Restoring C610 - 1G side (female)

[BigBrother-84]

Hi Bullnose aficionados!

As some of you already know, Big Brother’s C-610 connector was cancelled somewhere in the past.

Before going to swap it's 1G to a 3G alternator, I want to rehabilitate this connector.  Thanks to Gary, I've got a male side in good shape, and I was able to grab a female side at my local salvage yard.

For the male side, no problem, I identified the wires to reconnect.

But I need your help for the female side (I know, I don't have to anyway to rebuild the 1G pigtail if I go right to the 3G swap, but I would prefer to do so).

Here's a picture of the C-610 male and female connectors.  To facilitate the discussion, I've numbered the wires.  There’s also a partial screenshot of the wiring diagram.

My question:  Accordingly to the wiring diagram (Splice S-202), I have to splice wires #7, #10 and #12 together, with the alternator Black/Orange wire?
They all go to the Starter Relay through the black Fusible Link #13?




Just as info, here is Big Bro's current wiring situation:

[ArdWrknTrk]

Yellow (37) is main power to the cab.this should go to the hot stud (batt +) of the fender relay.
Bk/or is charge out, and goes to the new Megafuse, then on to the hot stud of the fender relay.
Yellow/green & Red/orange are to and from the ammeter (now voltmeter) so one side goes to ground and the other to 'key on' power.

[Gary Lewis]

Jeff - I'm confused.  But I think what is confusing both me and you is that you are trying to use the wires after S201.  You'll cut the R/O wire before the splice so you only have 4 wires to deal with off of C610:

Y/LG, which is your #7, goes to ground

Big Yellow goes to the megafuse or the starter relay, but not both - as shown on the schematic

Y/LG, your #7, goes to ground

R/O splices to LG/R coming from C610 and goes on to the regulator

[BigBrother-84]

Sorry guys, I wasn’t clear.

I am focusing on the 1G pigtail, for now.  3G will be another subject.

I am confused about what wires are spliced together by S-202.

This is what the wiring diagram shows:


And this is how I understand it (custom numbers are the same than in the previous harness picture):

[Gary Lewis]

Jeff - I am getting lost with all of the other diagrams.  Why do we need more than this one?

[BigBrother-84]

Gary Lewis wrote

Why do we need more than this one?

Gary, just because this is the 3G wiring diagram.

And I suppose that it is different than the 1G wiring.

I am wrong?

[Gary Lewis]

I thought the object was to wiring Big Brother up for a 3G.  Not a 1G or 2G.

If we stick with the diagram I posted then I think it is pretty simple.  But I get lost with the others you've posted.

If you trim the wire as I suggested you only have 4 connections on that side of C610:

Y/LG, which is your #7, goes to ground

Big Yellow goes to the megafuse or the starter relay, but not both - as shown on the schematic

Y/LG, your #7, goes to ground

R/O splices to LG/R coming from C610 and goes on to the regulator

[BigBrother-84]

Gary Lewis wrote

I thought the object was to wiring Big Brother up for a 3G.  Not a 1G or 2G.

Sorry Gary, I made you confused.


I will do the 3G job next days.

But since I first had to reinstall a C610 connector, I was looking to restore the 1G female side too.  Before taking the «1G alt+ 1G regulator + 1G harness» kit out of the engine compartment.

Just for fun...

[Gary Lewis]

If you restore the 1G you'll then have to remove what you've done to do the 3G.  I wouldn't want to make those changes and then rip them out.

[BigBrother-84]

You're right, all the "female" side of the C610 will go out with the 1G itself and its external regulator.

But the job I did today to reconnect the «male» part of the C610 won't be lost, it stays in the truck and it will plug into the 3G harness you sent me.

I know I am losing my time trying to rebuild the 1G harness (female side of the C610).  But I am on vacations and I have all my time.

[ArdWrknTrk]

So why did you butcher the existing harness?

How about a compromise that at least we can all agree is better than the Clymer manual covered in scribble?



Here we see C610 in 4 locations.
Either side of the ammeter, at the bottom going to the regulator, and in 37 the cab power wire, before it splits at splice 101 for the constant & key on fuselinks

[Gary Lewis]

Ok, in the light of day I may be starting to understand a bit.

I missed that the title of the thread is "Restoring C610 - 1G side (female)".  

So NOW I understand a little bit of what you are trying to do, Jeff.  Not WHY you are trying to do it mind you, but WHAT.

So help me understand the "why"?  What are you trying to accomplish?  And, what does your harness on Big Bro look like?  In other words, what are we trying to connect to?

If we can stay with the EVTM page that Jim posted, and which I think I understand quite well, and if you could show us where your harness is cut by showing cut lines on the schematic, then we might be able to help you.

And, sorry for the confusion.  Somehow last night I totally missed the title of the thread.  

[BigBrother-84]

Gary Lewis wrote

Ok, in the light of day I may be starting to understand a bit.

I missed that the title of the thread is "Restoring C610 - 1G side (female)".  

So NOW I understand a little bit of what you are trying to do, Jeff.  Not WHY you are trying to do it mind you, but WHAT.

So help me understand the "why"?  What are you trying to accomplish?  And, what does your harness on Big Bro look like?  In other words, what are we trying to connect to?

If we can stay with the EVTM page that Jim posted, and which I think I understand quite well, and if you could show us where your harness is cut by showing cut lines on the schematic, then we might be able to help you.

And, sorry for the confusion.  Somehow last night I totally missed the title of the thread.  

Haha!  No problem Gary!

I know y'all are so excited about my "plug'n play 3G swap" that any post I make is considered as a step in that direction.


But no, not right now guys.  Be patient one more day:
1- Yesterday, I reinstalled the C-610 connector in Big Bro, since the original was butchered in the past. And I need the "male" side properly installed in the truck in order to plug the futur 3G harness.
2- It's raining A LOT here today, no garage at our chalet, so I have to wait until tomorrow (maybe this afternoon?) to step in the 3G swap project itself.

For now, the goal of this specific thread is not about the 3G project, it is only focussed on the C-610 connector restoration.

Proceeding to this reconstruction, I was wondering about the "female" side of that connector (the 1G alternator side).  I have absolutely no question about the "male" side (the truck side), all clear for me.

And the more I read, the more I realize that I correctly understood the "female" harness wiring, yep there are 4 wires splined at S-202, including the Big Yellow one.

I admit I should have started with the EVTM diagram...
The other sources are correct but much more difficult to follow.

Here below, I colored separately the "male" and "female" sides of the famous C-610 connector.
I'm confident that I restored the wiring correctly, these EVTM diagrams are matching with the other ones I previously look at.

The female side of C-620:


And the male side of C-610:


If nobody has objection, at soon as the rain slows down I'll reconnect the battery and try a start.


For the 3G swap itself, I'll return to the «Big Brother is going 3G» original thread.

[BigBrother-84]

ArdWrknTrk wrote

So why did you butcher the existing harness?

Jim, I did not cut out this connector...  I'm Big Bro's third owner (first an outfitter, second my wife's father).  I own Big Bro for about 20 years, they had plenty of time to do it before I came.

In Salt Kingdom, this C-610 connector is exposed to accelerated ageing and corrosion.  I supposed they found easier to cut it out and spline the wires.

ArdWrknTrk wrote

How about a compromise that at least we can all agree is better than the Clymer manual covered in scribble?

Thanks Jim to have reminded me to the EVTM!  It's a shame that I went to more complicated diagrams without thinking to look at it!

[BigBrother-84]

Gentlemen,

Starting test made, everything works!  C-610 back at its place (male AND female), all connections properly made.


So, this thread is closed, let's go back to Big Brother is going 3G thread!

[ArdWrknTrk]

I would generally say "cab side" and "engine side" as, often enough, the male plastic housing has female wire terminals and the 'shell' or female plug has male pins....

Oh well....  off to the actual job at hand!

[Gary Lewis]

Congratulations!!!

And I agree with cab vs engine instead of male/female. That kept me looking last night as I was replying.

[BigBrother-84]

ArdWrknTrk wrote

[...] the male plastic housing has female wire terminals and the 'shell' or female plug has male pins....!

Lol, yeah I have to think twice each time I name them.
And sometimes to look at the diagram --<<-- to confirm I am thinking right.