1979 DATSUN 210 battery

2

Inspect
silldered
conneetibn
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
core
or
shaft
and

other
onto
each

commutator
bar

If
tester

shows

continuity
armature

is

grounded
and
must
be

replaced

L
L

I

EE022

F
EE
17

Teating
Armature

for

Ground

4
Check

armature
for
short

by
plac

ing
it
on

armature
tester

growler

with
a

piece
of
iron

over
arma
t
ure

core

rotating
armature
If
the

plate

vibrates
armature
is

shorted

jeBel

EE023

Fig
EE

18

Testing
Armature
or

Short

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
or

reduction

gear
Screw
sleeve

must
slide

freely
along
armature
shaft

splines
or

pinion

gear
shaft
must
slide

freely
through
reduction

gear
If

dam

age
is
found
or
resistance

except
nor

mal
resistance
due
to

spring
felt

when

sliding
it

must
be

repaired

Inspect

pinion
teeth
If
excessive

rubbing
is

found
on

teeth

replace
Flywheel
ring

gear
also
must
be

inspected
Engine
Electrical

System

@

ll

EE278

Fig
EE
19

Overrunning
Clutch

Assembly

1
Pinion

gear

2

Reduction

gear

EE617

Fig
EE
20
Pinion
and

Reduction

Gear

Overrunni11C
Clutch

AS5em

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
hold

er

is
shorted
to

ground
Replace
brush

holder

EE025

Fig
EE

21

Testing
Brush

for

Ground

BEARING
METAL

Non
reduction

gear
type

spect
bearing
metal
for

wear
or

side

play
If
the
clearance
between

bearing
metal
and
armature
shaft
is

more
than
0
2
mm

0
008
in

replace

metal

EE

8
BAI
L

BEARING

Reduction

gear
type

Holding
outer
race
with

finger

rotate

bearing
to
see
if
there
is

any

play
or
bind
If

necessary
replace

bearing

MAGNETic

SWITCH

ASSEMBLY

I

Using
a
circuit
tester

check
con

tinuity
between
S

terminal
of

mag

netic
switch
and

switch

body
metal

If

continuity
does
not
exist

shunt
coil
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

perfo
rmance
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

loadtest

Connect

starting
motor
in
series

willi

specified
12
volts

battery
and

an
ammeter

capable
of

indicating

1

000

amperes

Specified
current
draw
and
rev6lu

tion
in
this
test
are
shown
in

Sp
ci

Cications

Starting
motor

S

DIAGNOSES
OF
TEST

I
Low

speed
with
no
load
and

high

current
draw

may
result
from
the

following

I
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
terminal

b
Raise
two

negative
side
brushes

from
commutator

c

Using
a
circuit

tester

place
one

probe
onto

input
terminal
and
the

other

onto

yoke

d
If

tester
indicates

continuity

raise

the
other
two
brushes
and
check

field

and
armature

separately
to
deter

mine

whether
field
or

armature
is

grounded

2
Failure
to

operate
with

high
cur

rent

draw
may
be

caused

by
the

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
Engine
Electrical

System

Switch

Battery

Vultmeter
Ammeter

EE738

Fig
EE

22
No
load

Testing

brush

spring
rubber
bush
thrust
out

of
mica

in

commuta
tor
or
a

loose

contact
between
brush
and

conunuta

tor
would
cause
commutator
bar

to

burn

3
Low
current

draw
and
low

no

load

speed
would

cause

high
internal

resistance
due
to
loose

connections

damaged
leads

dirty
commutator
and

causes
listed
on
item
2
3

MAGNETIC

SWITCH

ASSEMBLY
TEST

Switch

2

1
6

11

p
IB
b

I

Battery
Starter
motor

EE351

Fig
EE

23
Circuit

of
Magnetic

Switch

Assembly
Test

If
the

starting
motor

check
is

OK
check

magnetic
switch
assem

bly
Connect

cables
between

negative

battery
terminal

and
start

ing
motor
M

terminal

positive

battery
terminal

and

starting
motor

8
terminal

connecting
a

switch
in

series

as
shown
above

EE
9
Non
reduction

gear
type

With
the
switch

on

push
pinion

back
to
remove
all

slack
and
measure

the
clearance
between

pinion

front

edge
and

pinion
stopper

Clearance
L

0
3

to
2
5
mm

0
012
to
0

098
in

EE644

Fig
EE
24

Measuring
Clearance

l

Reduction

gear
type

Compare
difference
2
in

height

of

pinion
when
it
is

pushed
out

with

magnetic
switch
energized
and
when
it

is

pulled
out

by
hand
until
it
touches

stopper

Difference

L

0
3

to
1
5

mm

0
012
to
0
059
in

Pull

out

by

hand
until

pinion
stops
Push
out

1

1

n

11

r

L

Difference
EE688

Fig
EE
25

Measuri
g
Difference
L

If

necessary

adjust
it

by

changing

or

adding

adjusting
washer
s

Adjust

ing
washers
are
available

into

two

different
sizes
0
5

mm
0

020
in
and

0

8
mm
0
031

in

The

charging
circuit
consists
of
a

battery
an

alternator

incorporating
an

IC

voltage
regulator
and

wiring
that

connects
these

parts

The

purpose
of

this

system
is
to

convert
mec
hanka

energy
from
the

engine
into
electrical

energy
which
is

used
to

operate
all

electrically
operat

ed
units
and
to

keep
the

battery

fully

charged

With
the

ignition
switch
in
ON
the

circuit
between

transistor
uTr

I
of
the

lC

voltage
regulator
and

ground
is

closed
Current
from
the

battery
then

flows

along
the
route

shown

by
the

arrOW
in

Fig
EE
26

turning
on
the

charge

warning
lamp
and

flowing
on

through
terminal
L

to
excite
the

rotor

When
the
alternator

begins
to

oper

ate
three

phase
alternating
current
is
ngine
Elect
ical

System

CHARGING
CIRCUIT

indicated

in
the
stator

coil
This
alter

nating
current
is

rectified

by
the

posi

tive
and

negative
silicon

diodes

When
the

voltage
at
terminal
8
is

higher
than

battery
voltage
current

produced
at
the

stator
flows

to
re

charge
the

battery
While
the

battery
is

being
re

charged
the

voltage
at
termi

nal
L

is

equal
to
that
of
terminal

8
At
this

point
there
is
no

voltage

differential
on
either
side
of
the

charge

warning
lamp
which
causes
the

charge

warning
lamp
to
turn
off
In

other

words
current
does

not
flow
from
the

battery
to
terminal
L

Accordingly

current
flow

through
the
rotor
as

shown
in

Fig
EE
27

is
taken
over

by

current

produced
at
the
stator
The

circuit
between
terminal
F
and

Tr
is

then
closed
See

Fig
EE
27

The
IC

voltage
regulator
monitors
generating
voltage
to
be

applied
to
the

battery
at
terminal
S
When
current

exceeds
the

specified
value
it
then

flows

through
the
zener
diode
ZD

closing
the

circ
it

consisting
of

transis

tor
Tr
and
resistor

R1
At
this

point
current
neither
flows

through

transistor
Tr

I
to

ground
nor
to
the

rotor

thereby

reducing
the

voltage

generated
at
the

stator
See

Fig

EE
28

When

voltage
generated
at
terminal

S
is

reduced
to
the

specified
value

transistor

allows
current
to
flow

through
the

rotor

increasing
the

generating
voltage

In

this
manner

output
voltage
from

the
alternator
does

not
rise
above
the

specified
value

by
the
ON
OFF

opera

tion

of
the

rotor
coil

through
the
IC

voltage
regulator

16

L

R
l
I

01
0

ls

CHARGE
LAMP

J
011

L

e
0

u

a

M
e

i
J

0

io
o
IGNITION

a

0

09

SWITC1
R2

El1
STATOR
COIL

04
0
R

F

1
BATTERY

8

ZD

ALTERNATOR

7
I

1
AJ

TI
3

IC
VOLTAGE
REGULATOR
Aa

E

1

7

EE760

Fig
EE
26

Simplified
Charging
Circuit
Initial
excitation

current

EE
10

J

o

u

o

ll

ALTERNATOR

nJn
l

0
0
Engine
Electrical

System

F
00IB

RJ
1

1s

0111
CHARGE
LAMP

rt
ei

tOlD

11

1
IGNITION

SWITC1
R2
i
I
oJor

EB

R

BATTERY
f

3

07

09

0
4
0

1
8

r

I
G
XiJ

Tts
R
o

s
o

E

1

J

IC

VOLTAGE
REGULATOR

Fig
EE

27

Simplified
Charging
Circ14it
When

battery
voltage
is
lower
than

regulating

voltage
EE761

I

h
it

r

f

1
0
0
J

o

U

ll

o

I

o

cr

ALTERNATOR
m
l

01

03

1

X
RJ
16

I

1s

OIlI

r
CHARGE
LAMP

L

l

@
R2
IGNITION

SWITCH1
w

Lp

R
l
Q7

BATTERY

T

8

T
F
i
R

j

JZO

RS

E

J

7

Ie

VOLTAGE
REGULATOR

EE762

Fig
EE
28

Simplified
Cluzrging
Circuit

When

battery

voltage
i

higher
than

regulating

voltage

EE
11

FUSIBLE
LINK

FUSIBLE
LINK

f
BATTERY

@@

V

R

@@

G
G

FUSleLE

ImrnI
LI
NK

MTI

I
En

g
n
l
Electrical

Syst
lOl

IGNITION

SWITCH
FUSE

lOA

o
v

FUSE

lOA

C
V

L@@

BAT

f
L

S

BI

I

I

sl
fRO

L

I

I

F

I

EI

i
K
a

ALTERNATOR

lE
Ie

VOLTAGE

REGULATOR

I
I

L
WR

I
1

d

I

t
J

t
IGNITION

WR
SWITCH

BW

U
0

AUTO

CHOKE

RELAY
G
1

WR

J
I

00

00

gg
1

00

VR

1

E
lDID
I

@
O

BAT
mID

W

J
WR

W
FUSE

BLOCK

CHARGE

WARNING

LAMP

5J

BL

Note

@

V

@
California
models

Non
Qilifomo
18
models

FU
models

Fig
EE
29
Circuit
Dinrswr
EE742

mofCIuJ

Tg
ng
Sy
t
m

EE
12

REMOVAL

1

Disconnect

battery

negative

cable

2

Disconnect
two

lead
wires
and

oonnector
from
alternator

3

Loosen

adjusting
bolt

4

Remove
alternator
drive

belt

5

Remove

parts
associated
with

alternator
from

engine

6
Remove
alternator

from
car

DISASSEMBLY

I
Remove

through
bolts

Separate

front
cover
with
rotor

from
rear
cover

with
stator

by
lightly

tapping
front

bracket
with
a

wooden
mallet

rnJ

J

i

EE525

Separating
Front

COI
T

Fig
EE

31

2

Place
rear
cover
side
of

rotor
in
a

vise

with
soft

jaw
and

remove

pulley

nuts
Then
remove

pulley
and
fan

from
rotor
shaft

3

Remove

setscrews
from

bearing

retainer
and

separate
rotor
from
front

EE526

Fig
EE
32

Removing

Pulley
and
Fan

tr

s

0
27

Fig
EE
33
Removing
Rotor
Engine
Electrical

System

4
Pull

rear

bearfug
off
rotor

assem

bly
with
a

bearing
puller
or

press

EE037

Fig
EE
34

Pressing
Out

Rear

Bearing

I

EO

Fig
EE

35
Pulling
Out
Rear

Bearing

5

When

removing
IC

regulator

only

proceed
as
follows

I

Using

soldering
iron

disconnect

wire

connecting
diode

set

plate
to

brush
at
brush

terminal

2

Remove

bolt

securing
diode
set

plate
to
rear
cover
side
face

3

Remove
nut

securing
battery

terminal
bolt

4

To
facilitate
removal

s1ighly
lift

stator

coil

together
with
diode
set

plate
from

re
r
cover
Then
remove

screw

connecting
diode
set

plate
with

brush

5

Separate
stator
coil
and
diode

together
with

rear
cover
and

remove

brush
and

IC

regulator

6
Disconnect
stator

coil
lead
wires

from
diode
terminals
with

a

soldering

iron

Remove

screws

securing
brush
re

move
stator
from

rear
cover

EE648

Fig
EE
36

Removing
Stator

Coil

EE
14
7

Disconnect
wire
from
diode
tor

minal
at
brush
terminal
with

soldering

iron

Remove

brush

assembly
with
IC

regulator
by
loosening
screws

8
Remove
diode

holder

by
loosen

ing
screws

acefii
li

E
E649

Fig
EE

37

Removing
Diode
Holder

INSPECTION
AND

REPAIR

ROTOR
INSPECTION

I

Continuity
test
of
rotor
coil

Apply
tester
between

slip

rings
of

rotor
If

there
is

no

continuity
field

coil
is

open

Replace
rotor

assembly

Fig
EE

38

Continuity
Test

of

Rotor
Coil

2

Ground
test
of
rotor
coil

Check

continuity
between

slip
ring

and

rotor
core
If

continuity
exists

replace
rotor

assembly
because
rotor

coil

or

slip
ring
may
be

grounded

EE532

Fig
EE
39
Te

ting
Rotor
Coil

for
Ground

Engine
Electrical

System

6

Tighten
through
bolts

rfl
Tightening
torque

Through
bolts

60
to
70

kg
cm

52
to
61
in
lb
ALTERNATOR
TEST

Before

conducting
an
alternator

test
make
sure
that
the

battery
is

fully

charged

A
30
Volt
voltmeter
and
suitable

INSPECTION
TABLE

With
alternator

aide
L
tenninal

grounded
internal

short
occurs

when
diode
is
short

circuited

@
test

probes
are

necessary
for
the

test

The
alternator

can
be

checked
easi

ly
by

referring
to
the

Inspection
Table

Bumed
out

bulb

Replace

and
Proceed

toUA

Ignition

switch

ON

Check

light

for

operation
Disconnect
Light
OFF

f

Light
OFF
connector
S

L

and

ground

L

lead
wire

Light
ON

Check

light

for

operation
Light
ON

I
Faulty
IC
RG

Replace
Connect
con

nector
S
L

and

ground
F

a1light
Light
OFF

I
FaultyA
C

G

I

Dim

light
for

operation

tf
i
rs

1
I
Faulty
A

C
G

I

Light
ON
I

Contact

positive
lead
of

voltmeter
on
B

lennina
and

negative
lead
to
L
tenninal
Light
ON

1

Engine
idling

Check

light

for

operation

Light
OFF

I
Engine
idling

Measure
the

voltage
across

B

and
L

terminals

Engine
speed

1

500

rpm

Ligh
tin

switch

ON

Check

light

for

operation
r
Dim

light

Light
OFF
Note

1
Use

fully
charged

battery

2

Light
Charge

warning
light

A

C
G
Alternator

parts
except
IC

regu
tor

IC
RG
IC
n

guJator

OK
IC
altemator
is
in

good
condition

3

When

reaching
Faulty
A
C
G
remove

alter

nator

from
car
and
disassemble

inspect
and

correct
or

replace
faulty
parts
Engine
speed

1
500

rpm

Measure
B

terminal
volt

sge

Make
sure
S

terminal
is

con

nected

correctly

4

Method
of

grounding
F

terminal

Contact

tip
of
wire
with

brush
and
attach

wire
to

alternator

body

Suitable
wire
I

Fig
EE
50

Grounding
F
Terminal

5
Terminals

S
L
BA
Tn

and
E
are

marked
on
rear
cover
of

alternator

EEl7
More

thanO
5V

I
Faulty
A
e

G

1

Less
thanO
5V

I
OK

T
Mon
than

15
5V

I
Z
C
RG

I

I3
to
15V

Engine
idling

Lighting

switch
ON

Check

light

for

operation

Light
ON

I
Faulty
A
C

G

I

Light
OFF

I
OK

DESCRIPTION

The

regulator
consists

essentially
of

in

egrated
circuits

incorporating
tran

sistors

These
transistors
int

errupt
and

admit

current
flow

to
the
alternator

rotor

coil
thus

maintaining
its

output

voltage
at
a
constant
value
Unlike
in
a

mechanical

type
regulator
an
electron

ic

relay
employing
transistors
is
uti

lized
These
transistors

are
enclosed
in

a

very
compact
sealed

case
The

electronic

relay
is

soldered
to
the

Brush

Ie

regulator

R

J

DIO

F

i
ZD

Tn
Engipe
Electrjcal
Syst
em

REGULATOR

brush

assembly
inside
the

alternator

Should

any

problem
with
the

relay

arise
it

should
be

replaced
together

with
the

brush

assembly
In
the

charge

warning
lamp
circuit
a
diode
is
at

tached
to
the
stator
coil
to

monitor

generating
voltage
at
the
stator

so
that

when
the

monitored

voltage
and

charging
voltage
are

equal
during
re

charging
the

charge

warning
lamp
is

turned
off

Accordingly
a

charge

warning
relay
is

not

employed
in

this

circuit

s

r
t

E

F
L
S
B

EE629

Fig
EE
51
lC

Voltage
RegultJtor

I

B

S

L

I

R

R

E
B
S
L

E
F
Terminal

R
Resistor

Rh
Thermistor

Tr
Transistor

ZD
Zener
diode

EE766

Fig
EE
52

Circuit
of
RegultJtor

EE
18
INSPECTION

To

check
the

IC

regulator
proceed

as
follows

Remove
IC

regulator
and

brushes
as

an

assembly
as
outlined
in

Disas

sembly
and

Assembly
section
under

the

heading
Alternator

CAUTION

When

performing
test

continuously

resistor

may
generate
heat
If

it
be

comes

high
temperature
stop
testing

for
a

while
to
avoid

burning

The

following
test

equipment
and

accessories
are

required

I
Resistor
R
10

ohms
20

watts
x
I

2

Variable
resistor

Rv
0
to
300

ohms
20
watts
x
I

3

Batteries
I

and
2
12

volts

x2

4
DC

voltmeter
0
to
30
volts

x
I

2
Connect

wiring
as
shown
in

Fig

EE
S3
and

perform
tests
as
follows

I

Measure

voltage

VI
at

battery
If

it
is

not
within

10
to
13

volts
re

charge
or

replace
battery
as

necessary

2
Disconnect
lead
wire

at
terminal

s

measure

voltage
V

2
between

terminals
F

and
E
If
it
is

below

2
0
volts

regulator
is

functioning

properly
Connect

lead
wire

to
termi

nalS

3

Measure

voltage
V

3
total
volt

age
of

batteries
I

and
2

If
it

is
not

within

20
to
26
volts
re

charge
or

replace
either
or

both
batteries

4

Gradually
decrease
resistance
of

variable
resistor

Rv
from
300
ohms

and
measure

voltage
V

2
between

terminals
En
and
F
As
resistance