zLK 1.

PERBAIKAN SISTEM STARTER/STARTING SYSTEM REPAIR

DATA KENDARAAN / VEHICLE DATA Contoh/Example

Tipe / Type Toyota ……
Nomor Identifikasi
Kendaraan / Vehicle
Identification No.(VIN)
No. Mesin / Engine No.
Nomor Plat / License No. K. 1853 AV, Or
Training Unit
Odometer 750 km

Pengecekan Kelengkapan Keamanan/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*
* Gunakan APD selama melaksanakn praktek di bengkel (bukti foto)/All Personal Protective Equipment/PPE
must be worn during practice in the workshop (photo)
** Berikan tanda ceklis pada kolom yang sesuai kondisi sesungguhnya/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
* Lakukan pemeliharaan dan atasi kondisi mesin yang belum sesuai sebelum melanjutkan kegiatan/Make sure
the item must be corrected until all item in good condition.
** Berikan tanda ceklis pada kolom yang sesuai kondisi sesungguhnya/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/
PS
Drive belt Good/Bad Visual check the belt from cracking
or separation of the ribs, worn ribs.

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
Hasil/Result Keterangan/Remarks
Good/Bad
Good/Bad
Good/Bad
Good/Bad
Cell 1 ............................. Check the amount of electrolyte
Cell 2 ............................. in each cell. If insufficient, refill
Cell 3 ............................. with distilled 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.
mm If the run out is greater than
maximum corret on a lathe or
replace
................................. Check that all segment are clean
mm and free of foregn particles.
Correct the segment groove with
a hacksaw blade and smooth out
the edge
................................. - Minimum dia.: ................ mm
mm - Result : Good/Bad
- Overruning clutch
4. Brushes
- Length of brushes
- Measure Brush Spring load
with a pull scale
- Check insulation of brush
holder
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
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
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
- Voltage drop (Battery .............................. Volt - Specification: .......... Volt
Cranking Voltage) - Result : Good/Bad
- Terminal 30 - ground of .............................. Volt Good/Bad
solenoid
- Terminal 50 - ground of .............................. Volt Good/Bad
solenoid

……………………….., ……………………………… 2020

Peserta/Trainee,

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