1977 DATSUN PICK-UP engine

DATSUN
PICK

UP

MODEL
620

SERIES

I
NISSAN

I

NISSAN
MOTOR

CO
LTD

TOKYO
JAPAN
SECTION

EE

ENGINE

ELECTRICAL

SYSTEM

BATTERY

EE
2

STARTING

MOTOR
EE

4

CHARGING

CIRCUIT
EE

12

ALTERNATOR
EE
15

REGULATOR

EE
20

IGNITION

CIRCUIT
EE

26

DISTRIBUTOR

EE

30

Non

California

models

DISTRIBUTOR
California
models
EE

33

TRANSISTOR
IGNITION
UNIT

California
models

IGNITION
COIL

SPARK
PLUG
EE
36

EE

46

EE
47

REMOVAL

CHECKING
ELECTROLYTE
LEVEL

CHECKING
SPECIFIC
GRAVITY

REMOVAL

I
Disconnect

negative
and

positive

cables

2
Remove

nuts
from

battery

clamps
take
off

clamps

3
Remove

battery

CHECKING

ELECTROLYTE
LEVEL

Remove
six

vent

plugs
and
check

for

electrolyte
level
in
each
cell

If

nccessaJ

pour
distilled
water

CHECKING

SPECIFIC

GRAVITY

Specific
gravity
of

battery
electro

lyte
is
tested

by
a

hydrometer
If
the

srate

of

charge
of

battery
is

60
or

specific
gravity

reading
is
below
1
20

as
corrected
at
200e
680F
bat

tery
must
be

recharged
or

battery

electrolyte
concentration

adjusted

Add
or
subtract

gravity
points

according
to
whether
the

electrolyte

temperature
is
above

or
below
200e

680F

standard

The

gravity
of

electrolyte
chlll

ges

0

0007
for

every
Ioe
1
80F
tem

petature
A
correction

can
then
be

made

by
using
the

following
formula
Engine
Electrical

System

BATTERY

CONTENTS

EE
2

EE
2

EE
2
BATTERY
FREEZING

CHARGING

INST
ALLA
TION

S

20
St
0

0007
t
20

Where

St

Specific
gravity
of

electrolyte

at
tOe

520

Specific
gravity
of

electrolyte

corrected
at
200e
680F

t

Electrolyte

temperature

For

example
A

hydrometer

reading
of

1
260
at
300e

860F

would

be
1
267
corrected

to
200e

6goF

indicating
fully
charged

battery
On
the
other
hand
a

hydro

meter

reading
of
1
220
at
lOoe

140
F
would
be
1
199
corrected
to

200e
680F

indicating
a

partially

charged
battery

The
state
of

charge
of

battery
can

be
determined

by
the

following
table

if

the

specific
gravity
of

electrolyte
is

known
BefOIe

checking
be
sure
that

cells
are
filled
to
correct
level

G
U

o

N

b
t

E

u

ol

1
lilt

I
i
I

m
J

I
I

I
I

J
1
I

J
Sf
to
7
1
II

It
100

0wJIztI
COJJditioD

EE002

Fig
EE
2

ChaJ
ffing
condition

EE
2
1
28

@

126

S

Sow

E

l

l

u

o

o

l

e

u

0

U21

1

101
EE

3

EE

3

EE
3

Read

top
level

with
scale

1
Thermal

gauge

2

Hydrometer
feOOl

Fig
EE

l

Checking
pccme
gravity

Converted

specific
gavity

20

1
Je

I

dOldlOiJ
OSQ

Electrolyte
temperature
oC

EEOO3

Fig
EE
3

Specific
lNWity
at

eiectroly
te
temperature

BATTERY
FREEZING

Battery
electrolyte
freezing
point

varies
with
acid
concentration
or
its

specific
gravity
A

battery
with
an

insufficient

charge
will
freeze
at
lower

temperatures
If

specific
gravity
of
a

battery
falls
below
1
1
this
is

an

0

10

20

30

g

40
I
u

il

SO
I
0

e

60
0

E

70
Engine
Electrical

System

indication
that

battery
is

completely

discharged
and
will

freeze

readily

when

temperatures
fall
below

freezing

Note
Use
extreme
caution
to
avoid

freezing
battery
since

freezing
will

generally
ruin
the

battery

1

80

1
00
1
04
1
08
t
l2
1
16
t
20
1
24
1
28

Specific
gravity
of

electrolyte

CHARGING

I

f
electrolyte
level
is

satisfactory

battery
must
be

charged
when
electro

lyte
gravity
reading
falls
below
1
20
If

battery
on

car
is

quick
charged
to
1
32

EEOQ4

Fig
EE

4
Froezing
point
of
electrolyte

bring
it

up
to
full

charge
the

opera

tion
should
be
carried
out

with
nega

tive
cable
removed

Prior

to
charging
corroded
termi

EE
3
nals
should
be

cleaned
with
a

brush

and
common

baking
soda
solution
In

addition
the

following
items

should

be
observed
while

battery
is

being

charged

I
Be

sure
that
electrolyte
level
is

above

top
of

each
plate

2

Keep
removed

plugs
in

a
safe

place

3
Do

not
allow

electrolyte
tempera

ture
to

go
over
450C
I130F

4

After

charging
check
to
be
cer

tain
that

specific
gravity
does
not

exceed
1
260
at
200C
680P
Cor

rection
can
be
made

by
adding
dis

tilled
water
into

cells
as

necessary

5

Keep
battery
away
from

open

flame
while
it
is

being
charged

6
After
all
vent

plugs
have
been

tightened
clean
all

sprayed
electrolyte

off

upper
face

of

battery

INSTALLATION

1
Install
and

tighten
clamps
secure

Iy

2
After

clamps
have
been

tightened

clean

battery
cable
terminals
and

apply
grease
to
retard
formation
of

corrosion

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