materi training

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1 1.ENGINE TUNE UP 2. ENGINE OVERHOULE 3. DIFFERENTIAL 4. S/T MOTOR & ALTERNATOR 5. BRAKE SYSTEM 6. HEAD LAMP & RELA

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Page 1: Materi training

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1.ENGINE TUNE UP 2. ENGINE OVERHOULE

3. DIFFERENTIAL 4. S/T MOTOR & ALTERNATOR

5. BRAKE SYSTEM 6. HEAD LAMP & RELAY

Page 2: Materi training

ENGINE TUNE UP , definisinya adalah :

Pekerjaan yang dilakukan terhadap suatu Engine dengan langkah meliputi : pemeriksaan , penyetelan , penggantian , pembersihan serta perawatan sesuai spesifikasi Standarisasi (STD) nya masing – masing Engine

Agar kondisi Engine tadinya ada masalah menjadi lebih prima kembali sehingga kemampuannya mendekati pada saat Engine tersebut kondisinya masih baru

Definisi ENGINE TUNE UP

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Kenapa diperlukan ENGINE TUNE UP ?

ENGINE TUNE UP , alasannya antara lain adalah :

1. Engine tenaganya kurang 2. Engine tersendat ( mbrebet ) pada saat diakselerasi / digas 3. Engine tidak stabil / pincang waktu Idling / stasioner 4. Engine saat ada beban AC , Pwr steer , Electrical load . ( Rpm nya menjadi turun / tidak stabil ) 5. Konsumsi bahan bakar boros dibandingkan STD nya 6. Engine noise / suara berisik di mekanisme Valve nya 7. Engine mogok total / tidak mau hidup sama sekali 8. Perawatan / Periodical Maintenance setiap 5.000 km

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Persiapan untuk ENGINE TUNE UP ?

ENGINE TUNE UP , persiapannya meliputi :

a. Tools Caddy ( Open wrench , offset wrench , screw driver , torque wrench , combination

pliers , sochet & rachet handle , dsb )b. Fender cover , seat cover , T/M handle cover & steering cover c. Buku panduan / workshop manual ( standarisasi Engine )d. Spesial Tools & alat ukur ( dwell , tacho meter , timing light , hidrometer ,

radiator cap tester , vaccum tester & compression tester , dsb )e. Peralatan pendukung ( air gun & compressor , selang pembuangan gas buang

, washing pan , part stand , kain lap , amplas , grease secukupnya )

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Open wrench

Torque wrenchSocket & rachet handle

Fender cover Offset wrench

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Std Bj Batere = 1.270 ( warna hijau )

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Langkah kerjanya Proses ENGINE TUNE UP ?

A . Pekerjaan ENGINE TUNE UP ( saat engine masih dingin ) : 5. Pemeriksaan & pengukuran Ignition system ( Coil, Disributor ,

spark plugs cable , spark plugs ) & kinerja Vac Chamber , Sentrifugal.

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Langkah kerjanya Proses ENGINE TUNE UP ? A . Pekerjaan ENGINE TUNE UP ( saat engine masih dingin ) :

5. Pemeriksaan & pengukuran Ignition system ( Coil, Disributor , spark plugs cable , spark plugs ) & kinerja Vac Chamber , Sentrifugal.

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Std = 0.75 – 0.80 mm

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Langkah kerjanya Proses ENGINE TUNE UP ? A . Pekerjaan ENGINE TUNE UP ( saat engine masih dingin ) :

5. Pemeriksaan & pengukuran Ignition system ( Coil, Disributor , spark plugs cable , spark plugs ) & kinerja Vac Chamber , Sentrifugal.

Dicheck kondisi carbonnya

Std Tahanan Cable busi = < 12.5 k.ohm

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Dicheck kondisi Carbon nya

Std tahanan Cable busi < 12.5 k.ohm

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A. Pekerjaan sebelum Engine hidup , yaitu :

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A . Pekerjaan ENGINE TUNE UP ( saat engine masih dingin ) : 5. Pemeriksaan & pengukuran Ignition system ( Coil, Disributor ,

spark plugs cable , spark plugs ) & kinerja Vac Chamber , Sentrifugal.

Page 16: Materi training

Langkah kerjanya Proses ENGINE TUNE UP ? A . Pekerjaan ENGINE TUNE UP ( saat engine masih dingin ) :

5. Pemeriksaan & pengukuran Ignition system ( Coil, Disributor , spark plugs cable , spark plugs ) & kinerja Vac Chamber , Sentrifugal.

Kinerja dari sentrifugal Advance

Kinerja dari Vaccum Advance/oktan selektor

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Kinerja dari Centrifugal Advance

Kinerja dari Vacum Advance & Oktane selector

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Langkah kerjanya Proses ENGINE TUNE UP ?

A . Pekerjaan ENGINE TUNE UP ( saat engine masih dingin ) : 5. Pemeriksaan & pengukuran Ignition system ( Coil, Disributor ,

spark plugs cable , spark plugs ) & kinerja Vac Chamber , Sentrifugal.

Ignition coil with external Resistor

Ignition coil with internal Resistor

Pemeriksaan Primary Coil = 0,9 - 1,6 ohm

Pemeriksaan Secondary coil = 10,0 - 13,5 k.ohm

Pemeriksaan external resistor = 1,2 - 1,6 ohm

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Pemeriksaan external resistor = 1.2 – 1.6 ohm

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Cara penyetelan fan belt

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Valve Clearance Exh = 0,3 mmIn = 0,20 mm

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Std Torque = 5.5 – 6.5 kgm Valve Clearance Exh = 0,3 mmIn = 0,20 mm

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Langkah kerjanya Proses ENGINE TUNE UP ?

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Pemeriksaan / pengukuran Engine Overhoule , meliputi :

1. Kelengkungan Cyl Head & Crank Shaft.2. Oil Clearance Piston & Cylinder.3. Keovalan & Ketirusan Cylinder Liner.4. Oil Clearance Crank Pin Journal Crankshaft & B/g Connecting Rod.5. Oil Clearance Main Journal Crank Shaft & Main B/g Cyl Block. 6. Ring Piston End Gap No. 1 & 2 .7. Ring Piston & Groove side clearance pada Ring piston No.1 , 2 & 3.

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan / pengukuran Engine Overhoule , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan / pengukuran Engine Overhoule , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan / pengukuran Engine Overhoule , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan / pengukuran Engine Overhoule , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan / pengukuran Engine Overhoule , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan / pengukuran Engine Overhoule , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan / pengukuran Engine Overhoule , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan / pengukuran pada Differential , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

1. Reduction Gear Bachlash.2. Ring Gear Run Out.3. Side Bearing Starting Torque.4. Pinion Gear Starting Torque.5. Flens Yoke Run Out.6. Check Tooth Contact , posisi maju & mundur .

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Pemeriksaan / pengukuran pada Differential , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan / pengukuran pada Differential , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan / pengukuran pada Differential , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pengechekan Bachlash antara Side gear & Satelite Gear

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Pemeriksaan / pengukuran pada Differential , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Rumus menghitung Gear Ratio pada Differential

Rpm Axle shaft 1 sisi = Rpm E/g x Gear ratio Diff ( Pinion : Crown )Gear ratio T/M ( posisi masuk gigi )

Sehingga : Total putaran Axle shaft = kanan + kiri

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Pemeriksaan / pengukuran pada Differential , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan / pengukuran pada Differential , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan / pengukuran pada Differential , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan / pengukuran pada Differential , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan / pengukuran pada Differential , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Note :Jumlah film tooth contact sama dengan jumlah gigi pinion gear

Pengukuran dilakukan pada saat maju & mundur

Maju MundurBag.DalamBag.DalamBag.Luar Bag.Luar

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A. Pemeriksaan / pengukuran pada ALTERNATOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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A. Pemeriksaan / pengukuran pada ALTERNATOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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1. Alternator dengan IC Regulator System

Netral

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A. Pemeriksaan / pengukuran pada ALTERNATOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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2. Alternator dengan Tiiril / Voltage Regulator

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A. Pemeriksaan / pengukuran pada ALTERNATOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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2. Alternator dengan Tiiril / Regulator konvensional

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A. Pemeriksaan / pengukuran pada ALTERNATOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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1. B/g Front & Rear ( diputar )

2. Brush Alternator ( panjangnya )

3. Stator Coil ( Hub.terbuka & Kebocoran )

4. Rotor Coil ( Hub.terbuka & Kebocoran )

5. Diode ( Hub.dengan Terminal B Alternator )

6. Diode ( Hub.dengan Ground )

7. Pengechekan Stall Test ( saat Idle & Medium speed )

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A. Pemeriksaan / pengukuran pada ALTERNATOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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A. Pemeriksaan / pengukuran pada ALTERNATOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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A. Pemeriksaan / pengukuran pada ALTERNATOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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A. Pemeriksaan / pengukuran pada ALTERNATOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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A. Pemeriksaan / pengukuran pada ALTERNATOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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A. Pemeriksaan / pengukuran pada ALTERNATOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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A. Pemeriksaan / pengukuran pada ALTERNATOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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B. Pemeriksaan / pengukuran pada S/T MOTOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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1. Magnetic s/w2. Overunning Cluth3. Rotor Coil4. Stator Coil5. Brush6. Bushing S/T Motor Front & Rear7. Hold in Coil ( s/w magnetic ) & Pull in Coil ( s/w magnetic )8. Return Test Magnetic s/w & No Load Performance Test

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B. Pemeriksaan / pengukuran pada S/T MOTOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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B. Pemeriksaan / pengukuran pada S/T MOTOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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B. Pemeriksaan / pengukuran pada S/T MOTOR , meliputi :

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B. Pemeriksaan / pengukuran pada S/T MOTOR , meliputi :

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B. Pemeriksaan / pengukuran pada S/T MOTOR , meliputi :

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B. Pemeriksaan / pengukuran pada S/T MOTOR , meliputi :

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B. Pemeriksaan / pengukuran pada S/T MOTOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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B. Pemeriksaan / pengukuran pada S/T MOTOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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B. Pemeriksaan / pengukuran pada S/T MOTOR , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan & penyetelan pada BRAKE SYSTEM , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan & penyetelan pada BRAKE SYSTEM , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan & penyetelan pada BRAKE SYSTEM , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan & penyetelan pada BRAKE SYSTEM , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan & penyetelan pada BRAKE SYSTEM , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan & penyetelan pada BRAKE SYSTEM , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan & penyetelan pada BRAKE SYSTEM , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan & penyetelan pada BRAKE SYSTEM , meliputi :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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Pemeriksaan & merangkai HEAD LAMP & RELAY :

AUSTRALIAN RESCUE PARIS – DAKAR RALLY

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( Honda ) VTEC = Variable Valve Timing & Lift Electronic Control System ( Pengaturan di Rocker Arm nya )

( MITSUBISHI ) MIVEC = MITSUBISHI Innovative Valve Timing Electronic Control System. ( Pengaturan di Rocker Arm nya ) ( Toyota ) VVT-I = Variable Valve Timing – Inteligent ( Pengaturan di Cam shaft sprocket nya ) ( Honda ) VTC = Variable Timing Control

( Pengaturan di Cam shaft Sprocket nya )

( Honda ) i-DSI = Inteligent Dual & Sequential Ignition ( Menggunakan 2 pcs busi & Pengaturan di Ignitionnya )

( MITSUBISHI ) CRS = Common Rail System ( Sistem Diesel Engine Inj.Pump less )