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T-630 Tier III Engine Wiring Start Sequence

Start sequence:
Key to Run position: Dash lights Warning Lamp, Oil Pressure, Stop Lamp, and
Wait to Start are controlled by the ECM on the engine. These lights come on for
2 seconds (as a test) and go out. The Low Water and Low Hydraulic lights are
timed on for 5 seconds by the Amperite Relay in the Black Box by the engine.
If the Wait to Start light stays on, the ECM is activating the Glow Plugs and you
should wait until the ECM turns the Wait to Start light off before trying to start the
engine.
Key to Start position: Electric flow to start passes through the key switch to
Terminal E on the lower terminal in the black box. From E through the Neutral
Start switch on the Main Hydraulic Pump to Terminal 1 on the upper strip. Then
through one of the N/C contacts on the E-Stop to the Start Relay in the Black
Box. This relay should then energize the starter.

E-Stop pressed:
The Low Water and Low Hydraulic diagnostic lights come on and stay on. The
circuit to the ECM indicating the key is on, is opened, and the circuit to activate
the starter is opened. (It will not even try to turn the starter)

Tier III T-630 Engine Trouble Shooting

Key Switched on, Low


Water and Low Hydraulic
indicator lights stay on and
engine will not try to start.
Engine will not even turn
over.

E-Stop is pushed in on
Black Box on drivers side
of engine.

Key Switched on, No


lights light, nothing works
at all

Check and Re-Set Circuit


Breaker in Black Box on
drivers side of engine.

Check all fuses in Black Box by engine.

Check 25 Amp fuse in power wire from Battery to ECM.


This fuse is near the positive terminal of the battery.

Double check battery


voltage

Tier III T-630 Engine Trouble Shooting


Key on, Diagnostic lights
come on and all go out
after 5 seconds, but engine
does not even try to start
(starter does not engage at
all).

Probably Neutral Start


safety on main pump.
With key off, confirm
continuity between
terminal E on lower strip
and 1 on upper strip in
Black Box. Is there
Continuity?

Refer to Black Box wiring


schematic. Blue wire from
Terminal 1 goes to E-Stop, 1 of
the Normally Closed contact
blocks. Is there continuity
through the contacts with the
E-Stop out?

Replace N/C Contact

Move pump lever by


hand back and forth
slightly to see if
continuity can be
established.

Remove bolt connecting Air


Cylinder eye to actuator arm on
main pump. Check continuity
again. Is it OK now?

Adjust eye on cylinder rod turn


at a time to correct alignment.

Check Start relay in Black Box


for proper operation. Is it OK?

Refer to wiring diagram and


confirm wiring not broken.

Refer to wiring diagram and


confirm wiring not broken.

Wiring OK

Replace Relay
Wiring OK

Contact your local


CAT Dealer.

Refer to Neutral Start adjustment


procedure in pump manual. Possible
Switch replacement necessary.

+ 1

5
Black #18

2
- 3 4
Black #18
Red #18
Black #18
Black #18
Black #12 Ground

Red #14 Switch On

4
Blue #18

Red #18

86

85

Air Dryer

87

E-Stop

86
2

30

85
2

Start

87

5 Amp
5 Amp
5 Amp

Water Level,
Alternator
Excite, etc

30

N/O
Air Switch

Red #14
Red #12
30 Amp 10 Amp
20 Amp

Black #8
Ground

20 Amp

Black #18

Red #12
Orange #14

White #12 BU
#18 Pin 52 49, & 35-Throttle
#18 Pin 50-Throttle

Red #12

Yellow #18
Water Level Signal

Black #18 Pin 57-Glow Plug Gnd


Gray #18 Water Level +12v

Red #8

Blue #18 N/S


1

10 11 12

Orange #14
Optional Air Dryer

Black #18 Glow


Plug Relay

Breaker

5
60 Amp
Red #14
Alternator Excite

Red #18
Switched Fuse
Black #18
Terminal 4

Black #18

Starter
Red #18 Glow Plug Relay

Red #8 +12V on Starter


Red #12 Start Signal
Blue #12 Drive Lights

Green #18
Low Hydraulic
Signal
Hydraulic
Level
#6 Wire
50A
Indicator
Lights in Cab
Starter
12v

Blue #18 Neutral Start

Main Harness Red #18


Pin 40
Switch On

Green #18 Pin 63-Glow Plug Wait

Brown #18 Pin 62-Oil Pres


Yellow #12 High/Low
Blue #18 Neutral Start
Gray #18 Pin 60-Stop Lamp
Yellow #18 Pin 59-Warning Lamp

Yellow Warning Lamp


Red Stop Lamp
Brown Oil Pressure
Green Wait to Start

Glow Plug
Cab Main

White #8 Power to Cab


Red #10 Ignition On
Black #12 Start

Green # 12 Low Hydraulic

Blue #10 Drive Lights


Yellow # 12 High/Low
Brown #12 Low Water

Starting Serial #
07355

T-4
Glow Plug Gnd

Cat Engine Wiring BOM


E-Stop

Grainger

Tucker #

Push-Pull
NC/NO Contact
Block w /Base
NO Contact

6HW12

80575-111

6HX35

80575-112-NO-NC

6HZ06

80575-112-NO

T-12
Warning Lamp

Quantity

NC Contact

6HZ09

80575-112-NC

Name Plate

6JC63

80575-113

Tyco Relay's

Tyco

Relay

VF7-41F11

80130-12

Relay Socket

VCF7-1000

80130-13

Terminal 6-10

280755-4

80130-14

Terminal 12-10
Amperite Time
Delay Relay

280756-4

80130-15

12DSPDT5SC

80130-11

80130-16

Terminal Strip 10 47360

80575-109-10

Terminal Strip 12 47312

80575-109

T-11
Stop Lamp
T-10
Oil Pressure
T-9
Glow Plug Wait

Throttle Switch

T-5

Waytek
Fuse Panel

46060

Throttle Switch

Red #12

25A
Black #12

+ -

+ -

Wiper (Optional)

Main Power - White


Ignition On - Red
Low Hyd - Green
Start - Black
Drive Lights - Blue
Ground Stud

Hi-Low - Yellow
Low Water - Brown

20 Amp
5 Amp
Oil Pressure - Brown
Warning Lamp - Yellow
Glow Plug Wait - Green
Stop Lamp - Red

20 Amp

12
4
Off
ACC

11

Hours

Ign
+

0000

20 Amp

Start

10 11 12

20 Amp

20 Amp

5
Tier III Engine Dash Wiring BOM
Tucker #

Qty

956-9100 CH 80130-36

2 Hour Meter

040022 GBI

80575-13

3 Push-Pull

50001

80132

5 Terminal Strip 12 47312

80575-110

6 12v LED Red

47662

80130-3

6-1 12v LED Yellow

47664

80130-3Y

7 Wiper Sw itch

Option

81995-03

8 Wiper Motor

Option

81995-06

Wiper Arm

Option

81995-02

Wiper Blade

Option

81995-07

81985-01

10 Cab Heater
Option
81995-15
11 4 Wire - 120 Ohm Resistor Assy 8197320
12 2 Wire - 120 Ohm Resistor Assy 8197320-2

1
1
1

Drive Lights

Wiper
(Option)

Wait to Start
(Red)

+ -

+ -

+ -

Warning
(Yellow)

Low Hyd
(Red)

Stop Lamp
(Red)

+ -

+ -

+ -

6-1

Hi-Low Speed

Warning
Lamp
+Starting Serial #
07355

Low Water
(Red)

Oil Pressure
(Red)

Push/Pull

Push/Pull

80130-16

9 Work Light

46060

7
3

Work Lights

Waytek
4 Fuse Panel

Push/Pull

1 Key Sw itch

Low
Hyd
+-

Low
Oil Pres Water
++-

6
Stop
Lamp
+Wait
+-

Dash
Closed

Heater (Optional)

10

HS
10

#18 Purple
76"
#18 Purple 17" Ext.
76"
17" Ext.

39"

#12 Black
14"

#12
Yellow
#12 White
17" Ext.

#18 Green
76"
16" Ext.

High/Low
G

HS

HS

HS

Glow Plug Wait


4

10

Throttle Air Switch


Oil Pressure
10

High/Low Speed Selector


Hydraforce SV08-40-6T-12DS
Tucker # 80202

BU Alarm
Switch
Hobbs # 76575 4 N/O
Tucker # 80604

#12 White
80"
17" Ext.

6-

Neutral Start
1

1/

High/Low
Ground to
Engine

1/

1/

6-8

#12 Yellow
77"
10" Ext.

#12 White
80".

#18 Blue
81"
9- Ext.

S
10 H

#18 Brown
76"
16" Ext.

4"

16"
3/8"

BU Alarm
Preco Model 6003
Tucker # 80125

#12 Black
14"

4"

10
HS

#18 Blue

26"
3/8

#18 Blue

3/8 HS

10
HS

Neutral Start
Sunstrand # 80020S40
Tucker # 80203-07

3/4

3/4

2-

2-

3/4

3/4

3/4

.350

.350
3/4

3/4

3/4

3/4
7-

Glow Plug Ground


4

.350

#18 Black
71-
12" Ext.

#18 Black

.350

at
He

#12 Black

#12 Red

17"

#18 Blue
80"
9 Ext.

#18 Yellow
76-
17" Ext.

#18 Red
69-
10" Ext.
#12 White
61-
12" Ext.

Neutral Start
E

#18 Green

25 Amp Fuse
Heat Shrink
Non-Ins

#12 Red
60"
35" Ext.

3/8 HS

6
6

Stop Lamp
11

Warning Lamp
12

BU Alarm
30 A Fuse

#18 Purple
#18 Red

#18 Yellow

#12 Black
60"
35" Ext.

Switch On
5

#18 Red
Ins
Non-

#18 Black
#18 Purple

22"

Sealed Fuse Holder 12 Ga


Waytek Wire # 46033
Tucker # 80130-31
HS
3/8

#18 Gray
77-
18" ext.

31"
3/8"

k
rin
Sh
ns
n-I
No

Starting Serial #
07355

#18 Gray

#18 Brown

16
5/
HS

#8 Red
31"
5- Ext

10

#8 Red
#18 Red

Glow Plug
Relay

14-

20"

3/4

3/4

9-

#18 Red
51"
14 Ext

#18 Black
49"
12 Ext

3/4

#10 Red

Starter
Terminal
2
8
6-

10
HS

#12 Red
#12 Blue
265
9" Ext

#8 Black
9-
3/8"

5/16
HS

1
/
4
HS

#8 Black
42"
11- Ext

#10

6-8

5/16

Start
Signal

6 l4
ina ug
m
l
r
Te w P
o
Gl elay
R

#12 Red
33-
8- Ext

.350

#18 Black

Sw
lo itc
w he
Pl d
ug F
R use
el
ay

Circuit
Breaker

#12 Blue

HS

1/4 **

235

Main
Power

Drive
Lights

Charging
From Alt.

#10 Red
28"
1- Ext

Ground

Starting Serial #
07355

1/4 H

Starter / Charging/
Glow Plug Wire
Assembly
81974-W2-T3

Alternator
Charging
Post

Drive
Lights
Terminal F

Fuse Block
Ground

1/4

Glow Plug
Connector
on Engine

Tier III Glow Plug Wire


81974-W5-T3
46"
3/8"

81974-W6-T3
Tier III Glow Plug Fuse Wire
Glow Plug Relay
Positive on
Starter
5/16

5/16

50 Amp Fuse
Holder w/Cover

Description
Maxi-Fuse Holder Red 8"-#6
Leads
Maxi-Fuse Holder Cover
Maxi-Fuse 50 Amp Red

Relay

Waytek #

Tucker #

46024
46028
46243

80130-32
80130-33
80130-34

Cole Hersee # Tucker #


2411701
80587

#6 Red
46-

5/16

#18 Gray
28"
15- Ext

1/2
12"
1/2

3/4

3-

6-8
Water
Level
Terminal 5

3/4
#18 Yellow
32-
17" Ext

.350

6-8
#18 Black
24"
7-1/4" Ext

#14 Red
36"
18" Ext

Water
Level
Terminal 11

12"
3/8"

8
6-

#14
Red

Water
Level

10 HS

Alternator
Terminal C
Gray
Black
3

Yellow

Alternator
Excite

Water
Level
To Water Level Switch
Kohler # 273404
Tucker # 80575-57

Starting Serial #
07355

3/8" Synflex
83"

Ground
Terminal

Black

#18 Black
97"

Green
#18 Green
103"

6-8
Hydraulic
Oil Level
Terminal 8
Hydraulic
Oil Level
Sensor

Starting Serial #
06316