DCV 1044 AMALAN BENGKEL

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1 DCV 1044 AMALAN BENGKEL TOPIK 2: PERALATAN BENGKEL Disampaikan oleh: Muhammad Amirul bin Abdullah Unit Automotif, KKBD cikguamirul.wordpress.com

2 TOPIK 2.0 PERALATAN BENGKEL 2.1 PENGENALAN KEPADA PERALATAN BENGKEL 2.2 MENGENAL PASTI PERALATAN TANGAN ASAS 2.3 MENGENAL PASTI PERALATAN TANGAN AUTOMOTIF 2.4 MENGENAL PASTI PERALATAN BERKUASA 2.5 MENGENAL PASTI PERALATAN PENGUKURAN 2.6 MENGENAL PASTI PERALATAN MENGANGKAT BAHAN DAN KENDERAAN

3 2.1 PENGENALAN KEPADA PERALATAN BENGKEL

4 Alatan tangan digunakan dalam proses melonggarkan dan mengetatkan skru / bolt / nat dalam bidang Automotif. Alatan tangan mestilah sesuai dengan bahan dan tujuan untuk mengelakkan kerosakan pada alat tangan, skru, bolt, atau nat. Kemahiran mengendalikan alatan tangan dan faktor keselamatan semasa menggunakan alatan juga perlu dijaga.

5 Bolts, screws and nuts Types of bolts Through Bolt Tap Bolt Stud Bolt Types of Nuts Hex Slotted Hex Castle (or Castellated) Collar Acorn Square Self-Locking Interference Self-Locking Palnut Various Types of Screw heads Hexagonal Head Internal Hex (Allen) Fluted Phillips Round Head Flat Head Fillister Head Oval Head

6 Bolt and nut size indication B Hexagonal bolt Hexagonal nut M 10 x 1.25 Pitch Nominal diameter (d) B Metric Thread B 60 A D Pitch p Bolt (External Thread) Nut (Internal Thread) Thread nominal diameter D Diameter P Pitch B Width across flats M5 5mm 0.8mm 8mm M6 6mm 1mm 10mm M8 8mm 1.25mm 12mm M10 10mm 1.25mm or 1.5mm 14mm Examples of General Bolts and Nuts

7 Bolt and nut tightening torque 1kg (Mass) 1m 1 kg.f or 9.8N (Force in this case) 1 kg.f or 9.8N (Weight or force) 10cm (0.1m) 20cm (0.2m) 100kg.f x 0.1m = 1kg.m or 100N x 0.1m = 10N.m 10kg (100N) 100kg.f x 0.2m = 2kg.m or 100N x 0.2m = 20N.m 10kg (100N) Torque wrench

8 Bolt property class Thread Pitch Standard tightening Torque (Nm.cm, lb.ft) Head Mark 4 Head Mark 7 M ~ 4 (30 ~ 40, 2.2 ~ 2.9) 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3) M ~ 6 (50 ~ 60, 3.6 ~ 4.3) 9 ~ 11 (90 ~ 110, 6.5 ~ 8.0) M ~ 15 (120 ~ 150, 9 ~ 11) 30 ~ 50 (300 ~ 500, 22 ~ 36) M ~ 30 (250 ~ 300, 18 ~ 22) 60 ~ 80 (600 ~ 800, 43 ~ 58) M ~ 45 (350 ~ 450, 25 ~ 33) 120 ~ 140 (1,200 ~ 1,400, 85 ~ 100) M ~ 85 (750 ~ 850, 54 ~ 61) 120 ~ 140 (1,200 ~ 1,400, 85 ~ 100) M ~ 130 (1,100 ~ 1,300, 80 ~ 94) M ~ 180 (1,600 ~ 1,800, 116 ~ 130) M ~ 250 (2,200 ~ 2,500, 160 ~ 180) M ~ 330 (2,900 ~ 3,300, 210 ~ 240) M ~ 420 (3,600 ~ 4,200, 260 ~ 300) 180 ~ 210 (1,800 ~ 2,100, 130 ~ 150) 260 ~ 300 (2,600 ~ 3,000, 190 ~ 215) 360 ~ 420 (3,600 ~ 4,200, 260 ~ 300) 480 ~ 550 (4,800 ~ 5,500, 350 ~ 400) 610 ~ 700 (6,100 ~ 7,000, 440 ~ 505)

9 Washers, pins and keys Washer Nut (or screwhead) Lock Washer Flat Washer Plain Spring Lock External Tooth Lock Internal Tooth Lock Lock Washer Pins Keys Split pin Taper pin Straight pin Roll pin Square key Flat key Woodruff key

10 Correct usage of wrench and screwdriver No good No good OK No good OK Safety Precautions

11 2.2 MENGENAL PASTI PERALATAN TANGAN ASAS

12 60 OFFSET RING SPANNER OPEN-END SPANNER 10 OFFSET RING SPANNER RATCHETING RING SPANNER RING SPANNER

13 COMBINATION SPANNERS OPEN-END AND RING SPANNER OPEN-END AND SOCKET

14 SOCKET SPANNERS DOUBLE HEXAGONAL SINGLE HEXAGONAL TORX DRIVE EXTRA DEEP

15 SOCKET ACCESSORIES BREAKER RATCHET & SOCKET SET BREAKER EXTENSION

16 SOCKET ACCESSORIES SPEED BRACE BAR UNIVERSAL JOINT SLIDING HANDLE

17 SPECIAL RING SPANNERS C-SHAPE S-SHAPE FLARE NUT

18 ADJUSTABLE SPANNER

19 PIPE WRENCH STRAPWRENCH

20 SCREWDRIVERS PHILIPS FLAT TIP ELECTRICAL POZIDRIZ

21 POZIDRIZ

22 TOOL KIT WHEEL BRACE CROSS WHEEL BRACE

23 PLIERS COMBINATION SLIP JOINT LONG-NOSE BENT-NOSE

24 PLIERS MULTI-GRIP END-CUTTING DIAGONAL-CUTTING

25 CIRCLIP PLIERS CURVED EXTERNAL STRAIGHT EXTERNAL INTERNAL EXTERNAL CURVED INTERNAL STRAIGHT INTERNAL

26 VICE-GRIP PLIERS STANDARD GRIP LONG NOSE

27 BENCH VISE STANDARD VISE OFFSET VISE

28 CLAMPS SHEET METAL G-CLAMP SHEET METAL PIPE CLAMP

29 WELDING CLAMP

30 HAMMERS BALLPEIN MALLET CROSSPEIN CROSSPEIN

31 BRONZE-TIP PANEL BEATER PLASTIC HEAD

32 PUNCHES CENTRE PUNCHES PIN PUNCHES

33 HACKSAW

34 COLD CHISELS

35 FILES

36 METAL SHEARS &BOLTCUTTERS BOLTCUTTERS METAL CUTTING SHEARS

37 SCRIBER/PENGGARIT DIVIDER

38 TAP & DIE Taper Plug Bottoming Round cutting die Turn one turn forward Back out half a turn Cutting oil

39 EXTRACTOR Corrective steps against tightening failures Punch Pipe wrench Removal of Broken Bolt Using another screw Using a screw extractor Screw Extractor Removal of Broken Bolt remained within the thread

40 T-WRENCH

41 SPARK PLUG OPENER

42 AIR GUN

43 IMPACT SCREWDRIVER

44 Saiz kecil Saiz besar TYRE LEVER

45 TYRE INFLATION GAUGE

46 SCRAPER

47 2.3 MENGENAL PASTI PERALATAN TANGAN AUTOMOTIF

48 TORQUE WRENCH SKALA / BACAAN TORQUE

49 ANGLE TORQUE WRENCH DIGITAL TORQUE WRENCH

50 ALLEN KEY ANGULAR TORQUE GAUGE & SOCKET DRIVE TORX WRENCH

51 JENIS GELANG JENIS RANTAI JENIS TALI OIL FILTER OPENER JENIS PENUTUP

52 PISTON RING COMPRESSOR

53 PISTON RING OPENER

54 VALVE COMPRESSOR Valve

55 VALVE SEAL OPENER Valve Seat Valve Valve Seal

56 VALVE LAPPER SET

57 Valve core TYRE VALVE CORE OPENER

58 WEIGHT TOOL PLIER

59 TYRE REPAIR KIT

60 AUTOMOTIVE STETHOSCOPE

61 BEARING PULLER

63 SPECIAL SERVICE TOOL BOLT JOINT REMOVER

64 SPECIAL SERVICE TOOL COIL SPRING COMPRESSOR

65 SPECIAL SERVICE TOOL STEERING-WHEEL PULLER GUIDE & BUSH DRIVER BEARING INSTALLER

66 2.4 MENGENAL PASTI PERALATAN BERKUASA

67 PORTABLE AIR-OPERATED POWER TOOLS AIR DRILL AIR IMPACT WRENCH GASKET SANDER AIR RATCHET

68 PORTABLE ELECTRIC POWER TOOLS 240V DRILL 240V ANGLE GRINDER 240V DRILL WITH HANDLE 18V IMPACT WRENCH

69 AIR IMPACT WRENCH IMPACT SOCKET

70 SCREW AIR IMPACT SCREWDRIVER

71 HAND POLISH MACHINE

72 HYDRAULIC PRESS Pressure gauge Cradle lock pin Hydraulic pump

73 CUTTING MACHINE (DISC CUTTER)

74 BENCH GRINDER

75 DRILL MACHINE

76 2.5 MENGENAL PASTI PERALATAN PENGUKURAN

77 STEEL RULER

78 CALIPERS OUTSIDE CALIPERS INSIDE CALIPERS

79 TRY SQUARE (SESIKU-L)

80 FEELER GAUGE

81 FEELER GAUGE WIRE GAUGE

82 Rahang Dalam VERNIER CALIPER Badan Rahang Luar Skru Pengunci Skala Utama Skala Vernier Bilah Kedalaman

86 Bacaan Skala Utama yang hampir dengan 1 mm : 66 X 1.00 = mm Bacaan Skala Vernier senggatan yang ke-39 yang sejajar dengan skala satu garisan pada skala utama : 39 X 0.02 = 0.78 mm Jumlah = mm

87 Correct and incorrect usage of the Vernier Caliper Object to be measured Vernier scale jaw Incorrect usage Regular scale jaw A B C Regular scale Correct usage A B C Depth stick (Outside diameter) (Inside diameter) (Depth)

88 1. Bingkai 2. Andas 3. Spindal 4. Pengunci Spindal 5. Sarung 6. Jidal 7. Richet MICROMETER

89 Micrometer Anvil Spindle Tapered nut Sleeve Clamp lock Thimble Ratchet stop click click click

92 INSIDE MICROMETER

93 DEPTH GAUGES

96 MULTIMETER Digital Analog

97 BATTER TESTER

98 BATTERY HYDROMETER

99 COMPRESSION TESTER

100 TYRE PRESSURE GAUGE

101 TYRE THREAD GAUGE

102 AUTOMOTIVE SCAN TOOLS

103 AUTOMOTIVE STRAIGHT EDGE

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105 CYLINDER BORE DIAL GAUGE

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108 HOLE GAUGES

109 COMBINATION SET

110 SURFACE PLATE VEE BLOCKS

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112 2.6 MENGENAL PASTI PERALATAN MENGANGKAT BAHAN DAN KENDERAAN

113 ENGINE STAND

114 ENGINE HOIST

115 FLOOR JACK

116 CAR STAND

117 AUTOMOTIVE SCAN TOOLS

118 4 POST LIFT

119 SCISSOR LIFT

120 Garage jack, rigid rack and auto lift Saddle seat Saddle seat arm Handlebar Caster wheel Lift block Lift block Rigid Rack Auto Lift

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129 PENTAKSIRAN: KUIZ UJIAN AMALI

ACCREDITATION FACILITY AUDIT CHECKLIST

ACCREDITATION FACILITY AUDIT CHECKLIST Institution Name: Date: Designated Trade: Machinist AC #: Contact: Location: Course Duration: of weeks: of hours total: of hours per day: Instructor(s) of Students