Buku Teknik Bodi Otomotif Jilid 1 Kelas 10 SMK

Materi Teknik Bodi Otomotif Jilid 1

Pengantar Direktur Pembinaan SMK .................................... . i
Pengantar Penulis ............................................................... ii
Daftar Isi ................................................................................ . iii
Peta Kompetensi .................................................................. . viii

JILID 1
1. Pendahuluan.................................................................. . 1
1.1. Sejarah Bodi Kendaraan ........................................... . 2
1.2. Konstruksi Bodi Kendaraan ....................................... . 4
1.3. Desain Bodi Kendaraan............................................. . 9
1.4. Mesin ........................................................................\. . 13
1.5. Metode Sambungan .................................................. . 16
1.6. Metode Perbaikan Bodi ............................................. . 18
1.7. Pengecatan ............................................................... . 19
2. Keselamatan dan Keselamatan Kerja .......................... . 22
2.1. Sebab-sebab Kecelakaan Kerja ................................ . 23
2.2. Bahaya Terjadinya Kebakaran .................................. . 30
3. Menggambar Teknik...................................................... . 40
3.1. Peralatan gambar ...................................................... . 40
3.2. Dasar Menggambar Teknik ....................................... . 46
3.3. Proyeksi ..................................................................... . 49
3.4. Ukuran ....................................................................... . 52
3.5. Toleransi .................................................................... . 54
3.6. Simbol-simbol ............................................................ . 55
4. Alat-alat Ukur................................................................. . 57
4.1. Penggaris (Mistar) ..................................................... . 57
4.2. Penggaris Siku .......................................................... . 59
4.3. Straightedge .............................................................. . 60
4.4. Meter Pita .................................................................. . 60
4.5. Busur derajat ............................................................. . 61
4.6. Screw Pitch Gauge .................................................... . 62
4.7. Jangka sorong ........................................................... . 62
4.8. Dial indicator .............................................................. . 64
4.9. Spooring .................................................................... . 66
4.10. Tram gauge ............................................................... . 67
4.11. Wheel Balancer ......................................................... . 67
4.12. Tyre gauge ................................................................ . 69
4.13. Tracking ..................................................................... . 69

5. Alat-alat Tangan ............................................................. . 71
5.1. Obeng ........................................................................\. 72

5.2. Kunci pas dan ring ..................................................... . 74
5.3. Kunci Shock............................................................... . 75
5.4. Kunci hexagonal dan kunci bintang .......................... . 79
5.5. Kunci Inggris .............................................................. . 80
5.6. Kunci pipa .................................................................. . 82
5.7. Kunci momen............................................................. . 82
5.8. Tang ........................................................................\
.. . 84
5.9. Gunting dan pemotong plat ....................................... . 85
5.10. Palu ........................................................................\
... . 86
5.11. Dolly........................................................................\
... . 90
5.12. Body spoon................................................................ . 92
5.13. Gergaji ....................................................................... . 92
5.14. Kikir........................................................................\
.... . 94
5.15. Pahat ........................................................................\
. . 95
5.16. Penitik ........................................................................\
. 97
5.17. Penggores ................................................................. . 97
5.18. Jangka penggores ..................................................... . 98
5.19. Skrap ........................................................................\
. . 100
5.20. Ragum/ cekam .......................................................... . 100
5.21. Sikat logam ................................................................ . 102
5.22. Kape dempul ............................................................. . 103
5.23. Tap dan snei .............................................................. . 103
5.24. Bolt Ectractor ............................................................. . 107

6. Alat-alat Hidrolik............................................................ . 108
6.1. Pengertian ................................................................ . 109
6.2. Alat-alat Pengangkat ................................................. . 110
6.3. Hydraulic Power Jack ................................................ . 114
6.4. Atachment ................................................................. . 117
6.5. Peralatan Tekan ........................................................ . 120
6.6. Peralatan Tarik .......................................................... . 121
6.7. Body-Frame Straighteners ........................................ . 123
6.8. Anchor pots ............................................................... . 127
6.9. Keselamatan kerja dengan peralatan hidrolik ........... . 132

JILID 2
7. Las Oxyacetylene .......................................................... . 133
7.1. Teori Dasar Las Oxyacetylene .................................. . 133
7.2. Acetylene ................................................................... . 134
7.3. Oksigen ..................................................................... . 137
7.4. Api Oxyacetylene....................................................... . 137
7.5. Peralatan Las Oxyacetylene...................................... . 141
7.6. Bahan tambah ........................................................... . 162
7.7. Prosedur pengelasan dengan Oxyacetylene............. . 162
7.8. Pemotongan dengan Oxyacetylene .......................... . 180
8. Las Busur Nyala Listrik ................................................. . 188
8.1. Klasifikasi las busur nyala listrik ................................ . 188
v v
8.2. Prinsip las busur nyala listrik ..................................... . 189
8.3. Parameter pengelasan .............................................. . 192
8.4. Peralatan las busur nyala listrik ................................. . 195
8.5. Perlengkapan mengelas ............................................ . 203
8.6. Prosedur pengelasan busur nyala listrik ................... . 206

9. Teknik Pematrian........................................................... . 229
9.1. Proses terjadinya ikatan patri .................................... . 232
9.2. Prosedur dan aturan dasar pematrian ....................... . 234
9.3. Klasifikasi pematrian secara umum ........................... . 244
9.4. Peralatan pematrian .................................................. . 250
9.5. Pematrian lunak pada logam berat............................ . 252
9.6. Pematrian Keras pada logam berat ........................... . 253
9.7. Aplikasi Sambungan Pematrian pada beberapa
Konstruksi .................................................................. .
260
9.8. Keseamatan Kerja ..................................................... . 266

10. Metode Sambungan ...................................................... . 268
10.1. Rivets (keling) ............................................................ . 268
10.2. Sekrup (screw) .......................................................... . 275
10.3. Baut dan mur ............................................................. . 277
10.4. Push-On clip .............................................................. . 299
10.5. Perekat/Adhesive ...................................................... . 306

JILID 3
11. Abrasive dan Peralatan ................................................. . 315
11.1. Material abrasive ....................................................... . 315
11.2. Peralatan abrasive..................................................... . 318
11.3. Peralatan Pendukung ................................................ . 325
11.4. Keselamatan Kerja dan Prosedur menggerinda........ . 331

12. Fiberglass....................................................................... . 334
12.1. Bahan pembuat fiberglass ......................................... . 336
12.2. Peralatan Fiberglass.................................................. . 339
12.3. Pembuatan fiberglass ................................................ . 340
12.4. Perbaikan bodi fiberglass .......................................... . 343
12.5. Keselamatan kerja ..................................................... . 344

13. Komponen Bodi Kendaraan ......................................... . 345
13.1. Konstruksi Luar.......................................................... . 345
13.2. Konstruksi Dalam ...................................................... . 346
13.3. Lantai ........................................................................\
. . 347
13.4. Engine hood .............................................................. . 348
13.5. Fender ....................................................................... . 352
13.6. Cowl dan Dash Panel ................................................ . 354
13.7. Atap Kendaraan......................................................... . 354

13.9. Pillar Tengah ............................................................. . 356
13.10. Pintu Kendaraan ............................................ 357
13.11. Deck Lid .................................................................. . 361
13.12. Bumper ................................................................... . 363
13.13. Kaca Kendaraan ..................................................... . 364
13.14. Plafon Kendaraan ................................................... . 365
13.15. Tempat Duduk ........................................................ . 368
13.16. Dashboard Kendaraan ............................................ . 370
13.17. Grill dan Moulding ................................................... . 372

14. Kaca Kendaraan............................................................ . 373
14.1. Peralatan, perawatan dan perbaikan kaca ................ . 374
14.2. Adhesive (perekat) .................................................... . 376
14.3. Windshield ................................................................. . 380
14.4. Kaca Belakang .......................................................... . 386
14.5. Kaca samping ............................................................ . 389

15. Teknik Perbaikan Bodi .................................................. . 392
15.1. Tegangan dan Ragangan .......................................... . 394
15.2. Teknik vacuum cup.................................................... . 399
15.3. Teknik Batang Penarik dengan sliding hammer ........ . 400
15.4. Teknik Perbaikan dengan alat hidrolik....................... . 402
15.5. Teknik batang pengungkit (pry bar) ........................... . 403
15.6. Teknik On-Dolly Hammering ..................................... . 403
15.7. Teknik Off-Dolly Hammering ..................................... . 406
15.8. Teknik Pengikiran ...................................................... . 406
15.9. Teknik Hot Shrinking ................................................. . 407
15.10. Teknik Pemotongan bodi ........................................ . 408

16. Kelistrikan Bodi ............................................................. . 410
16.1. Baterai ....................................................................... . 410
16.2. Jaringan Kabel........................................................... . 412
16.3. Kawat dan kabel ........................................................ . 412
16.4. Komponen Pelindung ................................................ . 413
16.5. Komponen Penghubung ............................................ . 413
16.6. Baut massa................................................................ . 415
16.7. Sambungan (connector)............................................ . 416
16.8. Pengaman sirkuit ....................................................... . 417
16.9. Switch dan rellay ....................................................... . 419
16.10. Wiring Diagram ....................................................... . 421
16.11. Sistem Penerangan ................................................ . 422
16.12. Wiper dan Washer .................................................. . 430
16.13. Meter kombinasi...................................................... . 435
16.14. Air Conditioner (AC) ................................................ . 439

17. Peralatan Pengecatan ................................................... . 442
17.1. Kompresor Udara ...................................................... . 442
17.2. Air Transformer/Regulator ......................................... . 444
17.3. Selang Udara............................................................. . 445
17.4. Ruang Cat (Spray Booths) ........................................ . 446
17.5. Ruang Pemanas (Oven) ............................................ . 448
17.6. Spray Gun ................................................................. . 449
17.7. Air brush pen kit......................................................... . 459
17.8. Blok Tangan .............................................................. . 459
17.9. Sander ....................................................................... . 460
17.10.Pengaduk/ Paddle ..................................................... . 461
17.11.Spatula (Kape) ......................................................... . 461
17.12. Pistol Udara ............................................................ . 462
17.13. Papan Pencampur .................................................. . 462
17.14. Kertas Masking ....................................................... . 462
17.15. Masker Pernafasan ................................................. . 463
18. Bahan-bahan Pengecatan ............................................. . 464
18.1. Refinishing Material ................................................... . 464
18.2. Cat ............................................................................. . 468
18.3. Masking ..................................................................... . 471
19. Proses Pengecatan ....................................................... . 476
19.1. Persiapan Permukaan ............................................... . 476
19.2. Aplikasi Dempul ......................................................... . 477
19.3. Pengamplasan........................................................... . 477
19.4. Prosedur Masking...................................................... . 478
19.5. Pengoperasian Spraygun .......................................... . 489
19.6. Pengecatan Akhir ...................................................... . 494
19.7. Spot Repainting ......................................................... . 497
19.8. Membersihkan spraygun ........................................... . 497
19.9. Pengkilapan dan pemolesan ..................................... . 498

Daftar Pustaka ................................................................
Glosarium .......................................................................


A1-A3
B1-B7