Caterpillar 515 4LR & 525 1DN Wheel Skidder Workshop Repair Service Manual PDF - MCAT515WS525.zip
A full-service repair guide, complete with electrical wiring diagrams, for the Caterpillar 515 and 525 Wheel Skidders—containing everything needed to service, troubleshoot, fix, and rebuild these machines the way professional technicians do.
The workshop service and repair manual for the Caterpillar 515 (4LR) and 525 (1DN) Wheel Skidders covers:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
WHEEL-TYPE SKIDDER
Model Prefix
515 WHEEL SKIDDER 4LR
525 WHEEL SKIDDER 1DN
PRODUCT DETAILS:
Total Pages: 1,596 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
RENR2147 - Schematic (Caterpillar 515 and 525 Wheel Skidders Electrical System).pdf
RENR3057 - Specifications (515, 525, 525B, 525C, 535B, 535C, 545 and 545C Wheel Skidders Winch).pdf
RENR3057 - Systems Operation (515, 525, 525B, 525C, 535B, 535C, 545 and 545C Wheel Skidders Winch).pdf
RENR3057 - Testing and Adjusting (515, 525, 525B, 525C, 535B, 535C, 545 and 545C Wheel Skidders Winch).pdf
SENR1360 - Schematic (Caterpillar 515 & 525 Wheel Skidders Electrical System).pdf
SENR1361 - Schematic (Caterpillar 515 & 525 Wheel Skidders Electrical System).pdf
SENR6684 - Specifications (515 Wheel Skidder and 525 Wheel Skidder Power Train).pdf
SENR6685 - Systems Operation (515 Wheel Skidder and 525 Wheel Skidder Power Train).pdf
SENR6685 - Testing and Adjusting (515 Wheel Skidder and 525 Wheel Skidder Power Train).pdf
SENR6686 - Systems Operation (515 Wheel Skidder and 525 Wheel Skidder Transmission and Grapple Electronic Control System).pdf
SENR6686 - Testing and Adjusting (515 Wheel Skidder and 525 Wheel Skidder Transmission and Grapple Electronic Control System).pdf
SENR6690 - Specifications (515 Wheel Skidder and 525 Wheel Skidder Braking System).pdf
SENR6691 - Systems Operation (515 Wheel Skidder and 525 Wheel Skidder Braking System).pdf
SENR6691 - Testing and Adjusting (515 Wheel Skidder and 525 Wheel Skidder Braking System).pdf
SENR6692 - Specifications (515 Wheel Skidder and 525 Wheel Skidder Hydraulic and Steering System).pdf
SENR6693 - Disassembly and Assembly (515 and 525 Wheel Skidders Machine Systems).pdf
SENR6694 - Schematic (Caterpillar 525 Wheel Skidder Electrical System).pdf
SENR6696 - Systems Operation (515 Wheel Skidder and 525 Wheel Skidder Hydraulic and Steering System).pdf
SENR6696 - Testing and Adjusting (515 Wheel Skidder and 525 Wheel Skidder Hydraulic and Steering System).pdf
SENR6718 - Schematic (515 and 525 Wheel Skidders Steering and Hydraulic System) (For Serial Numbers 1DN1-UP 4LR1-UP).pdf
MAIN SECTIONS
RENR2147 - Schematic (Caterpillar 515 and 525 Wheel Skidders Electrical System)......3
Collage......4
Main......19
RENR3057 - Specifications (515, 525, 525B, 525C, 535B, 535C, 545 and 545C Wheel Skidders Winch)......21
Gear Pump (Differential Lock) (Winch)......22
Winch Drive Shaft......24
Winch Hydraulic Control......26
RENR3057 - Systems Operation (515, 525, 525B, 525C, 535B, 535C, 545 and 545C Wheel Skidders Winch)......28
Gear Pump (Differential Lock) (Winch)......29
General Information......30
Winch Hydraulic Control - Mechanically Controlled......33
Winch Hydraulic System - Mechanically Controlled......36
RENR3057 - Testing and Adjusting (515, 525, 525B, 525C, 535B, 535C, 545 and 545C Wheel Skidders Winch)......44
Bevel Gear and Pinion - Adjust......45
Drum Bearing (Cable) - Adjust......55
Machine Preparation for Troubleshooting......58
Visual Inspection......61
Winch Lubrication Oil Flow - Test......62
Winch Pressures - Test and Adjust......68
Winch Troubleshooting......83
SENR1360 - Schematic (Caterpillar 515 & 525 Wheel Skidders Electrical System)......87
Collage......88
Main......111
SENR1361 - Schematic (Caterpillar 515 & 525 Wheel Skidders Electrical System)......113
Collage......114
Main......139
SENR6684 - Specifications (515 Wheel Skidder and 525 Wheel Skidder Power Train)......141
Axle Housing......143
Bevel Gear and Pinion......145
Brake and Planetary......148
Cab Mounting......154
Clutch (First and Third)......155
Clutch (Forward High and Forward Low)......157
Clutch (Reverse and Second)......159
Differential Lock Manifold and Relief Valve......161
Differential Lock Oil Filter......165
Differential Oil Pressure Switch......166
Differential......167
Drive Shaft (Machine)......169
Drive Shaft (Winch)......171
Front Axle Support......173
Gear Pump (Differential Lock)......175
Gear Pump (Winch and Differential Lock)......176
Output Transfer Gears......178
Rim Group......182
Torque Converter Oil Temperature Sender......183
Torque Converter......184
Transmission Case......189
Transmission Clutch Solenoid Valve......201
Transmission Dump Valve......203
Transmission Hydraulic Control......205
Transmission Oil Filter Bypass Switch......208
Transmission Oil Filter......211
Transmission Oil Pump......214
Transmission Oil Temperature Switch......217
Transmission Selector and Pressure Control Valve......218
Transmission......220
Window Wiper and Wiper Motor......222
SENR6685 - Systems Operation (515 Wheel Skidder and 525 Wheel Skidder Power Train)......224
Axle (Front and Rear)......225
Differential Lock ......227
Differential Lock......233
Differential......241
Flow Control Valve......247
General Information......249
Torque Converter......252
Transmission ......256
Transmission Dump Valve......277
Transmission Electrical System......280
Transmission Hydraulic Control......284
Transmission Hydraulic System......301
Transmission Lubrication......304
Transmission Oil Filter......305
Transmission Oil Pump......309
Transmission......310
SENR6685 - Testing and Adjusting (515 Wheel Skidder and 525 Wheel Skidder Power Train)......329
Axle Housing and Bearing Preload - Adjust......330
Differential Backlash and Bearings - Adjust......333
Differential Pinion Preload - Adjust......339
Machine Preparation for Troubleshooting......342
Power Train Troubleshooting......345
Relief Valve (Differential Lock) - Test and Adjust......365
Relief Valve Pressure (Front Differential Lock and Rear Differential Lock) - Test and Adjust......367
Solenoid Valve (Transmission Clutch) - Test......370
Torque Converter Stall - Test......374
Transmission Clutch Running Clearance - Check......376
Transmission Pressures - Test and Adjust......379
Visual Inspection......384
Winch Lubrication Oil Flow - Test......387
Winch Pressures - Test and Adjust......391
SENR6686 - Systems Operation (515 Wheel Skidder and 525 Wheel Skidder Transmission and Grapple Electronic Control System)......402
Backup Alarm......403
CAT Data Link......405
Caterpillar Monitoring System......407
Diagnostic Operation......409
Electronic Control Module (Transmission and Grapple)......411
General Information......421
Grapple Electronic Control Operation......424
Relay (Backup Alarm)......426
Relay (Grapple Solenoid Return)......427
Sensors......429
Solenoid Valve (Clutch)......432
Solenoid Valve (Grapple)......436
Start Relay......438
Start Switch (Key)......442
Switches......446
Transmission Electronic Control Operation......454
SENR6686 - Testing and Adjusting (515 Wheel Skidder and 525 Wheel Skidder Transmission and Grapple Electronic Control System)......464
CID 0168 FMI 00 Electrical System Voltage Above Normal Range - Test......468
CID 0168 FMI 01 Electrical System Voltage Below Normal Range - Test......469
CID 0417 FMI 03 Relay (Grapple Solenoid Return) Voltage Above Normal - Test......471
CID 0417 FMI 06 Relay (Grapple Solenoid Return) Current Above Normal - Test......474
CID 0417 FMI 07 Relay (Grapple Solenoid Return) Improper Mechanical Response - Test......477
CID 0444 FMI 03 Magnetic Switch (Start Relay) Voltage Above Normal - Test ......480
CID 0444 FMI 03 Magnetic Switch (Start Relay) Voltage Above Normal - Test......483
CID 0444 FMI 05 Magnetic Switch (Start Relay) Current Below Normal - Test......486
CID 0444 FMI 06 Magnetic Switch (Start Relay) Current Above Normal - Test......492
CID 0449 FMI 02 Control Switch (Grapple Rotation) Incorrect Signal - Test......500
CID 0450 FMI 02 Control Switch (Tong Open, Tong Close) Incorrect Signal - Test......504
CID 0451 FMI 03 Solenoid Valve (Grapple Clockwise Rotation) Voltage Above Normal - Test......508
CID 0451 FMI 05 Solenoid Valve (Grapple Clockwise Rotation) Current Below Normal - Test......511
CID 0451 FMI 06 Solenoid Valve (Grapple Clockwise Rotation) Current Above Normal - Test......514
CID 0452 FMI 03 Solenoid Valve (Grapple Counterclockwise Rotation) Voltage Above Normal - Test......517
CID 0452 FMI 05 Solenoid Valve (Grapple Counterclockwise Rotation) Current Below Normal - Test......520
CID 0452 FMI 06 Solenoid Valve (Grapple Counterclockwise Rotation) Current Above Normal - Test......523
CID 0453 FMI 03 Solenoid Valve (Tong Open) Voltage Above Normal - Test ......526
CID 0453 FMI 03 Solenoid Valve (Tong Open) Voltage Above Normal - Test......529
CID 0453 FMI 05 Solenoid Valve (Tong Open) Current Below Normal - Test......532
CID 0453 FMI 06 Solenoid Valve (Tong Open) Current Above Normal - Test......535
CID 0454 FMI 03 Solenoid Valve (Tong Close) Voltage Above Normal - Test......538
CID 0454 FMI 05 Solenoid Valve (Tong Close) Current Below Normal - Test......541
CID 0454 FMI 06 Solenoid Valve (Tong Close) Current Above Normal - Test......544
CID 0455 FMI 00 Pressure Sensor (Tong Close) Above Normal Range - Test......547
CID 0455 FMI 01 Pressure Sensor (Tong Close) Below Normal Range - Test......551
CID 0621 FMI 02 Push Button Switch (Transmission Downshift) Incorrect Signal - Test......556
CID 0622 FMI 02 Push Button Switch (Transmission Upshift) Incorrect Signal - Test......559
CID 0623 FMI 02 Rocker Switch (Transmission Direction) Incorrect Signal - Test......562
CID 0641 FMI 03 Solenoid Valve 1 (Direction Clutch) Voltage Above Normal - Test......565
CID 0641 FMI 05 Solenoid Valve 1 (Direction Clutch) Current Below Normal - Test......569
CID 0641 FMI 06 Solenoid Valve 1 (Direction Clutch) Current Above Normal - Test......572
CID 0642 FMI 03 Solenoid Valve 2 (Direction Clutch) Voltage Above Normal - Test......575
CID 0642 FMI 05 Solenoid Valve 2 (Direction Clutch) Current Below Normal - Test......579
CID 0642 FMI 06 Solenoid Valve 2 (Direction Clutch) Current Above Normal - Test......582
CID 0643 FMI 03 Solenoid Valve 3 (Direction Clutch) Voltage Above Normal - Test......585
CID 0643 FMI 05 Solenoid Valve 3 (Direction Clutch) Current Below Normal - Test......589
CID 0643 FMI 06 Solenoid Valve 3 (Direction Clutch) Current Above Normal - Test......592
CID 0644 FMI 03 Solenoid Valve 4 (Speed Clutch) Voltage Above Normal - Test......595
CID 0644 FMI 05 Solenoid Valve 4 (Speed Clutch) Current Below Normal - Test......599
CID 0644 FMI 06 Solenoid Valve 4 (Speed Clutch) Current Above Normal - Test......602
CID 0645 FMI 03 Solenoid Valve 5 (Speed Clutch) Voltage Above Normal - Test......605
CID 0645 FMI 05 Solenoid Valve 5 (Speed Clutch) Current Below Normal - Test......609
CID 0645 FMI 06 Solenoid Valve 5 (Speed Clutch) Current Above Normal - Test......612
CID 0646 FMI 03 Solenoid Valve 6 (Speed Clutch) Voltage Above Normal - Test......615
CID 0646 FMI 05 Solenoid Valve 6 (Speed Clutch) Current Below Normal - Test......619
CID 0646 FMI 06 Solenoid Valve 6 (Speed Clutch) Current Above Normal - Test......622
CID 0687 FMI 02 Option Code Incorrect Signal - Test......625
Electrical Components And Connector Locations......627
Electrical Connector - Inspect......630
Electrical General Information......632
Electrical Service Tools......634
Electronic Control Module (Transmission and Grapple) - Replace......636
Glossary of Electrical Terms......637
Machine Preparation for Troubleshooting......639
System Schematic 1......642
System Schematic 2......645
Troubleshooting Backup Alarm......648
Troubleshooting Key Start Switch......655
Troubleshooting Pressure Switch (Parking Brake Oil)......659
Troubleshooting Service Codes......662
Troubleshooting Start Relay......665
Troubleshooting Switch (Neutral Lock)......671
Troubleshooting Switch (Tong Auto_Manual)......673
Using Caterpillar Electronic Technician (ET) To Determine Service Codes......676
Using Caterpillar Monitoring System to Determine Service Codes......678
Using Electronic Control Analyzer Programmer (ECAP) to Determine Service Codes......682
Visual Inspection......684
SENR6690 - Specifications (515 Wheel Skidder and 525 Wheel Skidder Braking System)......687
Accumulator Charging Valve (Brake)......688
Brake Accumulator (Charged)......689
Brake Accumulator (Uncharged)......693
Brake Control (Parking Brake)......695
Brake Control Valve (Parking)......696
Brake Control Valve (Service)......697
Foot Brake Control (Pedal)......699
Parking Brake Actuator......700
Parking Brake......701
Pressure Switch (Brake Accumulator Charge)......702
Pressure Switch (Parking Brake Oil)......703
Priority Valve......704
Service Brakes......707
SENR6691 - Systems Operation (515 Wheel Skidder and 525 Wheel Skidder Braking System)......713
Accumulator Charging Valve (Brake)......714
Brake Accumulator......716
Brake Control Valve (Parking)......719
Brake Control Valve (Service)......723
General Information......727
Monitoring System......731
Parking Brake......734
Pressure Switch (Brake Accumulator Charge)......737
Pressure Switch (Parking Brake Oil)......739
Priority Valve (Brake)......741
Service Brakes......748
SENR6691 - Testing and Adjusting (515 Wheel Skidder and 525 Wheel Skidder Braking System)......750
Accumulator Charging Valve (Brake) - Test and Adjust......751
Brake Accumulator - Test and Charge......756
Brake System Air - Purge......763
Braking System Troubleshooting......765
Hydraulic Oil Contamination - Test......769
Machine Preparation for Troubleshooting......771
Parking Brake - Manual Release......774
Parking Brake - Test......776
Parking Brake Control - Adjust......778
Parking Brake System Pressure - Test......782
Priority Valve (Brake) - Test and Adjust......784
Service Brake Control - Adjust......791
Service Brake System Pressure - Test......797
Service Brake Wear Indicator - Check......800
Service Brakes - Test......805
Visual Inspection......807
SENR6692 - Specifications (515 Wheel Skidder and 525 Wheel Skidder Hydraulic and Steering System)......808
Articulated Hitch......809
Bank Valve (Four) (Grapple)......813
Bank Valve (Six) (Grapple)......815
Bank Valve (Three) (Grapple)......817
Breaker Relief Valve (Hydraulic Tank)......819
Check Valve (Pilot)......820
Control Valve (Decking Blade)......821
Control Valve (Grapple Arch and Grapple Boom)......823
Control Valve (Grapple Rotator)......825
Control Valve (Grapple Swing Boom)......827
Control Valve (Grapple Tong)......829
Control Valve (Hydraulic Retrieval Device)......833
Control Valve (Steering)......835
Control Valve (Steering, Decking Blade)......837
Decking Blade......841
Hydraulic Tank and Filter......845
Lift Cylinder (Decking Blade)......851
Main Control Valve (Hydraulic Retrieval Device)......853
Pilot Valve (Grapple)......855
Piston Pump (Implement, Pilot, Steering, Brake)......861
Pressure Sensor (Tong Oil)......866
Pressure Switch (Primary Steering Oil and Secondary Steering Oil)......870
Priority Valve (Brake)......872
Secondary Steering Pump and Electric Motor......875
Selector and Pressure Control Valve (Grapple)......877
Solenoid Valve (Hydraulic Retrieval Device)......879
Steering Control Linkage......881
Steering Cylinder......882
Temperature Sender (Hydraulic Oil)......883
SENR6693 - Disassembly and Assembly (515 and 525 Wheel Skidders Machine Systems)......884
Accumulator Charging Valve (Brake) - Remove and Install......888
Bank Valve (Four) (Grapple) - Assemble......892
Bank Valve (Four) (Grapple) - Disassemble......904
Bank Valve (Four) (Grapple) - Install......916
Bank Valve (Four) (Grapple) - Remove......920
Bank Valve (Six) (Grapple) - Assemble......925
Bank Valve (Six) (Grapple) - Disassemble......939
Bank Valve (Six) (Grapple) - Install......953
Bank Valve (Six) (Grapple) - Remove......955
Bank Valve (Two) (Decking Blade, Steering) - Disassemble......958
Brake Accumulator - Remove and Install......966