 4.35

300 11.41 2.39 9.94

400 15.60 3.40 15.51

500 19.85 4.46 21.02

600 24.11 5.57

700 28.34 6.73

800 32.50 7.95

900 36.56 9.21

1000 40.51 10.51

1100 11.55

1200 12.59

TABLE 2 : Calibration Table

MV Feed

Standard Temperature (degree Centigrade)

Actual Temperature (degree Centigrade)

Error

Before Cal.

After Cal.

Before Cal.

After Cal.

100

200

300

400

500

600

700

800

900

1000

1100

1200

Cont. STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/05 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 3 OF 3 Cont: ACTUAL STD. READING (mean) % ERROR = ______________________________ X 100 FULL SCALE DEFLECTION (FSD) TABLE 3: STANDARD READING FOR PT—100

Resistance Feed (Ohm) Standard Temperature (deg Cent)

100 0

103.9 10

107.79 20

111.67 30

115.54 40

119.40 50

123.24 60

127.07 70

130.89 80

134.70 90

138.50 100

TABLE 4: CALIBRATION TABLE

Resistance Feed

Standard Temperature

(degree Centigrade)

Actual Temperature (degree Centigrade)

Error

Before Cal.

After Cal.

Before Cal.

After Cal.

100 0

103.9 10

107.79 20

111.67 30

115.54 40

119.40 50

123.24 60

127.07 70

130.89 80

134.70 90

138.50 100

ACTUAL STD. READING (mean) % ERROR = ______________________________ X 100 FULL SCALE DEFLECTION (FSD)

STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/06 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR WELD CURRENT MEASURMENT AND ELECTRODE FORCE

MEASUREMENT WITH WELD MONITOR ( MIYACHI MAKE – MODEL 315, WM2) AND FORCE METER ( ERICHEN- FM1)

This activity is being carried out jointly by LIC (MNT) and LIC (QC) DETAILS: (A) WELD CURRENT MEASUREMENT 1. Put the copper plate between the electrode tips of the spot welding machine 2. Put the toroid coil around one of the electrodes. (upper or lower) 3. Put the main switch on. 4. Press the hand switch / foot switch (whichever is applicable) and allow the weld current to flow

through the copper plate. 5. Note down the readings of the weld current on Miyachi weld monitor. 6. Specified range of the weld current is KA -11.0 KA 7. Note down the corresponding reading of the heat control knob. (B) ELECTRODE FORCE MEASUREMENT. 1. Put weld ON / OFF switch in OFF condition. 2. Place force meter FM1 between two electrode tips. 3. Press hand switch / foot switch (which ever is applicable) and note down the force meter reading. 4. Repeat the procedure 2/3 times to ensure repeatability of the meter. 5. Specified range of electrode force is between 2.4 KN – 3.0 KN STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/07 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION TO START THE BOILER

DETAILS: 1. Start the main switch of boiler, the indication lamp should glow. 2. Check the pre-heater water level. 3. Check furnace oil service tank oil level. 4. Check Thermic fluid level in expansion tank, it should be min. 3” max 6” 5. Switch on the pre-heater and heat the water upto 100 degrees. 6. Start cooling water of Thermic fluid circulation pump. 7. After pre-heater temperature reaches to 100 degree centigrade start Thermic fluid circulating

pump and run boiler in cold position. 8. Check Thermic fluid circulating pump pressure, it should be 4 – 5 Kg/sq cms and circuit pressure

2 –2.5 Kg/sq cms. If pump pressure indication is vibrating then operate air vent of Thermic fluid in paint shop to remove air in line.

9. Check burner, nozzle and photo cell glass for its cleanliness. 10. After temperature of pre-heater reaches 100 degrees centigrade start boiler in auto mode, low

flame condition. 11. Open the damper ¼ only. 12. After starting boiler in auto, check if ignition is started or not and fuel pressure 14 to 20 Kg/sq

cms. 13. Run boiler in high flame mode after reaching outlet temperature to 100 degree centigrade. 14. If boiler is tripping in high mode then adjust damper accordingly. 15. After starting boiler check the smoke at chimney, if it is black adjust the air damper. 16. Record all necessary readings in daily record book properly. 17. Ensure that thermic fluid level in expansion tank in boiled cold condition (i.e. at ambient

temperature of thermic fluid) to be just above 0 mark on glass tube provided on expansion tank. This is to ensure that air trap wont occur in thermic fluid line.

18. Whenever it is observed that thermic fluid is drained by any means in large amount, immediately air trap is to be checked and removed before topping up the thermic fluid. This MUST be strictly adhered.

STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/08 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 2 TITLE:- WORK INSTRUCTION FOR CALIBRATION OF LOAD CELL

DETAILS: 1. Make sure that the display of torque indicator shows zero when there is no load. 2. If display is not zero, adjust it by zero pot in torque / speed indicator. 3. Connect the calibration arm on the dynamometer from both sides with the respective key if

available. 4. Make sure arms fitment is well tightened. 5. Put the counter balance on the opposite side of the weight pan and adjust the counter weight in

such a way that the torque display should show zero. 6. As per the calibration chart for various dynamometer ( A,B,C) apply the weights in weight pan and

check for the torque display. 7. If torque display varies with the standard weight, adjust it by calibration pot / gain switch /

attenuator switch 8. After applying weights in ascending order, check the torque display for descending order also. 9. Note down the torque reading in the calibration chart of respective bed in calibration chart

register. 10. Remove calibration set from dynamometer. 11. Hand over the dynamometer to production. 12. Record he reading as per table A / B / C in register R-07 TABLE A : CALIBRATION CHART FOR SAJ-HYDRO DYNAMOMETER

Sr.No Load in KG

Torque (N-m) Before Calibration Display

Torque (N-m) After Calibration Display

Up Loading of weights

Down Loading of

weights


Down Loading of weights

1 0 0 0

2 10 50.0 50.0

3 20 100.0 100.0

4 30 150.0 150.0

DISPLAY TOLERANCE + / - 1.0 % TABLE B : CALIBRATION CHART FOR SAJ-EDDY CURRENT DYNAMOMETER

Sr.No Load in KG




Down Loading of

weights



1 0 0.0 0.0

2 1 4.0 4.0

3 2 8.0 8.0

4 3 12.0 12.0

5 4 16.0 16.0

6 5 20.0 20.0

DISPLAY TOLERANCE + / - 0.5 % CONT STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/08 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 2 OF 2 CONT: TABLE C : CALIBRATION CHART FOR BENZ SYSTEM EDDY CURRENT DYNAMOMETER

Sr.No Load in KG




Down Loading of

weights



1 0 0.0 0.0

2 1 5.0 5.0

3 2 10.0 10.0

4 3 15.0 15.0

5 4 20.0 20.0

6 5 25.0 25.0

DISPLAY TOLERANCE + / - 0.5 % STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/09 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR CARRING OUT RECONDITIONING WORK

DETAILS: 1. Report to the section at the beginning of the shift. 2. Take safety measures while working. 3. Clean the machine thoroughly. 4. Check missing parts and damaged parts as per user memo. 5. Dismantle the assemblies one by one. 6. Dismantle the panel and motor. 7. Clean the dismantled parts and keep the parts in bin. 8. Prepare the damaged / missing parts list. Make proposal, take management approval. 9. Prepare the damaged / worn out parts drawings which can be made in tool room. 10. Prepare indent for worn out parts / damaged / missing parts. 11. Take the readings of worn out beds as per m/c test chart. 12. Scrap and align the worn out beds. 13. Overhaul all the motors. 14. Repair / rewire / modify if required the existing panel. 15. Assemble the machine after receiving all the parts. 16. Take and record GAT as per master test chart 17. Take trial running. 18. Take GAT and trial with user dept and concerned maint. person. 19. Paint the machine STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/10 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 2 TITLE:- WORK INSTRUCTION FOR DG SET AND COMPRESSOR ATTENDENT

DETAILS: 1. Read the report of previous two shifts. 2. Go through the working parameters ( as under) which are recorded in the log book by the

previous shift operator. 3. Check the parameters physically on the equipment. 4. Stop the equipment in case the parameters are not within the acceptable limits. 5. Correct the differed parameters. Take the guidance from your engineer in case not able to correct

it. 6. Start equipment after the desired parameters are achieved. 7. Run the spare compressor if the air pressure is found below 6.5 Kg / sq cm. 8. Check the diesel stock and record the quantity in the register ( R-09) 9. Inform the shift engineer, in case the diesel level goes below 13000 litres. 10. Infirm the shift engineer, in case of lubrication oil ( ENCLO 68, HLP 68 & High Extra 20 W 40 )

stock goes below 100 litres. 11. Drain moisture from the diesel service tank daily. 12. Write down the working parameters in the respective log book every hour. 13. Drain moisture from drain points provided on compressor, air receiver, air dryers, air line filters

hourly. 14. Take hourly readings of equipments and record in log book accordingly. COMPRESSOR PARAMETERS

Sr. No

Parameters

Requirements

1. Delivery Air Pressure 6 to 6.5 Kg / cm2

2 Lub oil temperature a) KPC Screw b)KPCReciprocating

Max. 105 degree centigrade Max. 65 degree centigrade

3 Air oil temperature- Atlas Copco Screw Max. 110 degree centigrade

4 Lub oil level… HLP 68 for KPC screw & Atlas Copco Screw Enclo 68 for KPC Reciprocating

Upto the mark of the lever gauge

5 Inter cooler pressure – KPC reciprocating Below 2.5 Kg/cm2

6 Lub oil Pressure a) KPC Reciprocating b) KPC Screw c) Atlas copco

Above 2.5 Kg/cm2 Above 3.0 Kg/ cm2–Below 7 Kg/cm2 NIL

7 Load Current a) KPC Reciprocating b) KPC Screw c) Atlas copco GA 1107 d) Atlas copco GA 1408 e) Atlas copco GA 2007

Max 135 Amps Max 140 Amps Max 170 Amps Max 260 Amps Max 300 Amps

8. Water inlet temperature-Atlas Copco Screw 24 to 28 degree centigrade

9 Air outlet temperature- Atlas Copco screw Max. 45 degree centigrade

CONT.

STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/10 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 2 OF 2 CONT. GENERATOR PARAMETERS

Parameters Requirements

Oil pressure Should not be below 3 Kg/cm2

Lub Oil temperature Should not be above 105 degree centigrade

Water temperature Should not be above 90 degree centigrade

Water level in tank Full

Lub oil level in sump & governor Between low & high marking

Average electric Current ( in Amps) For 750 KVA GEN For 1000 KVA GEN For 1100 KVA SKL GEN

Should not be above 600 Amps Should not be above 900 Amps Should not be above 950 Amps

STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/11 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR UNLOADING THE DIESEL FROM TANKER

DETAILS: 1. Check the existing level of Diesel in the storage tank with an initial dip in the presence of stores

and security personnel. 2. Switch off the pump “ Provided to fill the diesel in the over head service tank” ( if applicable) 3. Unload the diesel into an empty tank. 4. Wait for ten minutes before taking the dip 5. Take the final dip after unloading in the presence of security and stores personnel. 6. Plug the diesel tank caps / valves. 7. Conform that the following details are noted down by the stores person. a. Initial Dip. b. Final Dip c. Total diesel unloaded ( b – a ) d. Total storage of diesel. e. Tanker number. f. Challan number. g. Signature of stores and security person. h. Storage of Fuel received. STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/12 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION WHILE SHIFTING / MOVING THE MACHINES / WEIGHT

DETAILS: 1. Refer machine manual. Confirm weight & Proper method of lifting / movement. 2. Choose the material handling equipment according to the weight to be moved / shifted. 3. Operate the material handling equipment to confirm that all functions are in order. 4. Check for the proper working condition of the chosen material handling equipment. 5. Do not use worn out, broken wire rope and chain slings. 6. Check for proper balancing of the machine / weight while lifting. 7. Do not allow any second person to sit along with the forklift driver. 8. Do not drive / move fast the material handling equipment while shifting the machine / weight. 9. Responsible person should accompany the driver while machine / weight movement. 10. Take necessary precautions to avoid damage to machine while movement. STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/13 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION WHILE WORKING ON CAPACITOR BANK DETAILS: 1. Switch “OFF” the respective capacitor’s OCB/ACB. 2. Operate the change over switch to OFF (neutral) position manually and draw out respective

OCB/ACB. 3. Display board (DO NOT SWITCH ON) on OCB / ACB. 4. Wait for few minutes to allow the capacitor to discharge. 5. Check physically with the help of Test lamp on the Main Bus at capacitor bank that the supply is

OFF. 6. Use 7/20 or 7/18 PVC insulated copper wire to discharge the capacitor across the terminal of the

individual capacitor. 7. Check and change the blown off fuse if any. 8. After completion of intended work check for any tools kept on the bank, bus bar and close the

capacitor bank door. 9 draw in the respective OCB / ACB manually and operate the change over switch to MSEB

position. 10 Switch ON the OCB / ACB manually. STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/14 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION WHILE WORKING ON LOW TENSION PANELS

DETAILS: 1. Switch OFF respective outgoing feeder. 2. Draw out the OCB / ACB after operating the changeover switch in OFF (neutral) position. 3. Switch OFF the transformer incoming OCB / ACB and display a board ‘DO NOT SWITCH ON’. 4. Isolate the respective Bus Coupler of the generator. 5. Open the rear door of the panel and check physically with test lamp for supply on the MSEB /

GENERATOR Bus. 6. Carry out the intended work. 7. Check for any tools left inside the compartment and on busbar and close the rear door. 8. Switch ON the transformer incoming OCB / ACB manually 9. Switch ON the bus coupler of Generator manually. 10. Draw in the feeder OCB / ACB. 11. Bring the changeover switch in MSEB / GEN position manually. 12. Change the outgoing feeder’s OCB / ACB. 13. Remove the display board. STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/15 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION WHILE WORKING IN HIGH TENSION YARD. DETAILS: 1. Use helmet and hand gloves (22 KV) where ever required 2. Switch OFF outgoing OCB/ACB on LT panel. 3. Switch OFF transformer ACB at LT panel. 4. Switch OFF the MOCB (minimum oil circuit breaker ) through Remote switch on MOCB panel. 5. If in case MOCB does not get OFF through switch, go in HT yard and operate OFF knob on MOCB directly. 6. Switch OFF/OPEN GOD manually of all the feeders and transformer. 7. Switch OFF/OPEN main incoming MSEB feeder GOD (Group operating device) manually. 8. Before working on HT line ensure visually all GOD are OFF / IOPEN and ensure main line is earthed with earthing rod. 9. Display the board (DO NOT SWITCH ON ) at the handle of MSEB GOD and MOCB switch ( knob). 10. Carry out the intended work. 11. Make sure all the material used while working are brought down and are kept outside the yard. 12. Disconnect the earthing wire connected to main line. 13. Switch ON/CLOSE the respective transformer GOD manually. 14. Remove the board displayed on MSEB GOD handle and switch ON/ CLOSE the GOD manually. 15. Switch ON/ CLOSE MOCB through remote control panel knob if switch does not operate, charge the spring of MOCB manually with handle and press the ON knob manually to close the MOCB. 16. Check the transformer voltage on the LT panel. 17. Switch on the main OCB / ACB of all LT panel 18. Switch ON the respective outgoing feeder OCB / ACB one by one.

STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/16 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTIONS WHILE WORKING ON AIR CONDITIONING / RFRIGERATION

SYSTEM

DETAILS: A PRESSURE LEAKAGE TESTING 1. Isolate the equipment electrically 2. Use a nitrogen regulator to supply nitrogen gas pressure to the system at charging point 3. Set the pressure as recommended by equipment manufacturer displayed on equipment name

plate. 4. Open the pressure regulator valve slowly of Nitrogen gas regulator. 5. Close the valve as soon as the pressure reaches to the recommended value. 6. Apply the soap water at all the joints & bends. 7. If leakage observed, rectify the leakage point and repeat step 2 to 6. 8. Keep the system under the pressure with nitrogen gas for 24 hours. 9. Check the pressure drop if any & take the further instructions if required. B FOR EVACUATION 1. Isolate the equipment electrically. 2. Release the nitrogen pressure through release valve and Vacuum the system. 3. Connect the vacuum pump through charging line to the system and Vacuum the system. 4. Maintain the Vacuum level at -30 inches of hg. Rated on vacuum pump 5. Close the valve of system firmly and then switch OFF vacuum pump. 6. Disconnect the charging line. C FOR REFRIGERANT CHARGING TO THE SYSTEM 1. Isolate the system electrically. 2. Select the suitable refrigerant specified on the equipment name plate. 3. Connect the refrigerant cylinder to the system through the service line / charging line with the help

of adopter. 4. Open the refrigerant gas cylinder valve and purge the air in the service line and re-tight the same. 5. Wait till the pressure in the cylinder and system recommended valve of the refrigerant gas. 6. Switch on the system. 7. Keep the system “ON” till the HP & LP pressure reaches to the recommended value of the

system. 8. Observe the cooling performance of the equipment and shut off the valve on the cylinder &

system. 9. Check the rated full load current of the compressor. STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/17 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR POWER HOUSE ATTENDENTS DETAILS: 1. Read the report of previous two shifts. 2. Take the following readings of Transformer / MSEB / Generator and note down in the log book. 3. Start the generator as and when required and give the load. 4. Switch ON the capacitor bank in power house which are OFF 5. If required check the on –line capacitor in shop ( applicable in plant 1 only) 6. Take respective readings as per the log book every 2 hours. 7. As and when required switch on the compressor along with the compressor attendant. 8. Check visually the high tension yard, if any sparking observed and oil level of the transformer. 9. Before switching OFF the generator, check that all the load has been transferred on MSEB and

then switch OFF the generator 10. IN case if the maximum demand on HT meter is reaching the limit inform respective SIC / LIC and

start the generator along with generator attendant. 11. If required to control the maximum demand contact plant 2 / foundry power house attendant to

start the generator ( applicable to plant 1 only) 12. In case of MSEB failure, wait 5 – 10 minutes and then change the MSEB feeder ( applicable to

plant 1 only) 13. Contact MSEB sub station / Chinchwad RS / Akurdi complaint centre through internal telephone (

Dial 7100, 7101,7102) STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/WI/18 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR STARTING / OPERATING / STOPPING D.G SETS

DETAILS: A) FOR STARTING. 1. Check and top up the oil (20W40) in the sump and governor and water level in the water

overhead tank. 2. Run priming pump ( Lubricating oil) till the oil pressure develops upto 1 Kg/ cm2 3. Open the cooling water supply and return valves, ensure cooling tower water pumps running. 4. Start the engine by operating switch. 5. Set the electrical frequency to 50 Hz by adjusting the speed of engine. B) WHILE IN OPERATION. 1. Check and maintain the following parameters

PARAMETERS REQUIREMENTS

Oil pressure Should not be below 3 Kg/ cm2

Lub Oil Temperature Should not be above 105 deg. centigrade

Water Temperature Should not be above 90 deg. centigrade

Water level in tank Full

Lub oil level in sump & Governor Between low and high marking

Average electric Current ( in Amps) For 750 KVA GEN For 1000 KVA GEN For 1100 KVA GEN (SKL)

Load upto 600 amps Load upto 900 amps Load upto 950 amps

2. Ensure no abnormality in sound. 3. Ensure no oil, water, fuel leaksge. C. FOR STOPPING 1. Isolate the electric load by tripping ACB / OCB of the individual feeder which are fed by generator 2. Trip main ACB of the generator. 3. Bring down DG set speed to 1000 rpm ( This is applicable to DG sets operating on auto start

operation) 4. Keep it running for 2 to 5 minutes on NO LOAD at reduced speed. 5. Operate the “stop” button to stop the DG set. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/WI/19 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION TO STARTING / OPERATING AND STOPPING COMPRESSORS

DETAILS: A. WHILE STARTING 1. Keep the switch ( of the Governor) to “Unload mode” 2. Conform water inlet & outlet gate valves are open. 3. Conform air is released from oil tank / oil separator tank. 4. Conform level of the lube oil to its mark. 5. Switch ON the compressor. 6. Wait till the motor reaches to “Delta mode” 7. Switch on the governor to “Loading mode” B. WHILE POERATING. 1. Check & maintain following parameters.

Sr. No

Parameters

Requirements

1. Delivery Air Pressure 6 to 6.5 Kg / cm2

2 Lub oil temperature a) KPC Screw b)KPCReciprocating

Max. 105 degree centigrade Max. 65 degree centigrade

3 Air oil temperature- Atlas Copco Screw Max. 110 degree centigrade

4 Lub oil level… HLP 68 for KPC screw & Atlas Copco Screw Enclo 68 for KPC Reciprocating

Upto the mark of the lever gauge

5 Inter cooler pressure – KPC reciprocating Below 2.5 Kg/cm2

6 Lub oil Pressure a) KPC Reciprocating b) KPC Screw c) Atlas copco

Above 2.5 Kg/cm2 Above 3.0 Kg/ cm2–Below 7 Kg/cm2 NIL

7 Load Current a) KPC Reciprocating b) KPC Screw c) Atlas copco GA 1107 d) Atlas copco GA 1408 e) Atlas copco GA 2007

Max 135 Amps Max 140 Amps Max 170 Amps Max 260 Amps Max 300 Amps

8. Water inlet temperature-Atlas Copco Screw 24 to 28 degree centigrade

9 Air outlet temperature- Atlas Copco screw Max. 45 degree centigrade

C. WHILE STOPPING. 1. Keep the switch ( of the governor) to “Unload mode” 2. Wait for few minutes. 3. Switch “OFF” the compressor motor. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/WI/20 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 2 TITLE:- WORK INSTRUCTION FOR CALIBRATION OF PRESSURE GAUGES / RPM METER / CURRENT METERS / VOLT METERS / MV CONTROLLER

DETAILS: A. CALIBRATION OF PRESSURE GAUGES. (REF : IS: 3624 / 1987 ) 1. Connect the pressure gauge to be calibrated on one side of test pump and master gauge on the

other side. 2. Note down minimum five readings for various pressures in the chart as shown below in register

R-07

Sr. No

Standard reading Kg/cm2/Bar

Actual reading Kg/cm2/Bar

Error after calibration

3. Calculate % error after calibration using formula.

% ERROR = ACTUAL - STD READING (mean) X 100 FULL SCALE DEFLECTION (FSD) 4. Prepare status report using the above data. 5. Check if the % Error is within permissible limits as per status. 6. If the instrument is not in permissible limit, inform user to scrap the same. B. CALIBRATION OF RPM METER. (REF : IS : 1248 ( 9 ) / 2003 1. By comparing RPM meter with respect to master tachometer ( Comparison mode) 2. Note down minimium four readings in the chart shown in register R-07

Sr no Std.RPM RPM before calibration

RPM after calibration

Error shown

3. ERROR = STD RPM – RPM Before calibration 4. Prepare status report using the above data. CONT. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/WI/20 PUNE REV. NO:- 01 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 2 OF 2 CONT C. CALIBRATION OF VOLT METER / CURRENT METER / MV CONTROLLER (REF : IS : 1248 ( 9 ) / 2003 ) 1. Can be calibrated by comparing standard Voltage 2. Also by feeding Std. Volt / Current to the meter/Controller as per specification on the meter/

controller 3. Note down minimum five readings in the chart shown in register R-07 Volt meter table

Volts fed Std volts Actual volts before cal

Actual volts after cal

Error before calibration


Current / Ammeter table

mV feed Std current

Actual current Before calibration

Actual current after calibration

Error before calibration


mV controller

mVolts feed

Std.mVolts

Actual mVolts

before Cal

Actual mVolts after Cal

Error before Cal

Error After Cal

4. Calculate % error before and after calibration using formula

% ERROR = ACTUAL - STD READING (mean) X 100 FULL SCALE DEFLECTION (FSD) 5. Prepare status report using the above data. 6. Check if the % error after calibration is within permissible limits as per status report. 7. Correct the error on meters/ controller which have provision for adjustment 8. If the instrument is not in permissible limit, inform user to scrap the same. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/WI/21 PUNE REV. NO:- 00 MAINTENANCE. ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR CALIBRATION OF TRACTOR ROLLER BRAKE TESTER ( BT NO 4783)

DETAILS: A. L.H.DRIVE UNIT. 1. Drive tractor on the roller carefully (The vehicle should be straight and positioned centrally on the

roller). 2. Release the foot brake of the vehicle. 3. Put the vehicle in NEUTRAL gear. 4. Press the roller start button and wait until sensor indicators stop flashing. 5. Note down the dial reading (This is rolling resistance of L.H.wheel). 6. Put the master weights one after the other on the plate provided on L.H.motor’s gear box. 7. Note down the dial readings accordingly 8. Compare the readings with standard chart below for L.H drive unit, available with MNT dept. 9. Rectify the discrepancy if any to bring the readings within tolerance. B. R.H.DRIVE UNIT 1. Repeat the procedure for R.H.Drive unit as per points A5 to A9 in the same order.

STANDARD CHART FOR L.H AND R.H DRIVE UNITS

L.H DRIVE UNIT R.H.DRIVE UNIT

WEIGHT IN Kg

DIAL READING IN KN

WEIGHT IN Kg

DIAL READING IN KN

0 0.60 0 0.40

20 0.75 20 0.50

40 0.80 40 0.55

60 0.95 60 0.65

80 1.00 80 0.70

100 1.10 100 0.80

130 1.60 130 1.50

150 1.75 150 1.70

180 2.00 180 1.90

200 2.20 200 2.00

220 2.30 220 2.10

240 2.40 240 2.20

260 2.50 260 2.40

280 2.60 280 2.50

300 2.60 300 2.50


FORCE MOTORS LTD. DOC NO:-MNT/III/WI/22 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR ELECTRICALLY HEATED OVEN IN WINDING DEPARTMENT

DETAILS: 1. Clean the item / winding to be varnished by cotton waste, kerosene etc. 2. Start the electrical control of the oven. 3. Place the item inside the oven to be varnished for heating for 20 to 30 minutes for 60 to 80

degree centigrade. 4. Take out the item from oven, varnish the winding by diluted varnish from all sides by pouring the

varnish by small pot. 5. Put varnished item inside the oven again and heat for 4 to 6 hours to bake the varnish at 60 to 80

degrees centigrade. 6. Make the electrical circuit cut OFF of the oven and open the door of the oven to cool the items

varnished and baked. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/WI/23 PUNE REV. NO:- 00 MAINTENANCE. ISSUE NO/DT :- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR REWINDING MOTOR

DETAILS: 1. Take the motor (burnt) as per priority discussed with section incharge. 2. Clean the motor from outside and dismantle the motor with proper punch marking on both end

covers. 3. Check physical status of winding and winding resistance if necessary 4. Take out terminal box, terminal block from the starter. 5. Open the end connection side winding to collect connection data and winding details. 6. Check the motor is rewound previously if punch number stamped on the stator. 7. Start removing burnt winding wire from slots and check the correct gauge of the winding wire 8. After removing the complete burnt winding clean the slots. 9. Punch the winding number and enter the data in the register. 10. Check the winding wire availability in the stock and not arrange for procurement. 11. Insulate the slots with winding paper cut pieces. 12. Make the coils with necessary forma if available or prepare forma before making coils 13. Place the coils inside the slots as per data of old winding. 14. Make end connections and taping with leads and check the winding resistance and series lamp

test. 15. Varnish the stator in the oven. 16. Clean / repair all parts of the motor. 17. Procure new bearings from store if old one needs replacement. 18. Take out the old bearing from shaft and fit new bearing on the shaft. 19. Assemble the motor as per the punch marks. 20. Take NO LOAD trials by giving supply. 21. Note down NO LOAD current and winding resistance in the motor data register. 22. Fix cooling fan and cover, make connections of winding terminal on terminal block with box. 23. Note down name plate details in winding data register with winding punch number. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/WI/24 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR REWINDING CONTROL TRANSFORMER.

DETAILS: 1. Dismantle the frame of stamping stack and remove connector with necessary marking. 2. Start removing stampings pieces from the core. 3. After removing complete stampings, measure number of turns for primary and secondary winding

with necessary taping the wire gauge for both winding is to be checked. 4. Check condition of bobbins and if not suitable make new bobbins with required steel forma. 5. Rewind primary and secondary winding with necessary paper insulation between two windings

and layer, primary should be always inside and secondary should be outside and if required varnish the rewound bobbins

6. Assemble the stampings inside the bobbins to make core. 7. Check the voltages are correct as per transformer rating, make final end connection strip. 8. Note down data in winding register with necessary punch Number stamped. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/WI/25 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR REWINDING CLUTCH COIL AND OTHER COILS

DETAILS: 1. Remove the burnt winding from clutch body / solenoid bobbin and count number of turns and gauge of the wire. 2. Prepare forma / mandrel for rewinding on winding machine. 3. Clamp clutch body / bobbin on mandrel with necessary forma, place winding paper in between layers and wrap by cotton / fibre glass tape on outer diameter and varnish it. 4. Place the coil in clutch body with taking out necessary end connections. 5. Fill the gap between body and coil with epoxy solution. 6. Make end connections on the clutch body, in case of solenoid coil assemble coil with other parts. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/WI/26 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR OVERHAULING OF MOTORS.

DETAILS: 1. Clean the motor from outside. 2. Disassemble the motor by removing end cover, cooling fan etc with necessary punch mark on

both end covers. 3. Clean the stator by long cloth, if required wash the winding by kerosene and bake the winding in

oven. 4. See the condition of bearings, end covers and shaft. 5. Repair end covers, shaft with the help of Tool Room.(New shaft can be made if old shaft is

broken and if beyond repairs) 6. Withdrew the bearings from stores / making indent if old bearings are beyond use. 7. Fit the new bearings on shaft and grease the bearings. 8. Assemble the motor as per the punch mark made. 9. Take the trial at NO LOAD by giving the supply, check the current and note down for further

reference. 10. Fix the cooling fan on the shaft and close the end cover. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/WI/27 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR GEOMETRICAL ACCURACY TEST (GAT)

DETAILS:- 1 Report to working table and take instructions from the superiors. 2 Follow MNT/SOP/01 of m/c maintenance. 3 Check whether production has removed the fixture and clean the machine 4 Take all the necessary calibrated instruments for checking as per schedule to the machine. 5 Test the Geometrical Accuracy as per MNT/00/75 derived from master test chart applicable to that machine 6 Note all the readings on MNT/00/75. 7 Hand over the machine for regular production. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/WI/28 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR DISPOSAL OF NC PRODUCTS DETAILS:-

1.Prepare list of items for disposal. 2.Segregate items like copper / brass and weigh them. 3.Prepare note for disposal to put up to HOB for approval through DH mnt. 4.Take the approval note along with the material to scrap yard for items other than copper and brass and hand over to security. 5.Items like copper and brass are to be handed over to plant 2 stores dept duly approved by HOB through DH maintenance. 6.File the approved note STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/WI/29 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR SENDING MATERIAL TO OUTSIDE PARTY DETAILS:-

1. Fill the Good Dispatch note ( MNT/01/08) in duplicate 2. Get the approval from HOB 3. Handover the approved copy with material to dispatch stores. 4. Collect the copy of GDN 5. After receipt of material from party clear the RCIA 6. Note down the RCIA NO and close the GDN STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/WI/30 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR ISSUING MATERIAL FROM STORES DETAILS:-

1. Confirm part code & availability on SAP 2. Enter the part code and do reservation through SAP 3. Take print out using ZPP03 4. Get it approved from concerned authority 5. Hand over to store and collect the material STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/31 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTION FOR CARRYING OUT PREDICTIVE MAINTENENCE DETAILS:-

1. Understand that PRM is to monitor the condition of the equipment 2. Follow SOP of machine maintenance. MNT/SOP/1 3. Confirm PRM activity is planned as per MNT/00/57 4. Refer the PRM check list and carry out the checks 5. Use your five senses for attribute method 6. For variable method use measuring instruments 7. Record the observations on check list. 8. Carry out the activity and hatch the same after completion on MNT/00/57. 9. Get the sign of Production SIC 10. Carry forward the activity to next month if not completed. 11. Carry out the corrective action either Time based OR condition based. STAMP

REV ISSUED BY :- REV. DATE:- 09.12.2020 FORCE MOTORS LTD. DOC NO:-MNT/III/WI/32 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTIONS FOR ATTENDING BREAK DOWN OF ON – LINE UPS

DETAILS: 1. Switch OFF the Load on the UPS. 2. Check the fault alarm indication on the UPS panel. 3. Switch OFF the UPS by following sequence. a. Switch off the OUTPUT Ckt breaker b. Switch off Battery Ckt. Breaker c. Switch off Input Ckt breaker d. Switch off Incoming SFU 4. Check All the Fuses In UPS. Replace if any. 5. Check the Respective PCBs & repair / replace if any. 6. Switch ON the Incoming SFU. 7. Check Input Voltage & Input Current of the UPS. 8. Switch ON the Input Ckt breaker. 9. Check Battery Charging Voltage & repair / correct if any. 10. Switch ON the Battery Ckt. Breaker. 11. Check battery voltages. 12. Check Invertor Out put Voltage & Repair if any. 13. Switch ON OUTPUT Ckt. Breaker. 14. Take UPS trial ON LOAD. 15. Check Back-UP of UPS on load by switching OFF SFU. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD DOC NO:-MNT/III/WI/33 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTIONS FOR ATTENDING PREVENTIVE MAINTENACE OF ON – LINE UPS

DETAILS: 1. Switch OFF the Load on the UPS. 2. Switch OFF the UPS by following sequence. a. Switch off the OUTPUT Ckt breaker b. Switch off Battery Ckt. Breaker c. Switch off Input Ckt breaker d. Switch off Incoming SFU 3. Clean the UPS using air blower. 4. Tighten all the cable connections & connectors. 5. Check Water level indication of batteries. 6. Check individual battery voltages. 7. Check specific gravity of all batteries. 8. Switch ON the Input Ckt breaker. 9. Check Battery Charging Voltage. 10. Switch ON the Battery Ckt. Breaker. 11. Check battery voltages. 12. Check Invertor Out put Voltage. 13. Switch ON OUTPUT Ckt. Breaker. 14. Take UPS trial ON LOAD. 15. Check Back-UP of UPS on load by switching OFF SFU. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD DOC NO:-MNT/III/WI/34 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTIONS FOR WORK ON HEIGHT

DETAILS:

1) Take work permit from safety department 2) Display maintenance WIP board on m/c 3) Ensure all safety measures & instruct the workmen 4) Switch off bus bar / m/c supply as necessary 5) Inform hoist / crane operator about the work 6) Use proper tools & rope for shifting parts to or from ground 7) Keep one attendant on ground properly instructed 8) Carryout the work as per plan 9) Take trials after work completion 10) On satisfactory work completion remove all the tools etc from work place 11) ensure proper housekeeping 12) Inform Production & h/o the machine.


FORCE MOTORS LTD DOC NO:-MNT/III/WI/35 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTIONS FOR WORK IN PIT AREA

DETAILS:

1) Carryout proper housekeeping in pit area 2) Display maintenance WIP board on m/c 3) Ensure adequate light & ventilation provision 4) Switch off m/c supply as necessary 5) Take work permit from safety dept 6) Educate workmen for special precautions needed 7) If required provide sufficient life line to person working in pit area. 8) See that work is carried out as per plan in healthy work environment 9) Take trials after work completion 10) On satisfactory work completion remove all the tools etc from work place 11) ensure proper housekeeping 12) Inform Production & h/o the machine


FORCE MOTORS LTD DOC NO:-MNT/III/WI/36 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTIONS FOR HYD OIL SAMPLE CHECKING DETAILS:

1) Collect the hydraulic oil sample from hydraulic oil tank of the scheduled machine in a clean container. 2) Clean the glass flask , tube etc test articles thoroughly. 3) Set the arrangement for oil testing. Connect vacuum pump. 4) Take 10 ml of oil & add it to 4 times the Benzene C6H6. Stir it well. 5) Pass it through 0.8 micron filter paper by using vacuum pump. 6) Compare the filter paper patch with the standard patch provided by M/s Ferrocare. 7) Take corrective action as per sample patch indication. 8) Clean the entire test equipment thoroughly. 9) Same procedure to be repeated for every sample.


FORCE MOTORS LTD DOC NO:-MNT/III/WI/37 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT:-01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTIONS FOR COOLANT CONCENTRATION CHECKING USING REFRACTOMETER DETAILS : 1) Clean the glass with clean plain water & wipe with clean cloth 2) Add two / three drops of plain water on screen 3) Set the zero line with the help of knob 4) Then add two / three drops of coolant on screen 5) See the result on eye sight glass 6) Write down the actual value of coolant concentration STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD DOC NO:-MNT/III/WI/38 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT :-01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTIONS FOR PM OF HOIST

DETAILS : 1) Prepare list of Hoists with Identification no.at individual plant. 2) Follow Safety dept check list no. SLP/00/58 3) Take corrective action in consultation with User 4) Carry out pending work in monthly plan MNT/00/57 5) Submit monthly report to Safety department STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD DOC NO:-MNT/III/WI/39 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT :- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTIONS FOR PRESERVATION OF MACHINE

DETAILS : 1) Clean the m/c completely. Remove coolant. 2) Lubricate all moving parts & set their position. 3) Put a tag on m/c giving details as per Not In Use Tag. 4) Periodically carry out idle running cycle of the m/c. Re lubricate. 5) Check electrical panel & battery charging etc. 6) Strictly Avoid parts removal from the m/c. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD DOC NO:-MNT/III/WI/40 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT :- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTIONS FOR CASH PURCHASE OF SPARES

DETAILS : 1) Study the cash purchase budget & limits applicable to concerned department. 2) Cash purchase to be done in case of urgency / spare not available in stores. 3) Confirm availability of required spares with Vendor & its approx. cost 4) Fill up slip & withdraw approved amount from accounts cash counter 5) Send a person on Official gate pass , duly authorised 6) The material entry to be done at material gate. 7) Verify & enter the information needed into cash purchase register 8) RCIA to be prepared by stores. Enter RCIA no. in register 9) Take approval of HOD, ED (OPN) & Audit department. 10) Fill up yellow slip ACC/01/29 , take approval & submit to audit dept. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD DOC NO:-MNT/III/WI/41 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT :- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 CL : 8.5.1.5 TITLE:- WORK INSTRUCTIONS FOR TOTAL PRODUCTIVE MAINTENANCE

DETAILS : 1) Understand the TPM philosophy followed vide FMLPRD/00/1 - 14 2) PM, PRM & Planned maintenance activities to be carried out as per schedule 3) See that these activities are completed & records are maintained 4) Ensure participation of all Team members from respective departments for TPM 5) Decide definite time for TPM & put it in practice 6) Clean the machine thoroughly as per responsibility allotted to members 7) Follow TPM check points as per check list & locate red / white tags 8) Team members to Clear the white tags 9) Red tags to be cleared by Maintenance department. 10) Review action taken on chronic issues periodically 11) Maintain records for further improvements STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD DOC NO:-MNT/III/WI/42 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT :- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTIONS FOR REWORK / LESSON LEARNT

DETAILS : 1) By Rework we mean rectifying a wornout m/c part to achieve its original dimensions in specified or improved material & method for its desired performance 2) We may also modify the part as applicable with proper care & technical concern 3) Root cause to be found out for wear / failure of the part 4) To cross check its past failures as per the m/c history card 5) Now decide the action to be taken either rework, modification or replacement. In case of rework, prepare sketch / drawing. 6) Check the feasibility of Inhouse rework OR plan to send it to outside party 7) Further follow the procedure MNT/II/P/06 8) Assemble the reworked part on m/c & confirm its performance ok 9) In case a new lesson is learnt during above exercise , record it in specified format 10) Once approved , circulate it to concerned for their use STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD DOC NO:-MNT/III/WI/43 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT :- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 CL : 6.1.2.3 TITLE:- WORK INSTRUCTIONS FOR REVIEW & VALIDATION OF CONTINGENCY PLAN GP/00/27

DETAILS : 1) Contingency plan of Maintenance dept as per GP/00/27 should be validated for parameters feasible to be checked in regular interval. 2) For example : Stand by Generator mentioned in Contingency plan, should be run & confirmed performance ok on load condition 3) Similarly other feasible checks shall be done at decided frequency 4) The record of above mentioned checks should be available in file / register etc. 5) The contingency plan shall be reviewed yearly 6) Revisions to be communicated horizontally by HOD. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD DOC NO:-MNT/III/WI/44 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT :- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTIONS FOR SERVICE LEVEL AGREEMENT WITH INTERNAL CUSTOMER Service level agreement to be done with internal customer & score card to be maintained in the prescribed format below to ensure customer satisfaction.


SLA SCORE CARD

SLA No :

Supplier : CC No :

Customer :

CC No :

SLA Subject : Service

Month / Year : REMARKS

1

2

Total

Average

Score guidelines

Assign 5 marks for excellence performance, Zero non conformances in a month.

Assign 4 marks for excellence performance, 1 non conformances in a month.



Assign 1 marks for excellence performance, more than 3 non conformances in a month.

Customer Sign Supplier Sign

Date : Date :

Sr.

No

FORCE MOTORS LTD DOC NO:-MNT/III/WI/45 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT :- 01/ 08.04.2022 WORK INSTRUCTIONS PG:- 1 OF 1 TITLE:- WORK INSTRUCTIONS FOR CALIBRATION OF SAJ BED TORQUEMETER 1 Start panel & make edit key ON 2 start water pump . 3 select proper scale by entering in scale mode refer manual for more information. 4 remove calibration arms if fitted with dynamometer. 5 Enter in to torque calibration mode .(F + E & Power ON) 6 Make display zero by zero keys ( throttle side keys as in manual ) 7 fit calibration arms if any display change from zero adjust mechanically display zero by rider weights. 8 Put all provided weights in weight pan. 9 Adjust span by function and speed keys at dynamometer side. 10 press Exit key for 3 sec to enter in to normal mode. 11 Remove weights insure zero display 12 Remove calibration arms . Minor deviations from zero drift can be adjusted by F + E + Function key from dynamometer side


FORCE MOTORS LTD DOC NO:-MNT/III/WI/46 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT :- 01/ 08.04.2022 WORK INSTRUCTIONS PG:- 1 OF 1 CL : 6.1.2.3 TITLE:- WORK INSTRUCTIONS FOR CALIBRATION OF SAJ BED THROTTLE UNIT

1. TDTM 01 throttle actuator After proper connections start power of panel . 2. TDTM will take its own zero Idle position adjust 200 mv feed back by POTS Provided on TDTM Inside PCB . 3. It will adjust feedback 0 % on display. 4. In position mode rotate throttle encoder clock wise to give demand 100 % 5. To check throttle full span % 6. It should be done without throttle linkage of engine . 7. With linkage throttle can reach to any % as per engines throttle span may be 20 % may be 60 % and so on. . Pin no Signal Remark 1 M+ Motor 2 M- Motor 3 P1G GND 4 P1IN F/B 5 P1V Supply STAMP REV ISSUED BY :- REV. DATE:- 08.04.2022

FORCE MOTORS LTD DOC NO:-MNT/III/WI/47 PUNE REV. NO:- 00 MAINTENANCE ISSUE NO/ DT :- 01/ 09.12.2020 WORK INSTRUCTIONS PG:- 1 OF 1 CL : 6.1.2.3 TITLE:- WORK INSTRUCTIONS FOR CALIBRATION OF SAJ BED DIESEL FLOW METER 1. Clean Measuring Jar. 2. Measure Empty Jar Vessel Weight (X). 3. Remove Diesel Pipe Outlet of Flow Meter ( At Yantra Unit) 4. Start Diesel And After Flow is Constant Collect it in above jar for 5 Minutes

Note Flow Value (C). 5. Reconnect Diesel Pipe Again to Yantra Unit. 6 Measure Diesel Wieght Collected With Jar (Y). Y-X= A (Net Diesel Weight in gm) 7. Now Calculate Total Weight Of Diesel/Hour Diesel wt A * 60/5 = B

8. Calculate Error Reference flow C - B = E

9. Calculate Error (E) in Percentage. 10. Tolerance range should be in +/- 0.5%. STAMP REV ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/D/00 PUNE REV. NO:- 00 MAINTENANCE. ISSUE NO/ DT :- 01/09.12.2020

MASTER LIST OF QUALITY SYSTEM DOCUMENTS PG:- 1 OF 1

SR. DOC.NO DOC. DESCRIPTION ISSUE/REV NO

CL : 7.5.1.1 1. FORCE/I/D/02 Quality Manual 01/00 2. MNT/II/D/01 Procedure Manual 01/00 3. MNT/III/D/00 Master list of Quality System Documents 01/00 4. MNT/III/D/01 WI Content List 01/00 5. MNT/III/D/02 Issue & Revision Sheet 01/00 6. MNT/III/D/03 Master List of Quality Record 01/00 7. MNT/III/D/04 List of Forms & Formats 01/00 8 MNT/III/D/05 Issue & Revision Sheet 01/00 9. MNT/III/D/11 List of Check List ---- 10. MNT/III/D/13 List of Files & Registers ---- 11 MNT/III/D/19 Applicability of Level III documents ---- APPROVED BY STAMP REVIEWED BY: - REV.DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/D/04 PUNE REV. NO:- 00 MAINTENANCE. ISSUENO/DT :-01/ 09.12.2020 LIST OF FORMS AND FORMATS PG:- 1 OF 1 TITLE:- FORMS AND FORMATS CONTENT SHEET

FORMT NO DESCRIPTION MNT/00/01 Tool Room Job Order MNT/00/02 Indent / RCIA Clearance Record Register MNT/01/08 Goods Dispatch Note (GDN) Requisition MNT/00/10 Winding requisition cum Analysis Sheet MNT/00/11 Details for Record after Rewinding MNT/01/20 Breakdown log Book MNT/01/22 Indent (For Machinery Spares ) MNT/00/25 Material Master Form MNT/00/51 Master List of Machines / Equipments MNT/00/52 Yearly P.M. Calendar MNT/00/53 Preventive Maintenance Schedule Monthly MNT/00/54 Preventive Maintenance Check List MNT/00/55 Monthly PM Compliance graph MNT/00/56 Deviation Note for PM MNT/00/57 Predictive & planned Maintenance MNT/00/58 Review breakdown analysis & Corrective action MNT/00/59 KPI Proactive plan MNT/00/60 List of Critical Spares MNT/00/61 Master List of Instruments / Gauges / Equipments for Calibration MNT/00/62 Yearly Calibration Calendar MNT/00/63 Calibration Status MNT/00/64 Calibration Status MNT (Sticker) MNT/00/71 CNC Machine Master List MNT/00/72 Geometrical Accuracy Checking Calendar (Recn) MNT/00/73 Geometrical Accuracy Test Schedule Monthly (Recn) MNT/00/74 Machine Reconditioning Requisition (Recn) MNT/00/75 Corrective Action for Inaccuracy as per Test Chart (Recn) MNT/00/82 List of Statutory requirements (Soft copy ) APPROVED BY STAMP REVIWED / ISSUED BY :- REV. DATE:- 09.12.2020

FORCE MOTORS LTD. DOC NO:-MNT/III/D/05 PUNE REV. NO:- 00 MAINTENANCE. ISSUENO/DT :-01/ 09.12.2020 F & F ISSUE & REVISION SHEET PG:- 1 OF 1 TITLE:- ISSUE AND REVISION SHEET Sr No DCN No DATE CHANGE DOC. REFERENCE

1 MNT/DCN/01 09.12.2020 MNT/III/D/04 APPROVED BY STAMP REVIEWED / ISSUED BY :- REV. DATE:- 09.12.2020