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)

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.

Tier III T-630 Engine Trouble Shooting

Key Switched on, No lights light, nothing works

at all

Check and Re-Set Circuit Breaker in Black Box on

drivers side of engine.

Double check battery voltage

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.

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?

Remove bolt connecting Air Cylinder eye to actuator arm on main pump. Check continuity

again. Is it OK now?

Move pump lever by hand back and forth

slightly to see if continuity can be

established.

Contact your local CAT Dealer.

Refer to Neutral Start adjustment procedure in pump manual. Possible

Switch replacement necessary.

Adjust eye on cylinder rod ½ turn at a time to correct alignment.

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 Relay

Refer to wiring diagram and confirm wiring not broken.

Wiring OK

Check Start relay in Black Box for proper operation. Is it OK?Replace N/C Contact

Refer to wiring diagram and confirm wiring not broken.

Wiring OK

Tier III T-630 Engine Trouble Shooting

E-Stop

A B C D E F G H I J

60 Amp

Breaker

1 2 3 4 5 6 7 8 9 10 11 12

8586

3087

8586

3087

Red #8 +12V on Starter

Red #12 Start SignalBlue #12 Drive Lights

Black #8Ground

Air Dryer Start

Orange #14Optional Air Dryer

White #8 Power to CabRed #10 Ignition On

Green # 12 Low HydraulicBlack #12 Start

Blue #10 Drive LightsYellow # 12 High/Low

Brown #12 Low Water

White #12 BU

Blue #18 Neutral StartYellow #12 High/Low

Blue #18 Neutral Start

Green – Wait to StartBrown – Oil Pressure

Red – Stop LampYellow – Warning Lamp

Red #8

Green #18Low Hydraulic

Signal

Black #18

Yellow #18Water Level Signal

Gray #18 Water Level +12v

Red #14Alternator Excite

Black #18Red #14

Orange #14

Red #18

Red #12

Red #12

Blue #18 – N/S

Blue #18

Hydraulic Level

Indicator Lights in Cab

Cab Main

Main Harness

Starter

Water Level, Alternator Excite, etc

Starting Serial #07355

1

2 2

4

5

6

7

9

10 A

mp

20 A

mp

30 A

mp

20 A

mp

Red #12

Red #18 Glow Plug Relay

Black #18 GlowPlug Relay

Black #18 Pin 57-Glow Plug Gnd

#18 Pin 50-Throttle#18 Pin 52 49, & 35-Throttle

Yellow #18 Pin 59-Warning LampGray #18 Pin 60-Stop Lamp

Brown #18 Pin 62-Oil PresGreen #18 Pin 63-Glow Plug Wait

5 A

mp

5 A

mp

5 A

mp

N/OAir Switch

Red #14 Switch On

Red #18Pin 40Switch On

Black #12 Ground

4

50A

Starter12v

Glow Plug

#6 Wire

Red #18Switched Fuse

Black #18Terminal 4

+

- 3 4

51

2Black #18

Black #18

Black #18

Black #18Red #18

E-Stop Grainger Tucker # QuantityPush-Pull 6HW12 80575-111 1NC/NO Contact Block w /Base 6HX35 80575-112-NO-NC 1NO Contact 6HZ06 80575-112-NONC Contact 6HZ09 80575-112-NC 1Name Plate 6JC63 80575-113 1Tyco Relay's TycoRelay VF7-41F11 80130-12 5Relay Socket VCF7-1000 80130-13 5Terminal 6-10 280755-4 80130-14 2Terminal 12-10 280756-4 80130-15 2Amperite Time Delay Relay 12DSPDT5SC 80130-11 1

WaytekFuse Panel 46060 80130-16 1Terminal Strip 10 47360 80575-109-10 1Terminal Strip 12 47312 80575-109 1

Cat Engine Wiring BOM

Black #12

Red #12

25A

T-5

T-9Glow Plug Wait

T-10Oil Pressure

T-11Stop Lamp

T-12Warning Lamp

Throttle Switch

Throttle Switch

T-4Glow Plug Gnd

Hours

0 0 0 0

+ -+ -

Push/P

ullP

ush/Pull

Push/P

ull

+Start

ACCOff

Ign

+ -+ -

+ -+ -

1 2 3 4 5 6 7 8 9 10 11 12

Main Power - White

Ignition On - RedLow Hyd - Green

Start - Black

Hi-Low - YellowDrive Lights - Blue

Low Water - Brown

Oil Pressure - BrownWarning Lamp - Yellow

Stop Lamp - RedGlow Plug Wait - Green

Wiper (Optional)

Heater (Optional)

1 2

3

3 3

4

89

9

10

5

7

6 6

6-1 6

Tucker # Qty1 Key Sw itch 956-9100 CH 80130-36 12 Hour Meter 040022 GBI 80575-13 13 Push-Pull 50001 80132 3

Waytek4 Fuse Panel 46060 80130-16 15 Terminal Strip 12 47312 80575-110 16 12v LED Red 47662 80130-3 5

6-1 12v LED Yellow 47664 80130-3Y 1

7 Wiper Sw itch Option 81995-03 18 Wiper Motor Option 81995-06 1

Wiper Arm Option 81995-02 1Wiper Blade Option 81995-07 1

9 Work Light 81985-01 210 Cab Heater Option 81995-15 111 8197320 112 8197320-2 1

Tier III Engine Dash Wiring BOM

4 Wire - 120 Ohm Resistor Assy2 Wire - 120 Ohm Resistor Assy

Work Lights

Drive Lights Hi-Low Speed

Wiper(Option)

Oil Pressure(Red)

Wait to Start(Red)

Stop Lamp (Red)

Warning (Yellow)

5 Amp

20 Amp

20 Amp

20 Amp

20 Amp

20 Amp

Starting Serial #07355

+- +-

+- +-

StopLamp

WarningLamp

Oil Pres Wait

DashClosed

Ground Stud

+-

+-

LowHyd

LowWater

+ -

6

Low Water(Red)

+ -

6

Low Hyd(Red)

11

12

3/8 HS

3/8 HS

#12 Black

#18 Black

#18 Red

#12 Red

25 Amp Fuse

#18 Red

#18 Green

#18 Brown#18 Gray#18 Yellow

#18 Purple#18 Purple

#18 Black

3/4

.350

3/4

3/4

.350

3/4

3/4

.350

3/43/4”

7-½”¾”

17"¾”

2-½”¾”

2-½”¾”

22"¾”

1/21/21/2

26"3/8”

HS

HS

#12Yellow

#12 Black14"

6-½”½”

10 HS

10 HS

3/8 HS

4"¼”

4"¼”

#12 Black14"

#18 Blue

#18 Blue

High/LowGround to

Engine

Neutral StartSunstrand # 80020S40

Tucker # 80203-07

High/Low Speed SelectorHydraforce SV08-40-6T-12DS

Tucker # 80202

16"3/8"

10 H

S10

HS

BU AlarmSwitchHobbs # 76575 4 N/OTucker # 80604

#12 White17" Ext.

#12 White80"

17" Ext.

31"3/8"

#12 Black60"

35" Ext.

#12 Red60"

35" Ext.

Sealed Fuse Holder 12 GaWaytek Wire # 46033

Tucker # 80130-31

39"¼”

BU AlarmPreco Model 6003Tucker # 80125

10 HS

#12 White80".

6#18 Green

76"16" Ext.

Glow Plug Wait4

6

#18 Blue81"

9-½” Ext.

Neutral Start1

66

#18 Purple76"

17" Ext.#18 Purple76"

17" Ext.

Throttle Air Switch

6-8

#12 Yellow77"

10" Ext.

High/LowG

6

#18 Brown76"

16" Ext.

Oil Pressure10

#12 White61-½”

12" Ext.

BU Alarm30 A Fuse

6

#18 Red69-½”

10" Ext.

Switch On5

6

#18 Yellow76-½”

17" Ext.

Warning Lamp12

6

#18 Blue80"

9” Ext.

Neutral StartE6

#18 Gray77-½”

18" ext.

Stop Lamp11

6

#18 Black71-½”

12" Ext.

Glow Plug Ground4

Starting Serial #07355

3/4

.350

3/4

Non-Ins

Heat Shrink

Non-Ins

Non-Ins

Heat Shrink

#8 Red

#8 Black

1/4

**

6-8

3/4”9-½”¾”

3/4

.350

3/4

9-½”3/8"

1/4 HS

1/4 HS

5/16 HS

5/16

#12 Red

#10 Red

#10 Red28"

1-¼” Ext

#8 Red31"

5-¼” Ext

#12 Red33-½”

8-¼” Ext

#8 Black42"

11-¾” Ext

Main Power

Start Signal

ChargingFrom Alt.

Ground

AlternatorCharging

Post

Circuit Breaker

Starter Terminal

2

Fuse BlockGround

Starter / Charging/Glow Plug Wire

Assembly81974-W2-T3

235”¼”

6-8

#12 Blue265”

9" Ext

#12 Blue

Drive Lights

Terminal F

Drive Lights

Starting Serial #07355

HS

5/16

#10#18 Red

51"14” Ext

#18 Black49"

12” Ext

#18 Black

#18 Red

Glow PlugRelay

20"¼”

14-¾”¾”

10 H

S

10 HS

6

Terminal 4

Glow Plug

Relay

Switche

d Fus

e

Glow P

lug R

elay

+

5/16

5/16 5/1646"3/8"

#6 Red46-½”

1/4

Positive onStarter

50 Amp Fuse Holder w/Cover

Glow Plug Connector on Engine

Description Waytek # Tucker #Maxi-Fuse Holder Red 8"-#6 Leads 46024 80130-32Maxi-Fuse Holder Cover 46028 80130-33Maxi-Fuse 50 Amp Red 46243 80130-34

Cole Hersee # Tucker #Relay 2411701 80587

Tier III Glow Plug Wire81974-W5-T3

81974-W6-T3Tier III Glow Plug Fuse Wire

Glow Plug Relay

3/4”3-½”¾”

.350

1/2 3/412"1/2”

12"3/8"

#14Red

10 HS

6-86-8

6-8

#18 Gray28"

15-¼” Ext

#18 Yellow32-½”

17" Ext

#14 Red36"

18" Ext

#18 Black24"

7-1/4" Ext

WaterLevel

WaterLevelTerminal 11

AlternatorTerminal C

WaterLevel

AlternatorExcite

WaterLevelTerminal 5

Starting Serial #07355

3 4

21

1 2

43

GrayBlack

Yellow

To Water Level SwitchKohler # 273404Tucker # 80575-57

6-8

3/8" Synflex83"

#18 Black97"

#18 Green103"

Black

Green

½”

Ground Terminal

HydraulicOil LevelTerminal 8

HydraulicOil LevelSensor

Starting Serial #06316