Service Manual Datsun Electrical Service Guide

8/12/2019 Service Manual Datsun Electrical Service Guide

1/90f d

k jf JW u


2/90

VOLTMETER

OHMMETER

AMMETER

SHORT DETECTOR

ELECTRICAL

SERVICE

GUIDE

BATTERY

STARTING

SYSTEM

CHARGING

SYSTEM

HOW TO TROUBLESHOOT

CIRCUIT PROBLEMS

@Nissan Motor Corporation in U S A


3/90

LOW SCALE

RED POSITIVE

POSITIVE

HOW TO READ A VOLTMETER

POS NEG

READING

3 VOLTS

HIGH SCALE

SCALE

SELECTOR

BLACK NEGATIVE

6 AH

NEGATIVE

VOLTAGE DROPS

Turn Page

M


4/90

VOLTAGE DROPS IN POSITIVE SIDE

TURN VOLTMETER TO LOW SCALE

2 CONNECT POSITIVE LEAD TO BAT

TERY TERMINAL

3 TURN ON CIRCUIT TO BE TESTED

4 CONNECT NEGATIVE VOLTMETERLEAD TO HOT WIRE AT APPLI

ANCE LIGHT MOTOR ETC IN

CIRCUIT TO BE TESTED

3 8

oPOS NEG

5 READINGS

BELOW 2 VOLTS

Positive Side of CirCUit OK

ABOVE 2 VOLTS

Move negative lead back along Crcuttoward battery and check at each Junctlon o connect i on When reading dropsbelow 2 volts you will find fault be

tween last and next to last pOintstested

M


5/90

VOLTAGE DROPS IN NEGATIVE SIDE OF CIRCUIT


2 CONNECT NEGATIVE LEAD TO BAT

TERY TERMINAL

3 TURN ON CI RCUIT TO BE TESTED

4 CONNECT POSITIVE VOLTMETER

LEAD TO GROUND WIRE AT APPLI o 3 O 8ANCE LIGHT MOTOR ETC IN

CI RCUIT TO BE TESTED

NEG

5 READINGS

BELOW 5 VOLT

Ground side of CirCUit IS OK

ABOVE 5 VOLT

BAD GROUND CONNECTION Move

positive lead back along ground crcut

toward negative terminal of batteryWhen reading drops below 5 vot youwill find fault between last two pOints

tested

M


6/90


7/90

WHAT THE OHMMETER IS USED FOR

USE IT TO CHECK

SWITCHES

Set to x I Scale Connect the leads acr oss two pOints then work the sWitch Ohmmetershould mov e from open Crcut high resistance to no resistance

SPAR K PLUG AND COI L WI RES

Set to x Scale Reading should be between 8 and thousand ohms per foot

IGNITION COI L

24 Z Transistor Ignition Other Through 75

Primary Winding 5 7 45 55 7 43x Scale Ohms Ohms Ohms

Secondary Winding 95 6 85 27 2 68xIOOO Scale Thousand Ohms Thousand Ohms Thousand Ohms

BALLAST RESISTOR

3 7 Ohms at 68 degrees

26 Z Ballast Resistor 2 4 Ohms both sections together

TRANSISTOR IGNITION PICKUP COIL

974 62 Ohms 9745 975 72 Ohms

DIODES

Set to x Scale Connect the leads acr oss the diode then sWitch the leads In one

position you should get a reading In the other you should have either very little o no

reading For alternator testing see Alternator Overhaul section In thiS manual

CROSSOVERS IN THE WIRING HARNESS

Disconnect battery and set to x scale A harness connect or connect one lead to

pin of Crcut which IS malfunctioning Touch the other lead to all the other pinS Inthe connect or

If you find continUity look at the wIring diagram to determne whether thiS continUityIS normal If It Isn t hen you have located a cros sover See Troubleshooting Sectionentitled Strange Things Happen

M 5


8/90

HOW TO USE INDUCTION AMMETER

ISOLATE A SINGLE WIRE IN THE

CIRCUIT YOU WANT TO TEST

NOTE IF YOU DON T SEPARATE

THE WIRES YOU ARE LI KELY TO

GET A FALSE READING

2 HOLD THE AMMETER OVER THE

WIRE SO THAT THE WIRE FITS

IN THE CLIP PROVIDED

3 TURN ON THE CIRCUIT AND READ

THE METER

M 6


9/90

HOW TO USE AMMETER

NEG

MAKE SURE YOUR AMMETER CAN

HANDLE THE AMOUNTOF

CUR

RENT FLOWING IN THE CIRCUIT

OTHERWISE THE METER MAY BE

DAMAGED WHEN YOU HOOK IT UP

2 BREAK THE CIRCUIT AT SOME

POINT THIS COULD BE AT THE

BATTERY TERMINAL THE COMPO

NENT WHICH THE CIRCUIT FEEDS

OR ATA CONNECTOR

3 CONNECT THE POSITIVE LEAD OF

THE AMMETER TOWARDS THE BAT

TERY PLUS SIDE CONNECT THE

NEGATIVE LEAD TOWARDS THE

NEGATIVE SIDE OF THE CI R

CUlT

4 TURN ON THE CI RCUIT I F THE

READING IS DOWN SCALE RE

VERSE THE AMMETER LEADS

5 NOW YOU CAN READ THE AM

METER

M


10/90

HOW TO USE A SHORT DETECTOR

Locate wIring harness layout In vehIcle shop

manual

2 Determne which fuse IS blowing

3 Clip leads of flasher unt acrossfuse clip

4 When flasher sart s clicking move detector along

wIring harness uSing diagram In shop manual

Needle will mov e when current IS flOWing

5 When you pass the shorted pOintthe needle

will stop pulsating

M B


11/90

HOW TO CHECK OUT THE BATTERY

FIRST KNOW THE BASIC SAFETY RULES FOR BATTERY CHARGING

CHARGE BATTERIES IN A WELL VENTILATED SHOP HAVE A FIRE EXTINGUISHER

HANDY

2 LOOSEN VENT CAPS BEFORE CHARGING

3 WHEN YOU CONNECT A CHARGER HOOK UP THE LEADS FIRST THEN TURN ON

THE CHARGER DO NOT TURN ON THE CHARGER FIRST YOU MAY GET A SPARK

WHICH COULD MAKE THE BATTERY EXPLODE

BATTERY TESTING Turn Page

BATTERY RATINGS BY MODEL ORIGINAL EQUIPMENT

AMPERE HOURS

976 975 974 973 972 997 97 969 968

7 6 6 6

2 6 6 6

6 6 6 6 6

62 6 6 6 6 6

S3 6 6 6 6 6 5

5 6 6 6 5 5 5

B 5 5 5

52 6 6 5 6 4 4

52 4

SR L3 4 5 4 5 4 5

SPL3 4 5 4 5 4 5

L6 6

M


12/90

How to check the battery

PRELIMINARY CHECKS Visual Inspection

Check battery rating against thatof

originalfactory equipment see chart

b Check for cracks and warpage of the case

c Make sure cables are clean and tight

d Check aCid level 3 8 Inch above plates

e

f

a

Make sure vents aren t clogged

Make sure top of battery IS clean

o

Q

OVER 5 VOLT

CLEAN BATTERY

M l

o o

PROPER ACID LEVEL

CLOGGED VENTS

CORROSION

CRACKS

CHECK

A H RATING

WARPED CASE

2 BATTERY LEAKAGE TEST Check to make

sure the battery IS no discharging acr oss the

top between the two posts

a Set voltmeter to low range

b Touch negative lead of voltmeter to negati ve battery post

c Touch the positive lead of the voltmeter

to the top of the battery and mov e It

around

If the reading goes over 5 volts then clean off

the top of the battery and retest


13/90

A S VOLTS

o o

Oll BOd

BATTERY

CAPACITY

TEST

LOAD CONTROL 3 TIMES

o AMP HOUR RATING

5 SECOND HOLD

4 THREE MINUTE CHARGE TEST

To be performed only If batteryhas failed the Capacity Test In step

number 3

a Connect a good quality bat

tery Remove cell caps

b Turn the charger to a fast

charge rate no over 4 amps

c Ater three minutes check

voltmeter reading If It IS over

5 5 volts 6 5 for Mainte

nance Free Batteries the bat

tery should be replaced If It

IS below 5 5 volts then pro

ceed to step number 5

3 BATTERY CAPACITY TEST

a With battery connected to tester as shown

turn load knob until a draw of 3 t i mes the

battery rating IS shown

Example Battery rating 6 Ampere Hours

Turn load to 8 Amps draw

b Hold thiS draw for 5 seconds then look

at voltage If voltage remans at 96 volts

o above THE BATTERY IS GOOD You

need no perform any further tests If vot

age drops below 96 volts then proceed to

the next tes

THREE MINUTE

BATTERY

CHARGE TEST

ABOVE 5 5V

REPLACE BATTERY

M


14/90

5 CELL TEST UNDER CHARGE Connect the

tester and the battery charger as In step number

4 Set to fast charge rae 35 Amps

a Turn to low range voltmeter

b Attach special cell probes to voltmeter

leads

c Touch positive probe to battery positiveterminal

d Stick the black probe In the battery cellnearest the battery positive post WR ITE

DOWN the voltmeter reading

e Now put the positive probe In the cell near

est the positive post Put the negative probeIn the next cell down Record the reading

f Continue on down the battery recordingthe reading each t i me

g When you get to the pOint where the POSIti ve probe IS In the last cell of the batterytouch the negative probe to the negative

post Record thiS reading

h You should now have seven readings Now add

the first reading to the last thiS Will give you

SIX readings They should all be wthn 2 two

tenths vot of each other If one cell vari es

mor e than thiS amoun from any other then the

battery IS bad and must be replaced

24

26

26 2426

226 2626

2

M 2


15/90

SA TTERY CELL TEST UNDER CHARGE

FAST CHARGE RATE ALL CELLS WITHIN 2 VOLT

READING READING 2

READINGS 3 6 READING 7

M 3


16/90

I STARTING SYSTEM I

STARTER TESTING

STARTER OVERHAUL PROCEDURES

2 AND 8 2 TO 975

STARTER OVERHAUL PROCEDURES

ALL L SERIES ENGINES


17/90

STARTING SYSTEM

Testing

I First Check The Battery I

I Turn Key To Start I

No Click Cick or Starter turns

See Page S 2

Pull Ignition Start Wire Usu

ally Back Yellow Off A Starter

Connect Test Light Between ThisLead And Battery Negative Ter

mmal Have Someone Turn Key

No Light LightSee Page S 5 See Page S 2

8


18/90

TESTING STARTER CURRENT DRAW

Connect Tester Turn SWitch To Starter

Pull Out COil WIre From Distributor Cap No From Coil And Ground It

I Crank Engme Read Current Draw Amps

Less than 5 Amps

Speed sow

See Page S 3

S 2

Speed normalStarter O K

IkStarter turns fast

less than 6 Amps

Tight EngineMechamcal

Problem

More than 5 Amps

Plug COIl Wire Back In Start

Engme But Hold Key Over To

Start So That Starter Does Not

Stop

Starter draws moe

than 6 Amps

Short In

Sta rt er

Overhaul

I


19/90


20/90


21/90

TESTING FOR VOLTAGE DROPS INIGNITION SWITCH STARTER SOLENOID CIRCUIT

I Turn Voltmeter To Low Scale I

Connect POSitive Lead To Positive Termnal Of Battery

Connect Negative Lead To Bayonet Connector Back Yellow A Solenoid SWitchLeave BY Wire Connected

I Ground COil Wire I

I Crank Engine I

More than 5 Vots Less than 5 Volts

Open In StarterConnect Jumper Wire Between

OverhaulBattery Positive Termnal AndThe S Termnal On SolenOId

Cick Starter turns No click Starter

OpenIn Circuit

IgnitionSWItch does no turn

Connectors Neutral Safety Relay Bad SolenoidAutomatic Transmssion Inter

lock Relay

L Series Engines Ot hers

R R R ROverhaul

SolenOid Starter

5 5


22/90

I2 AND B 2 TO 975

D @ j

Gear housl ng

2 Dust cove

3 Shift lever

4 Gasket

5 Shift lever pIn

6 Sol enold sWitch

7 Center support

8 Armature

9 Thrust washer

BushIng PInion stopper re aner

2 Snap ring 3 PInIon stopper

4 PInion

5 Overrunning c tuch Bendix 6 Field cOil

7 Field hOUSIng 8 Brush band

9 Brush

2 Rear cove

2 Through bolt

6

@ j

@ @I

J

SOLENOID SWITCH TERMINALS

B Battery connected to battery

M Motor connected to sart er field

S Solenoid activated by IgnitionsWitch In sart position

8


23/90

B 2

f

D

flRemove the nu securing the sart er field lead

to the solenoid M termnal and remove the

lead

Remove the brush cover o band and then re

mov e the screw which connects the positivebrush to the field

Now remove the two through bolts and pull offthe end plate

c y rL

Jlf INow remove the coter key and the shift lever

locking pin then remove the solenoid

Remove the two scr ews whIch secu re the sole

nOid

Now remove the positive brush ThiS Will be

easer to do If you make a Simple tool by

bending a nail Now hook the end of the tool

underneath the brush spring pull up on the

spring and remove the brush

Next separate the field housing from the sart er

gear housing You may have to tap lightly on

the armaur e shaft uSing a plastiC hammer

B


24/90

B 2

Next pull the armaur e ou of the gear housing

Next push the stop ring down toward the ar ma

ture This will expose the snap ring

Preliminarychecks before

cleaning

Check the ring gear on the engine for chippedteeth o excessve wear of the teeth You may

have to replace the ring gear In sever e cases

B 3

To remove the overrunning clutch first remove

thelocking clip

fromthe stop ring

Remove the snap ring uSing a tool as shown and

slide the overrunning clutch off the armaur e

shaft

Inspect the field cOil lead where It goes through

to grommet Ino the sart er ThiS of n pecomes grounded ou causing a SHORT


25/90

B 2

Check the inside of the brush cover and the

field housing around the commuaor Youmight find a ring of solder here which wouldtell you that the armaur e has spun too fast

overheated and lost some of ItS solder It mightalso tell you that the sart er has been hanging

up on the ring gear because the overrunning

clutch IS no working properly

Cleaning

O NOT USE SOLVENT except on the gear

housing I If you do you might damage the insul

ai on on the field Windings o dissolve the

grease In the overrunning clutch causing It to

fall later on

USing ar carefully blow all parts clean

CHECK THE ARMATURE A visual inspectionshould show you whether the armaur e has been

dragging on the fields This Will cause shorts and

might have permanently damaged the armaur e

I nspectl on

Look at the solder JOnts around the commu a

tor Be sure to check this If you found solder

inside the field hOUSing

8


26/90

8 2

Inspect the commuaor It should be clean and

shinY when you put the sart er back togetherso It will be necessary to clean It uSing a stripof sandpaper o commuaor paper Checkto make sure there IS a groove between the bars

of the commuaor If there Isn t you will have

to make one

Now place the armaur e on a growler and turnthe growler on Lay a hacksaw blade on top ofthe armaur e and turn the armaur e If the

blade sticks to the armaur e then you have a

short and the armaur e will have to be replaced

I

Next check the armaur e for opens USing thetes light section of the growler touch one leadto anyone of the commuaor segments Take

the other lead and run It around the commutaor touching all of the segments The lightshould be lit on every segment If It Isn t hen

there IS an open In the solder connect i on at that

segment o there IS an open inside the armature

If any opens are indicated replace the armaur e

6


27/90


28/90

B 2

CHECK THE FIELDS Look at the insulationaround the windings and the solder JOintbetween the fields Check the fields for OPENS

by connecting one lead of the tester to theman field lead and touching the brush With theother lead The light should turn on If nothen there IS an open In the field and the fields

should be replaced

Check the fields for shorts touch one lead of

the continUity tester to the field lead and the

other lead to the field hOUSing The light shouldno light If It does you have a short and Willhave to replace the fIelds

r qTo replace the fields use an Impact tool Place

the hOUSing on a Vse but do no tighten as thiS

may cause warpage of the hOUSing Remove thescr ews and replace the fields

B 7


29/90

B 2

CHECK THE BRUSH PLATE First check thepositive brush holder to make sure It IS Insulated

from the plate Touch one lead of the tester to

the plate and then touch the other lead to the

brush holder If the light comes on then the

eni re brush plate Will have to be replaced

Check the brush plate negative brush holder

for opens touch one lead to the plate and the

other lead to the negative brush If the lightdoes no go on then REPLACE THE BRUSH

PLATE

CHECK THE STARTER BUSHINGS In the

sart er gear hOUSing Place the armaur e shaft

In the bushing and check for Side play Too

much play here will allow the armaur e to dragon the fields causing a short Replace the eni re

brush cover If that bushing IS bad The other

bushing can be replaced separately If you re

place the bushings be sure to check that the

armaur e shaft turns freely In them before

putting the sart er back together

I

B 8


30/90

8 2

CHECK THEBRUSHES

forwear They shouldbe at least 3 4 of their original length If there IS

any doubt replace them

TESTING THE SOLENOID You will need two

jumper wres Connect a jumper wre from the

S terminal to the positive post of a batteryNext connect a second jumper wre to the nega

ti ve post of the battery and touch this wre to

the solenoid housing The solenoid should en

gage with a weak pu II you may have to push It

part of the way In This IS a tes for the hold In

winding which keeps the sart er engaged with

the flywheel If you feel no pull at all replacethe solenOid

Next check the pull In Winding Leave the

pOSitive jumper lead hooked up and simplymov e the ground wre to the M terminal theterminal connected to the sart er field wre

When you ground thiS terminal the solenoid

should be activated and should pull In much

mor e strongly than It did In the first tes If

no replace the solenoid

NOTE Even If the solenoid passes these tests

replace It If earlier tests Indicated It to bedefective

8

J

ii


31/90

8 2

The solenoid travel should also be InspectedJust push the plunger against a hard surface as

shown and measu re the distance between the

tip of the plunger and the face of the solenoid

The distance should be 3 7323 millimeterso 248 272 Inches THIS MEASUREMENT

IS VERY IMPORTANT If It IS Incorrect then

the solenoid Will no engage properly with the

flywheel and Will either hang up causingbendlx damage o else grind off the teeth ofthe rI ng gea r

Re Assembly

Install the cener support and the bendlx on

the armaur e shaft Next place the stop ringdown on the shaft and Install the snap ring and

snap ring clip

Install the armaur e and shift lever In the

gear hOUSing and engage the solenoid Inthe shift lever I nstall the shift lever Pin

A

I

8


32/90

8 2

Now mstall the coter key

Install the two solenoid attachmg screws

Next slide the fIeld housmg over thearmature

B


33/90

B 2

Install the brushes and tIghten the screw termlnals connecting them to the field and toground

Now Install the end plate Don t forget to restall any spacers o shIms whIch you mIght

have removed from this end

Next replace the brush band

8 2


34/90

8 2

Finally Install the field wre on thesolenoid M terminal

Final bench tes

This tes requires some expertise so perform It

carefully

Install the sart er firmy In avi se

Connect the negative clamp of a high qualitybattery charger to the sart er gear housing flange

Connect the positive lead of the battery chargerto the solenoid 8 terminal

Turn the charger on

Connect a Jumper wre between the 8 term

nal and the solenoid 5 terminal The solenoid

should engage and the sart er should turn and

the curren draw should no exceed 6 amps

B 3


35/90


36/90

L SERIES

Disassembly

Remove the nu securing the sart er field lead

to the solenoid M terminal and remov e the

lead Remove the two scr ews which sec ure the

solenoid and remove the solenoid

Remove the two small scr ews securing the brush

cover over the end plate Remove the two

through bolts holding the sart er together

Now remove the two pOSitive brushes brushes

which are soldered to the fields Make a Simplehook ou of a nail and hook It behind the

spring on each brush Pull up on the spring and

remove the brush

L2


37/90

L SERIES

Now slide the brush plate off the commutator

Be careful no to lose any washers o spacers

Remove the fIeld housing You may have to

tap lightly with a plastic hammer on the arma

ture shaft to separate the field housing from

the gear housing

Now remove the nu washer and the shift lever

locking pin Next pull the armaur e ou of the

gear housing

l3

p@

r

JiJ IlI

J

C D I


38/90

L SERIES

Now remove the overrunning clutch First slide

the locking clip off the gear stop ring

Now push the stop ring toward the gear Now

you can see the snap ring Removal of this snap

ring will be easer If you have a tool such as the

one shown When the snap ring has been removed slide the overrunning clutch off the

armature

I

I f

f

Preliminary checks before cleaning

Check the ring gear on the engine for chippedteeth o excessve wear of the teeth You mayhave to replace the ring gear In sever e cases

L


39/90

L SERIES

Inspect the field coil lead where It goes throughthe grommet Ino the sart er This often be

comes grounded ou causing a SHORT

Check the Inside of the brush cover and the field

housing around the commuaor You mightfind a ring of solder here which would tell

you that the armaur e has been overheated spuntoo fast and lost some of ItS solder It mightalso tel you that the sart er has been hanging

up on the nng gear because the overrunning

clutch IS no working properly

Cleaning

q

LL

DO NOT USE SOLVENT except on the gear

housing OtherWise you might damage the insulaion on the field Windings o dissolve the

grease In the clutch causing It to fall later on

USing ar carefully blow all parts clean

L 5


40/90

L SERIES

InspectIOn

CHECK THE ARMATURE A vlsualmspectlonshould show you whether the armaur e has

been dragging on the fields This will cause

shorts and might have permanently damagedthe armaur e

Look at the solder JOnts around the commu

taor Be sure to check this If you found solder

Inside the field housing

Inspect the commuaor It should be clean and

sh InY before you put the sart er back togetherso It will be necessary to clean It uSing a strip of

sandpaper o commuaor paper Check tomake sure there IS a groove between the bars

of the commuaor If there Isn t you Will have

to make one

L 6


41/90

L SERIES

Now place the armaur e on a growler and turnthe armature If the blade sticks to the armature

then you have a short and the armaur e will

have to be replaced

Next check the armaur e for opens USing thetes light section of the growler touch one leadto anyone of the commuaor segments Take

the other lead and run It around the commu a

tor touching all of the segments The lightshould be lit on every segment If It Isn t hen

there IS an open In the solder connect i on at

that segment o there IS an open inside the

armaur e

If any opens are indicated replace the armaur e

L7


42/90

L SERIES

Next touch onelead of

the continuitytester

to the shaft and touch the other lead to any

segment of the commuaor If there IS a short

the light will go on If It does replace the

armaur e

Inspect the splines on the armaur e shaft If

there are any rough spots o burrs they will

keep the overrunning clutch from sliding one

way o the other and cause the sart er to hangup on the flywheel o else no to engage at allFile off any burrs

CHECK THE OVERRUNNING CLUTCH Hold

the outside of the clutch and turn the gear It

should turn with a slight smooth drag In onedirection In the other direction It should no

turn If It does no give you positive indications

replace the assembly Also check the gear teeth

for damage and replace If you find any

JI

L S


43/90

L SERIES

CHECK THE FIELDS Look at the insulation

around the windings and at the solder JOint

between the fields Check the fields for OPENS

by con nectlng the lead of the tester to the

man field lead and touching each of the brushesIn turn The light should go on each t i me Ifno there IS an open and the fields must be

replaced

Check the fields for shorts touch one lead of

the continUity tester to the field hOUSing The

light should no go on If It does you have ashort and will have to replace the fields

To replace the fields use an Impact tool Placethe hOUSing on a Vse but do no tighten asthiS may cause warpage of the hOUSing Removethe scr ews and replace the fields

L 9


44/90

L SERIES

CHECK THE BRUSH PLATE First check the

positive brush holder to make sure It IS insul

ated from the plate Touch one lead of the

tester to the plate and then touch the other

lead to each of the two positive brush holders

If the light comes on then the eni re brush platewill have to be replaced

Check the brush plate negative brush holders

for opens touch one lead to the plate and the

other to each of the negative brushes If the

light does no go on then REPLACE THEBRUSH PLATE

CHECK THE STARTER BUSHINGS In the

brush cover and In the sart er gear hOUSingPlace the armaur e shaft In the bushing and

check for side play Too much play here willallow the armaur e to drag on the fields causinga short Replace the eni re brush cover If that

bushing IS bad The other bushing can be re

placed separately If you replace the bushingsbe sure to check that the armature shaft turns

freely In them before putting the sart er back

together

J

J

4

J

L


45/90

L SERIES

CHECK THE BRUSHES for wear and If there

IS any doubt replace them When you solder Innew brushes be sure to use a well tinned hot

solder Ir on to ens ur e a good JOint

NOTE Brushes should be replaced when theyare less than 3 4 of their Original length

TESTING THE SOLENOID You Will need two

jumper wres Connect a jumper wre from theS terminal to the positive post of a battery

Next connect a second jumper wre to the

negative post of the battery and touch thiswre to the solenoid hOUSing The solenoidshould engage with a weak pull you may haveto push It part of the way In Th IS IS a tes forthe hold In Winding which keeps the sart er

engaged With the flywheel If you feel no pullat all replace the solenoid

Next check the pull In Winding Leave the

positive Jumper lead hooked up and Simplymov e the ground wre to the M terminal

the terminal connected to the sart er field

wre When you ground thiS terminal the solenOid should be activated and should pull Inmor e strongly than It did In the first tes If no

replace the solenoid

NOTE Even If the solenoid passes these tests

replace It If earlier tests indicated It too be

defective

L

L f

r


46/90

L SERIES

Reassembly

Replace the overrunning clutch on armaur eBe sure clip IS firmly In place

Reinstall the armaur e In the gear housmgwhile also positioning the solenoid shift

lever core and lockmg pm

Slide the field housmg over the armaur e and upto the gear housmg Now mstall the end plate

pullmg up on the negative brush springs to allow

the plate to slide ono the commuaor Placethe plate part way on the commuaor

L

Jq r

rol

r

I

r

F

L 2


47/90

L SERIES

Now place the positive brushes m their holders

pulling back on the sprmgs to allow the brushes

to slide mo place Next push the brush plate

all the way mo place

Install the brush cover Don t forget the thrust

washer sl which you may have removed upon

disassembly Install the through bolts and the

small cap re aner screws

Install the solenoid and ItS gasket

L 3

c f

jf r r

Q

r


48/90

L SERIES

Install the field wre on the solenoid M

terminal

Measuring Cearance

With the solenoid energized push the drive

pnon toward the front of the sart er to remove

all slack and measur e clearance between the

o m l O rear edge and the pnon stopper Theclearance should be between 3 and 5mm

2and 59 In If necessary adjust clearance by adding o removing the adjusting washers

located between the solenoid and the gear case

AdJustmg washers are available In two Sizes5mm 2 In and 8mm 3

NOTE 978 models only Cearance IS3 25 mm 2 98m

Final Bench Test

This tes requires some expertise so perform It

carefully

Install the sart er firmly In avi se

Connect the negative clamp of a high qualitybattery charger to the sart er gear housingflange

Connect the positive lead of the battery chargerto the solenoid B term mal

Turn the charger on

Connect a Jumper wre between the B term

nal and the solenoid 5 terminal The solenoid

should engage and the sart er should turn on

and the curren draw should no exceed 6 amps

o 3 I 5 mm

2 I JIl

L 4


49/90

SPECIFICATIONS

SCOPE

I THE CHARGING SYSTEM

Check Battery Make Sure It Is OK Before

Going On

2 Check Alternator Belt

3 If You Have

CHARGING

SYSTEM

TESTER

TESTING

TEST LIGHT

ND VOLTMETER

ALTERNATOR

VERHAUL

PROCEDURES


50/90


51/90


52/90

CHARGING CIRCUIT TESTING WITH A SCOPE

TURN SCOPE ON DISPLAY PATTERN POSITION

2 SET VOLTAGE SWITCH TO PRIMARY

3 TURN VOLTAGE TO LOW SCALE 4 VI

4 ATTACH LOW VOLTAGE PICKUP LEADS

RED TO ALTERNATOR BAT OR A TERMINAL

BLACK TO ALTERNATOR GROUND OR E TERMINAL

5 START ENGINE OBSERVE PATTERN ADJUST PAHERN FOR GREATEST

SPREAD HORIZONTAL CHECK PATTERN AGAINST THOSE SHOWN

NORMAL

AI PATTERN NORMAL See Page C 5

OPEN DIODE

Bl PATTERN BAD See Page C 7

HORTED DIODE

OPEN STATOR

Cl NO PATTERN See Page C 9

r tt r r r

SHORTED STATOR

C3


53/90

PATTERN NORMAL

ATTACH VOLTMETER TO BATTERY TERMNALS START ENGINE RUN AT 2 RPM

FOR SECONDS CHECK VOLTMETER READING

LOW OR HIGH

4 3 5 3 VOLTS

SYSTEM

POSITIVE CIRCUIT RESISTANCE TEST SET VOLTMETER TO LOW SCALE TOUCH POSITIVE

LEAD TO ALTER NATO R A OR BAT TERMNAL TOUCH NEGATIVE LEAD TO BATTERY

POSITIVE TERMNAL TURN ON HEADLI GHTS HIGH BEAM AND HEATER FAN HIGH

SPEED RUN ENGINE AT 2 RPM

BELOW 2 VOLTS

TOUCH NEGATIVE VOLTMETER LEAD TO AL TERNA

TOR E TERMNAL TOUCH POSITIVE VOLTMETER

LEAD TO BATTERY NEGATIVE TERMNAL LOW

SCALE RUN ENGINE LIGHTS AND FAN ON

BELOW 5 VOLTS

LEAVE NEGATIVE LEAD CONNECTED AT AL TERNA

TOR TOUCH POSITIVE LEAD TO OUTSIDE OF REG

ULATOR RUN ENGINE HEADLIGHTS AND FAN ON

BELOW 5 VOLTS

I REPLACE REGULATOR

NOTE MAKE SURE THAT THE BATTERY IS IN

A CHARGED CONDITION FOR THIS TEST OTHERWISE

VOLTAGE READING COULD BE INCORRECT

I

ABOVE 2 VOLTS

CHECK FOR BAD CONNECTION IN WIRE BETWEEN

ALTER NATO R A TERMNAL AND BATTERY 973

9746 CHECK CONNECTOR BLOCK AT RIGHT KICK

PANEL IN PASSENGER COMPARTMENT

ABOVE 5 VOLTS

BAD GROUND CONNECTION BETWEEN ALTERNATOR

AND BATTERY

ABOVE 5 VOLTS

BAD GROUND CONNECTION BETWEEN ALTERNATO R

AND REGULATOR

C 5


54/90

B W B

B W

o

WL

REGULATOR CONNECTOR

HARNESS SIDE

B Ground

y Neuter to Alternator N terminal

W B Field

W From A Termrnal

B From Ignition SWitch early models W L

W R From Dash Charge Warning Light

y W W R

C G


55/90

BAD PATTERN

SET VOLTMETER TO LOW SCALE TOUCH POSITIVE LEAD TO ALTERNATOR A OR

BAT TERM NAL TOUCH NEGATIVE LEAD TO BATTERY POSITIVE TERMNAL TURN

ON HIGH BEAM HEADLIGHTS AND HEATER FAN HIGH SPEED RUN ENGINE AT 2

RPM CHECK READING

BELOW 2 VOL TS ABOVE 2 VOLTS

TOUCH NEGATIVE VOLTMETER LEAD TO AL TERNA

TOR E TERM NAL TOUCH POSITIVE VOLTMETER CHECK FOR BAD CONNECTION IN WIRE BETWEEN

LEAD TO BATTERY NEGATIVE TERM NAL RUN EN AL TERNATOR A TERMNALAND BATTERY

GINE AT 2 RPM LIGHTS AND FAN ON

BELOW 5 VOLTS ABOVE 5 VOLTS

LEAVE NEGATIVE LEAD CONNECTED TO AL TERNABAD GROUND CONNECTION BETWEEN ALTERNATOR

TOR E TERMNAL TOUCH POSITIVE LEAD TOAND BATTERY

OUTSIDE OF REGULATOR RUN ENGINE LIGHTS AND

FAN ON

BELOW 5 VOLTSABOVE 5 VOLTS

REMOVE FIELD WIRE AT AL T TOUCH TEST LI GHT BAD GROUND CONNECTION BETWEEN ALTERNATO R

TO THIS WIRE WHITE BLACK AND REGULATOR

LIGHT OFF OR FLICKERING LIGHT ON STEADY

AT REGULATOR CONNECTOR KEY ON TOUCH TEST

LI GHT TO BLACKIWHITE OR WHITE BLUE WIRE REMOVE ALTERNATOR FOR REPAIRS

LEAVE CONNECTOR PLUGGED IN

Overhaul

LIGHT ONLIGHT OFF

TOUCH LI GHT TO WHITE BLACK WIREOPEN CIRCUIT BETWEEN IGNITION SWITCH AND

REGULATOR

LIGHT OFFLIGHT ON

IHITE BLACK WIRE BETWEEN REGULATOR AND AL REPLACE REGULATORTERNATOR FIELD IS OPEN

Co7


56/90

B W

B W B or

W L

y W W R

B

Y

W B

W

B W

W R

Coa

REGULATOR CONNECTOR

HARNESS SIDE

Ground

Neuter to Alternator N termnal

Field

From A Termnal

From Ignition SWitch early models W L

From Dash Charge Warning Light


57/90

NO SCOPE PATTERN

TURN KEY ON HOLD SCREWDRIVER IN FRONT OF ALTER NATO R PULLEY CHECK

FOR MAGNETISM

NO MAGNETISM

UNPLUG FIELD LEAD WHITE BLACK AT AL TERNA

TOR TOUCH TEST LI GHT TO THIS LEAD KEY ON

LIGHT OFF

AT REGULATOR CONNECTOR KEY ON TOUCH TEST

LI GHT TO BLACKIWHITE OR WHITE BLUE WIRE

LIGHT ON

TOUCH LI GHT TO WHITE BLACK WIRE KEY ON

LIGHT ON

WHITE BLACK WIRE BETWEEN REGULATOR AND AL

TERNATOR FIELD IS OPEN

MAGNETISM

CHECK TO MAKE SURE YOU CONNECTED THE SCOPE

PROPERLY IF YOU DID THEN REMOVE THE ALTER

NATOR FOR REPAIRS

Overhaul

LIGHT ON

REMOVE ALTERNATOR FOR REPAIRS

Overhaul

LIGHT OFF

PEN CIRCUIT BETWEEN IGNITION SWITCH AND

REGULATOR

LIGHT OFF

I IEPLACE REGULATOR

C 9


58/90

RATED OUT PUT

ACTUAL OUTPUT

ALTERNATOR SPECF CATIONS

To Fnd T M I Raft I Output Of The A erna O You Are

Wonung On Look On The AlternatO Fron Housmg YouWll FInd A Snn Of Idend Cltlon Man s N I look For M

F IS T The Nex Two Numbers A TheAmpll l Rating Of The Aternaor

EXAMPLE L 6 6 Ampern R Output

Ths Is The Max mum Output Mum The Alternator Is

Actually Capable Of Produang And WlIch You ShouldLook FOI Whe n Y au Test The

glng System

RATED OUTPUT AMPS

25

33

35

5

6

ACTUAL OUTPUT AMPS

24

28

n

45

N OTE Do n t Forgrrt To Add 5 Amps To The Mater Rng If You Are Ilng A g System Test r Sum

The Va 28

3 VOLTAGE SETTING NoL FuIIyCharg8d

43 53Volts

IAII Mode

B

Y

B W B

B W

o

W L

y W R

REGULATOR CONNECTOR

HARNESS SIDE

Ground

Neuter to Alternator N termnal

W B Field

W From A Termnal

B

W R

Co

From Ignition SWitch early models W L

From Dash Charge Warning Light

AMPS

o o

i HH i 9


59/90

CHECKING THE CHARGING SYSTEM WITH A SPECIAL TESTER

CONNECT TESTER TO VEHICLE SEE SAMPLE ILLUSTRATIONI LEAVE ALL VEHICLE

ELECTRICAL UNITS TURNED OFF

RUN ENGINE AT 25 RPM TURN LOAD KNOB UNTI L AMMETER GETS TO HIGHEST

READING ADD 5 TO AMPS TOTHIS FIGURE

BELOW SPECIFIED AMPERAGE

UNPLUG FIELD LEAD WHITE BLACKI FROM AL TER

NATOR PLUG TESTER FIELD LEAD INTO ALTERNA

tOR TURN TESTER TO INTERN AL GROUND TYPEFIELD RUN AT 25 RPM TURN LOAD KNOB TOOBTAIN HIGHEST READING ADD 5 TO AMPSCURRENT OUTPUT NORMAL

TOUCH THE TEST LI GHT TO FIELD

LEAD AT ALTERNATOR WHITE

BLACK IGNITION ON

NO LIGHT REPLACE REGULATOR

LIGHT

IGNITION ON TEST LI GHT TO THE

WHITE BLACK WIRE AT THE REG

ULATOR CONNECTOR LEAVE

CONNECTOR PLUGGED IN

NO LIGHT

LIGHT

OPEN IN FIELD WHITE BLACK

WIRE BETWEEN REGULATOR AND

ALTERNATO R

AT REGULATOR CONNECTOR TEST

LI GHT TO BLACKlWHITE OR WHITE

BLUE WIRE IGNITION ON CON

NECTOR STILL PLUGGED IN

NO LIGHTOPEN IN IGN CIRCUIT TO REG

ULATOR

LIGHT

REPLACE REGULATOR

AT OR ABOVE WORKING

AMPERAGE SEE CHARTISYSTEM

CURRENT OUTPUT LOW

RECONNECT FIELD TURN VOLTMETER SELECTOR

TO LOW RANGE CONNECT POSITIVE LEAD TO AL

TERNATOR A OR BAT TERM NAL CONNECT

NEGATIVE LEAD TO POSITIVE TERM NAL OF BAT

TERY RUN ENGINE AT 25 RPM TURN LOAD TO

AMPS CHECK VOLTAGE READING

ABO OLTSOPEN IN WIRING BETWEEN ALTER

NATOR A AND BATTERY TERMI

NAL

BE LOW 2 VOLTS

NOW CONNECT NEGATIVE LEAD

OF VOL TMETER TO E OR

GROUND TERM NAL OF ALTERNA

TOR PUT POSITIVE LEAD ON NEG

ATIVE TERMNAL OF BATTERY

RUN ENGINE AT 25 RPM APPLYA LOAD OF AMPS CHECK VOLT

AGE READING

ABOVE 5 VOLTBAD GROUND CONNECTION BE

TWEEN ALTERNATO R AND BAT

TERY

BELOW 5 VOLT

MOVE POSITIVE LEAD TO REGU

LAT OR COVER REPEAT TEST

ABOVE 5 VOLTBAD GROUND CONNECTIONS AL

TERNATOR REGULATOR

BELOW 5 VOLT

REMOVE ALTERNATOR FOR RE

PAIRS

verhaul

C


60/90

CHECKING THE CHARGING CIRCUIT

WITH A TEST LIGHT AND A VOLTMETER

NOTE BEFORE STARTING TEST MAKE SURE BATTERY IS FULLY CHARGED

TEST LI GHT TO YEL LOW WIRE AT REGULATOR CONNECTOR LEAVE CONNECTOR

tLUGGED IN ENGINE RUNNINGLIGHT ON

CHECK BATTERY VOLTAGE ENGINE RUNNING AT 3 RPM NO LOAD APPLIED

VOLTAGE LOW 4 3 5 3 VOLTS VOLTAGE GOOD

POSITIVE CIRCUIT RESISTANCE TEST SET VOLTIF BATTERY PROBLEMS PERSIST CHECK AGAIN TO

METER TO LOW SCALE TOUCH POSITIVE LEAD TOMAKE SURE THAT BATTERY IS AND THAT

ALTERNATOR A OR BAT TERM NAL TOUCHTHERE IS NO LEAKAGE CURRENT EITHER ACROSS

NEGATIVE LEAD TO BATTERY POSITIVE TERM NALTHE TOP OF THE BATTERY OR THROUGH A DEFEC

TURN ON HIGH BEAM HEADLI GHTS AND HEATERTIVE CIRCUIT IN THE VEHICLE IF PROBLEMS STILL

FAN HIGH SPEED RUN ENGINE AT 3 RPM CHECKEXIST CHECK FOR AN OPEN DIODE

READING

ABOVE 2 VOLTS

BELOW 2 VOLTSCHECK FOR BAD CONNECTION IN WHITE WIRE BE

TOUCH NEGATIVE VOLTMETER LEAD TO AL TERNATWEEN ALTER NATO R A TERM NAL AND BATTERY

FOR E TERM NAL TOUCH POSITIVE VOLTMETER

LEAD TO BATTERY NEGATIVE TERM NAL RUN EN

GINE AT 2 RPM LIGHTS AND FAN ON

ABOVE 5 VOLTS

BELOW 5 VOLTSBAD GROUND CONNECTION BETWEEN ALTERNATOR

LEAVE NEGATIVE LEAD CONNECTED TO AL TERNA AND BATTERY

TOR E TERM NAL TOUCH POSITIVE LEAD TO

OUTSIDE OF REGULATOR RUN ENGINE LIGHTS AND

FAN ON

ABOVE 5 VOLTS

BELOW 5 VOLTSBAD GROUND CONNECTION BETWEEN ALTERNATOR

HIGH RANGE VOLTMETER TO BATTERY TERMNALS AND REGULATOR

UNPLUG ALTERNATOR FIELD LEAD CONNECT JUMP

ER WIRE FROM ALTERNATO R A TO ALTERNATOR

F FIELD TERM NAL RUN ENGINE CAUTION DO

NOT Al OW VOLTA GE TO EXCEED 6 VOL TS I

VOLTAGE NORMAL 4 3 5 3 OR ABOVEBELOW 4 3 VOLTS

I ICHECK CONNECTORS REGULATOR ALTERNATOR

REMOVE ALTERNATOR FOR REPAIRSFIELD WIRE W B IF REPLACE REGULATOR

Overhaul

C 2


61/90

LIGHT OFF

tt ENGINE OFF IGNITION ON HOLD SCREWDRIVER IN FRONT OFALTERNATO R PULLEY

CHECK FOR MAGNETISM

NO MAGNETISM MAGNETISM

PULL OFF FIELD WIRE AT ALTERNATOR TEST LI GHT

TO FIELD WIRE W BI KEY ON

TEST LI GHT PROBE YELLOW NEUTER WIRE AT

ALTERNATO R LEAVE CONNECTOR PLUGGED IN

ENGINE RUNNING

LIGHT ONLIGHT ON

OPEN CIRCUIT IN YELLOW NEU

TER WIRE ALTERNATOR TO REG

ULATOR

REMOVE ALTERNATOR FOR RE

PAIRS

LIGHT OFFOverhaul

LIGHT OFF

TEST LI GHT TO WHITE BLACK

WIRE AT REGULATOR CONNEC

TOR KEY ON CONNECTOR PLUG

GED IN

REMOVE ALTERNATO R FOR RE

PAIRS

Overhaul

LIGHT ON

OPEN IN FIELD WIRE W B BE

TWEEN REGULATOR ANDALTER

NATOR

LIGHT OFF

TEST LI GHT TO BLACK WHITE OR

WHITE BLUE WIRE KEY ON CON

NECTOR PLUGGED IN

I REPLACE REGULATORLIGHT ON

LIGHT OFF

IPEN IN IGNITION CIRCUIT TOREGULATOR

REGULATOR CONNECTOR

HARNESS SIDE

B WB Ground

oy Neuter to Alternator N termnal

W L W B Field

W From A Termnal

W R B W From Ignition SWitch early models W L

W R From Dash Charge Warning Light

B W B

y W

C 3


62/90

ALTERNATOR OVERHAUL PROCEDURES

C DA

mry

r IDI Pulley asm b l y

2 Front cover

3 rront be nng4 Rotor

5 Rear beanng

6 Stator

7 Rear cover

8 Bru h assembly9 DIOde et pia te em ly

DIOde cover

II Through bots

A


63/90

ALTERNATOR OVERHAUL

Alternator dlssassembly bench tes

Calibrate an Ohmmeter on the X scale Touch one

lead to the alternator F o field terminal Touch

the other lead to the E o ground terminal The

me er should read between 5 and 2 ohms Spinthe

pulleywhile

youare

dOngthis and the

readingshould vary slightly

If the reading IS too high then there IS an open In

the field crcut brushes slip rings roor windingsand termnals If the reading IS too low then there

IS a short

IIi

lilt

Remove the scr ews securrng the brush holder

and remove the brush holder cover Pull the

brushholder forward and

removethe brushes

together with the brush holder

r

V

J

USing a screwdriver make a scratch mark alongthe side of the alternator so you will be able to

lineup

the sections whenyou

reassemble them

p

Unscrew the three through bolts Tapping lightlywith a plastiC hammer separate the front hous

Ing and roor from the rear housing and saor

as shown MAKE SURE THAT THE STATOR

STAYS WITH THE REAR HOUSING If the

saor housing comes off with the front housingthe saor wres will be damaged

A 2


64/90


65/90

ALTERNATOR OVERHAUL

oQC

Remove the A terminal nu and the diode

pack installation nu Spread the wre retaining

clamps and remove the wres from the clampsRemove the diode pack

Cleaning

t

ii

Now you can remove the saor from the front

hOUSing

Bow off all parts with compressed ar DO NOT USE

SOLVENTI If you do the solvent might dissolve the

insulation on the roor and saor windings

InspectIOn

ROTOR TESTS First Inspect the slip rings

They should be clean and shinY If they aren t

then clean them uSing 4 grit o finer paper

Check the solder JOint between the roor Wind

Ings and the slip rings Often thiS connect i on

breaks loose and causes alternator failure If

It has broken loose you Will have to resolder

the connect i on and re glue the lead to the roor

uSing epoxy cemen

A 4


66/90

ALTERNATOR OVERHAUL

Next check the roor resistance Calibrate the

ohmmeter on the X scale Touch one lead to

each slip ring The reading should be 4 5 ohms

If It s too high then check the connect i onsbetween the roor Winding and the slip ringsIf It s too low then there IS a short In the roor

Windings If you are unable to repair the roor

replace It

Next check the roor for grounds Calibrate

the ohmmeter on the X scale Touch one

lead to one of the slip rings and touch the

other lead to the roor shaft The needle should

no move at all If It does then replace the

roor It IS shorted to ground

STATOR TESTS Visually Inspect the saor

for broken connect i ons and burned insulation

Next check thesaor

for continuity Calibratethe ohmmeter on the X scale Touch an

ohmmeter lead to one of the saor Wres and

touch the other lead to each of the other three

leads one at a t i me The needle should move all

the way over each t ime shOWing continuityIf It doesn t hen look for opens In the saor

A 5

t


67/90

ALTERNATOR OVERHAUL

Check the saor for grounds Leave the ohm

meter calibrated on the X scale Touch one

lead toanyone

saor lead wre Touch the

other lead to the saor support The needle

should no mov e If It does then replace the

stator as It IS shorted to ground

DIODE TESTS First check the positive diodes

Note THE STATOR MUST BE UNSOLDERED

FIRSTI Calibrate the ohmmeter on the X

scale Connect the negative blackl lead to the

positive diode plate Touch the other lead to

each of the three saor connection termnals

The needle should show mov emen at each

terminal Now reverse the leads The me er

should no mov e at any of the three termnals

If the diodes fail any of these tests then replace

the eni re pack

Check the negative diodes Leave the ohmmeter

calibrated on the X scale Connect the

positive redl lead to the negative diode platethe plate which IS groundedl Touch the ohm

meter negative lead to each of the three saor

connect i on termnals The needle should mov e

at each termnal If the diodes fall either of these

tests then replace the enire pack

A G


68/90

ALTERNATOR OVERHAUL

INSPECTTHE BRUSHES and If

theyare won

to near the brush wear limit line replace them

BEARINGS should be carefully Inspected If the

alternator has been used for an extended period

of t i me o If there IS any question about the

condition of the bearrngs then replace them

Install the saor In the front housing lining up

the marks you made durrng assembly

A 7


69/90

ALTERNATOR OVERHAUL

hInstall the diode pack In place and tighten the

fiXing nu Loosely Install the A terminal nu

Resolder the three saor coil lead wres to the

diode termnals Note DO THIS AS QUICKLY

AS POSSIBLEI Otherwise you risk damagingthe diodes with the heat

ii

Now Install the diode cover and tighten the

negative diode plate fiXing nu and the diode

cover screw

Reinstall the roor bearings on the shaft uSing a

press A driver IS no recommended because It

might result In bearing damage When you Install the front bearing don t forget to slide

the bearing re aner on the shaft flrstl

A 8


70/90

ALTERNATOR OVERHAUL

Reinstall the grease seal and seal re aner In thefront housing

Next moun the rotor In a vise Be sure to

protect the roor with two blocks of woodNow Install the front spacer pulley and nuassembly and tighten the nu to 25 29 ft bs

A

Now slide the roor shaft mo the front housingas far as It will go and tighten the re aner fixingscrews

Now assemble the front housing roor assemblyto the rear housing stator assembly Be sure toline up the scratch marks you made when youdisassembled the alternator Install the threethrough bolts and tighten securely

Frnally Install the brushes Insulator and brushholder cover Tighten cover screws

A 9


71/90


72/90


73/90

TROUBLESHOOTING

ENGINE KEEPS RUNNING WITH KEY OFF

I Ik

ENGINE STOPS

PLUG COIL WIRE BACK IN START ENGINE

TURN KEY OFF UNPLUG IGNTI ON SWITCH

ENGINE KEEPS RUNNING

IUNPLUG VOLTA GE REGULATOR


DOES CARBURETOR HAVE ANTI DIESELING

SOLENOID

NO YES

I

UNPLUG COIL WIRE I


ENGINE IS DIESELING CARBURETOR PROB

LEM

II

UNPLUG THIS SOLENOID AND CONNECT A

JUMPER WIRE FROM THE BATTERY TER

MNAL TO THE SOLENOID RESTART ENGINE

AND TURN KEY OFF AGAN

UNPLUG FUSES ONE AT A TI ME

ENGINE KEEPS RUNNINGWITH FUSES OUT

See Page TR 4

ENGINE STOPS

REPLACE IGNITION SWITCH

ENGINE STOPS

REPLACE REGULATOR

PROBLEM PERSISTS

CROSS BETWEEN ALTERNATO R NEUTER

WIRE YELLOW AND IGNITION WIRE IN

HARNESS OR b AUTOMATIC CHOKE

RELAY

I

ENGINE STOPS

See Page TR 5

I

TR 2


74/90

TROUBLESHOOTING

ENGINE KEEPS RUNNING WITH ALL FUSES OUT

NOW STUDY THE WIRING DIAGRAM IN THE VEHICLE SERVICE MANUAL DETERMINE WHAT

COMPONENTS GET CURRENT DIRECTLY FROM THE IGNITION SWITCH WITHOUT FIRST GOING

THROUGH A FUSE NOW UNPLUG THESE COMPONENTS ONE AT A TI ME


ENGINE STOPS

REPLACE THE SHORTED COMPONENT

THERE IS A CROSS IN THE HARNESS BETWEEN THE IGNITION FEED LINE AND THE

BATTERY FEED LINE

USING THE SERVICE MANUAL MAKE A LIST OF ALL THE CONNECTORS AND

HARNESSES I NVOLVED IN THE IGNITION LINE

2 MAKE A VSUAL INSPECTION OF THESE CONNECTORS AND THE HARNESSES THEM

SELVES LOOK FOR WIRES WHICH HAVE BEEN IMPROPERLY INSTALLED OR SHORTED

TOGETHER REMOVE THE FUSE BLOCK AND INSPECT FOR SHORTS SOMETIMES ON

NEW CARS YOU WLL FIND A WIRE INSERTED INTO THE WRONG PIN OF A CON

NECTOR CHECK ALL WIRES AGANST THE WIRING DIAGRAM

PROBLEM PERSISTSON RARE OCCASIONS YOUWLL FIND TWO WIRES CROSSED IN THE HARNESS

TO CHECK

DISCONNECT BATTERY

2 UNPLUG ALL CONNECTORS AND COMPONENTS

3 CALI BRATE OHMMETER ON x SCALE

4 AT EACH CONNECTOR WHICH HAS BOTH BATTERY AND IGNITION WIRES

RUNNING THROUGH IT LOCATE THE RELEVANT PINS

5 TEST FOR CONTINUITY ACROSS THESE PINS WHEN YOU FI ND CONTINUITY YOU

Wll KNOW WHERE YOU SHOULD EITHER REPLACE A HARNESS OR UNWRAP THE

HARNESS AND NSULATE THE WIRES

TR 3


75/90

TROUBLESHOOTING

ENGINE STOPS

THE SHORT BETWEEN BATTERY AND THE IGNITION CIRCUIT IS LOCATED IN THE CIRCUITS

CONTROLLED BY THIS FUSE

MAKE A LIST OF ALL THE COMPONENTS AND RELAYS WHICH ARE CONTROLLED BY THIS FUSE

2 UNPLUG THESE COMPONENTS ONE AT A TI ME

ENGINE KEEPS RUNNING ENGINE STOPS

I REPLACE THE SHORTEDCOMPONENT

THERE IS A CROSS IN THE CIRCUITS SERVED BY THIS FUSE

MAKE A VSUAL INSPECTION OF ALL THE CONNECTORS I NVOLVED LOOKING FOR

WIRES WHICH HAVE BEEN IMPROPERLY INSTALLED OR SHORTED TOGETHER DON T

FORGET TO CHECK THE FUSE BLOCK ITSELF SOMETIMES ON NEW CARS YOUWLL

FIND A WIRE INSERTED INTO THE WRONG PIN OF A CONNECTOR CHECK ALL WIRES

AGAINST THE WIRING DAGRAM

NO PROBLEM FOUNDON RARE OCCASIONS YOUWLL FI ND TWO WIRES CROSSED IN THE HARNESS

TO CHECK

DISCONNECT BATTERY

2 UNPLUG ALL CONNECTORS SERVING CIRCUITS CONTROLLED BYTHIS FUSE

3 CALIBRATE OHMMETER ON x SCALE

4 AT EACH CONNECTOR WHICH HAS BOTH BATTERY AND IGNITION FUSE WIRES

RUNNING THROUGH IT LOCATE THE REL EVANT PINS

5 TEST FOR CONTI NUTY BETWEEN THESE PINS WHEN YOU FI NDCONTI NUTY YOU

WLL KNOW WHERE YOU SHOULD EITHER REPLACE A HARNESS OR UNWRAP THE

HARNESS AND INSULATE THE WIRES

I

TR 4


76/90

TROUBLESHOOTING

SOMETHING DOESN T WORK

CHECK BATTERY VOLTAGE IT SHOULD BE FULLY CHARGED IF NOT THEN CHARGE THE

BATTERY BEFORE PROCEEDING WITH FURTHER TESTS

CHECK FUSES

TURN ON THE CIRCUIT YOU ARE TESTING

2 TURN IGNITION KEY TO IGNITION ON POSITION

3 CONNECT TEST LI GHT CLIP TO GROUND

4 TOUCH LIGHT TO BOTH SIDES OF EACH FUSE IT SHOULD BE LIT ON BOTH SIDES

NOTE DON T FORGET ANY INLlNE FUSES WHICH MAY BE IN THE CIRCUIT

FUSES K

GET OUT THE SERVICE MANUAL ANDFI ND THE SECTION DESCRIBING

THE CIRCUIT I NVOLVED CHECK TO SEE WHETHER THE CIRCUIT HAS

A RELAY IN IT

CIRCUIT HAS RELAY

LOCATE THE RELAY ON THE CAR

2 STUDY THE WIRING DIAGRAM TO DETERMINE WHAT TURNS THE

RELAY ON AND OFF THIS CAN BE DONE USING A SWITCH IE G

INHBTOR SWITCH USING THE IGNTI ON KEY OR USING A

SWITCH IN THE CONTROLLED CIRCUIT IE G DIMMER SWITCHI

3 ACTIVATE THE RELAY AND LISTEN TO IT

RELAY CLICKS

See Page TR

RELAY DOESN T CLICK

See Page TR l

FUSES BAD

See Page TR 2

JINO RELAY

See Page TR

TR 5


77/90


78/90

TROUBLESHOOTING

RELAY POSITIVE CIRCUIT RESISTANCE TEST

USING THE SERVICE MANUAL CIRCUIT DIAGRAM DETERMINE THE LOCATION OF THE RELAY

ACTIVATING SWITCH I E IS IT IN THE POSITIVE OR NEGATI VE SIDE OF THE CRCUIT

SWITCH IN POSITIVE SIDE OF THE CIR

CUIT BETWEEN THE BATTERY POSITIVE

POST AND THE RELAY

SWITCH IN NEGATIVE GROUND SIDE

OF CIRCUIT

FIND OPERATIONAL DAGRAM OF THE

SWITCH IN THE SERVICE MANUAL TEST

THE SWITCH USING AN OHMMETER SEE

OHMMETER SECTION OFTHIS MANUAL

IF SWITCH IS K

LEAVE THE CIRCUIT TURNED ON AND MALFUNCTIONING ALL

CONNECTORS PLUGGED IN

2 LEAVE THE POSITIVE VOLTMETER LEAD CONNECTED TO THE

POSITIVE BATTERY TERM NAL

3 NOW TAKE THE NEGATIVE VOLTMETER LEAD AND PROBE ALL

AL ONG THE CIRCUIT BACKING UP TOWARD THE BATTERY TAKE

YOUR TIME ANDYOU Wll LOCATE THE POINT OF HIGH RESIST

ANCE WHEN THE VOLTA GE FINALLY DROPS BACK TO NORMAL

TR


79/90


80/90

TROUBLESHOOTING

LOCATE THE CONNECTOR AT THE COMPONENT IN QUESTION IF THE COMPONENT IS A GAUGE

OR LI GHT IN THE INSTRUMENT CLUSTER THEN YOU SHOULD PULL THE CLUSTER OUT TO

GAIN ACCESS TO HE CONNECTOR

USING THE SERVICE MANUAL DETERMINE WHICH PIN OF THE CONNECTOR SHOULD BE HOT

HAVE CURRENT TO ITl WHEN THE CIRCUIT IS ACTI VATED

SET VOLTMETER TO LOW RANGE IO 3V CONNECT THE POSITIVE LEAD TO THE POSITIVE

TERMNALS OF THE BATTERY

I TURN THE CIRCUIT ON I

NOW PROBE THE POSITIVE WIRE AT THE CONNECTOR WITH THE NEGATIVE VOLTMETER LEAD

LEAVE THE CONNECTOR PLUGGED IN AND CHECK THE READING

BELOW 2 VOLTS ABOVE 2VOLTS

USING THE SERVICEMANUAL

DETERMINE WHICH PIN OF THESee Page TR 6

CONNECTOR SHOULD BE GROUNDED NEGATIVE WHEN THE CIR

CUT S ACTI VATED

2 WITH THE VOLTMETER STILL SET TO THE LOW RANGE O 3VI

CONNECT THE NEGATIVE LEAD TO THE NEGATIVE TERMNAL OF

THE BATTERY

3 NOW PROBE THE NEGATIVE WIRE AT THE CONNECTOR USING THE

POSITIVE VOLTMETER LEAD LEAVE THE CONNECTOR PLUGGED

IN ANDTURN ON THE CIRCUIT

4 CHECK THE READING

BELOW VOLTSee Page TR 4

REPLACE THE COMPONENT

TR 9


81/90

TROUBLESHOOTING

STRANGE THINGS HAPPEN

EXAMPLE ALL PARKING LIGHTS FLASH WHEN TURN SIGNALS ARE ENERGIZED I

PROBLEMS LIKE THESE ARE CAUSED BY

BAD GROUND CONNECTIONS

2 BAD CONNECTIONS IN POSITIVE SIDE OF CIRCUIT

3 CROSSOVER BETWEEN POSITIVE SIDES OF TWO CIRCUITS

4 CROSSOVER BETWEEN GROUND OF ONE CIRCUIT AND POSITIVE SIDE OF ANOTHER

CIRCUIT

PRELIMINARY ITEMS TO CHECK

GROUND CONNECTIONS

2 IF ONE OF THE CIRCUITS I NVOLVED IS A LI GHT CIRCUIT REMOVE THE TWO STOP

LI GHT BULBS

TEST PROCEDURE

CHECK BATTERY VOLTA GE IT SHOULD BE FULLY CHARGED IF NOT THEN CHARGE

THE BATTERY BEFORE PROCEEDING WITH FURTHER TESTS

2 CHECK FUSES

A TURN ON THE CIRCUIT YOU ARE TESTING

B TURN IGNITION KEY TO IGNITION ON POSITION

C CONNECT TEST LI GHT CLIP TO GROUND

D TOUCH LI GHT TO BOTH SIDES OF EACH FUSE IT SHOULD BE LIT ON BOTH SIDES

NOTE DON T FORGET ANYINLINE FUSES WHICH MAY BE IN THE CIRCUIT

FUSES K

See Page TR 3

FUSES BAD

See Page TR 2

TR


82/90


83/90

TROUBLESHOOTI NG

FUSES O K

MAKE A LIST OF ALL THE CIRCUITS WHICH ARE ACTING UP WRITE THIS DOWN

NOW CHOOSE ONE OF THESE CIRCUITS FIND THE CIRCUIT DESCRIPTION AND DIAGRAM IN

THE SERVICE MANU AL FAMLIARIZE YOURSELF BRI EFL Y WITH THIS CIRCUIT

2 NOW ON THE CAR FIND THE PLUG CONNECTING THE COMPONENT LI GHT BULB HORN

RELAY ETC CONTROLLED BYTHIS CIRCUIT

NOTE IF COMPONENT IS A GAUGE OR LI GHT IN THE INSTRUMENT CLUSTER YOU SHOULD PULL

THE CLUSTER OUT TO GAIN ACCESS TO THE PLUG


2 CONNECT NEGATIVE LEAD OF VOLTMETER TO NEGATIVE TERMNAL OF BATTERY

3 TURN CIRCUIT ON AND SET UP MALFUNCTION THIS MAY NECESSITATE TURNNG ON

ANOTHER CIRCUIT AT THE SAME TI ME

4 TOUCH POSITIVE LEAD OF VOLTMETER TO GROUND TERMNAL OF COMPONENT LEAVE

ALL CONNECTIONS PLUGGED IN

5 CHECK VOLTMETER READING

ABOVE VOLT

See Page TR 4

BELOW VOLT

See Page TR 5

TR 2


84/90


85/90

TROUBLESHOOTING

BELOW VOLT

NOW CONNECT THE POSITIVE LEAD OF THE VOLTMETER TO THE POSITIVE BATTERY

TERM NAL

2 TOUCH THE NEGATIVE LEAD TO THE HOT POSITIVE WIRE AT THE COMPONENT COMPO

NENT STILL PLUGGED IN TURNED ON AND MALFUNCTIONING

3 CHECK VOLTAGE READING

ABOVE 2 VOLTS

See Page TR 6

BELOW 2 VOLTS

SeePage TR ll

TR 4


86/90

TROUBLESHOOTING

POSITIVE CIRCUIT RESISTANCE

ABOVE 2VOLTS

IN THE SERVICE MANUAL FIND THE DIAGRAM FOR THE CIRCUIT ON WHICH YOU ARE WORKING

NOW STUDYIT TO FIND THE LOCATION OF THE SWITCH

SWITCH IN POSITIVE SIDE OF THE CIR

CUIT BETWEEN THE BATTERY POSITIVE

POST AND THE COMPONENT

SWITCH IN NEGATIVE GROUNDI SIDEOF THE CIRCUIT

FIND OPERATIONAL DIAGRAM OF SWITCH IN SERV

ICE MANUAL TEST THE SWITCH USING AN

OHMMETER SEE OHMMETER SECTION OF THIS

MANUAL

LEAVE THE CIRCUIT TURNED ON AND MALFUNCTIONING

2 LEAVE THE POSITIVE VOLTMETER LEAD CONNECTED TO THE POSITIVE BATTERY TERM NAL

3 NOW TAKE THE NEGATIVE VOLTMETER LEAD AND PROBE ALL ALONG THE CIRCUIT BACKING

UP TOWARD THE POSITIVE TERM NAL OF THE BATTERY LEAVE ALL CONNECTORS PLUGGED

IN TAKE YOUR TI MEAND YOU WLL LOCATE THE POINT OF HIGH RESISTANCE WHEN THE

VOLTA GE FI NALLY DROPS BACK TO NORMAL

TR 5


87/90

TROUBLESHOOTING

BELOW 2 VOLTS

THERE S A CROSS BETWEEN

THE POSITIVE SIDES OF TWO CIRCUITS

2 THE POSITIVE SIDE OF ONE CIRCUIT AND THE NEGATIVE SIDE OF ANOTHER CIRCUIT

TO FI ND THE CROSS FIRST SET UP THE MALFUNCTION

ENGINE RUNNING

NO YES

WITH ENGINE OFF DISCONNECT BATTERY CABLESRECONNECT CABLES

WITH IGNITION ON ENGINE OFF DISCONNECT AL

TERNATOR FIELD LEAD CHECK TO BE SURE THE

WIRES ARE IN THE CORRECT PLACES IN THE FIELD

PLUG F TERMNAL WHITE BLACK WIRE

MALFUNCTION HAS STOPPED

CONNECT JUMPER WIRE FROM BATTERY AND

NEUTER YEl OW WIRE AT CONNECTORTHERE IS A RELAY MALFUNCTIONING

SHORTING TWO CIRCUITS TOGETHER

MALFUNCTION PERSISTSMALFUNCTION DOESN T RETURN

MALFUNCTION RETURNS

UNPLUG AUTOMATIC CHOKE RELAY

2 UNPLUG ELECTRIC FUEL PUMP RELAY

9 74 3

3 TRY NEW VOLTA GE REGULATOR

MALFUNCTION PERSISTS

THERE IS ACROSS

BETWEEN THENEUTER

YELLOW WIRE

AND SOME OTHER WIRE IN THE HARNESS

DISCONNECT BATTERY CABLES AGAN ENGINE OFF

See Page TR t8

TR G


88/90

TROUBLESHOOTING

BELOW 2 VOLTS CONTINUED

DISCONNECT BATTERY CABLES AND UNPLUG COIL WIRE

2 CALI BRATE AN OHMMETER ON THE x SCALE

3 USING THE SERVICE MANUAL LOCATE THE MAN WIRING HARNESS IN WHICH THE COM

PONENT CONTROLLING WIRES ARE LOCATED

4 UNPLUG THIS HARNESS FROM THE OTHER MAIN HARNESS ES IN THE CAR USUAlY THERE

WLL BE ONE OR TWO MAIN JUNCTION BLOCKS NOTE WHEN YOU UNPLUG THE HARNESS ES

MAKE A VSUAL INSPECTION OF THE PINS SOMETIMES YOUWLL FIND THAT THE CONNEC

TORS HAVE HEATED UP AND MELTED ALLOWING TWO PINS TO TOUCH EACH OTHER

5 CONNECT ONE OHMMETER LEAD TO THE HOT WIRE AT THE COMPONENT AND LEAVE IT

THERE

6 NOW AT THE MAN HARNESS CONNECTOR S TOUCH THE OTHER OHMMETER LEAD TO EVERY

OTHER PIN ONE AT A TI ME CHECK FOR CONTINUITY

CONTINUITY NO CONTINUITY

CHECK THE WIRING DIAGRAM TO FIND OUT WHAT CIRCUIT THIS PIN See Page TR 9CONTROLS DETERMINE WHETHER THERE SHOULD BE CONTINUITY

BETWEEN THAT CIRCUIT AND THE ONE WHICH IS MALFUNCTIONING

CONTINUITY NORMAL

CONTINUE TESTING UNTI L ALL PINS HAVE BEEN

TESTED

CONTINUITY NOT NORMALPROBLEM NOT LOCATED

THERE IS A CROSSOVER BETWEEN THESE TWO CIR See Page TR 9CUlTS EITHER AT A UNT WHICH PLUGS INTO THE

HARNESS OR IN THE HARNESS ITSELF

TO DECIDE WHICH IS THE CASE

ONE AT A TI ME UNPLUG THOSE UNITS COMPONENTS SWITCHES ETC WHICH ARE CONNECTED

TO THE SUSPECT CIRCUITS

CONTINUITY STOPS CONTINUITY CONTINUES

I REPLACE THE UNT ITHERE IS A CROSSOVER IN THE WIRING HARNESS

BETWEEN THESE TWO WIRES YOU WLL HAVE TO

UNWRAP THE HARNESS TO FIND THE CROSSOVER

OR REPLACE IT

TR 7


89/90

TROUBLESHOOTING

NOW DISCONNECT THE OHMMETER LEAD FROM THE COMPONENT HOT LEAD CONNECT IT TO

THE COMPONENT GROUND LEAD AT THE HARNESS CONNECTOR S ONCE AGAN PROBE EVERY

WIRE WITH THE OTHER OHMMETER LEAD LOOKING FOR CONTI NUTY

CONTINUITY

CHECK THE WIRING DIAGRAM TO FIND OUT WHAT CIRCUIT THIS PIN

CONTROLS DETERMINE WHETHER THERE SHOULD BE CONTINUITY

BETWEEN THESE CIRCUITS

NO CONTINUITY

See Page TR 2

CONTINUITY NORMAL

CONTINUE TESTING UNTI L ALL PINS HAVE BEEN

TESTED

CONTINUITY NOT NORMAL

THERE IS A CROSSOVER BETWEEN THESE TWOWIRES

EITHER AT A UNT WHICH PLUGS INTO HE HARNESS

OR IN THE HARNESS ITSELF

TO DECIDE WHICH IS THE CASE

ONE AT A TI ME UNPLUG THOSE UNITS COMPONENTS SWITCHES ETC

WHICH ARE CONNECTED TO THE SUSPECT CIRCUITS

PROBLEM NOT LOCATED

See Page TR 2

CONTINUITY CONTINUES CONTINUITY STOPS

I REPLACE THE UNT IHERE IS A CROSSOVER IN THE WIRING HARNESS

BETWEEN THESE TWO WIRES YOU WLL HAVE TO

UNWRAP THE HARNESS TO FIND THE CROSSOVER

OR REPLACE IT

TR 8


90/90

TROUBLESHOOTING

NOW DISCONNECT THE OHMMETER FROM THE COMPONENT LEAD

AT THE MAIN HARNESS CONNECTOR FI ND THE COMPONENT HOT

LEAD ON THE OTHER SIDE OFTHE CONNECTOR WHERE THE CIRCUIT

CONTINUES INTO HE NEXT HARNESS

CONNECT AN OHMMETER LEAD TO THIS PIN AND CHECK EACH OTHER

PIN IN THE CONNECTOR S ON THAT OTHER HARNESS CONTINUE AS

BEFORE DISCONNECTING EACH UNT IN THIS HARNESS AND THEN

CHECKING THE GROUND CIRCUIT FOR CROSSOVERS IF YOU CON

TINUE TRACING THE CIRCUIT YOU WLL LOCATE THE PROBLEM

Date post:	03-Jun-2018
Category:	Documents
Upload:	diego-arevalo
View:	230 times
Download:	1 times

Service Manual Datsun Electrical Service Guide

Documents