1977 DATSUN PICK-UP battery

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

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