DAFTAR ISI

HALAMAN JUDUL..................................................................................i
LEMBAR PERSETUJUAN LAPORAN PKL..........................................ii
LEMBAR PENGESAHAN LAPORAN PKL..........................................iii
LEMBAR PENGESAHAN LAPORAN PKL..........................................iv
ABSTRAK.................................................................................................v
KATA PENGANTAR................................................................................vi
DAFTAR ISI............................................................................................vii
DAFTAR GAMBAR.............................................................................. xi
DAFTAR TABEL...................................................................................xiv
DAFTAR LAMPIRAN............................................................................xv
BAB I PENDAHULUAN
1.1. Latar Belakang....................................................................................1
1.2. Tujuan Praktek industri.......................................................................2
1.2.1.Bagi Mahasiswa......................................................................................2
1.2.2.Bagi Lembaga Pendidikan......................................................................2
1.3. Manfaat Praktek Kerja Industri...........................................................2
1.3.1.Bagi Lembaga Pendidikan......................................................................2
1.3.2.Bagi Perusahaan......................................................................................3

BAB II KEGIATAN PRAKTIK KERJA LAPANGAN

2.1. Sejarah bengkel warsito......................................................................4
2.2. Struktur organisasi bengkel.................................................................4
2.3. Orientasi proses jasa dan pemasaran...................................................6
2.4.Kegiatan umum................................................................................7
2.4.1 Pengenalan bengkel....................................................................7
2.4.2. Ganti oli mesin...........................................................................7
2.4.3. Ganti oli transmisi......................................................................7
2.4.4. Ganti oli gardan..........................................................................7
2.4.5. Ganti filter oli.............................................................................8
2.4.6. Servis servis ringan pada mobil.................................................8
2.4.7. Memeriksa dan membersihkan busi...........................................8
2.4.8. Menyetel celah platina...............................................................8
2.4.9. Inspeksi berkala mobil pada 1000km.........................................8
2.4.10 Inspeksi berkala mobil pada 2000km........................................9
2.4.11.Inspeksi berkala mobil pada 10000km....................................10
2.4.12.Diagnosa sistem pengapian.....................................................10
BAB III KAJIAN PUSTAKA
3.1. Pemindah Daya.................................................................................11
3.2. Bagian bagian sistem pemindah daya...............................................11
3.2.1 Sistem kopling.......................................................................................12
3.2.2.Syarat kopling...................................................................................... 12
3.2.3 Bagian utama kopling.......................................................................... 12
3.2.4 Sistem transmisi................................................................................... 14
3.2.5 Syarat transmisi.....................................................................................14
3.2.6 Transmisi manual..................................................................................14
3.2.7 Tranmisi otomatis..................................................................................16
3.2.8 Sistem propeller shaft...........................................................................17
3.2.9 Sambungan universal............................................................................18
3.2.10 Sistem differential...............................................................................19
3.2.11 Fungsi differential...............................................................................20
3.2.12 Bagian-bagian utama differential........................................................20
3.2.13 Final gear...........................................................................................21
3.2.14 Differential gear..................................................................................22
3.2.15 Konstruksi differential........................................................................23
3.2.16 Cara kerja differential.........................................................................23

3.2.17 Bentuk rumah axle..............................................................................25

3.2.18 Perhitungan.........................................................................................26
3.2.19 Sistem poros penggerak roda..............................................................27
3.2.20 poros penggerak depan........................................................................27
3.2.21 poros penggerak belakang...................................................................27
BAB IV PEMBAHASAN SISTEM DIFFERENTIAL DAN REAR AXLE
SHAFT TOYOTA KIJANG 5K
4.1. Identifikasi Differential Pada Toyota Kijang 5K................................30
4.2. Identifikasi Rear Axle Shaft Pada Toyota Kijang 5K.........................31
4.3. Kerusakan Umum Yang Sering Terjadi..............................................31
4.4. Perawatan Dan Perbaikan...............................32
4.4.1. Tujuan servis..............................................................................32
4.4.2. Keselamatan kerja.....................................................................32
4.4.3. Alat dan bahan...........................................................................32
4.4.4. Melepas rear axle shaft ............................33
4.4.5. Pemeriksaan rear axle shaft. ............ 36
4.4.6. Perakitan rear axle shaft. ..................37
4.4.7. Perbaikan differential. ......................39
4.4.8. Pemeriksaan umum. .........................43
4.4.9. Pemasangan dan Penyetelan Pinion Penggerak........................43
4.4.10 Pemasangan dan Penyetelan Bak Differential..........................47
4.4.11 Pemasangan dan Penyetelan Unit Differential.........................49
4.4.12 Penyetelan Kontak Gigi Antara Roda Gigi Pemutar Dan Roda Gigi
Ring.....................................................................................................52
4.5. Gambar-gambar kunci SST................................................................54
4.5.1. Kunci SST untuk differential.....................................................54
4.5.2. Kunci SST untuk rear axle shaft.............................. ............55
4.6. Spesifikasi.......................................................................... ...............56
4.6.1. Spesifikasi differential...............................................................56
4.6.2. Spesifikasi rear axle shaft.........................................................56
4.7. Troubleshooting................................................................ .............56
BAB IV KESIMPULAN DAN SARAN

5.1. Kesimpulan.........................................................................................58
5.2. Saran ..................................................................................................58
DAFTAR PUSTAKA ..............................................................................60
LAMPIRAN

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DAFTAR GAMBAR
Gambar 2.1 Skema Organisasi Bengkel.....................................................5
Gambar 2.2 Skema aktifitas pkl.................................................................6
Gambar 3.1(a) Tipe FR........................................................................11
Gambar 3.1(b) Tipe FF.........................................................................11
Gambar 3.2(c) RR................................................................................11
Gambar 3.1(d) Tipe 4WD.....................................................................11
Gambar 3.2
Posisi kopling...............................................................12
Gambar 3.3
bagian utama kopling...................................................13
Gambar 3.4
Slidingmesh Type.........................................................14
Gambar 3.5
Constantemesh Type....................................................15
Gambar 3.6
Syncronmesh Type........................................................16
Gambar 3.7
Transmisi Otomatis......................................................16
Gambar 3.8
Poros Propeller............................................................17
Gambar 3.9
Hook Joint....................................................................18
Gambar 3.10
Flexsible Joint..............................................................18
Gambar 3.11
Trunion Joint................................................................19
Gambar 3.12
Slip Joint......................................................................19
Gambar 3.13
Putaran Propeller Diteruskan Ke Differential.............20
Gambar 3.14
Bagian Utama Differential...........................................20
Gambar 3.15
Hypoid Bevel Gear......................................................21
Gambar 3.16
Helical Gear................................................................21
Gambar 3.17(a) Prinsip Kerja Differential..............................................22
Gambar 3.17(b) Prinsip Kerja Differential.............................................22
Gambar 3.18
Kontruksi Differential..................................................23
Gambar 3.19
Cara Kerja Differential Saat jalan lurus.......................24
Gambar 3.20
Cara Kerja Differential Saat belok kanan....................24
Gambar 3.21
Cara Kerja Differential Saat belok kiri........................25
Gambar 3.22
Banjo Axle....................................................................25
Gambar 3.23
Spicer Axle...................................................................26
Gambar 3.24
Terompet Axle..............................................................26
Gambar 3.25
Tipe Semi Floating.......................................................28
Gambar 3.26
Tipe Floating............................................................28
Gambar 3.27
Tipe full Floating.........................................................29
Gambar 4.1
Bagian-bagian Differential..........................................30
Gambar 4.2
Bagian-bagian Rear Axle Shaft....................................31
Gambar 4.3
Mengendorkan Mur Roda............................................33
Gambar 4.4
Mendongkrak Kendaraan.............................................34
Gambar 4.5
Melepas Mur Oli Differential......................................34
Gambar 4.6
Melepas Backing Plate................................................34
Gambar 4.7
Melepas Poros Roda Belakang....................................34
Gambar 4.8
Menggerinda Dan Memotong Penahan Dalam............35
Gambar 4.9
Melepas Bantalan.........................................................35
Gambar 4.10
Melepas Stud Bold.......................................................36

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Gambar 4.11
Gambar 4.12
Gambar 4.13
Gambar 4.14
Gambar 4.15
Gambar 4.16
Gambar 4.17
Gambar 4.18
Gambar 4.19
Gambar 4.20
Gambar 4.21
Gambar 4.22
Gambar 4.23
Gambar 4.24
Gambar 4.25
Gambar 4.26
Gambar 4.27
Gambar 4.28
Gambar 4.29
Gambar 4.30
Gambar 4.31
Gambar 4.32
Gambar 4.33
Gambar 4.34
Gambar 4.35
Gambar 4.36
Gambar 4.37
Gambar 4.38
Gambar 4.39
Gambar 4.40
Gambar 4.41

Melepas Oil Seal..........................................................37

Memeriksa Kelengkungan Poros Dan Keolengan Flens 37
Pemasangan Bantalan Poros .......................................38
Pemasangan Cincin Pengunci......................................38
Pemasangan Paking Sim..............................................39
Melepas Baut Mur Sambungan Universal...................39
Melepas Mur Rumah Differential................................40
Melepas Baut Tutup Bantalan Dan Baut Penggunci....40
Melepas Mur Pengikat Gigi Pinion.............................41
Melepas Flame.............................................................41
Melepas Poros Roda Gigi Pemutar..............................42
Melepas Baut Pengunci Roda Gigi Ring....................42
Melepas Pin Pengunci..................................................42
MelepasPoros Pinion...................................................43
Menyetel Kedalaman Pinion langkah 1.......................44
Menyetel Kedalaman Pinion langkah 3.......................44
Menyetel Kedalaman Pinion langkah 5.......................45
Memasang Unit Pinion Penggerak..............................45
Memasang Oil Seal......................................................46
Menyetel Preload Mula................................................46
Memeriksa Gerak Bebas Roda Gigi Samping Dan Pinion 47
Memasang Poros Pinion Dan Pin Pengunci................48
Memasang Bantalan Sisi Kanan Dan Kiri..................48
Memasang Baut Penggunci Roda Gigi Ring...............49
Memasang Tutup Bantalan Dengan Menyatukan Tanda 49
Menyetel Backlash Roda Gigi Ring............................50
Menyetel Preload Komposit........................................51
Memasang Baut Tutup Bantalan Dan Pengunci..........52
Merusak Mur Flame....................................................54
Kunci SST Untuk Differential.....................................54
Kunci SST Untuk Rear Axle Shaft...............................55

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DAFTAR TABEL
Tabel 3.1
Tabel 4.1
Tabel 4.2
Tabel 4.3
Tabel 4.4

Perhitungan RPM Ring Gear.......................................27

Pola Kontak Gigi.........................................................52
Spesifikasi Differential................................................56
Spesifikasi Rear Axle Shaft..........................................56
Trooubleshoting...........................................................56

DAFTAR LAMPIRAN
Lampiran I

: Surat Pengantar PKL

Lampiran II

: Surat Keterangan Diterima PKL

Lampiran III

: Surat Keterangan Selesai PKL

Lampiran IV

: Lembar Monitoring Pembimbingan PKL

Lampiran V

: Lembar Presensi Kegiatan PKL

Lampiran VI

: Jurnal Kegiatan PKL

Lampiran VII : Lembar Penilaian PKL

Lampiran VIII : Lembar Revisi Seminar PKL

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