BBPP MPV BMTI/Automotive Reskilling & Upskilling 2020

LK 3. STARTING SYSTEM REPAIR

VEHICLE DATA Example

Type Daihatsu TAFT
Vehicle Identification No.
(VIN)
Engine No.
License No. D. 1326 SY, or
Training Unit
Odometer 750 km

Safety Inspection
Description Available** Not Availble**
Fender Cover*
Seat Cover*
Floor Mate*
Steering Cover*
Chooker/Ganjal (Front and Rear Tyre)*
Wearpack*
Safety Shoes*
Safety Glass*
Safety Glooves*
Masker*
* All Personal Protective Equipment/PPE must be worn during practice in the workshop (photo)
** Give a Check Mark (Tick “√”) in the column where relevant, specify your real condition.

Persiapan / Preparation
Description Good** Bad**
Visual Check engine cleanless*
Visual Check Wiring harness condition & repaired*
Check Engine Oil Level & Condition*
Check Engine Cooling*
Check Battery Condition*
Multimeter, Digital
Multimeter, Analog
Vernier Caliper
Tools Set
Growler (if Available)
Battery Tester (if Available)
Workshop Manual
*Make sure the item must be corrected until all item in good condition.
** Give a Check Mark (Tick “√”) in the column where relevant, specify your real condition.

I. Observation

Description Nilai/Value Keterangan/Remarks

Capacity of Battery .................................................... --
AH
Battery Voltage .................................................. Volt Good/Poor/Bad
Type of Starter Motor - Conventional/Reduction/Planetary/P

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BBPP MPV BMTI/Automotive
Drive belt
II. Inspection of Starter Motor Components
A. Visual Inspection
- Isolator field coil
- Field coil
- Starting Motor Cable
Connections Point
- Starting Motor Cable
Connections Point
B. Inspection on Bench
1. State of Charge
- Check baterry Specific
Gravity
2. Check fusible link
3. Armature Coil
- Inspect commutator for
dirty and burnt
- Check that commutator
is not grounded
- Check commutator for
open circuit
- Run out of armature
- Depth of commutator
groove
- Diameter of commutator
- Overruning clutch
4. Brushes
- Length of brushes
- Measure Brush Spring
load with a pull scale
- Check insulation of brush
holder
Reskilling & Upskilling 2020
S
Good/Bad Visual check the belt from cracking
or separation of the ribs, worn ribs.
Hasil/Result Keterangan/Remarks
Good/Bad
Good/Bad
Good/Bad
Good/Bad
Cell 1 ............................. Check the amount of electrolyte in each
Cell 2 ............................. cell. If insufficient, refill with distilled
Cell 3 ............................. water
Cell 4 ............................. - Full Charge: ........... at 200C
Cell 5 ............................. - Result : Good/Bad
Cell 6 .............................
Continuity/No continuity Check the fusible links for continuity
Good/Bad If the surface is dirty or burn, clean it with
sand paper (N0. 400)
Good/Bad Using an ohm meter, check that there is
no continuity
Good/Bad Using an ohm meter, check for continuity
between the segment of the commutator
................................. Maximum circle run out : 0,4 mm. If the
mm run out is greater than maximum corret
on a lathe or replace
................................. Check that all segment are clean and free
mm of foregn particles. Correct the segment
groove with a hacksaw blade and smooth
out the edge
................................. - Minimum dia.: ................ mm
mm - Result : Good/Bad
Good/Bad Rotate the pinion clockwisw and check
that it turs freely. Try to ratate the pinion
counterclockwise and check that it locks
................................. Good/Bad
mm
.......................... kg/lb/N - Min. Intalled load: ........... kg/lb/N
- Result : Good/Bad
Good/Bad Check the fusible Using an ohm meter,
make sure that there is no continuity
between the positive and negative brush
holder
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BBPP MPV BMTI/Automotive
5. Field Coil
- Check field coil for open
circuit
- Check that field coil is not
gounded
6. Solenoid (magnetic
Switch)
- Plunger
- Pull in coil open circuit
test
- Hold in coil open circuit
test
- Perform Pull in coil test
- Perform Hold in coil test
- Pinion return test
7. No Load Test
C. Inspection On Vehicle
- Voltage drop (Battery
Cranking Voltage)
- Terminal 30 - ground of
solenoid
- Terminal 50 - ground of
solenoid
Note: Each activity must be completed by picture/photo
Reskilling & Upskilling 2020
Continuity/No continuity Using an ohm meter, check for continuity
between the fiel coil brush leads.
Continuity/No continuity Using an ohm meter, make sure that
there is no continuity between the fiel coil
end and field frame
Good/Bad Push in the plunger and release it. Check
taht it returns quickly to its original
position
Good/Bad Using an ohm meter, check for continuity
between terminal 50 and switc body
(ground), if there is no continuity, replace
magnetic switch
Good/Bad Using an ohm meter, check for continuity
between terminal 50 and terminal C.if
there is no continuity, replace magnetic
switch
Good/Bad Connect the battery to the magnetic
switch. Check that the pinion moves
outward
Good/Bad With the battery connected to the
magnetic switch and with the pinion out,
disconnect the negative lead from
terminal C. Check that the pinion remains
out
Good/Bad Disconnet the negative lead from the
switch body. Check that the pinion
retracts
.............................. Amp. - Specified current: .... Amp/11 V.
- Result : Good/Bad
.............................. Volt - Specification: .......... Volt
- Result : Good/Bad
.............................. Volt Good/Bad
.............................. Volt Good/Bad
……………………….., ……………………………… 2020
Trainee,
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