INTERACTIVE SCHEMATIC

Bookmarks X

Options

Features
This document is best viewed at a
Cover Page screen resolution of 1024 X 768.
Information To set your screen resolution do the following:
Component Table
Tap Table
RIGHT CLICK on the DESKTOP.
Fluid Power Symbols Select PROPERTIES.
Electrical Symbols CLICK the SETTINGS TAB.
Schematic
MOVE THE SLIDER under SCREEN RESOLUTION
Machine Views
Front Frame
until it shows 1024 X 768.
Rear Frame CLICK OK to apply the resolution.
Tap Views

The Bookmarks panel will allow you to

quickly navigate to points of interest.

EC-C2 E-C60
EC-C3

E-C61

Click on any text that is BLUE and underlined.

These are hyperlinks that can be used to navi-
gate the schematic and machine views.

EC-C1

When only one callout is showing on a machine view this

VIEW ALL CALLOUTS button will make all of the callouts visible. This button is
located in the top right corner of every machine view page.

HOTKEYS (Keyboard Shortcuts)

FUNCTION KEYS
Zoom In CTRL / +
Zoom Out CTRL / -
Fit to Page CTRL / 0 (zero)
Hand Tool SPACEBAR (hold down)
Find CTRL / F
 UENR3696
October 2012

525C, 535C, and 545C Wheel Skidder

Hydraulic System
525C: 535C: 545C:
5251461-UP 535579-UP 545955-UP

2012 Caterpillar, All Rights Reserved Printed in U.S.A.

COMPONENT LOCATION
Part Machine Schematic
Description
Number Location Location
Accumulator Gp - Front Brake 238-8232 1 F-4
Accumulator Gp - Pilot Manifold 170-8531 2 B-6
Accumulator Gp - Rear Brake 239-9941 3 F-4
Actuator As - Parking Brake 7I-3759 4 F-3
Control Gp - Foot Brake 148-9774 5 F-6
Cooler Gp - Hydraulic Oil 252-6557 7 A-5
Cylinder Gp - Boom 298-2520 8 E-4
Cylinder Gp - Decking Blade Lift 160-0492 9 D-5
Cylinder Gp - LH Arch 298-2523 10 D-4
Cylinder Gp - LH Steering 252-5871 11 D-6
Cylinder Gp - RH Arch 298-2525 12 D-4
Cylinder Gp - RH Steering 252-5872 13 D-6
Note A 278-1194
Cylinder Gp -Tong 278-1765 14 E-3
Note E 278-2235
Filter Gp -Implement Steering Return 214-6589 15 A-4
Filter Gp -Pilot Manifold Return 266-8954 16 A-5
Pump Gp -Implement / Steering
Note B 6E-6012 A-7
17
Note C 161-5715
Pump Gp -Mech Winch Pilot 252-0796 18 A-6
Pump Gp -Cooler 251-4315 19 A-6

Rotator Gp -Grapple Note A 351-2495

20 D-3
Note E 351-2496
Sensor -Auto Grab Pressure 296-5270 21 D-2
Switch Gp -Low Brake Pressure 3E-7806 22 E-5
Switch Gp -Parking Brake Pressure 174-4312 23 E-3
Tank Gp -Hydraulic Oil 249-3441 24 A-4
Valve -Flow Divider 276-5034 25 E-3
Valve Gp - Accumulator Charging 9U-2886 26 F-5

Valve Gp - Bank 4 Arch / Tong / Rotate/Winch Note A 381-7956

29 C-4
Boom / Arch / Tong / Rotate 381-7957

Valve Gp - Bank 5 Boom / Arch / Tong / Rotate / Winch 381-7958 29 C-3

Valve Gp - Check 132-1204 27 A-4
Valve Gp - Check Imp / Steer Return 253-7537 27 A-4
Valve Gp - Check Manifold Return 192-2684 27 A-4
Valve Gp - Free Spool Solenoid 257-6364 28 B-4
Valve Gp - Parking Brake 252-0741 30 F-4
Valve Gp - Brake control 215-3685 38 F-6
Valve Gp - Pilot, Differential Lock 331-8167 31 B-6
Valve Gp - Pilot 370-2264 6 E-6
Valve Gp - Steer / Decking Blade Control 299-9532 32 C-6
Valve Gp - Tank Relief Breaker 4T-4145 33 A-3
Winch Gp - Hydraulic 252-5206 34 E-1
Secondary Steering Attachments
Pump Gp -Secondary Steering Note D 177-9742 35 A-5
Sensor -Imp / Steer Pressure Note D 221-3417 36 B-6
Valve Gp -Check Imp / Steer Note D 183-9322 37 B-7
Valve Gp -Check Sec Steering Note D 9T-1013 37 B-7
NOTE A: 525C ONLY NOTE D: FOR SECONDARY STEERING MACHINES ONLY
NOTE B: 525C/535C ONLY NOTE E: 535C/545C ONLY
NOTE C: 545C ONLY Check Part Numbers in the Parts Manuals for your Specific Machine
TAP LOCATION

Tap Schematic
Description
Number Location
TP1 Imp/Steer Pump Discharge Pressure A-7
TP2 Imp/Steer Pump Signal Pressure A-7
TP3 Pilot Oil Pressure B-6
TP4 Pilot Differential Lock Pressure B-6
TP5 Rear Service Brake Accumulator Pressure E-5
TP6 Front Service Brake Accumulator Pressure E-5
TP7 Rear Service Brake Pressure F-7
TP8 Front Service Brake Pressure F-7
TP9 Auto Grab Presure D-3
FLUID POWER SYMBOLS
BASIC COMPONENT SYMBOLS

MAIN AUX.
PUMP: VARIABLE and
PUMP or MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION 2-SECTION PUMP PRESSURE COMPENSATED
(FIXED)

VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
(ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES VARIABLE and PRESSURE
COMPENSATED

VALVE ENVELOPES
VALVES
VALVE PORTS

ONE POSITION TWO POSITION THREE POSITION TWO-WAY THREE-WAY FOUR-WAY

CONTROL VALVES CHECK VALVES

AB AB

P T P T
BASIC SPRING SHUTTLE PILOT
NORMAL POSITION SHIFTED POSITION INFINITE POSITION
SYMBOL LOADED CONTROLLED

FLUID STORAGE RESERVOIRS

VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL

MEASUREMENT ROTATING SHAFTS

PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL

COMBINATION CONTROLS

SOLENOID SOLENOID SOLENOID SOLENOID and SERVO THERMAL DETENT

or MANUAL and PILOT PILOT or MANUAL

MANUAL CONTROL SYMBOLS

PUSH-PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING

RELEASED PRESSURE PILOT CONTROL SYMBOLS

REMOTE SUPPLY PRESSURE

EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL

SUPPLY PRESSURE

ACCUMULATORS CROSSING AND JOINING LINES HYDRAULIC AND PNEUMATIC CYLINDERS

SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING

HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS

FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT INFINITE THREE TWO

DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING POSITION POSITION

UNIDIRECTIONAL UNIDIRECTIONAL

FLOW IN ONE PARALLEL CROSS FLOW ALLOWED IN

BIDIRECTIONAL BIDIRECTIONAL DIRECTION FLOW FLOW EITHER DIRECTION
ELECTRICAL SYMBOLS
Hydraulic Symbols (Electrical)

G M
Transducer Transducer Generator Electric Motor
(Fluid) (Gas / Air)

Pressure Switch Pressure Switch Temperature Switch Electrical Wire

(Adjustable)

Electrical Symbols (Electrical)

Pressure Temperature Level Flow

Symbol Symbol Symbol Symbol

Wire Number Identification Codes

Electrical Schematic Example Hydraulic Schematic Example

Current Standard Current Standard

Harness identification code
This example indicates
wire 135 in harness "AG". Wire
Circuit Number Wire Color
Identification

325-AG135 PK-14
325-PK
Circuit Identification Wire Color Wire Gauge
Number

Previous Standard
Wire Color
Wire

325-PK-14
B A
Circuit Number Wire Gauge
Identification (EXAMPLE VALVE)
 7 6 5 4 3 2 1

(5) CONTROL GP (38) VALVE GP

FOOT BRAKE BRAKE CONTROL (26) VALVE GP
148-9774 215-3685 ACCUMULATOR (1) ACCUM GP (3) ACCUM GP LINE PATTERNS
FRONT AXLE (4) ACTUATOR AS
CHARGING FRONT BRAKE REAR BRAKE
238-8232 239-9941 PARKING BRAKE Pressure Line
9U-2886
7I-3759 Pilot / Load Sensing Pressure

Drain / Return Lines

F Component Group F
Attachment

TP7 Air Line

(30) VALVE GP
TP8 PARKING BRAKE (14) CYLINDER GP CALLOUTS
SOLENOID TONG YY Taps (Pressure, Sampling, Sensor - by letter)
252-0741 278-1194 NOTE A
278-1765 NOTE B
278-2235 NOTE E
TP6
TONG
(22) SWITCH GP (34) WINCH GP
TP5
REAR AXLE LOW BRAKE HYDRAULIC
PRESSURE (23) SWITCH GP 252-5206
3E-7806 PARKING BRAKE T

OPEN
PRESSURE
(8) CYLINDER GP 174-4312 G
BOOM U
E (6) VALVE GP E
298-2520
PILOT P T 24V
(25) VALVE
370-2264
FLOW DIVIDER FREESPOOL

RAISE
276-5034
1 4 BRAKE
3 2 WINCH
BOOM VALVE
BRAKE
(20) ROTATOR GP
HYDRAULIC BR
351-2495
(11) CYLINDER GP (10) CYLINDER GP NOTE A
LH STEERING LH ARCH 351-2496
252-5871 298-2523 NOTE E
STEERING
DR
DOZER
ARCH
(21) SENSOR
AUTO GRAB C B A
TP9
PRESSURE
296-5270
RAISE

(12) CYLINDER GP
D RH ARCH RAISE
D
298-2525
LEFT
(9) CYLINDER GP
(13) CYLINDER GP
DECKING
RH STEERING
BLADE LIFT
LS 252-5872 B A
B A 160-0492 TO PS A B A B A B A B A B

(32) VALVE GP
STEER\
DECKING BLADE
CONTROL
299-9532
L S

C C

(2) ACCUMLATOR GP T ARCH BOOM TONG ROTATE WINCH

TP3 TP4 PILOT MANIFOLD
170-8531
(29) VALVE GP-BANK 4 (29) VALVE GP-BANK 5
381-7956 ARCH/TONG/ROTATE/WINCH NOTE A 381-7958
(37) VALVE GP 381-7957 BOOM/ARCH/TONG/ROTATE BOOM/ARCH/TONG/ROTATE/WINCH
CHECK (37) VALVE GP
183-9322 CHECK (28) VALVE GP
NOTE D SEC STEERING FREE SPOOL
9T-1013 SOLENOID
B B
NOTE D 257-6364

(36) SENSOR (31) VALVE GP

IMP/STEER PILOT
PRESSURE DIFFERENTIAL LOCK (33) VALVE GP HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
221-3417 331-8167 TANK RELIEF PILOT PRESSURE
NOTE D (27) VALVE GP BREAKER IMPLEMENT/STEERING PUMP OUTPUT
SECONDARY PUMP OUTPUT
CHECK (IMP) 4T-4145 DOZER CYLINDER CONTROL CIRCUIT
TP1 (27) VALVE GP 253-7537 IMPLEMENT/STEERING PUMP LOAD SENSE CIRCUIT
STEERING CIRCUIT
TP2 (7) COOLER GP CHECK (15) FILTER GP AIR VACUUM TONG CYLINDER CONTROL CIRCUIT
LS
HYDRAULIC OIL 132-1204 HYDRAULIC OIL SUPPLY LINE
GRAPPLE MOTOR CIRCUIT
252-6557 214-6589 BRAKE CONTROL CIRCUIT
BOOM CYLINDER CONTROL CIRCUIT
(16) FILTER GP (24) TANK GP AIR RELIEF
HYDRAULIC WINCH CONTROL CIRCUIT
HYDRAULIC OIL HYDRAULIC OIL DRAIN / RETURN LINE
ARCH CYLINDER CONTROL CIRCUIT
266-8954 249-3441 MECHANICAL WINCH PILOT PUMP OUTPUT
NOTE A: 525C ONLY DIFFERENTIAL LOCK CONTROL
COOLER PUMP OUTPUT
(35) PUMP GP NOTE B: 525C/535C ONLY

A SECONDARY NOTE C: 545C ONLY A

M STEERING (27) VALVE GP NOTE D: FOR SECONDARY STEERING MACHINES ONLY
177-9742 CHECK NOTE E: 535C/545C ONLY
NOTE D 192-2684
THIS SCHEMATIC IS FOR THE 525C, 535C, AND 545C WHEEL SKIDDER HYDRAULIC SYSTEM
(17) PUMP GP
IMPLEMENT/ (18) PUMP GP MEDIA NUMBER: UENR3696
(19) PUMP GP MECH WINCH PILOT SCHEMATIC PART NUMBER: 383-9584, CHANGE: 01, VERSION: -
STEERING
COOLER 252-0796 Components are shown installed on a fully operable machine with the key and engine off, transmission shifter
6E-6012 NOTE B in neutral and with parking brake set.
251-4315
161-5715 NOTE C Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.

7 6 5 4 3 2 1
MACHINE COMPONENT LOCATIONS
VIEW ALL CALLOUTS

14 20 10 8 34 2 6 32 37 22 1 3 24 23 26 24 26 27 30 15 7 1 16

27 23 33

30 3 5

7 22 2

33 32 21

38 37 25

15 19 28

12 16 17 9

9 9 29
TP9

28 29 25 21 31 4 13 11 5 33 35 36 17 19 18 18 11 31 4 13 35 36
BRAKE ACCUMULATOR TEST PORTS
VIEW ALL CALLOUTS

3
1
23

TP5

TP6

30
26

16
IMP/STEER PUMP TEST PORTS
VIEW ALL CALLOUTS

16 24

15

32 TP2

17

TP1

FRONT
FRAME

FRONT VIEW
PILOT MANIFOLD TEST PORTS
VIEW ALL CALLOUTS

31

TP3

TP4
SERVICE BRAKE TEST PORTS
VIEW ALL CALLOUTS

TP7 TP8