engine oil DATSUN 210 1979 Workshop Manual

INSPECTION

Entire

system

I

Make
a

thorough
vjsual
check
of

E

G
R

control

system
If

necessary

wipe
away
oil
to
facilitate

inspection

If

any
hoses

are
cracked
or

broken

replace

2

With

engine
stopped
inspect

E

G
R

control
valve
for

any
indication

of

binding
or

sticking
by

moving
dia

phragm
of
control
valve

upwards
with

a

finger

3
With

engine
running
inspect

E

G
R

control
valve
and
thermal
vacu

um
valve
for
normal

operation

1
When

engine
coolant

tempera

tun
is
low

Make
sure
that
E

G
R

control
valve

does

not

operate
when

engine
speed
is

increased
from

idling
to
3
000
to

3

500

rpm

Place
a

finger
on
the

diaphragm
of

E
G
R

control
valve
to
check
for
valve

operation

EC773

Fig
EC
73

Checking
E
G
R
Control

2

When

engine
coolant

tempera

tureishigh
Emission
Control

System

Make

sure
that
E
G

R
control
valve

operates
when

engine
speed
is
in

creased
from

idling
to
3
000
to
3
500

rpm
Place

fingers
on
the

diaphragm
of

E

G
R
control
valve
to
check
for
valve

operation

If
E
G

R
control
valve
does

not

operate
check
as
follows

Disconnect
one
end
E

G
R

control

valve
side

of
vacuum
hose
connect

ing
ihermal

vacuum
valve
to

E
G
R

control
valve

Increase

engine
speed
from

idling
to

3
000
to
3

500

rpm

Make
sure
that

thermal
vacuum

valve
is

open
2

port
type
or

closed
3

port
type
and

that
car

buretor
vacuum
is

present
at
the

end
E
G
R

control
valve
side
of

vacuum
hose

If

vacuum
is

weak
or

not

present
at

all

replace
thermal

vacuum
valve
If

vacuum
is

present
check
E
G
R

control
valve
or
B
P

T
valve

If

any
difficulty
is
encountered
in

judging
the
condition
of

any
com

ponent
during
above

inspection
check

the

questionable

component
in

dependently
as
follows

U

S
A

models

Ie

EC160A

Canada
models

ET429

Fig
EC
74

Checking
Vacuum

of

E
G
R
Control
Valve

EC
25
E
G
R
control
valve

Dismount
E
G

R
control
valve

from

engine

I

Apply
vacuum
to
E
G
R
control

valve

referring
to
the

following
figure

If
the
valve
moves
to
full

position
it
is

normal

E

G
R

control
valve
will
remain

open
for
more
than

30
seconds
after

vacuum
has
cut
off

5t
orr

rl

1

1

Fig
EC
75
EC129A

Checking
E
G
R
Control

Valve

2

Visually
check
E
G
R
control

wive
for

damage
wrinkle

or
deforma

tion

3

Clean
the

seating
surface
of

E
G
R
control
valve
with
a

brush
and

compressed
air
and

remove

foreign

matter
from
around
the
valve
and

port

Fig
EC

76

Cleoning
E
G
R
Control

Valve

Thermal
vacuum
valve

3

port
type

Remove
thermal
vacuum
valve
from

engine
Inhale
air

from

port
ofE
G
R

system
and
check
to
be
sure
that

thermal
vacuum
valve

opens
or
closes

in

response
to
its

temperature

Thermal

vacuum
valve

dosing

temperature

Above
50

to
630
C

122
to
1450
F

e

In
o

L

1

Ignition
switch

2
Vacuum
switching

v3
lve

3

Top
detecting
switch

4
Function
check
connector

EC330A

i

Fig
EC
99

Checking
Top
Detecting

l

Switch

Vacuum

dela
valve

Remove
vacUum

delay
valve

2

Blow
air
from
th

port
of

the

distributor
side
The
vacuum

delay

valve
is
in

go
ij
condition
if
the
air

flows

through
the
valve

3

Try

again
from
the
opposit

side

of
the
valve
Th
valve
is
in

goo

condition
if
th
a
flow
resistance
is

greater
than

the

step
2
abov

Distributor
side

Carburetor
side

Distribu
tor
side

Carburetor
side

EC346

Fig
EC
100

Checking
Vocuum

Dewy
Valve
Emission

Control

Syst
m

4

If
the
condition
of

spark
delay

valve
is

questionable
dip
port
into

a

cup
filled
with
water
Blow
air
from

brown
face
side
Small
air
bubbles

should

appear

CAUTION

Be
c
areful
to
avoid

entry
of
oil
or
dirt

into
valve

7

E
C279

Fig
EC
101

Checking
Vacuum

D

lDy
Valve

CATALYTIC

CONVERTER

California
dels

DESCRIPTION

1

The

catalytic
converter

accelerates

the

chemical
reaction
of

hydrocarbons

CD
0
He
and

carbon
monoxide
O
in

the
exhaust

gas
and

changes
them
into

non
harmful

carbon
dioxide

C02

and
water

H20
This
chemical

reac

tiOD

process
requires
the

proper
a

mount
of
air
which
is

supplied
by
the

air

pump
Refer
to
the
item
AJ

S

This
air
is
called

secondary
air

The

Catalytic
converter
is
mounted

0

the
models
destinbd
for
California

OPERATION

Exhaust

gas
emitted

from
the
en

gine
contains

some
harmful
substances

due
to

incomplete
combustion
in

the

combustion
chamber
The
air

injection

stem
i

designed
to
reduce
the

con

tent
of

such
substances
in

the
exhaust

gas
In
this

system
the

secondary
air

is

led
from
the
ch
ck
valve
and

injected

in
o
the

exhaust
manifold
With
this

injection
of

the

secondary
air

hydro

carbons

He
and
carbon
monoxide

CO
in
the

exhaust

gas
are
gradually

oxidized
with

oxygen

02
in
the

secondary
air

and
converted
into
nOD

harmful
carbon
dioxide

C02
and

water

HP

The

catalytic
converter
further

cleans

engine
exhaust

gas
Through

catalytic
action
it

changes
residual

hydrocarbons
and

carbon
monoxide

contained
in

exhaust

gas
into

carbon

dioxide
and
water
before
exhaust

gas

is

discharged
to
the

atmosphere

0

Secondary
air

Carbon
monoxide

hydrocarbon

Carbon
dioxide

gas

Nater

EC

i

A

I
Front
tube

2

Catalytic
converter

3
Center
tube

4
Main
murner

EC
33
EC215

Fig
EC

I02
Function
of

Catalytic
Converter

REMOVAL

AND

INSTALLATION

I

Jack

up
the

car

Note

Apply
parking
brake
and

place
wheel

chocks

2
Remove

screws

securing
lower

shelter
of

catalytic
converter

Loosen

flange
bolt

connecting

catalytic
converter
to

front
and

rear

exhaust
tube

Catalytic
converter

assembly
can

then
be
taken
out

3

Installation
i
in
the

reverse
se

quence
of
removal

CAUTION

a
Be

careful
not
to

damage
catalytic

co
when

handliilg

b
Never
wet

catalyzer
with
water
oil

etc

t
J

Tightening
torque

Catalyti
converter
bolts

2
6
to
3
4

kg
m

19
to
25
ft
lb
Emission
Control

System

EC075A

EC076A

Fig
EC
103

Removing
Catalytic

Converter

INSPECTION

PrelimInary
In
pectlon

Vi

ually
check
condition
of
all

component

parts
including
hose

tubes
and
wires

replace
if

necessary

Refer
to
Air

Injection

System
for

inspection

EC
34
Catalytic
converter

Whether

catalytic
converter
is

nor

mal
or
not
can
e

checked

by
ob

serving
variation
in
CO

percentage

The
checking

procedure
is

as
follows

Apply
parking
brake
Shift

gears

into

Neutral
for
manual
transmis

sion

and
N
or

P
for

automatic

transmission

position

I

Adjust
engine
idling

speed
and

CO

percentage
Refer
to

Adjusting

Carburetor
Idle
RPM
and

Mixture

Ratio
for

adjustment

2
Race

engine
1
500

to
2
000

rpm

two
or

three
times

under
no
load
and

make
sure

that

specified
CO

percent

age
obtained

3
Remove

cap
and
connect

air
hose

to
air

check
valve

If

idling
speed
increases

readjust

it
to

specified
speed
with
throttle

adjusting
screw

4

Warm

up
engine
for
about
four

minutes

at
2
000

pm
under
no
load

S

Measure

Ci
percentage
at

idling

speed
After

stepAhas
been

complet

ed
wait
for

one
minute
before

making

CO

percentage
measurement

6
If
CO

percentage
measured
in

step
5
is

less
than
0
3
the

catalytic

converter

is
normaL

7

If
CO

percentage
measured
in

step
5
is

over
0
3
recheck
AJ
S
and

1

replace
air
check
valVe

The
perform

inspection
steps
4

and
S

8

If
CO

percentage
is

still
over
0
3

in

step
7

catalyt
iC

converter
i

mal

functioning
Replace
catalytic
con

verter

DATSUN

210
Model

8310
Series

SECTIONEE

ENGINE
ELECTRICAL
SYSTEM

CONTENTS

BATTERY

CHECKING
ELECTROLYTE
LEVEL

CHECKING

SPECIFIC
GRAVITY

CHARGING

INSTALLATION

STARTING
MOTOR

STARTING
CIRCUIT

CONSTRUCTION

REMOVAL
AND
INSTALLATION

DISASSEMBL
Y

CLEANING
AND
INSPECTION

ASSEMBL
Y

TEST

CHARGING

CIRCUIT

ALTERNATOR

DESCRIPTION

REMOVAL

DISASSEMBLY

INSPECTION
AND
REPAIR

ASSEMBLY

ALTERNATOR
TEST

REGULATOR

DESCRIPTION

INSPECTION

IGNITION

CIRCUIT
EE
2

EE
2

EE
2

EE
3

EE
3

EE
4

EE
4

EE
5

EE
6

EE
6

EE
6

EE
8

EE
8

EE
10

EE
13

EE

13

EE
14

EE
14

EE
14

EE
16

EE
17

EE
1B

EE
18

EE

18

EE

20
DESCRIPTION

DISTRIBUTOR

CONSTRUCTION

CHECKING
AND

ADJUSTMENT

I
ISASSEMBL
Y
AND
ASSEMBLY

IC
IGNITION
UNIT

DESCRIPTION

REMOVAL
AND

INSTALLATION

CHECKING
IC

IGNITION
SYSTEM

IGNITION
COIL

SPARK

PLUG

INSPECTION

CLEANING
AND
REGAP

SERVICE

DATA
AND

SPECIFICATIONS

GENERAL
SPECIFICATIONS

INSPECTION
AND
ADJUSTMENT

TIGHTENING
TORQUE

TROUBLE

DIAGNOSES
AND

CORRECTIONS

I
BATTERY

II
STARTING
MOTOR

III
ALTERNATOR

Including
voltage
regulator

IV
IGNITION
CIRCUIT
EE
20

EE
22

EE
22

EE
23

EE

23

EE
24

EE
24

EE
25

EE
25

EE
28

EE
29

EE

29

EE
29

EE
30

EE
30

EE
31

EE
33

EE

34

EE
34

EE
35

EE
36

EE
37

CONSTRUCTION

NON

REDUCTION
GEAR
TYPE

6

00

1

Magnetic
switch
assembly

2
Dust
cover

Adjusting
washer

3
Torsion

spring

4

Shift
lever

5
Dust
cover

6
Thrust
washer

7
E

ring

8
Rear
cover

metal

9

Through
bolt

10
Rear
cover

11
Brush
holder

12
Brush
U

Ul
@

13
Brush

spring

14
Brush

IS
Yoke

16
Field
coil

17
Armature

18
Center
bracket

19
Pinion

assembly

20
Dus

t
cover

21
Pinion

stopper

22

Stopper
clip

23
Gear
case

24

Gear
case
metal

REDUCTION
GEAR
TYPE

1

Magnetic
switch

assembly

2
Dust
cover

AdjUsting
was
r

3

Torsion

spring

4

Shift

lever

5

Through
bolt

6
Rear
cover

7

O

ring

8
Yoke

9
Field
coil

10
Brush

11
Armature

12

Ceo
tel

bearing

13
Brush

spring

14
Brush
holder
6

8
Engine
Electrical

Systeni

3

@

1

E
E660

Fig
EE
6
Non
Reduction
Gear

Type
Starting
Motor

4

4

15
Dust
cover

16
Center

housing

17
Reduction

gear

18
Pinion

gear

19

Packing

20
Gear
case
EE614

Fig
EE
7
Reduction
Gear

Type
Starting
Motor

EE
5

REMOVAL
AND

INSTALLATION

Disconnect

battery
ground
cable

Disconnect
harness

connector
and

battery
cable

at

magnetic
switch

2
Remove

bolts

securing
starting

motor
to
transmission

case
Pull

start

iog
motor

forward
and

remove
it

3
Inst
1I

starting
motor
in

reverse

order
of

removal

DISASSEMBLY

NON
REDUCTION
GEAR

TYPE

I
Disconnect

connecting
plate
from

M

terminal
of

magnetic
switch
Re

move
two

screws

securing
magnetic

switch
and
remove

magnetic
switch

assembly

2
Remove

dust
cover
E

ring
and

thrust
washer
s

EE311
@@

O

Fig
EE

8
Removing
DUll
Cover

E

ring
and
ThrUJJt

Washer

3
Remove
two
screws

securing

brush
holder

assembly

EE318

Fig
EE

9
Removing
Bru
h
Hold

Setacrews
Engine
Electrical

ystem

4
Remove
two
ihrough
bolts
and

rear
cover

5
Remove

brushes
from
their

hold

er

by
moving
each
brush

spring
away

from
brush
with
a
hook

Remove

brush
holder

6
Remove

yoke
assembly
and
with

draw

armature
assembly
and
shift

lever

7
Remove

pinion
stopper
located
at

the
end
of
armature
shaft
To
remove

stopper
first
move

stopper
toward

pinion
and
after

removing
stopper
clip

remove

stopper
with

overruniling

clutch
assembly
from
armature
shaft

EE271

Fig
EE

lg
Rf

moving
Pinion

Stopper

REDUCTION
GEAR
TYPE

1

Disconnect

connecting
plate
from

M
terminal
of

magnetic
switch
Re

move
two
screws

securing
magnetic

switch
and
remove

magnetic
switch

assembly

Note

Torsion

spring
can
be

pulled
off

magnetic
switch

2
Remove

through
baIts
and
rea

cover

Note

Rear
cover
can
be

pried
off
with

a
f1at
blade
screwdriver
inserted
be

tween
it

and

yoke
Be

careful
not

to
damage

packing
while

removing

reaf
cover

3
Remove

yoke
armature
and

brush
holder
as

an
assembly
from

center

housing

CAUTION

When

removing
be
careful
not
to

knock
brush
commutator
or
coil

against
any
adjacent
part

EE
6
o

7

EE615

Fig
EE
ll

Removing
Yo
and

Armature

4
To

remove
brush
holders

proceed

as
follows

I
Remove

brush
on

positive
side

from
its
holder

Note
Brush
on

positive
side
differs
in

that
it
is
isolated
from
brush
holder

and
its

lead
wire
is
connected
to

field
coil

2

Carefully
lifting
brush
on

nega

tive
side

away
from
commutator
sur

face
remove
it

from
brush
holder

EE616

Fig
EE
12

Removing
Br
h

5
Remove
bolts

securing
center

housing
to

gear
case
and
detach
center

housing

6
Remove

pinion

gear

CLEANING
AND

INSPECTION

Clean

all
disassembled

parts
but
do

not
use

grease
dissolving
solvents
for

cleaning
overrunning
clutch
armature

assembly
magnetic
switch

assembly

and
field
coils
since
such
a

solvent

would
dissolve

grease
packed
in
clutch

mechanism
and
would

damage
coils
or

other
insulators

Check
them
for
excessive

damage

or
wear
and

replace
if

necessary

TERMINAL

Check
terminal
for

damage
and

wear
and

replace
magnetic
switch

assembly
if

necessary

FIELD
COIL

Check
field
coil
for
insulation
If

the
insulation
of
oil
is

damaged
or

worn
it
should
be

replaced

Testing
field
coil
for

continuity

Connect
the

probe
of
a
circuit

tester
or
an
ohmmeter
to
field
coil

two

positive
terminal
of

positive
brush

holder

If
tester
shows
no

continuity
field

circuit

or
coil
is

open

Replace
it

Fig
EE

13

Testing
Field
Coil

for
Continuity

Testing
field

coli
for

ground

Place
one

probe
of
circuit
tester

onto
yoke
and
the
other

of
to
field

coil
lead

positive
terminal

If

very
little
resistance
is

read
field

coil
is

grounded

Replace
it

I

EE017

Fig
EE
14

Testing
Field
Coil

for
Ground
Engine
Electrical

System

BRUSHES
AND
BRUSH

LEAD
WIRE

Check
the
surface
condition
of

brush
contact
and
wear
of
brush
If
a

loose

contact
is
found
it
should
be

replaced

If
brush
is

worn
so
that
its
length
is

less
than

specified
value

replace

Minimum

length
of
brush

Non
reduction

gear
type

12
mm
0
47
in

Reduction

gear
type

11
mm
0
43
in

Check
the
connection

of
lead

clip

and
lead
wire

Check
brush
holders
and

spring
clip

to
see
if

they
are
not
deformed
or

bent
and
will

properly
hold
brushes

against
the
commutator

If

brushes
or
brush
holders
are

dirty
they
should
be
cleaned

BRUSH
SPRING
TENSION

Check
brush

spring
tension

by
a

spring
scale

as
shown
in

Fig
EE
l
5

If
it
is

faulty
replace
it

Spring
tension

Non
reduction

geaf
type

1
4
to
1
8

kg
3
1
to
4
0
Ib

Reduction

gear
type

1
6
to

2
0

kg
3
5
to
4
4
Ib

I

r

4
1

0
5

to
0
8
rom

O

iO

Correct

EE
7
ARMATURE
ASSEMBLY

Check
external

appearance
of

arma

ture
and

oommutator

I

Inspect
commutator
If
the

sur

face
of
commutator
is

rough
it
must

be
sanded

lightly
with
No
500

sand

paper
If

the

depth
of

insulating
mica

is

less
than
0
2
mm
0
008
in
from

commutator
surface

insulating
mica

should
also
be
undercut

so
that
its

depth
is
0
5

to
0

8
mm
0

020
to

0
031
in

The

wear
limit
of
commutator
dia

meter
is
I

mm
0
04
in
If
the

diameter
of
commutator

is
less
than

specified
value

replace
armature

assembly

Diameter
limit

Non
reduction

gear
type

32

mm
1
26
in

Reduction

gear
type

29
mm
1
14

in

I
@

EE018

Fig
EE

15
Inspecting
Bnah

Spring

Tension

c

I

File

Commutator

nt

I

1

11
Mica

Incorrect

EE021

Fig
EE
16

Undercutting
Imulating
Mica

2

Inspect
silldered
conneetibn
of

armature

lead
and

commutator
If

loose
connection
is
found

solder
it

using
resin
flux

3
Armature
test

for

ground

Using
a

circuit
tester

place
one
test

probe
onto
armature
core
or
shaft
and

other
onto
each

commutator
bar

If
tester

shows

continuity
armature

is

grounded
and
must
be

replaced

L
L

I

EE022

F
EE
17

Teating
Armature

for

Ground

4
Check

armature
for
short

by
plac

ing
it
on

armature
tester

growler

with
a

piece
of
iron

over
arma
t
ure

core

rotating
armature
If
the

plate

vibrates
armature
is

shorted

jeBel

EE023

Fig
EE

18

Testing
Armature
or

Short

5

Check
armature
for

continuity
by

placing
probes
of
tester
on
two

seg

ments
side

by
side
If
tester
shows
no

continuity
the
circuit

is

open

OVERRUNNING
CLUTCH

ASSEMBLY

Inspect
pinion
assembly
and
screw

sleeve
or

reduction

gear
Screw
sleeve

must
slide

freely
along
armature
shaft

splines
or

pinion

gear
shaft
must
slide

freely
through
reduction

gear
If

dam

age
is
found
or
resistance

except
nor

mal
resistance
due
to

spring
felt

when

sliding
it

must
be

repaired

Inspect

pinion
teeth
If
excessive

rubbing
is

found
on

teeth

replace
Flywheel
ring

gear
also
must
be

inspected
Engine
Electrical

System

@

ll

EE278

Fig
EE
19

Overrunning
Clutch

Assembly

1
Pinion

gear

2

Reduction

gear

EE617

Fig
EE
20
Pinion
and

Reduction

Gear

Overrunni11C
Clutch

AS5em

bly

BRUSH
HOLDER
TEST

FOR

GROUND

Using
a

circuit
tester

place
one
test

probe
onto

negative
side
of
brush

holder
and
another
onto

positive
side

If

tester
shows

continuity
brush
hold

er

is
shorted
to

ground
Replace
brush

holder

EE025

Fig
EE

21

Testing
Brush

for

Ground

BEARING
METAL

Non
reduction

gear
type

spect
bearing
metal
for

wear
or

side

play
If
the
clearance
between

bearing
metal
and
armature
shaft
is

more
than
0
2
mm

0
008
in

replace

metal

EE

8
BAI
L

BEARING

Reduction

gear
type

Holding
outer
race
with

finger

rotate

bearing
to
see
if
there
is

any

play
or
bind
If

necessary
replace

bearing

MAGNETic

SWITCH

ASSEMBLY

I

Using
a
circuit
tester

check
con

tinuity
between
S

terminal
of

mag

netic
switch
and

switch

body
metal

If

continuity
does
not
exist

shunt
coil
is

opened

Replace
switch

assembly

2
In
the

same
manner
as
above

check

continuity
between
terminals

S
and
M

If

continuity
does
not

exist
series
coil
is

opened

Replace
switch

assembly

ASSEMBLY

Reassemble

starting
motor
in
re

verse

sequence
of

disassembly

When

assembling
be
sure
to

apply

grease
to

gear
case

and
rear
cover

bearing
metal
and

apply
oil

lightly
to

pinion

TEST

PERFORMANCE
TEST

Starter
motor
should
be

subjected

to
a
no
load
test
whenever
it

has

been

overhauled

to
ensure
that

its

perfo
rmance
will
be

satisfactory
when

installed
on

engine
Starter
motor

should
also
be

subjected
to
the
test

when
the

cause
of
abnormal

operation

is

to
be
determined
A
brief
outline
of

the
test
is

given
below

No

loadtest

Connect

starting
motor
in
series

willi

specified
12
volts

battery
and

an
ammeter

capable
of

indicating

1

000

amperes

Specified
current
draw
and
rev6lu

tion
in
this
test
are
shown
in

Sp
ci

Cications

Starting
motor

S

DIAGNOSES
OF
TEST

I
Low

speed
with
no
load
and

high

current
draw

may
result
from
the

following

I
Tight
dirty
or
worn

bearings

2
Bent

armature
shaft
or

loosened

field

probe

3
Shorted
armature

Check
armature
further

4
A

grounded
armature
or
field

a
Remove

input
terminal

b
Raise
two

negative
side
brushes

from
commutator

c

Using
a
circuit

tester

place
one

probe
onto

input
terminal
and
the

other

onto

yoke

d
If

tester
indicates

continuity

raise

the
other
two
brushes
and
check

field

and
armature

separately
to
deter

mine

whether
field
or

armature
is

grounded

2
Failure
to

operate
with

high
cur

rent

draw
may
be

caused

by
the

following

I
A

grounded
or

open
field
coil

Inspect
the
connection
and

trace

circuit

with
a
circuit
tester

2
Armature
coil
does
not

operate

Inspect
commutator
for
excessive

burning
In
this

case
arc

may
occur
on

damaged
commutator
when
motor
is

operated
with
no
load

3

Burned
out

commutator
bar

Weak

brush

spring
tension
broken
Engine
Electrical

System

Switch

Battery

Vultmeter
Ammeter

EE738

Fig
EE

22
No
load

Testing

brush

spring
rubber
bush
thrust
out

of
mica

in

commuta
tor
or
a

loose

contact
between
brush
and

conunuta

tor
would
cause
commutator
bar

to

burn

3
Low
current

draw
and
low

no

load

speed
would

cause

high
internal

resistance
due
to
loose

connections

damaged
leads

dirty
commutator
and

causes
listed
on
item
2
3

MAGNETIC

SWITCH

ASSEMBLY
TEST

Switch

2

1
6

11

p
IB
b

I

Battery
Starter
motor

EE351

Fig
EE

23
Circuit

of
Magnetic

Switch

Assembly
Test

If
the

starting
motor

check
is

OK
check

magnetic
switch
assem

bly
Connect

cables
between

negative

battery
terminal

and
start

ing
motor
M

terminal

positive

battery
terminal

and

starting
motor

8
terminal

connecting
a

switch
in

series

as
shown
above

EE
9
Non
reduction

gear
type

With
the
switch

on

push
pinion

back
to
remove
all

slack
and
measure

the
clearance
between

pinion

front

edge
and

pinion
stopper

Clearance
L

0
3

to
2
5
mm

0
012
to
0

098
in

EE644

Fig
EE
24

Measuring
Clearance

l

Reduction

gear
type

Compare
difference
2
in

height

of

pinion
when
it
is

pushed
out

with

magnetic
switch
energized
and
when
it

is

pulled
out

by
hand
until
it
touches

stopper

Difference

L

0
3

to
1
5

mm

0
012
to
0
059
in

Pull

out

by

hand
until

pinion
stops
Push
out

1

1

n

11

r

L

Difference
EE688

Fig
EE
25

Measuri
g
Difference
L

If

necessary

adjust
it

by

changing

or

adding

adjusting
washer
s

Adjust

ing
washers
are
available

into

two

different
sizes
0
5

mm
0

020
in
and

0

8
mm
0
031

in

The

charging
circuit
consists
of
a

battery
an

alternator

incorporating
an

IC

voltage
regulator
and

wiring
that

connects
these

parts

The

purpose
of

this

system
is
to

convert
mec
hanka

energy
from
the

engine
into
electrical

energy
which
is

used
to

operate
all

electrically
operat

ed
units
and
to

keep
the

battery

fully

charged

With
the

ignition
switch
in
ON
the

circuit
between

transistor
uTr

I
of
the

lC

voltage
regulator
and

ground
is

closed
Current
from
the

battery
then

flows

along
the
route

shown

by
the

arrOW
in

Fig
EE
26

turning
on
the

charge

warning
lamp
and

flowing
on

through
terminal
L

to
excite
the

rotor

When
the
alternator

begins
to

oper

ate
three

phase
alternating
current
is
ngine
Elect
ical

System

CHARGING
CIRCUIT

indicated

in
the
stator

coil
This
alter

nating
current
is

rectified

by
the

posi

tive
and

negative
silicon

diodes

When
the

voltage
at
terminal
8
is

higher
than

battery
voltage
current

produced
at
the

stator
flows

to
re

charge
the

battery
While
the

battery
is

being
re

charged
the

voltage
at
termi

nal
L

is

equal
to
that
of
terminal

8
At
this

point
there
is
no

voltage

differential
on
either
side
of
the

charge

warning
lamp
which
causes
the

charge

warning
lamp
to
turn
off
In

other

words
current
does

not
flow
from
the

battery
to
terminal
L

Accordingly

current
flow

through
the
rotor
as

shown
in

Fig
EE
27

is
taken
over

by

current

produced
at
the
stator
The

circuit
between
terminal
F
and

Tr
is

then
closed
See

Fig
EE
27

The
IC

voltage
regulator
monitors
generating
voltage
to
be

applied
to
the

battery
at
terminal
S
When
current

exceeds
the

specified
value
it
then

flows

through
the
zener
diode
ZD

closing
the

circ
it

consisting
of

transis

tor
Tr
and
resistor

R1
At
this

point
current
neither
flows

through

transistor
Tr

I
to

ground
nor
to
the

rotor

thereby

reducing
the

voltage

generated
at
the

stator
See

Fig

EE
28

When

voltage
generated
at
terminal

S
is

reduced
to
the

specified
value

transistor

allows
current
to
flow

through
the

rotor

increasing
the

generating
voltage

In

this
manner

output
voltage
from

the
alternator
does

not
rise
above
the

specified
value

by
the
ON
OFF

opera

tion

of
the

rotor
coil

through
the
IC

voltage
regulator

16

L

R
l
I

01
0

ls

CHARGE
LAMP

J
011

L

e
0

u

a

M
e

i
J

0

io
o
IGNITION

a

0

09

SWITC1
R2

El1
STATOR
COIL

04
0
R

F

1
BATTERY

8

ZD

ALTERNATOR

7
I

1
AJ

TI
3

IC
VOLTAGE
REGULATOR
Aa

E

1

7

EE760

Fig
EE
26

Simplified
Charging
Circuit
Initial
excitation

current

EE
10