1. STARTER TESTING AND OVERHAUL
Teknik Kendaraan Ringan
Semester 3th Class XI
Kompetensi Kejuruan
SK-KD 18

2. DIAGRAM ALUR PENCAPAIAN KOMPETENSI

3. Disassembly Motor Starter
(Toyota Step 2 Electrical Group)
Dissasembly motor starting system according to picture
Teknologi dan Rekayasa

4. Disassembly Motor Starter Disassembly Motor Starter
1. Disconnect cable at C
terminal
2. Replace magnetic switch
3. Replace bolt, trhough
bolt and rear end cover.
4. Replace spring and
brush.
Teknologi dan Rekayasa

5. Disassembly Motor Starter
5. Replace brush holder.
6. Replace armature assy
6. Replace yoke assy.
7. Replacing bushing dan snap
ring
Teknologi dan Rekayasa

6. Inspection and Testing
A. FIELD COIL TESTING
OPENS CIRCUIT INSPECTION
Use Ohmmeter and continuity
SHORT TO GROUND INSPECTION
Use Ohmmeter and no continuity
Teknologi dan Rekayasa

7. (Pro Technician Toyota Astra Motor)
Inspection and Testing
B. ARMATURE UNIT TESTING
(Pro Technician Toyota Astra Motor)
Short to ground circuit Open circuit
(no continuity) (continuity)

8. Inspection and Testing
Run out komutator and armature unit (Spec. look at manual book)
Outside diameter komutator
(spec. look at manual book)
Width of comutator segmen
(spec. look at manual book)
Short armature circuit with growler
Teknologi dan Rekayasa 8

9. Inspection and Testing
C. BRUSH AND STARTER CLUTCH
Measure brush thickness
(specifikasi: look at manual book)
Pinion can be rotate at one
way and lock at other direction
Teknologi dan Rekayasa

10. Inspection and Testing
C. INSPECT PINION GEAR
Check teeth condition
Teknologi dan Rekayasa

11. Inspection and Testing
D. MAGNETIC SWITCH TESTING
Check plunger and spring
Check pull in coil
Check hold in coil
Teknologi dan Rekayasa

12. Assembly Motor Starter by Disassembly Method Reverse
Teknologi dan Rekayasa

13. Performance Testing Motor Stater
Use three cable, one cable at positif batteray terminal and connect to 50 terminal, two cable at negatif batteray terminal and connect to C terminal and body
After testing pull in coil as soon as disconnect cable from C terminal
Teknologi dan Rekayasa

14. Performance Testing Motor Stater
After testing hold in coil as soon as disconnect cable from body
Use three cable, one cable at negatif batteray terminal and connect to body, two cable at positif batteray terminal and connect to 30 terminal and 50 terminal
Teknologi dan Rekayasa

15. TROUBLESHOOTING FOUR CATEGORIES PROBLEMS NO CRANK SLOW CRANK
SPINS BUT NO CRANK
EXCESSIVE NOISE
Teknologi dan Rekayasa

16. THROUBLESHOOTING PROCEDURES
CONSISTENT METHOD
VISUAL INSPECTION
BATTERY PERFORMANCE
VERIFY ENGINE CONDITION IF NO CRANK OR SLOW CRANK

17. THROUBLE SHOOTING TABLENO
COMPONENT
PROBLEM AREA 1
Magnetic Switch
Dirty at main contact
Disconnect or short pull-in coil
Disconnect or short hold-in coil
Pluger stucks
Ground disconnect 2
Motor Starter
Disconnect or short field coil
Disconnect or short armatur
Short at comutator or bad thickness
Bad isolator
Bad at brush spring
Bushing timeworm 3
Over Running Clutch
Slip 4
Pinion Gear
Broken gear 5
Stater Relay
Broken 6
ST ignition
Bad contacted 7
Batteray
Dirty terminal
Low power

18. BIBLIOGRAPHY:
Kevin Sullivan, www. Autoshop101.com
Step 2 Electrical Group, Toyota Astra Motor

19. Compiled by Nanang Nurdiyanto SMK Negeri 1 Magelang
SEE YOU LATER!!!
Compiled by
Nanang Nurdiyanto
SMK Negeri 1 Magelang