< PreviousC8Gambar 8.30. Posisi Pengelasan Flat dan Horisontal........................211 Gambar 8.31. Posisi Pengelasan Vertikal dan Atas Kepala...............212 Gambar 8.32. Pengelasan Posisi Datar Sambungan Ujung..............213 Gambar 8.33. Pengelasan Posisi Datar Sambungan T......................214 Gambar 8.34. Pengelasan Datar Sambungan Tumpang...................214 Gambar 8.36.a. Pengelasan Posisi Horisontal I.................................215Gambar 8.36.b. Pengelasan Posisi Horisontal II................................215 Gambar 8.37. Pengelasan Posisi Vertikal Satu Jalur ........................216 Gambar 8.38. Pengelasan Posisi Vertikal Lapis................................217 Gambar 8.39. Pengelasan Posisi Vertikal Sambungan T..................218Gambar 8.40. Pengelasan Posisi Vertikal Tumpang..........................219 Gambar 8.41. Pengelasan Posisi Atas Kepala...................................220 Gambar 8.42. Pengelasan Posisi Atas Kepala Ujung........................221 Gambar 9.1. Teknik Pematrian ..........................................................229 Gambar 9.2. Prinsip Pematrian .........................................................231 Gambar 9.3. Bagan proses terjadinya ikatan patri ............................232 Gambar 9.4. Ikatan Pada Pematrian .................................................233 Gambar 9.5. Lapisan Suatu Ikatan Patri Normal................................233 Gambar 9.6. Grafik Pengaruh Besar Celah Pematrian......................234 Gambar 9.7. Lebar Celah Pematrian..................................................235 Gambar 9.8. Perbandingan Celah Pematrian....................................235 Gambar 9.9. Pengaturan Celah Pematrian........................................236 Gambar 9.10. Proses Kerja Bahan Pelumer......................................238 Gambar 9.11. Bahan Pelumer pada Pematrian.................................239 Gambar 9.12. Pematrian dengan Gas Pelindung ..............................241 Gambar 9.13. Tahap Lebur Patri .......................................................241 Gambar 9.14. Pematrian Celah..........................................................245 Gambar 9.15. Pematrian Sambungan................................................245 Gambar 9.16. Pematrian dengan Tuas Patri......................................246 Gambar 9.17. Pematrian dengan Api ................................................246 Gambar 9.18. Pematrian Tungku ......................................................247 Gambar 9.19. Pematrian Tahanan ....................................................248 Gambar 9.20. Pematrian Imbas ........................................................249 Gambar 9.21. Tuas Patri....................................................................251 Gambar 9.22. Tuas Patri Listrik (Solder Listrik)..................................251 Gambar 9.23. Berbagai Model Mesin Patri Otomatis.........................252 Gambar 9.24. Sambungan Pekerjaan Pematrian Keras ..................255 Gambar 9.25. Perbandingan Celah Patri Kuningan & Perak.............256 Gambar 9.26. Pematrian keras di udara bebas..................................259 Gambar 9.27. Pematrian keras Pada Ruang ....................................259 Gambar 9.28. Pematrian Baja dengan Gas Argon ............................259 Gambar 9.29. Pematrian dengan Sepatu Kabel.................................264 Gambar 9.30. Pematrian Ujung-ujung Kawat dan Kabel....................265 Gambar 10.1. Sambungan Tumpang.................................................269 Gambar 10.2. Sambungan Ujung.......................................................269 Gambar 10.3. Solid Rivets..................................................................270C9Gambar 10.4. Prosedur pengelingan.................................................273 Gambar 10.5. Konstruksi Blind Rivets................................................274Gambar 10.6. Pozidriv Head Self-Tapping Screws..........................275 Gambar 10.7. Spat System Screws...................................................276Gambar 10.8. Screw Nails..................................................................276Gambar 10.9. Steel Hammer Driven Screws.....................................277Gambar 10.10. Set Screws................................................................277Gambar 10.11. Clinch Nut (Hank Rivet Bushes)................................284Gambar 10.12. Proses pemasangan clinch nut.................................284 Gambar 10.13. Plastic Nuts................................................................285Gambar 10.14. Konstruksi Nyloc& Clevelock Nuts............................285Gambar 10.15. Konstruksi Spire Speed Nuts.....................................286Gambar 10.16. Konstruksi Captive Nut “U” – Type............................288Gambar 10.17. Konstruksi Captive nut “J” – type...............................290Gambar 10.18. Beberapa jenis Captive nut “J” – type.......................290Gambar 10.19. Konstruksi dan Pemasangan Grip Nuts...................291Gambar 10.20. Konstruksi dan Pemasangan Cable Clips.................291Gambar 10.21. The Avdelok System..................................................294Gambar 10.22. Proses Pemasangan Avdelok system.......................295Gambar 10.23. The Avlok system......................................................296 Gambar 10.24. Proses Pemasangan Avlok system...........................297Gambar 10.25. Konstruksi Nutsert system.........................................298Gambar 10.26. Konstruksi Jo-bolt System.........................................299Gambar 10.27. Simple Push-On Clips...............................................300Gambar 10.28. Konstruksi Tubular clips Blanked-types)...................301 Gambar 10.29. Pin & grommet...........................................................302Gambar 10.30. Posisi Pin & grommet................................................302 Gambar 10.31. Push Button...............................................................303Gambar 10.32. Cable Retainers.........................................................306Gambar 10.33. Peralatan dan Aplikasi Adhesif .................................308 Gambar 10.34. Aplikasi sealer pada body kendaraan........................309 Gambar 10.35. Aplikasi precuring sealer dan sealer biasa ...............310 Gambar 10.36. Alur pekerjaan aplikasi sealer ...................................310 Gambar 10.37. Menajamkan nozzle dan tempat aplikasinya.............311 Gambar 10.38. Bentuk ujung nozzle catridge dan hasilnya...............311 Gambar 10.39. Aplikasi sealer...........................................................312 Gambar 10.40. Hasil sealer yang baik...............................................313 Gambar 10.41. Penekanan dan kecepatan aplikasi sealer................313 Gambar 10.42. Arah aplikasi sealer...................................................313 Gambar 10.43. Sudut aplikasi sealer.................................................314 Gambar 11.1. Pekerjaan dengan Peralatan Abrasif.........................315 Gambar 11.2. Material Abrasif............................................................316 Gambar 11.3. Polisher........................................................................317 Gambar 11.4. Pelekatan Lapisan Terbuka.........................................319 Gambar 11.5. Pelekatan Lapisan Tertutup........................................319 Gambar 11.6. Amplas Berbentuk Lembaran.....................................321 C10Gambar 11.7. Amplas sabuk dan Belt Sander...................................321 Gambar 11.8. Amplas Spiral (Roll).....................................................322 Gambar 11.9. Grinding wheel.............................................................322 Gambar 11.10. Pemasangan Roda gerinda.......................................323 Gambar 11.11. Berbagai Material Abrasif Roda gerinda....................323 Gambar 11.12. Roda gerinda Dari Bahan Diamond ..........................324 Gambar 11.13. Roda gerinda Bahan Cubic Boron Nitride.................324 Gambar 11.14. Hand Block................................................................325 Gambar 11.15. Pneumatic Sander.....................................................326 Gambar 11.16. Single Action Sander.................................................326 Gambar 11.17. Orbital Action Sander................................................327 Gambar 11.18. Dual Action Sander....................................................327 Gambar 11.19. Mesin Gerinda Tangan..............................................328 Gambar 11.20. Pekerjaan Menggerinda............................................329 Gambar 11.21. Mesin Gerinda Duduk................................................329 Gambar 11.22. Mesin Gerinda Potong...............................................330 Gambar 11.23. Menggunakan Mesin Gerinda Potong.......................330 Gambar 11.24.Sarung Tangan Kulit...................................................331 Gambar 11.25 Kacamata Gerinda......................................................332 Gambar 11.26. Menyetel Dudukan Gerinda ......................................332 Gambar 12.1. Komponen bodi yang terbuat dari fiberglass ..............335Gambar 12.2. Resin ..........................................................................336 Gambar 12.3. Katalis .........................................................................337 Gambar 12.4. Mat ..............................................................................337 Gambar 12.5. Mirror ..........................................................................339 Gambar 12.6. Kuas............................................................................339 Gambar 12.7. Gunting .......................................................................340 Gambar 12.8. Adonan fiberglass .......................................................341Gambar 12.9. Adonan Fiberglass Diratakan ...................................343 Gambar 13.1 Konstruksi Luar Bodi Sedan.........................................345 Gambar 13.2 Konstruksi rangka.........................................................346 Gambar 13.3 Konstruksi Lantai (Under Body)....................................347 Gambar 13.4 Konstruksi pengunci engine hood ...............................348Gambar 13.5 Engine hood ................................................................349Gambar 13.7 Konstruksi engsel engine hood....................................350Gambar 13.8 Penyetelan hood lock...................................................351Gambar 13.9.Konstruksi fender.........................................................353Gambar 13.10Komponen Fender......................................................354Gambar 13.11 Konstruksi Cowl dan Dash.........................................355Gambar 13.12 Konstruksi Atap (Roof)...............................................355Gambar 13.13 Konstruksi Pillar Tengah.............................................356 Gambar 13.14Konstruksi Pintu Depan dan Belakang.......................357 Gambar 13.15 Konstruksi Pintu..........................................................358 Gambar 13.17 Konstruksi door glass, regulator dan door..................361 Gambar 13.16 Penyetelan engsel dan lock striker pintu....................361Gambar 13.18 Konstruksi Deck lid lock..............................................362 C11Gambar 13.19 Konstruksi Deck lid/Boot Lid.......................................363Gambar 13.21 Konstruksi Bumper.....................................................364Gambar 13.22 Wind shield.................................................................365 Gambar 13.23 Konstruksi Pemasangan Roof Head lining.................366Gambar 13.24Bagian headlining roof yang dilem.............................367Gambar 13.25Pemasangan retainer.................................................368Gambar 13.25Penempelan roof headlining pada bodi......................368Gambar 13.26 Seats..........................................................................369Gambar 13.27Konstruksi Tempat duduk...........................................370 Gambar 13.28 Konstruksi Panel Instrumen........................................371 Gambar 13.29Konstruksi Grill dan Moulding.....................................372Gambar 14.1 Laminated glass..........................................................374 Gambar 14.2 Peralatan perbaikan kaca.............................................376 Gambar 14.3 Sealent gun..................................................................377 Gambar 14.4 Sealent temperatur rendah dan tinggi .........................377 Gambar 14.5 Tipe pipih, oval dan bulat..............................................377 Gambar 14.6 Tipe khusus dan adaptor..............................................378 Gambar 14.7 Peralatan mengebor kaca untuk injeksi........................378 Gambar 14.8 Peralatan perbaikan kaca.............................................379 Gambar 14.9 Macam sealent dan sealent gun tipe listrik...................379 Gambar 14.10 Komponen kaca depan...............................................380 Gambar 14.11 Retainer......................................................................381 Gambar 14.12 Melepas moulding......................................................381 Gambar 14.13 Melepas weatherstrip dengan pemanas.....................381 Gambar 14.14 Melepas karet kaca dengan pisau razor.....................382 Gambar 14.15 Melepas karet kaca....................................................382 Gambar 14.16 Pemotongan bisa dilakukan sendiri............................382 Gambar 14.17 Pelepasan Kaca.........................................................383 Gambar 14.18 Tambang untuk pemasangan kaca depan.................383 Gambar 14.19 Cara menggunakan sealant gun................................384 Gambar 14.20 Ujung dari sealant disesuaikan...................................384 Gambar 14.21 Posisi tambang saat akan pemasangan.....................384 Gambar 14.22 Memasukkan tambang ke karet kaca.........................385 Gambar 14.23 Pemukulan kaca ke flange bodi..................................385 Gambar 14.24 Komponen kaca belakang..........................................386 Gambar 14.25 Melepas kaca belakang..............................................387 Gambar 14.26 Mengangkat kaca dengan vacuum cup......................388 Gambar 14.27 Alat pengangkat vacuum cup.....................................388 Gambar 14.28 Defogger pada kaca belakang....................................389 Gambar 14.29 Konstruksi kaca pintu.................................................389 Gambar 14.30 Konstruksi kaca tetap.................................................390 Gambar 14.31 Regulator kaca samping.............................................390 Gambar 14.32 Konstruksi kaca membuka samping...........................391 Gambar 15.1 Tegangan normal dan tegangan geser .......................394 Gambar 15.2 Regangan linier dan regangan geser...........................395 Gambar 15.3 Diagram regangan tegangan .......................................396 C12Gambar 15.4 Kerusakan bodi akibat tabrakan ..................................397 Gambar 15.5 Proses menekuk...........................................................397 Gambar 15.6 Bagian tekukan memiliki konstruksi lebih kuat.............398 Gambar 15.7 Bagian dilas dan kompresi akan menjadi kuat.............398 Gambar 15.8 Menggunakan vacuum cup..........................................400 Gambar 15.9 Menggunakan bumping spoon.....................................400 Gambar 15.10 Menarik dengan melubangi panel..............................401 Gambar 15.11 Peralatan perbaikan bodi hidrolik...............................402 Gambar 15.12 Panel ditarik dengan baut atau dilubangi...................402 Gambar 15.13 Menggunakan pry bar.................................................403Gambar 15.14 Teknik on-dolly hammering........................................404Gambar 15.15 Urutan memukul teknik on-dolly hammer...................404Gambar 15.16 Melatih pukulan..........................................................405 Gambar 15.17 Meratakan plat............................................................406 Gambar 15.18 Teknik off-dolly hammer.............................................406Gambar 15.19 Arah pengikiran..........................................................407 Gambar 15.20 Teknik hot shrinking....................................................407Gambar 15.21 Bentuk plat yang dipanasi..........................................408 Gambar 16.1. Baterai.........................................................................411 Gambar 16.2. Konstruksi kabel tegangan rendah..............................412 Gambar 16.3. Kabel pengapian..........................................................412 Gambar 16.4. Konstruksi kabel berisolasi..........................................413 Gambar 16.5 Pelindung Kabel...........................................................413 Gambar 16.6. Junction Block dan rellay block...................................414 Gambar 16.7. Pengaman fusible link, relay danfuse.........................414Gambar 16.8. Baut massa pada bodi.................................................415 Gambar 16.9. Pemasangan fuse .......................................................416 Gambar 16.10. Macam Konektor.......................................................416 Gambar 16.11. Sekring catridge dan blade........................................417 Gambar 16.12. Fusible link.................................................................418 Gambar 16.13. Circuit breaker...........................................................419 Gambar 16.14. Switch (saklar)...........................................................420 Gambar 16.15. Relay.........................................................................420 Gambar 16.16. Relay, konstruksi dan simbolnya...............................420 Gambar 16.17. Aplikasi relay pada lampu utama...............................421 Gambar 16.18. Wiring Diagram Sederhana.......................................421 Gambar 16.19. Contoh simbol-simbol komponen elektronik..............422 Gambar 16.20. Lampu penerangan...................................................422Gambar 16.21. Lampu belakang........................................................423 Gambar 16.22. Dimmer switch...........................................................423 Gambar 16.23. Lampu utama tipe sealed..........................................424 Gambar 16.24. Konstruksi Bola Lampu Biasa dan Halogen..............424 Gambar 16.25. Coloumb Switch ........................................................425Gambar 16.26. Lampu rem................................................................425 Gambar 16.27 Lampu sein ketika bekerja..........................................426 Gambar 16.28. Lampu kota dan plat nomor ......................................426 C13Gambar 16.29. Lampu hazard ketika bekerja....................................427 Gambar 16.30. Lampu mundur ketika bekerja...................................427 Gambar 16.31. Lampu ruangan ketika bekerja.................................427 Gambar 16.32 .Lampu depan.............................................................428 Gambar 16.33. Menyetel jarak lampu................................................428 Gambar 16.34. Lampu Kombinasi......................................................430 Gambar 16.35. Konstruksi wiper depan dan belakang.......................430 Gambar 16.36. Motor wiper................................................................431Gambar 16.37. Gerakan wiper...........................................................431Gambar 16.38. Tuas Wiper................................................................432Gambar 16.39. Wiper Blade...............................................................432Gambar 16.40. Washer......................................................................433Gambar 16.41.Tangki Washer...........................................................433Gambar 16.42. Motor Washer............................................................434Gambar 16.43. Circuit diagram motor wiper.......................................435Gambar 16.44. Meter Kombinasi........................................................436 Gambar 16.45. Fuel gauge unit (sensor) dan fuel gauge...................437Gambar 16.46. Temperatur gauge.....................................................438Gambar 16.47. Diagram alir refrigrant................................................440 Gambar 17.1. Kompresor two stage...................................................442Gambar 17.2. Unit kompresor berpenggerak motor listrik..................443 Gambar 17.3. Unit kompresor dengan penggerak motor...................443 Gambar 17.4. Air pipe line/ saluran pemipaan...................................444 Gambar 17.5. Regulator dan Filter Udara (Transformer)...................445Gambar 17.6. Selang Fleksibel spiral.................................................446Gambar 17.7. Selang Fleksibel roll....................................................446Gambar 17.8. Bagian dalam ruang cat (Spray Booths)......................447Gambar 17.9. Ruang Cat (Spray Booths)..........................................447Gambar 17.10 Ruang multi fungsi untuk pengecatan dan oven........448 Gambar 17.11 Lampu pemanas pada oven.......................................449Gambar 17.12 Prinsip kevakuman.....................................................449Gambar 17.13 Atomisasi cat..............................................................450Gambar 17.14 Tipe spraygun.............................................................450Gambar 17.15 Konstruksi Spraygun..................................................451Gambar 17.16 Setelan fluida..............................................................451Gambar 17.17 Fan spreader..............................................................452Gambar 17.18 Setelan Udara.............................................................452Gambar 17.19 Fluid tip.......................................................................453Gambar 17.20 Cap.............................................................................453Gambar 17.21 Kipas...........................................................................454Gambar 17.22 Kerja spraygun...........................................................454Gambar 17.23 Konstruksi spraygun...................................................455Gambar 17.24 Spraygun model pressure-feed..................................456Gambar 17.25 Kerugian spraygun model pressure-feed...................457Gambar 17.26 Spraygun model grafity-feed......................................457Gambar 17.27 Spraygun model pressure-feed..................................458C14Gambar 17.28 Aliran SpraygunModelPressure-feed........................458Gambar 17.29 Tangki Cat SpraygunmodelPressure-feed...............459Gambar 17.30 Pen Brush Kit..............................................................459Gambar 17.31 Blok Tangan...............................................................460 Gambar 17.32 Sanders Tipe Elektrik.................................................460 Gambar 17.33 Sanders Tipe Pneumatic............................................460Gambar 17.34 Batang pengaduk/paddle............................................461Gambar 17.35 Spatula/pisau dempul/kape........................................461 Gambar 17.36 Pistol Udara/Duster ...................................................462Gambar 17.37 Mixing Plate................................................................462Gambar 17.38 Kertas Maskingdan Mesin Pemotongnya..................463 Gambar 17.39 Masker Pernafasan....................................................463 Gambar 18.1 Amplas tipe rol dan lembaran.......................................465 Gambar 18.2 Permukaan kikis amplas...............................................466 Gambar 18.3 Amplas fiber..................................................................467 Gambar 18.4 Air Polisher...................................................................468 Gambar 18.5 Masking Paper..............................................................472 Gambar 18.6 Spesial Masking Cover.................................................473Gambar 18.7 Masking Tape...............................................................474 Gambar 18.8 Gap Tape......................................................................475 Gambar 18.9 Masking untuk weatherstrip.........................................475 Gambar 19.1 Spot Repainting............................................................479 Gambar 19.2 Spot RepaintingReverse Masking................................479 Gambar 19.3 Masking pintu...............................................................479 Gambar 19.4 Masking Blok Repainting..............................................480 Gambar 19.5 Masking quarter panel..................................................480 Gambar 19.6 Masking Ujung Kendaraan...........................................481 Gambar 19.7 Border pada gap diantara panel-panel.........................481 Gambar 19.8. Border pada body sealer.............................................482 Gambar 19.9 Masking tape pada lebar body sealer...........................482 Gambar 19.10 Border pada garis karakter.........................................483 Gambar 19.11 Border pada bagian yang rata....................................483 Gambar 19.12 Bagian Kendaraan yg dimasking lepas......................484 Gambar 19.13 Border Masking pintu belakang..................................484 Gambar 19.14 Masking pada handel luar pintu belakang..................484 Gambar 19.15 Masking bagian lipatan pintu belakang......................485 Gambar 19.16 Masking area belt molding..........................................486 Gambar 19.17 Masking bagian luar pintu belakang...........................486 Gambar 19.18 Masking area flange depan pintu belakang................487 Gambar 19.19 Masking bagian dalam pintu depan............................487 Gambar 19.20 Pemasangan vinyl sheet............................................488 Gambar 19.21 Masking tepi belakang pintu depan............................488 Gambar 19.22 Masking kaca pintu belakang.....................................488 Gambar 19.23 Masking quarter panel kendaraan..............................489 Gambar 19.24 Masking rumah roda dan roda....................................489C15Gambar 19.25 Menggerakkan Spray Gun..........................................490 Gambar 19.26 Jarak yang sesuai.......................................................490 Gambar 19.27 Jarak pengecatan........................................................491 Gambar 19.28 Posisi penyemprotan...................................................491Gambar 19.29 Kecepatan konstan.....................................................492 Gambar 19.30 Over lapping vertikal...................................................493Gambar 19.31 Over lapping horizontal...............................................493Gambar 19.32 Pengecatan sudut.......................................................494Gambar 19.33 Over lapping pada sambungan...................................494 Gambar 19.34 Spot repainting`...........................................................497 Gambar 19.35 Membersihkan spraygun.............................................497Next >