DATSUN PICK-UP 1977 Service Manual

DESCRIPTION

OPERATION

CONSTR
UCTI

ON

REMOVAL

DISASSEMBL
Y

CLEANING
AND
INSPECTION

TERMINAL

FIELD

COIL

BRUSHES
AND
BRUSH
LEAD
WIRE

BRUSH
SPRING
TENSION

ARMATURE
ASSEMBLY

DESCRIPTION

The
function
of
the

starting
system

which
consists
of
the

battery
ignition

switch

starting
motor
and
solenoid
is

to
crank
the

engine
The
electrical

energy
is

supplied
from
the

battery

the
solenoid

completes
the

circuit
to

operate
the

starling
motor
and
then

the
motor
carries
out
the
actual
crank

ing
of
the

engine
Engine
Electrical

System

STARTING
MOTOR

CONTENTS

EE
4

EE

6

EE

7

EE
7

EE

7

EE

8

EE

8

EE
B

EE

B

EE

B

EE

B
OVERRUNNING
CLUTCH
ASSEMBLY

BRUSH
HOLDER
TEST
FOR

GROUND

BEARING
METAL

MAGNETIC
SWITCH
ASSEMBLY

ASSEMBLY

TEST

PERFORMANCE
TEST

MAGNETIC

SWITCH
ASSEMBLY
TEST

SERVICE
DATA

AND
SPECIFICATIONS

TROUBLE
DIAGNOSES
AND

CORRECTIONS

5

@
EE
9

EE
9

EE
9

EE
9

EE
9

EE
9

EE
9

EE
O

EE

EE
11

I
Brush

2
Field
coil

3

Magnetic
switch

4

Pludgcr

5
Torsion

spring

6
Shifll
r

7

Overrunning
clutch

8
Pinion

9
Armature

9

EE315

Fig
EE
5
Sectioool
view

of

slarting
motor
Sl14
180B

EE
4

fB
WBBYBY
B

@@@@

I
I

FUSIBLE
lIN

r
T

H

BATTERY
rJ

BATTERY

f

EARTH
POINT

f

I
I
I

@@@

Y

BY

BWWB

@@@

I

I
I

AfT
E

quipped
with

cooler

COLOR
CODE

B
Black

OW
Black
with

white

stripe

BY
Black
with

yellow

stripe

W
White

WB
White

with
black

stripe
Engine
Electrical

System

FUSIBLE
LINK

1Y
O
b
INHIBITOR
RELAY

INHIBITOR
SWITCH

A

I
J
Y

@

I

A

l

rBW

j

CJ

B
W
BWI
000

000

ggg
For

California

I

Bd

f
00

00

00

00

Q

BW

B

Y

BY
WB

BY

@
@
@

BW

@

I
M
T

Equipped
with
cooler
@
I

@

BY

BY

@

I
STARTING

MOTOR

l
BY

BW

9

IGNITION
SWITCH

L

INHIBITOR
SWITCH
STARTER

MOTOR
Notes

a

@
M
T
only

@
A
T

only

b
Inhibitor
switch
is

on

in
neutral

EE
5
Fig
EE
6
Circuit

diagram
0

starting
systom
eE491

OPERATION

When
the

ignition
switch
turned

fully
clockwise
to
the
START

posi

tion

battery
current
flows

through

series

and
shunt

coils
of
the

solenoid

magnetizing
the

solenoid

The

plunger
is

pulled
into
the
solenoid

so
that

it

operates
the
shift
lever

to

move
the

drive

pinion
into

the

flywheel
ring
gear
Then
the

solenoid

switch

contacts
close
after
the

drive

pinion
is

partially
engaged
with
the

ring
gear

Closing
of
the

solenoid
switch

contacts
c
uses
the

motor
to
crank
the

engine
and
also
cut
out
the
series

coil
of

the
solenoid
the

magnetic

pull

of
the
shunt

coil

being
sufficient

to

hold
the

pinion
in

mesh
after
the

shifting
has
been

performed

After
the

engine
starts

running
the

driver

releases
the

ignition
key
and
it

automatically
returns
to
the

ON

posi

tion

The
torsion

spring
then

actuates
the

shift
lever

to

pull
the

pinion
which

allows
the

solenoid
swi

tch
contacts
to

open

Consequently
the

starting
mo

tor

stops
Engine
Electrical

System

I

I

Ring
gear

2

Shift
lever

guide

3
Armature

4

Battery

5
Field
coil

6

Stationary
contact

7
Monble

contactor

More

positive

meshing
and

demeshing
of

the

pinion
and
the

ring

gear
teeth
are

secured

by
means

of
the

overrunning
clutch
The

overruIUling

clutch

employs
a
shift

lever
to
slide

the

pinion

along
the

armature
shaft

EE
6
F

l
cp

o

r

1

I
I

W

m

EE274

8
Shunt
coil

9

Plunger

10

Ignition
switch

11

Series
coil

12
Torsion

spring

13

Shift
lever

14

Pinion

Fig
EE

7
Starting
motor
circuit

into
or

out
of

mesh
with
the

ring

gear

teeth
The

overrunning
clutch
is

de

signed
to
transmit

driving

torque
from

the
motor
armature

to
the

ring
gear

but

prevent
the

armature
from
over

running
after
the

engine
has
started

CONSTRUCTION

O

o

8

w

il
Engine
Electrical

System

V

1

Magnetic
switch
assembly
13
Brush

spring
jj

JI

2
Dust
cover
t4
Brush

Adjusting
washer
15
Yoke

P

3
Torsion

pring
t6
Field
coil
assembly

4
Shift
lever
17
Armature

assembly

5
Dust

cover
18

Center

plate
SI14
1808
only

6
Thrust
washer
19
Pinion
assem
bly

7
E

ring
20
Dust
cover

8
Rear
cover
metal
21
Pinion

stopper

9

Through
bolt
22

Stopper
clip

10
Rear
cover
23
Gear
case

tl
Brush
holder

assembly
24
Gear
case
metal

12
Brush

REMOVAL

Disconnect

battery
ground
cable

Disconnect
black
wire
with

yellow

stripe
from

magnetic
switch
terminal

and
black

battery
cable

from

battery

terminal
of

magnetic
switch

2
Remove
two

bolts

securing
start

ing
motor
to
transmission

case
Pull

starter

assembly
forward
and
remove

starting
motor

DISASSEMBLY

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
EE317
@

@

O

Fig
EE

9
Remouing
dUlt
cover
E

ring

and
thrust
washer
s

3
Remove

two
screws

securing

brush

holder

assembly

EE318

Fig
EE
IO

Removing
brush
holder

d
crt

w

EE
7
S

4

f

I
jl

I

EE316

Fig
EE
B

Exploded
view

of
starting
motor

4
Remove
two

through
bolts

and

rear
cover

5
Remove
b
rushes
from
their

hold

er

by
moving
each
brush

spring
away

from
brush
with
a
hook

Remove

brush
holder

6
Remov

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

overrunning

clutch
assembly
from
armature
shaft

Pinion

stopper

Pinion
stopper
clip

EE277

Fig
EE
l1

Removing
pinion
stopper

CLEANING
AND

INSPECTION

Clean
all
disassembled

parts
but
do

not
use

grease
dissolving
solvents
for

cleaning

overrunning
clutch
annature

assembly

magnetic
switch

assembly

and
field
coils
since
such
a

solvent

would
dissolve

grease
packed
in

c1u
tch

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
coil

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

positive
terminal

and

positive
brush

holder

If
tester
shows
no

continuity
field

circuit
or

coil
is

open

EE016

Fig
EE

I2
Testing
field
coil

for
continuity

TestIng
field
coD
for

ground

Place
one

probe
of
circuit
tester

onto

yoke
and
the
other

onto
field

coil
lead

positive
tenninal

If

very
little
resistance
is
read
field

coil
is

grounded
Engine
Electrical

System

EE017

Fig
EE

I3

Testing
rU
ld
coil

for

ground

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
12
mm
0
472
in

replace

Check

the
connection

of
lead

clip

and
lead
wire

o

@

EE
8
Check
brush
holders
and

spring
cUp

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

Figure
EE

13

The

reading
should

be
1

6

kg
3
5

Ib

Replace
spring
if

tension
is

lower
than

I
4

kg
3
1
Ib

ARMATURE

ASSEMBLY

Check
external

appearance
of

armature
and
commutator

1

Inspect
commutator
If
the
sur

face

of
commutator
is

rough
it

must

be
sanded

lightly
with
a
No

500

emery
cloth
If
the

depth
of

insulating

mica
is

less
than

0
2
mm
0

0079
in

from
commutator
surface

insulating

mica
should

also
be
undercut
so

that

its

depth
is
0
5
to
0
8

mm
0
01
97
to

0
0315
in

The
wear
limit
of
commutator
dia

meter
is

2
mm
0

0787
in
If
the

diameter
of
cammu

tator
is

less
than

31
mm
1
220
in

replace
annature

assembly

EE018

Fig
EE
14

Inspecting
brush

spring
tension

L

0
5
to
0
8
mm

71j

Correct

2

Inspect
soldered
connection
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
shaft
and
other

onto
each
commutator
bar

If
tester

shows

continuity
armature

is

grounded
and
must
be

replaced

EE022

Fig
EE

16

Testing
annature
for

ground

4

Check
armature
for
short

by

placing
it
on
armature
tester

growler

with
a

piece
of
iron

over
armature

core

rotating
armature
If
the

plate

vibrates
armature

is
shorted

j
l

EE023

Fig
EE

17

Testing
annature

for

ahort
Engine
Electrical

System

L

File
l

0

Commutator

Segmen
t

IWMica

Incorrect

EE021

Fig
EE
15

Undercutting
i118ulating
mica

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
Screw
sleeve

must
slide

freely

along
armature
shaft

splines
If

damage
is
found
or
resistance
is
felt

when

sliding
it
must
be

repaired

Inspect

pinion
teeth
If
excessive
rub

bing
is
found
on
teeth

replace

Flywheel

ring
gear
also
must
be
in

spected

l

EE278

Fig
EE
18

Overrunning
clutch

auem

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

holder
is

shorted
to

ground

Replace

brush

holder

EE
9
Ee026

Fig
EE
19

Testing
brush

for

round

BEARING
METAL

Inspect
bearing
metal
for
wear
or

side

play
If
the
clearance
between

bearing
metal
and
armature
shaft
is

more
than
0
2
mm
0
0079
in

replace

metal

MAGNETIC
SWITCH

ASSEMBLY

1

Using
a
circuit
tester

l
check

con

tinuity
between
S
terminal
of

mag

netic

switch
and
switch

body
metal
If

continuity
does
not
exist
shunt

coit
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

performance
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
load
test

Connect

starting
motor
in

series

with

specified
12
volts

battery
and

an
ammeter

capable
of

indicating

1

000

amperes

Starter
motor

Diagnoses
of
test

1
Low

speed
with

no
load
and

high

current
draw

may
result
from
the

following

1

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
tenninal

b

Raise
two

negative
side
brushes

from
commutator

c

Using
a
circuit
tester

place
one

probe
onto

input
tenninal
and
the

other
onto

yoke

d
I

f
tester
indicates

continuity

raise
the

other
two
brushes
and
check

field
and
armature

separately
to

determine
whether
field
or
armature
is

grounded

2
F

allure
to

operate
with

high

current
draw

may
be

caused

by
the
Engine
Electrical

System

Specified
current

draw
and

revolu

tion
in

these
test
are

shown
in

Specifications

Switch

6
Battery

Et

Voltmeter
Ammeter

Ee026

Fig
EE
20
No
load

l
ting

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

brush

spring
rubber
bush
thrust
out

of
mica
in

commu
tat
or
or
a
loose

contact
between
biush
and
com

mutator
would

cause
commutator
bar

to
burn

3
Low

current
draw
and
low

no
load

speed
would

cause

high

internal
resistance

due
to
loose
con

nections

damaged
leads

dirty
corn

mutator
and
causes
listed
on
item

2

3

EE10
MAGNETIC
SWITCH

ASSEMBLY
TEST

Switch

o

Fv
IB
I

I

D

Battery
Starter
motor

EE351

FiN
EE

21
Circuit

ofmagndic
awitch

assembly
ted

If
the

starting
motor
check
is

OK
check

magnetic
switch
as

sembly
Connect
cables

between

negative
battery
tenninal

and
start

ing
motor
M
terminal

positive

battery
terminal
and

starting
motor

S
terminal

connecting
a
switch
in

series
as

shown
in

Figure
EE

21

With
the
switch
on

push

pinion

back
to

remove
all
slack
and

measure

the
clearance
l
between

pinion

front

edge
and

pinion
stopper
The

clearance
should
be

held
within
0
3
to

1
5
mm

0
012
to
0

059
in

If
neces

sary
adjust
it

by
changing
or

adding

adjusting

washer
s

Adjusting
washers

are
available
in

to
two

different
sizes

0
5
mm
0

020
in

and
O
S

mm
0
031

in

0
3
to
I
S
rom

0
012
to
0
059
in

l

EE029

Fig
EE
22
MeO

uring
clearance

t

Engine
Electrical

System

SERVICE
DATA
AND
SPECIFICATIONS

Type

System
voltage

No
load

Terminal

voltage

Current

Revolution
v

V

A

rpm

Brush

length
Outer
diameter
of
commutator
mm
in

mm
in

Brush

spring
tension

kg
Ib

Clearance
between

bearing
metal
and

armature
shaft
mm
in

Clearance
L
between

pinion
front

edge
and

pinion
stopper
mm
in

TROUBLE
DIAGNOSES
AND
CORRECTIONS

Condition

Starting
motor
will

not

operate

Noisy
starting
motor

Starting
motor

cranks

slowly
Probable
cause

Discharged
battery

Damaged
solenoid
switch

Loose
connections
of
terminal

Damaged
brushes

Starti

g
motor

inoperative

Loose

securing
bolt

Worn

pinion

gear

Poor

lubrication

Worn
commutator

Worn
brushes

Discharged
battery

Loose
connection
of
terminal

Worn
brushes

Locked
brushes

EE
ll
Manual

transmission
Automatic

transmission

Optional

for

manual

transmission

SII4
ISOB

S114
170B

12

12

Less
than

60

More

than
7

000
More
than
6
000

More
than
39

1
54

More
than
12
0
47

1
4

to
I
S
3
1
to
4
0

Less
than

0
2
O
OOS

0
3
to
1
5
0
012
to
0

059

Corrective
action

Charge
or

replace
battery

Repair
or

replace
solenoid
switch

Clean
and

tighten
terminal

Replace
brushes

Remove

starting
motor
and
make
test

Tighten

Replace

Add
oil

Replace

Replace

Charge

Clean
and
tighten

Replace

Inspect
brush

spring
tension

or

repair
brush

holder

Condition
Engine
Electrical

System

Probable
cause

Starting
motor

cranks

slowly
Dirty
or
worn
commutator

Armature
rubs

field
coil

Damaged
solenoid
switch

Starting
motor

operates
but
does

not
crank

engine
Worn

pinion

Locked

pinion
guide

Worn

ring

gear

Starting
motor
will

not

disengage
even
if

ignition
switch
is

turned
off
Damaged
solenoid
switch

Damaged

gear
teeth

The

charging
circuit
consists

of
the

battery
alternator

regulator
and

necessary

wiring
to
connect
these

parts
The

purpose
of
this

system
is
to

convert
mechanical

energy
from
the

engine
into

electrical

energy
which

is

used
to

operate
all

electrically

operat

ed
units

and
to

keep
the

battery
fully

charged

When
the

ignition
switch
is

set
to

ON
current
flows
from
the

battery

to

ground
through
the

ignition
switch

voltage
regulator
IG
terminal

primary

side
contact

point
PI

movable

contact

point
P2

voltage

regulator

IF

terminal
alternator
IF
terminal

rotor

field
coil
and
alternator

E

terminal

as
shown
in

Figure
EE

23

by

full
line

arrow
marks
Then
the

rotor

in

the

alternator
is
excited

On
the

other
hand

current
flows

from
the

battery
to

ground

through
the

ignition

switch

warning

lamp
voltage
regula

tor
L

terminal

lamp
side
contact

point
P4

movable

contact

point

P5
and

voltage
regulator
E
termi

nal
as
shown

by
dotted

line
arrow
CHARGING
CIRCUIT

marks
Then

the

warning
lamp
lights

When
the
alternator

begins
to

op

erate
three

phase

alternating
current
is

induced
in

the

stator
armature
coil

This

alternating
current
is
rectified

by

the

positive
and

negative
silicon

diodes
The
rectified

direct
current

output
reaches
the
alternator
A

and

E

terminals

On
the
other
hand
the
neutral

point
voltage
reaches
N
and
E

terminals

nearly
a
half
of

the

output

voltage
and
current
flows
from

voltage
regulator
N
terminal
to
E

terminal
or

ground
through
the
coil

VCI
as
shown
in

Figure
EE
24

by

the
dotted
line
arrow
marks
Then
the

coil
VCI
is
excited
and
the

movable
contact

point
IPS
comes

into
contact
with

voltage
winding
side

contact

point
P6
This
action
causes

to
turn
off

the

warning
lamp
and

complete
the

voltage
winding
circuit

as
shown

by
the
full

line
arrow
marks

When
the
alternator

speed
is
in

creased
or
the

voltage
starts
to
rise

excessively
the
movable
contact

point

EE
12
Corrective
action

Clean
and

repair

Replace
assembly

Repair
or

replace

Replace

Repair

Replace

Repair
or

replace

Replace
damaged

gear

P2
is

separated
from

the

primary

side
contact
PI

by
the

magnetic

force

of
coil
VC2
Therefore

registor
RI
is

applied
into
the
rotor

circuit

and

output
voltage
is
decreased

AJ

the

output
voltage
is
decreased

the

movable
contact

point
P2
and

primary
side
contact
Pin

comes
into

contact
once

again
and

the
alternator

voltage
increases

Thus
the

rapid

vibration
of
the
movable

contact

point

IPl

maintains
an
alternator

output

voltage
constant

When
the
alternator

speed
is

further

increased
or
the

voltage
starts
to
rise

excessively
the

movable
contact

point

P2
comes

into
contact
with

secondllJ
side
contact

point
P3

Then
the
rotor
current
is

shut
off
and

alternator

output
voltage
is

decreased

immediately
This

action
causes

movable
contact
n
to

separate

from

secondary
contact
P3
Thus

the

rapid
vibration
of

the
movable

contact

point
P2

or

breaking
and

completing
the

rotor
circuit
maintains

an
alternator

output
voltage
constant

Engine
Electrical

System

r
l

I

I

I

i

r
Ye
Ff
p

Stator
ma

ture
coiJ

FF
vw

I

I
RI

L

Rot
r

field
C
oil

e
R

I

I

I
I

I

J

1
J

Alternator

Voltage
regulator
11

t

c

I

Fusible
link

t
8

c

J
5

9

i
c
c

0

Battery

t
u
J

EE029

Fig
EE
23

Charging
circuit

II

p
ns

1

Slator
ar

ature
coil

teJ

U

2iI
I

r
R
l
I

I

A3

R2
0
Fusible
link

Roto
field
coil

e

I
I
t
I

I
PS

M
g

j

t

i

H
U

Battery

Lh

A

l
a
o
J

L

V

It

g
t

f

EE030

Fig
EE

24

Charging
circuit
II

EE

13