1968 DATSUN 510 Service Repair Manual

91
CHAPTER
NINE

bon
the
serIes
coll

demagnetizes
agatnst
the

shunt
cOIl
The
return

spnng
causes
the

plunger

to
return
to
the

origmal
posItIon
stoppmg
the

starter
The

overrunnmg
clutch

provIdes
for

positIve
meshmg
and

unmeshmg
of
the

pmlOn

gear
and

flywheerrmg
gear
and

perinitStlie

pmlon
to
overrun
the
armature
after
the

engme

has
started

CONSTRUCIlON

A

typical
Datsun
starter
motor

is
shown
m

Figure
3
The

example
is
for

1971
models
but

about
the

only
dIfferences

existing
between
It
and

other
models
are
the
number
of
elements
used
in

the
dust
cover
and
the
number
of
thrust
washers

Removal

1
DIsconnect
the

battery
ground
cable

2
Disconnect

the
black

yellow
wire
from
the

magnetIc
sWitch
tennmal
on
the
solenoid

3
Disconnect
the
black

battery
cable
and
red

wire
from
the

battery
tennmal
on
the
solenOId

4
Remove
two
bolts

holdmg
the

startmg
motor

to

flywheel
hOUSIng
The

battery
ground
cable
is

attached
to
the

flywheel
hOUSIng
bottom
bolt

5
Pull
starter
motor
toward
front
of

engme
and

remove

Disassembly

1
Remove
the

nut

holdIng
the
electrIc
WIre
to

the

magnetIc
sWItch
M
tennmal
DIsconnect
the

WIre

2
Remove
three
screws

securmg
magnetic

switch

assembly
to

yoke
Remove

magnetic

sWItch

assembly
and
dust
cover
s

Figure
4

3
Remove
two

through
bolts
and
brush
cover

assembly
as
shown

m

Figure
5

4
Remove
the

yoke
assembly
by
tappmg
lIghtly

as
In

Figure
6

5
Remove
bolt

nut
and
washers
at
base
of

yoke
to
free
shut
lever
WIthdraw
the
armatlIre

and
shut
lever
as
shown
m

Figure
7

6
Remove
the

pInIOn
stop
nng
located
at
the

end
of
the
armature
shaft
To
remove
the

stop

nng
push
the

stop
nng
to
the
clutch
SIde
remove

the

snap
nng
and
Withdraw
the

stop
nng
and
CD

c

0
I

CD

Ml

ml

CD

a
I

II

0

l

g
I

o

5
2
Armeture
assembly

3
thrust
washer

4
PinIon
assembly

5
PInion
stopper
set

6
fle
rCOJ1
assembly

7
Screw

8
Brush
positIVe

9
Reer
co
er
assembly

10
Rear
co
er
beerlng

11
Brush
holder
essembly

12
Brush
negatl
e

13
Brush
spnng

14
through
bolt

15
Gear
case
essembly

16
Gear
case
bearing

17
Shift
Iwer
set

18
Oust
cover
set

19
Magnetic
sWitch
assembly

solenoid

20
Screw

21
Set
screw

4

@
e

rl
14
i
i
j

94
CHAPTER
NINE

clutch
WIthdraw
the

overrunnmg
clutch
assem

bly
from
the
armature
shaft
as
shown
m

Figure
8

C
J

oeo
CD

7
Remove
the
brushes
shown
m

Figure
9

by

unsoldenng
wIth
a

soldenng
Iron

Figure
10

shows
the
brush
holder
after

removal

CD

@
8

Figure
11
shows
the
starter
motor
after
dIS

assembly

@

O

oIlA

@

O@I
coO
o

r

CLEANING
INSPECI10N
AND
REPAIR

Clean
all
dISassembled

parts
thoroughly
Do

NOT
use

grease
dISsolVIng
solvents
on
the

over

runnmg
clutch
armature

assembly

magnetIc

sWItch

assembly
ot
field
colis
SInce
It
would

dIssolve

grease
packed
In
the
clutch
mechanISm

and

damage
the
cOIls
or
other
msulators
Check

all

parts
carefully
for

damage
or
wear

Replace

as

reqwred

TERMINALS

Check
all
electrIcal
termInals
and

WIres
for

SIgnS
of

damage
wear
and
detenoratIon
Re

place
as

reqUIred

FIELD
COIL

1
Check
InsulatIon
on
the
field
coll
If

damaged

or
worn

replace
the

coll

2
Test
the
field
coll
for

contlnulty
after
refer

rmg
to

Figure
12
Connect
the

test

probe
of
a

Clrcwt
tester
or
an
ohmmeter
t
the
field

coll

pOSItIve
termInal
Connect
the
other

probe
to
the

pOSItIve
brush
holder
If
the
tester
shows
no
con

ductIon
the
field
cirCUIt
or
coll
IS

open
and

should
be

replaced

3
To
test
for

groundmg

place
one

probe
on

the

yoke
and
the
other

on
the

pOSItIve
termmal

of
the
field
co1l1ead

Figure
13
shows
thIS
test

bemg
performed
If

very
lIttle
reSIstance
IS
read

the
field
colis

are

grounded
and
must
be
re

placed

ENGINE
ELECI
RlCAL
SYSTEM
9S

@

@

4
Test
the
COIls
for
shorts

by
unsoldermg
the

connectIons
of
each
coIl
and

repeatlng
the
test

given
m

step
3
If

a
defectIve
coil
IS
found
It

must
be

replaced

BRUSHES
AND
BRUSH
LEAD
WIRE

1
Check
condItIon
of
the
brush
contact
surface

and

general
wear
of
the
brush
If
the
brush
is

worn
to
under
02362
In

60mm
m

length

replace
It

Inspect
all
connectIons

carefully
for

looseness

or
cracks

Replace
or

reparr
as
re

qUIred

2
Check
the
connectIon
of
the
lead

clIp
and

WIre

3
Check
brush
holders
and

sprmg
clIps
for

damage
Replace
1f

they
will
not
hold
the
brushes

agaInst
the
commutator

properly
Clean
all

brushes
aIld
brush
holders

thoroughly

4
Check
brush

sprmg
tenSIon
WIth
a

spnng

scale
as
shown
m

Figure
14
The

reading
should

be
1
76
Ibs
0
8

kg
Replace
the

spnng
if
the

tenSIon
IS
under
1
54
Ibs
0
7

kg
@

ARMATURE
ASSEMBLY

1
Check
external

appearance
of
the
armature

and
commutator

2
Use
a

dIal

gauge
Figure
15
to
measure
the

armature
shaft
for
bend

Replace
the
armature

shaft
1f
the
bend
exceeds
0
001
in
0
08mm

@

3

Inspect
the
commutator
If
the
surface
IS

rough
sand

It
With
No
500

emery
paper
untIl

smooth
Use
a
dIal

gauge
to
check
the

commu

tator
If
out
of
round

IS
more
than
00079

In

0
2mm
or
the

depth
of
the

Insulatlng
mica
is

less
than
0
0079
In
0
2mm
from
the
commu

tator
surface
the
commutator
should
be
turned

on
a
lathe
Out
of
round
should
be
less
than

o
0020
in
0
05mm

Insulatmg
mica

should
be

undercut
as
shown

m

Figure
16

to
a

depth
of

from
0
0197
to
0
0315
in

0
5
to
0
8mm

4

Inspect
the

soldered
connectIon
of
the

arma

ture
lead
and
the
commutator
If
the
connection

is
loose
resolder
It

5

Usmg
a
clrcmt
tester
test
the
armature
for

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

@
@