DATSUN 510 1968 Service Repair Manual

96

CHAFTER
NINE

@

EK
lle

Correct

Incorrect

ground
As
shown
m

Figure
i
7

place
one
test

probe
onto
the
armature
shaft
and
the
other

probe
onto
each
commutator
bar

ContInuity

IndICates
a

groundt
and
the
armature
must
be

replaced

@

6
Check
the

armature
for
shorts

by
placmg
It

on
a

holdmg
fixture

holdmg
a
hack
saw
blade

over
the
core
and

rotatIng
the
armature
If
the

saw
blade
VIbrates
the
armature

Is
shorted
and

must
be

replaced

7
Check
for

contInuity
by
placmg
the

probes

of
a
tester
on
two
sIde

by
slde

segments
of
the

armature
No

current

passage
mdlcates

an

open

CIrcUIt
The

armature
must
be

replaced
If
read

mgs
are

InCOnslste
t

replace
the
armature

OVERRUNNING
CLUTCH
ASSEMBLY

1

Inspect
the

plmon
assembly
and

screw
leeve

The

screw
sleeve

must
slIde

freely
along
the

armature
shaft
If

damage
IS
detected
or
1f
It
does

not
move

freely
replace
It

Inspect
the

pmion

teeth
for

damage
and
wear

Replace
1f

required

2

Inspect
the
teeth

on
the

flywheel

nng
gear
for

mlssmg
or

damaged
teeth

If
defective
the

fly

wheel

must
be

replaced
BRUSH
HOLDER

1

Usmg
a
CirCUIt
tester

as
shown

In

Figure
18

place
one
test

probe
on
the

rear
cover
and
the

other

on
the

posltlve
SIde

of
the

brush
holder
If

the
tester
shows
conduction
the
brush
holder
IS

shorted
to

ground
or
the
msulator
IS
defective

Replace
the
brush
holder

@

STARTER

MOTOR
BEARINGS

1

Inspect
the

bearmgs
at
eIther
end
of
the
rear

cover
and
the

gear
case

assembly
If

they
show

SignS
of

sconng
or
other

damage
replace
them

Check
the

clearance
of
the
armature
shaft

to
the

bearmgs
It
should
be
less
than
0
0079

In

0
2mm

2
If
the

bearings
are

replaced
new

bearing

clearance
should
be
00012
to
00039

In
0
03

to
0
10mm

MAGNETIC
SWITCH
ASSEMBLY

1

Inspect
the

magnetic
sWItch
contacts
for
de

fects

and

damage
replace
1f

necessary

ASSEMBLY

To
reassemble
the
starter
motor

reverse
the

procedures
used

dUring
disassembly
When

as

sembly
has
been

completed
perform
the

follow

mg
tests

Testing

The
starter

motor
should
be

subjected
to
a

no
load
test
and
a
lock

torque
test

follOWIng

overhaul
to
ensure
that
Its

performance
will
be

satIsfactory
when
mstalled

on
the

engme
These

tests

are
also

helpful
In

detennmIng
the
cause

of

problems
before

dIsassembly

ENGINE
ELECI
RlCAL
SYSTEM
97

No
Load
Lock

Torque
Test

1
Connect
the
starter
motor
in
series
with

a

12
volt

battery
and
antmeter
as
shown
in

Figure

19
The
antmeter
should
be

capable
of

mdIcatIng

1
000

amps

@
Switch

Voltmeter
Ammeter

2
Use

torque
testlng
equipment
to
determine

the

torque
the
motor

develops

3
Connect
a
voltmeter
and
a
vanable
resistor

WhICh
IS
used
to

regulate
the

voltage
Into
the

circwt

4
Close
the
sWitch

and

regulate
the

voltage
as

reqUIred
Figure
20

proVIdes

power
voltage

amperage
and

torque
mformatIon

that
1f
fol

lowed
will
mdIcate
the
condItion
of
the
starter

motor

Power
kw

Voltage
v

@

Test

Diagnosis

1
Low

speed
with

high
current
draw

might
re

sult
from

tIght
dirty
or
worn

bearings
bent

armatlIre
shaft
loose
field
call
or
a
shorted

armatlIre

2
Fatlure
to

operate
With

htgh
current
draw

may
result
from
a

gromlded
or

open
field
coil
a
defectIve
armature
coll
or
a
burned

out
com

mutator
bar

3
Low

torque
low
current
draw
and

low

speed

would
be
caused

by
hIgh
Internal
reSIStance
due

to
loose
connectIons

dirty
commutator
defec

tIve
leads
and

a
burned
out
commutator
bar

4

HIgh
speed
With
low

torque
would
be
caused

by
a

grounded
field
coll

Magnetic
Switch

Assembly
Test

H
the
above
tests
are

satIsfactory
check
the

magnetIc
SWitch

assembly
as
follows

1
Connect

Jumper
cables
between
the

negative

battery
tennmal
and
the
starter
motor
M
term

inal

as
shown
In

Figure
21
Also
connect
the

positIve
battery
terminal
to
the
S
terminal
and

place
a
SWitch
m
senes
in
the
CIrCuit

@
Ignition
switch

9

I

i
j

Battery
Starter
motor

rr

2
Close
the
SWitch
and
measure
the

dimension

given
m

Figure
22
The
dimensIon
should
be
as

specIfied

o
0591m

15mm

98

CHAPTER
NINE

CHARGING
CIRCUIT

Figure
23
IS
a
schematIc

dIagram
of
the

charg

Ing
CIrcuIt
whIch

mcludes
the

battery
alter

nator

voltage

regulator
and
assocIated

wumg

f

08
ALTERNATOR

Figures
24
and
25

page
100

proVIde
ex

ploded
VIews
of
the
alternator

and
the
relatIve

locatIon
of
all

parts
In
an
alternator
the

mag

netic

pole
turns
and
the

armature
IS
fixed
The

magnetIc
field

IS
Induced

by
the
rotor
wh1ch

consists
of
alternator

shaft
field
coIl

pole
pIeces

and

slIp

nngs
The

slIp
rmg
pressed
In
the
shaft

conducts

only
a
small
field
current

Output
cur

rent
is

generated
In
the
armature
COIls
located

In

the

stator
The
stator
has
three

wIndmgs
and

generates
three

phoase
alternatIng
current
Six

dIodes
are
Installed

mto
a
heat

SInk

They
rectIfy

alternator

output
to
direct

current
for
use

by
all

electrIcal

systems
in
the

vehicle

Removal

1
DIsconnect
the

negatIve
battery
terrmnal

2
Remove

two
nuts

holdIng
electnc
leads

to

back

of
alternator
and
remove
the

Wire
leads

3

Unplug
the
electrIc
connector
from
the

back

of
the
alternator

4
Loosen

the

adJustlng
bolt
and
the

mounting

bolt

holdIng
the
alternator
In

positIon

@

r

I

I

I

L

Alternator
5
Remove

the
alternator
dnve
belt
from
the

alternator

pulley

6
Remove
the
bolts

holdmg
the
alternator

7
Remove
the

alternator
from
the
veh1cle

Disassembly

1
Unscrew
and

remove
the

through
bolts
as

shown

m

Figure
26

@

2

Separate
the
dIOde
end

housmg
from
the
dnve

end

hOUSIng
assembly
by
hlttmg
the
front

bracket

lIghtly
WIth

a
wooden
hatnnler
See

Fig

ure27

3

Usmg
SO
t

Jaws
on
a
VIse

place
the
dnve
end

housmg
m
the
VIse
and

remove
the

pulley
nut
as

shown
m

Figure
28

Cl

E

C

c5

i
u

5

o
l

co
c

c

0

1
T

Battery

r

r

L

J

Voltage

regulator

ENGINE
ELECfRlCAL
SYSTEM
99

2

3

r

I

J

20

2
Rotor
aS5em

bly

3
Ball

beanng

5
Rear
cover

assembly

6
Diode
assembly

7
Diode

8
Diode
assembly

9
Diode

10
Terminal
A
assembly

11
Terminal
B
assembly

14
Brush

15
Brush
holder

17
Brush
co
er

18
Screw

19
Sa
ew
@

8

Front
cover

assembly

Packing
retainer

Ball
beanng

Beanng
retainer
29
Screw

30
Screw

31

Spacer

32
Bolt
33

Pulley
assembly

34

Key

35

Pulley
nut
assembly

36
Bolt
set
20
Wire
leads

21
Screw

22
Screw

24
Insulator

@
@

100

CHAPTER
NINE

@

1
1

43

44

45

46

49

I

tYV
48

47

37
Alternator
bracket

38
Hex
bolt

39
Hex
bolt

40
lock

spnng
washer

41

8racket
shim

42

AdJusltng
bar

43
Hex
bolt

4
Remove
the

pulley
nut
pulley
rim

fan
and

spacer
from
the

hOUSIng
See

Figure
29

@

000

5
Remove
the
rotor
from
the
drive
end

housmg

by

tappIng
lIghtly
With
a
wooden
hammer

Refer

to

Figure
30

@
1

46
45
43
44

38
39

6
Remove
the

beanng
retainer

by
unscrewing

three
set
screws
and

push
out
the

bearmg
with
an

arbor

press
See

Figure
31

@
A
t

J
r

j

f
1

p
O

7
Pull

the
rear

bearmg
from
the
rotor

assembly

by

usmg
an
arbor

press
or

bearing
puller
as

shown
m

Figure
32

@

ENGINE
ELECTRICAL
SYSTEM
101

8
To

separate
the
stator
from
the
dIode
end

housmg
assembly
unsolder
the
three

negatIve

dIodes

from
the
three
co1l1ead
WIres
The

nega

tIve
dIodes
are
marked
WIth
black

figures
and
the

posItIve
ones
With
red

figures

CAUTION

Use

extreme
care
when

unsoldenng

the
diodes
to

prevent
excessive
heat

from
damagmg
thi
m
Use
a
100
to

200
watt

soldermg
Iron

for
no
more

than
two
seconds
at

the
dIOde

Junction

9
Remove
the
brush
cover

by
unscreWIng
the

two
set
screws

10
Unsolder
the

negatIve
terminal
lead
wire

Separate
dIOde
end
from
stator

Figure
33

@

11
Remove
the
heat
smk
and
the
brush
holder

from
the

rear
cover

by
unscrewmg
the
setscrews

as
shown

m

Figure
34

@
12
DIsassemble
the
brush
holder

by
unsolder

ing
the
F
lead
WIre
black
whIte
E
lead
WIre

black
and
the

negatIve
and

pOSItIve
brush

holder
Wires

Figure
35
shows
the
brush
holder

dIsassembled

O
tlII

I
@

13
To
remove
a
dIode
from
the
heat

smk
sup

port
the
heat
SInk
WIth
a
swtable
stand

Figure

36
and

push
out
the
dIode
With
an
arbor

press

Do
not

attempt
removal
WIth

a
hammer
as
the

shock

may
damage
all
the
dIodes
ill
the
heat
SInk

Press
out
so
as
not
to

Injure
the

mounting

bore
01
the
frame
or
the
heat
Sink

14
To

replace
a

dIode
m
the
heat
smk

support

the
heat
SInk
With
a
SUItable
stand
and

press
the

dIode
mto

place
as
shown
m

Figure
37

Inspection
and

Repair

I

InspectIon
of
the
alternator
Includes
electncal

testmg
and
mechanIcal

InspectIon
of
all

parts

for

damage
or
exceSSIve
wear
An
electrIcal

tester

proVIdmg
reSIstance

anI
contmUlty
testlng

IS

requIred
Before

dIsassembly
of
the
alternator

102
CHAPTER
NINE

@

I

lc@

it
should
be
tested

by
connectlng
the

probes
of

the
tester

t9
the
F
lead
WIre

blackfwmte
and

the
E
lead
wire

black
The
resistance
should

read
between
5
and
6
ohms
If
the
resIStance
is

incorrect
the
alternator
must
be

disassembled

and
tested
further
as
descnbed
below

ROTOR

INSPECTION

1
To
test

continwty
of
the
field
coll
connect

the
tester
between

the

shp
rmgs
of
the
rotor

Figure
38
shows
the
connectIon
No

contlnuity

mdIcates
the
field
COllIS
defectIve
and
must
be

replaced
Normal

readmg
should
be

approxi

mately
4
47
ohms
reSIStance

i

1

I

To

perform
the

ground
test
of
the
field
coll

r

check

continuity
between
the

shp
nng
and
the

rotor
core
as
shown
In

Figure
39
Low
reSIStance

indIcates
that
the
field
coll
or
the

slIp
nng
IS

grounded
and
the
rotor

assembly
should
be

replaced

r
3
Check
the

eccentrIcIty
of
the
rotor
With
a
dial

gauge
as
shown

In

Figure
40

Reparr
or

replace

the
rotor
IT
the

eccentrICIty
IS
more
than
0
0039

In
0
10mm

@

STATOR
INSPECTION

1
Check

contlnwty
of
the
stator

by

placmg
the

test

probes
to

the
N
lead
wire

yellow
and

each

lead
wire
of
the
armatl1re

coll
If
current

passes

at
all

pOlOts
the
stator
is

acceptable
No
conti

nwty
shows
the

circwt
to
be

open
Replace
the

stator

Figure
41
shows
the
connection
r

ENGINE
ELECTRICAL

SYSTEM

103

2
Check
the
lead

Wires
of
the
armature
coil

Includmg
the

neutral
wire

for

ground
as
shown

In

Figure
42

HIgh
reSIStance
no
current
flow

indicates

gqod
condItion

If

not
the
stator
must

be

replaced

DIODE

INSPECTION

The
diodes
can
be

inspected
through
the
use

of
a

lamp
and

battery
or
with

a
tester
The

lamp

and

battery
test
can
be
made
Without

disassembl

ing
the
alternator
wh1le
the

tester
should
be
used

when
the
dIodes

are

dIrectly
acceSSIble

1
Positive
Dwde
Test
Connect

the

battery

negative
terrmnal
WIth
the

connector
A
terrmnal

WhIte
and
the

battery

pOSItIve
terminal
With

the
connector
N

terrmnal

yellow
as
shown

m

Figure
43
The

lamp
m
the
circuit
should

hght

@

Reverse
the
connection
as

shown
m

Figure
44

If
the

lamp
does
not

hght
the

pOSItIve
diodes

are

satisfactory
If
the

lamp
does

light
one
or

all
of

the

pOSItIve
dIodes

are
defective
and
must

be

replaced
@

Qg

2

Negative
DIOde
Test

Connect
the

battery

negatIve
termmal
to

the
connector
N
terrmnal

yellow
and
the

battery

pOSItIve
termInal
to
the

connector
E
termmal

black
The

lamp
m
the

CIrcUit
should

lIght
Reverse

the
connectIons
If

the

lamp
does

not

lIght
the

nega1
ve
dIodes
are

satlsfactory
If
the

lamp
does

lIght
one

or
all

I

of
the

negatIve
dIodes

are
defectIve
and
must
be

replaced

To
test
the

indiVIdual
dIodes
With
a
tester

proceed
as
follows

1
There

are
two
kInds
of
diodes
as
shown
m

Figure
45
Check
dlOd
reSIstance

usmg
a
tester

In
both
dIrectIons

as

jl
own
in

Figure
46

f

Current
flow
@

Current
flow

re

ack

flgUre

e

terminal

r

Positive
diode

Negative
diode

@

104

CHAPTER

NINE

2
When

one
sIde
shows
low
resIstance

and
the

other
shows

high
resIstance
the

dIode
IS
satls

factory
If
both
sIdes
are
low

there
IS
a
short

CIrCUIt
If
both
sIdes
are

hIgh
there

IS
an

open

CIrcUIt
All
diodes
With

open
or
short
ClrC
ts

must
be

replaced

BRUSH

INSPECTION

1

VIsually
check
the
brushes

for

SIgnS
of
wear

or

damage
If

wear
IS

greater
than
the
wear
lIrmt

shown
in

Figure
47

replace
the
brush

2

ChecJ
the
movement
of
the

brush
for
smooth

ness
If

unsmooth
check

and
clean
the
brush

holder

3
To

check

spnng

pressure
place
a
SUItable

block

on
a

platform
scale
and

press
down

the

brush
holder

WIth
the
brush
and

spnng
on
the

block

untIl
the
brush
smks

In
the

holder
to

00394

m

lmm

heIght
from

the
holder
Sub

tract
the

block

weight
from

the

reading
to
derive

the

spnng
pressure
It
should

be
0
77
Ibs
035

kg
If
the

readmg
IS
under
0
44
Ibs
0
2

kg

replace
the

spring
Figure
48
shows
thIS

test

being

performed

ALTERNATOR
OUTPUT

INSPECTION

To
check
alternator

output
remove
the
alter

nator
from
the
vehIcle

and
connect

wumg
as

shown
m

Figure
49

Dq
ve
the
alternator
WIth

a

motor

Through
the
CIrcUItS
shown

m
the
Illustra

tIon

current
flows
from
the

battery
to
the
field

coll
of
the
alternator
RaISe
the

speed
of

the

alternator

slowly
to
the

pOInt
where
no
reverse

flow

eXISts
ThIs

pOInt
should
be
about

2

amps

I
at
1
000

rpm
Increase
the
load

reSIStance
untIl

the
load
current

IS
almost

stopped
and

tlI
rn
off

the
SWItch
RaIse
the
load

current

slowly
and

mcrease
the

speed
of
the

alternator
Observe

that
the

output
current
mcreases
as
the

speed

of
the
alternator

mcreases
If
the

output
is
wlthm

the
above

specmcatIon
at
the

proper

rp
ll
the

alternator

IS

satIsfactory

ALTERNATOR
ASSEMBLY

To
assemble
the
alternator

reverse
the

pro

cedures

given
for

dIsassembly
The
use
of
an

arbor

press
to

mstall
dIodes
and

bearmgs
is

essentIal

so
that

parts
are
not

damaged

VOLTAGE
REGULATOR

The

voltage
regulator
is

mounted
to
the

right

hand

engme
compartment
SIde

wall
and
has
a

removable
cover

Figure
SO
shows
the

regulator

With
the

cover
removed

AdjustIng
the

voltage

regulatpr

reqUIres
special
eqUIpment
not

or

dmanly
avallable
to
the

home
mechanlc
If

trouble
seems
to
be
in
the

regulator
refer
servIce

to
a
Datsun
dealer

or

competent
garage

ENGINE

ELECTRICAL
SYSTEM

105

VOLTAGE

REGULATOR

REMOVAL

To

remove
the

voltage
regulator
dISconnect

the
6

way
multIple
electrIcal

COlInector
and
the

screws

holdmg
the

regulator
to
the
SIde
wall

lJ

R
ftl5
C

Wt

Str

Ii

DISTRIBUTOR
W
I
vE

Dlstnbutors
used

on
models

covered
m
this

manual
are
SImilar

except
that

some
have
a

dual
contact

pomt
system
rather
than

a

single

contact

system
The
dual

pomt
system

applies

to
1970
and
newer
models

eqUIpped
With
the

exhaust
and

evaporatIve
ermsslOn
control
deVIce

The

pomts
are

placed
m

parallel
In
the
circuIt

so
that
there
IS
a

pqase
dIfference

In
their

opera

tIon
Phase
dlfference

IS
5

degrees
on
1970

19
71

models
and
31h

degrees
on
1972
models

This

can
be

adjusted
With
the

adjustIng
screw
on

what
IS

called
the
retarded
breaker
Figure
51
shows
the
dual

point
distributor

FunctIonally
the
dIStnbutor
consists

of
the

hIgh

voltage
electrical

system
the

ignitIon
switch
the

centrifugal
advance
mechanISm

a
vacuum
ad

vance

mechanIsm
and

a
mechanIcal

driving

mechanISm

Figure
52

next

page
IS
an

ignItion

diagram
that
shows

parts
of

the

IgnItIon
CIrCUIt

The
dIstributor
shown

IS

typIcal
of
the

single

contact

pomt
system

CONSTRUCTION

Figure
53
shows

a

typical
distributor
used
and

Figure
54
shows

the
dIStnbutor
in
an

exploded

VIeW

Figures
55

page
107
and
56

page
108

provide
detaIled

exploded
VIews
of
the

lugh

tenSIon
cable

system
and
the

single
point
contact

system
Figure
57

page
109
covers

dIStrIbutors

With
the
dual

pOInt
system
The

descnptions

given
below

for

dIsassembly
and

repair
apply

espeCIally
to
the

smgle
pOInt
system
but
are

generally
true
for
the
dual

point
system

@

@
ADVANCED
BREAKER

PHASE
DIFFERENCE

5

DEGREES