Caterpillar ASPHALT PAVERS AP500F Repair Service Manuals
Complete service repair manuals with electrical wiring diagrams for Caterpillar ASPHALT PAVERS AP500F, with all the workshop service information to maintain, diagnose, repair, and rebuild.
Caterpillar ASPHALT PAVERS AP500F Repair Service Manuals
workshop service manual includes:
* 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.
Total Pages: 1,341 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Manual Type: Disassembly & Assembly, Testing & Adjusting, Specifications, Systems Operation, Electrical Schematic, Troubleshooting...
Language: English
AP500F ASPHALT PAVER 449
AP500F ASPHALT PAVER 503
AP500F ASPHALT PAVER AF5
AP500F ASPHALT PAVER F5M
TABLE OF CONTENTS
UENR5851 - Schematic (AP500F Asphalt Paver Hydraulic System 451-8919-04)....2
M0069654 - Disassembly and Assembly (AP500F Asphalt Paver Machine Systems)....4
System Pressure - Release....9
Fuel Tank - Remove and Install....10
Hydraulic Oil Filter (Return) - Remove and Install....14
Hydraulic Oil Filter (Return) - Disassemble....16
Hydraulic Oil Filter (Return) - Assemble....18
Hydraulic Tank - Remove and Install....20
Hydraulic Oil Filter (Conveyor System Charge) - Remove and Install....24
Piston Pump (Right Drag Conveyor and Right Auger Conveyor) - Remove and Install....27
Piston Pump (Left Drag Conveyor and Left Auger Conveyor) - Remove and Install....30
Piston Pump (Drag Conveyor and Auger Conveyor) - Disassemble....33
Piston Pump (Drag Conveyor and Auger Conveyor) - Assemble....43
Piston Motor (Drag Conveyor) - Remove and Install....52
Piston Motor (Drag Conveyor) - Disassemble....54
Piston Motor (Drag Conveyor) - Assemble....59
Chain (Drag Conveyor) - Remove and Install....64
Final Drive Planetary (Drag Conveyor) - Remove and Install....66
Final Drive Planetary (Drag Conveyor) - Disassemble....67
Final Drive Planetary (Drag Conveyor) - Assemble....73
Drag Conveyor - Remove and Install....79
Feeder Drive Shaft Group - Remove and Install....82
Feeder Drive Shaft Group - Disassemble....86
Feeder Drive Shaft Group - Assemble....90
Footshaft - Remove and Install....95
Footshaft - Disassemble....96
Footshaft - Assemble....100
Plates (Drag Pans) - Remove and Install....105
Piston Motor (Auger Conveyor) - Remove and Install....106
Piston Motor (Auger Conveyor) - Disassemble....108
Piston Motor (Auger Conveyor) - Assemble....113
Chain (Auger Conveyor) - Remove and Install....118
Final Drive Planetary (Auger Conveyor) - Remove and Install....120
Final Drive Planetary (Auger Conveyor) - Disassemble....124
Final Drive Planetary (Auger Conveyor) - Assemble....130
Hydraulic Cylinder (Auger Hoist) - Remove and Install....137
Auger Conveyor - Remove and Install....140
Auger - Disassemble....143
Auger - Assemble....149
Hydraulic Filter (Suction Return) - Remove and Install....155
Piston Pump (Right Propel) - Remove and Install....157
Piston Pump (Left Propel) - Remove and Install....159
Piston Pump (Propel) - Disassemble....161
Piston Pump (Propel) - Assemble....182
Piston Motor (Propel) - Remove and Install....208
Brake Pump and Valve - Remove and Install....210
Brake Pump and Valve - Disassemble....212
Brake Pump and Valve - Assemble....214
Wheel (Front Wheel Assist) - Remove and Install....216
Front Wheel Drive Manifold - Remove and Install....220
Front Wheel Drive Manifold - Disassemble....222
Front Wheel Drive Manifold - Assemble....225
Piston Motor (Front Wheel Assist) - Remove and Install....228
Piston Motor (Front Wheel Assist) - Disassemble....231
Piston Motor (Front Wheel Assist) - Assemble....238
Wheel (Rear) - Remove and Install....244
Final Drive Planetary - Remove and Install....246
Duo-Cone Conventional Seals - Install....251
Piston Pump (Auxiliary) - Remove and Install....263
Piston Pump (Auxiliary) - Disassemble....266
Piston Pump (Auxiliary) - Assemble....275
Control Valve (Auxiliary) - Remove and Install....287
Control Valve (Auxiliary) - Disassemble....289
Control Valve (Auxiliary) - Assemble....292
Hydraulic Cylinder (Hopper Hoist) - Remove and Install....295
Hydraulic Cylinder (Apron) - Remove and Install....298
Control Valve (Apron) - Remove and Install....300
Control Valve (Apron) - Disassemble....302
Control Valve (Apron) - Assemble....304
Apron - Remove and Install....306
Hopper - Remove and Install....309
Seat - Remove and Install....312
Steering Wheel - Remove and Install....315
Steering Column - Remove and Install....317
Steering Control (Force Control) - Remove and Install....321
Steering Control (Force Control) - Disassemble....325
Steering Control (Force Control) - Assemble....329
Hydraulic Cylinder (Steering) - Remove and Install....333
Hydraulic Cylinder (Steering) - Disassemble - Steering....337
Hydraulic Cylinder (Steering) - Assemble - Steering....343
Canopy - Remove and Install....349
Operator Console - Remove and Install....353
Operator Console - Disassemble....356
Operator Console - Assemble....361
Operator Platform - Remove and Install....366
Piston Pump (Tamper Bar) - Remove and Install....369
Piston Pump (Tamper Bar) - Disassemble....371
Piston Pump (Tamper Bar) - Assemble....380
Control Valve (Vibratory) - Remove and Install....392
Control Valve (Vibratory) - Disassemble....395
Control Valve (Vibratory) - Assemble....396
Screed - Remove and Install....397
Main Frame Extension (Powered) - Remove and Install....400
Main Frame Extension (Powered) - Disassemble....402
Main Frame Extension (Powered) - Assemble....404
Hydraulic Cylinder (Screed Hoist) - Remove and Install....407
Counterbalance Valve (Hopper Hoist; Tow Point) - Remove and Install....409
Counterbalance Valve (Hopper Hoist; Tow Point) - Disassemble....411
Counterbalance Valve (Hopper Hoist; Tow Point) - Assemble....413
Hydraulic Cylinder (Tow Point) - Remove and Install....415
Tow Arm - Remove and Install....417
Gear Motor (Ventilation System) - Remove and Install....420
Gear Motor (Ventilation System) - Disassemble....422
Gear Motor (Ventilation System) - Assemble....424
Return Manifold and Oil Cooler Bypass Valve - Remove and Install....426
Push Roller - Remove and Install....429
Push Roller - Disassemble....431
Push Roller - Assemble....433
Control Valve (Truck Hitch) - Remove and Install....435
Control Valve (Truck Hitch) - Disassemble....437
Control Valve (Truck Hitch) - Assemble....439
Truck Hitch - Remove and Install....441
Truck Hitch - Disassemble....443
Truck Hitch - Assemble....448
Washdown Hose Reel - Remove and Install....453
Electric Motor (Washdown Pump) - Remove and Install....454
Gear Pump (Hydraulic Fan) - Remove and Install....456
Generator and Drive - Remove and Install....458
Generator - Disassemble....461
Generator - Assemble....470
Power Inverter - Remove and Install....480
Power Inverter - Disassemble....484
Power Inverter - Assemble....487
Power Receptacle Wiring - Remove and Install....489
M0069586 - Disassembly and Assembly (AP500F Asphalt Paver Engine Supplement)....491
System Pressure - Release....492
Air Cleaner - Remove and Install....493
Battery - Remove and Install....494
Alternator - Remove and Install....497
Electric Starting Motor - Remove and Install....499
Alternator Belt - Remove and Install....501
Belt Tensioner - Remove and Install....504
Fuel Cooler - Remove and Install....506
Fuel Filter (Secondary) and Fuel Filter Base - Remove and Install....508
Fan - Remove and Install....511
Gear Motor (Fan Drive) - Remove and Install....513
Radiator; Hydraulic Oil Cooler; and Fuel Cooler - Remove and Install....517
Radiator; Hydraulic Oil Cooler; and Fuel Cooler - Disassemble....523
Radiator; Hydraulic Oil Cooler; and Fuel Cooler - Assemble....528
Air Aftercooler - Remove and Install....533
Access Cover (Expansion Tank) - Remove and Install....535
Clean Emissions Module - Remove and Install....551
Diesel Exhaust Fluid Tank - Remove and Install....562
Electronic Control (Diesel Exhaust Fluid) - Remove and Install....565
Engine - Remove and Install....568
M0070514 - Specifications (AP555F Asphalt Paver Propel System)....579
Propel Lines....580
Propel Pump and Mounting....582
Pump Drive....584
Bogie....585
Bogie - Left....597
Front Wheel Assist....600
Brake Pump (Manual Release)....602
M0070528 - Specifications (AP555F Asphalt Paver Machine Systems)....603
Hydraulic Tank....606
Hydraulic Tank and Mounting....608
Hydraulic Oil Filter (Generator)....610
Hydraulic Oil Filter (Return)....613
Control Manifold....615
Check Valve....617
Pressure Sensor - BOOM DOWN....618
Pressure Sensor....619
Bypass Valve....620
Piston Pump (Auxiliary)....621
Lines (Auxiliary Hydraulic)....624
Control Valve (Apron)....626
Lines (Apron)....627
Hydraulic Cylinder (Apron)....628
Counterbalance Valve (Hopper Hoist; Tow Point)....631
Hydraulic Cylinder (Tow Point)....632
Lines (Truck Hitch)....636
Hydraulic Cylinder (Truck Hitch)....638
Push Roller....639
Truck Hitch....641
Oscillating Hitch....643
Hydraulic Fan Motor and Mounting....645
Hydraulic Cylinder (Hopper Hoist)....646
Lines (Auger Hoist)....649
Hydraulic Cylinder (Auger Hoist)....651
Lines (Screed)....658
Hydraulic Cylinder (Screed Hoist)....659
Apron....663
Hopper....664
Access Door....666
Lines (Conveyor)....668
Conveyor Drive (Drag)....670
Footshaft....674
Sensor (Paddle)....676
Auger Conveyor - Mounting....678
Auger Extension - 150.0 mm (5.90 inch)....682
Auger Extension - 305.0 mm (12.01 inch)....683
Auger Extension....684
Screed Extension....685
Screed Control and Mounting....689
Deflector....691
Main Frame....697
Extender Lines....699
Power Crown Group....700
Lines (Grade and Slope)....702
Screed Plate....703
Height Adjuster Group....705
Lines (Tamper)....707
Suction Fan....709
Coolant Lines....710
Lines (Hydraulic Fan)....712
Gear Pump (Hydraulic Fan)....713
Flow Divider Valve....715
Control Valve (Vibratory)....717
Flow Control Valve (Ventilation System)....719
Position Sensor (Sonic)....720
Generator....724
Washdown Group....727
Washdown Group - Ecology....729
Washdown Hose Reel....731
Canopy....733
Window - Front....734
Platform....735
Seat and Mounting....737
Grade Control....739
Operator Console....741
Steering Column....744
Steering Control....745
Lines (Steering)....746
Fuel Tank....747
Fuel Lines....749
Electric Starting Motor....751
Flood Lighting....753
Roading Lighting....755
Air Cleaner....758
Diesel Exhaust Fluid Lines....760
Return Lines....762
Flood Lamp....764
UENR5534 - Systems Operation (AP500F Asphalt Paver Propel System)....768
General Information (Propel System)....769
Location of Electrical Components (Propel System)....771
Location of Hydraulic Components (Propel System)....773
Operator Controls (Propel System)....775
Piston Pump (Propel)....781
Piston Motor (Propel)....790
Piston Pump (Front Wheel Assist)....793
Flow Divider Valve (Front Wheel Assist)....797
Piston Motor (Front Wheel Assist)....799
Final Drive Planetary....802
Electrical Schematic (Propel System)....804
Hydraulic Schematic (Propel System)....813
UENR5534 - Testing and Adjusting (AP500F Asphalt Paver Propel System)....825
Machine Preparation for Troubleshooting....826
Visual Inspection....827
Propel System Troubleshooting....831
Piston Pump (Front Wheel Assist) - Test and Adjust....834
Piston Pump Flow - Test....849
Piston Pump Neutral - Test and Adjust - Right Propel....857
Piston Pump Neutral - Test and Adjust - Left Propel....867
Relief Valve (Charge) - Test and Adjust - Right Propel....877
Relief Valve (Charge) - Test and Adjust - Left Propel....888
Pressure Reducing Valve - Test and Adjust - Shift Solenoid....900
Pressure Limiter Valve - Test and Adjust - Right Propel....908
Pressure Limiter Valve - Test and Adjust - Left Propel....922
Seal Leakage for Final Drive Planetary - Test....936
Solenoid (Shift) - Test....944
Rotary Position Sensor (Decelerator Pedal) - Test and Adjust....950
Steering Wheel - Calibrate....955
Forward Currents (EDC)- Calibrate....960
Reverse Currents (EDC)- Calibrate....966
UENR5536 - Systems Operation (AP500F Asphalt Paver Machine Systems)....972
General Information (Auxiliary Hydraulic System)....974
Operator Controls (Auxiliary Hydraulic System)....976
Electrical System (Auxiliary Hydraulic)....988
Hydraulic System (Auxiliary)....992
Piston Pump (Auxiliary)....999
Control Valve (Hopper Hoist; Tow Point)....1002
Control Valve (Auxiliary)....1004
Control Valve (Apron Fold)....1006
Control Valve (Truck Hitch)....1007
Paver Ventilation System....1008
Electrical Schematic (Auxiliary Hydraulic System)....1010
Hydraulic Schematic (Auxiliary Hydraulic System)....1029
General Information (Auger and Conveyor System)....1051
Operator Controls (Auger and Conveyor System)....1053
Electrical System (Auger and Conveyor)....1061
Location of Components (Auger and Conveyor System)....1063
Piston Pump (Auger and Conveyor)....1065
Piston Motor (Auger and Conveyor)....1071
Electrical Schematic (Auger and Conveyor System)....1074
Hydraulic Schematic (Auger and Conveyor System)....1081
General Information (Vibratory System)....1087
Operator Controls (Vibratory System)....1088
Vibratory Valve....1090
Electrical Schematic (Vibratory System)....1091
Hydraulic Schematic (Vibratory System)....1094
General Information (Tamper System)....1097
Operator Controls (Tamper System)....1098
Piston Pump (Tamper)....1102
Electrical Schematic (Tamper System)....1105
Hydraulic Schematic (Tamper System)....1108
General Information (Generator System)....1112
Operator Controls (Generator)....1115
Location Of Components (Generator System)....1116
Generator....1119
Electrical Schematic (Generator System)....1124
Hydraulic Schematic (Generator System)....1131
UENR5536 - Testing and Adjusting (AP500F Asphalt Paver Machine Systems)....1133
Machine Preparation for Troubleshooting....1134
Visual Inspection....1135
Machine System Troubleshooting....1139
Hydraulic Oil Contamination - Test....1143
Piston Pump Flow (Auxiliary) - Test....1150
Vibratory Shaft Speed - Calibrate....1160
Solenoid Valve (Tamper) - Calibrate....1170
Gear Pump Flow (Cooling Fan) - Test....1179
Pump Control Valve (Auxiliary) - Test and Adjust....1187
Relief Valve (Charge; Auger Conveyor and Drag Conveyor) - Test and Adjust....1196
Relief Valve (Main; Auger Conveyor and Drag Conveyor) - Test and Adjust....1209
Piston Pump Neutral (Auger Conveyor and Drag Conveyor) - Test and Adjust....1230
Piston Motor Case Drain Flow (Auger Conveyor and Drag Conveyor) - Test....1269
Conveyor Drive Chain (Auger) - Check and Adjust....1282
Conveyor Drive Chain (Drag) - Check and Adjust....1288
Conveyor Chain (Drag) - Check and Adjust....1293
Conveyor Speed (Auger) - Check....1299
Conveyor Speed (Drag) - Check....1308
Tow Point - Calibration....1318
Gear Pump (Generator Cooling) Pressure - Test....1325
Fan Speed (Ventilation) - Test....1333
Auger Conveyor - Calibrate....1338
Sensor (Paddle) - Calibrate - Auger Feed....1350
Drag Conveyor - Calibrate....1356
Caterpillar ASPHALT PAVERS AP500F Repair Service Manuals
