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[Datsun 1200 encyclopedia]

510 Headlight Wiring

From Datsun 1200 Club

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Category: Body Electrical System

Datsun 510 uses headlights that are always hot, but not connected to ground until the Lighting Switch is pulled.

Contents

510 Switched-Earth Wiring

Headlights are not permanently grounded as in newer Datsuns
Headlights are permanently connected to HOT via the Fuse Box
Original 1968-1969 6-fuse fuse box
One fuse powers both Headlights

1969-1973 Dual-Fuse Headlight Circuit]
510_headlamp_wiring_late.jpg

New for 1969 8-fuse modular fuse box
'HL' 10A RL Power to Left Headlights
'HR' 10A R Power to Right Headlights
Relay switches ground on for either
* High beams (all 4 lights) 
* Low beams (2 outer lights)
Relay does not switch the 12V HOT side
Relay switches the GROUND wires
Relay Coil is powered by GL wire from Lighting Switch
Relay Coil is switched by BR wire from Dimmer Switch
* ungrounded = Low beams switched to Ground
* grounded = High beams switched to Ground
Dimmer Switch
* Only connects to Ground (High beam position) or disconnected
* No 12V runs through it
Lighting Switch
* controls headlights, park lights, dash illumination lights
* does not control turn signals
* does not control dash pilot lights (OIL, CHG, P.B)
Dash Illumination Lamps (2) are grounded though Pin 2 Black wire. 
GW Pin 1 goes to Lighting Switch
OIL pilot lamp is grounded via Oil Pressure switch
G Pin 8 goes to 4-way Flasher Switch
CHG pilot lamp is grounded via Voltage Regulator
G Pin 8 goes to 4-way Flasher Switch
Parking Brake pilot lamp is grounded via Handbrake switch
G Pin 8 goes to 4-way Flasher Switch

Relay

25230-89915 RELAY ASSY-low beam lighting type K2
* S30 ignition/fuel pump RELAY B
* replaced by B5230-89985
25230-89905 JIDECO RELAY COMP-lighting type K5

25230-89905
25230-89905.jpg

25230-89915
25230-89915.jpg

The two relays on the back side of the RH strut tower in front of the fuse box are for the headlights and the horn. The headlight relay has a 6 prong plug, the horn has four individual wires.

Relay is on the RH side behind the headlights

Original JIDECO relay

P4040356_zpsd9c1d13a.jpg P3300343_zpsf8d20b06.jpg P3300345_zps78460418.jpg P3300347_zps2f150968.jpg P3300349_zpsa539b5ca.jpg

Low Beam Relay
B5230-28000

3-wire horn relay
[6729431907_92d9e3737e.jpg

Headlight Relay
B5230-89985

Alternate Relays

You can use many different relays if you jump the wires from the harness to the relay pins. For example Nissan 25230-C9900 is only $2 at Pick-n-pull and used by hundreds of Nissan. Or $10 new at RockAuto.com.

25230-C9900/25230-C9905/25230-C9907 25A 25230-W1300 25230-C9963
21854.jpgAlbum 21854 25230-C9905.jpg

Jumpers
Relay   Harness
D com   B   body ground (leave one B wire disconnected) 
A NC    RB  low beam ground
B NO    RW  high beam ground
C coil  GL  light switch +
E coil  BR  dimmer switch ground

510_headlamp_relay.jpg

Relay Repair

http://www.510coop.com/completed/HLrelay.htm
Carefully pry the cover loose. there are four crimps, one on each side. uncrimp carefully with a screwdriver and remove the cover. Now between the contact on the bottom of the plastic piece is a screw. Remove it and carefully lift the guts away from the base and you should see rust on the bottom. Sand that clean apply so dielectric grease, reassemble and you should have a working relay. It's the rust and corrosion that is interrupting the circuit. Be careful of the wiring in the relay. The unit itself is pretty tough but some of those fine wires can break if you get too rough.

So, that's what I did...and now I have headlights! Thanks Bruce!

Relay001.jpg Relay003.jpg Relay005.jpg Relay008.jpg 

¤

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