INTERACTIVE SCHEMATIC

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Information
Component Table
Tap Table
Fluid Power Symbols
Electrical Symbols

Schematic
Machine Views
Front Frame
Rear Frame
Tap Views

The Bookmarks panel will allow you to

quickly navigate to points of interest.
EC-C2
EC-C3

E-C60
E-C61

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EC-C1

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button will make all of the callouts visible. This button is
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KENR9566
March 2010

AP500E and BG500E Asphalt Paver

Hydraulic System
AP500E:
JWK1-UP

BG500E:
B5E1-UP

2010 Caterpillar, All Rights Reserved

Printed in U.S.A.

COMPONENT TABLE
Component Locations
Description

Part
Number

Machine
Location

Schematic
Location

Cooler As - Oil

312-4616

D-2

Cylinder Gp - Apron Fold

270-3560

C-3

Cylinder Gp - Auger, RH

194-7260

B-6

Cylinder Gp - Auger,LH

194-7259

B-6

Cylinder Gp - Grade Control, Left

342-9378

C-6

Cylinder Gp - Grade Control, Right

342-9378

C-5

Cylinder Gp - Left Hopper Hoist

275-0895

C-6

Cylinder Gp - Right Hopper Hoist

275-0895

C-5

Cylinder Gp -Screed Lift, Lift

270-2436

B-5

Cylinder Gp -Screed Lift, Right

270-2436

10

B-5

Cylinder Gp - Steering

337-4016

11

E-8

Filter Gp - Tank

176-9415

12

B-2

Filter Element As - Oil, Hydraulic Tank

255-1193

13

B-2

Hitch Gp - OSC

195-3182

14

C-4

Manifold - Front Return

107-0003

15

C-3

Manifold - Rear Return

107-0003

16

D-1

Motor Gp - Auger, Left

190-8789

17

F-3

Motor Gp - Auger, Right

190-8789

18

F-2

Motor Gp - Conveyor, Left

230-9384

19

F-4

Motor Gp - Conveyor, Right

230-9384

20

F-1

Motor Gp - Fan

344-7828

21

C-1

Motor Gp - FWA, Left 2WD

294-2887

22

B-8

Motor Gp - FWA, Front, Left, 4WD

294-2887

23

B-8

Motor Gp - FWA, Front, Right, 4WD

294-2887

24

B-8

Motor Gp - FWA, Right, 2WD

294-2887

25

B-8

Motor Gp - FWA, Rear, Left, 4WD

294-2887

26

B-8

Motor Gp - FWA, Rear, Right, 4WD

294-2887

27

B-8

Motor Gp - Paver, Ventilation

266-9833

28

A-5

Motor Gp - Propel, Left

269-0530

29

F-6

Motor Gp - Propel, Right

269-0530

30

F-5

Pump Gp - Auxiliary

230-9385

31

D-8

Pump Gp - Hydraulic Fan

327-8106

32

C-1

Pump Gp - Left Propel

339-3533

33

E-6

Pump Gp - Right Propel

339-3533

34

E-5

Pump Gp - Material Feed, Left

269-0533

35

E-3

Pump Gp - Material Feed, Right

269-0533

36

E-1

Pump Gp - Tamper

348-8146

37

B-5

Pump and Valve Gp - Brake, Manual Release

193-8539

38

B-6

Strainer - Suction

1G-7663

39

B-2

Strainer - Suction

250-2783

40

B-2

Tank Gp - Hydraulic

324-3253

41

B-2

Valve Gp - Control, 2 Bank

270-3549

42

C-3
C-3

Valve Gp - Check, FWA

145-8983

43

Valve Gp - Control, Main Auxiliary

269-0535

44

A-6

Valve Gp - Cooler Bypass

324-3255

45

D-2

Valve Gp - Counterbalnce, Grade Control / Hopper Hoist, Left

292-9094

46

C-6

Valve Gp - Counterbalnce, Grade Control / Hopper Hoist, Right

292-9094

47

C-5

Valve Gp - Flow Control, Ventilation

332-6609

48

A-5

Valve Gp - Flow Divider, FWA

326-6532

49

C-8

Valve Gp - Control, Hitch

230-9160

50

C-4

Valve Gp - Priority, Steering

346-9505

51

C-7

Valve Gp - Solenoid, Left Grade Control

219-3005

52

C-6

Valve Gp - Solenoid, Right Grade Control

219-3005

53

C-5

Valve Gp - Solenoid, Screed, Vibration Control

346-9504

54

B-4

Valve Gp - Steering, Left

285-4848

55

E-8

Valve Gp - Steering, Right

285-4848

56

E-8

2010 Caterpillar, All Rights Reserved

TAP TABLE
Tap Locations
Pressure and Sampling
Tap
Number

Description

Schematic
Location

TP1

Left Propel Forward

F-6

TP2

Left Propel Reverse

F-6

TP3

Right Propel Forward

F-5

TP4

Right Propel Reverse

F-5

TP5

RH Propel/RH Feeder Charge

F-2

TP6

LH Propel/LH Feeder Charge

F-3

TP7

LH Propel Case

E-6

TP8

RH Propel Case

F-1

TP9

LH Conveyor Forward

E-4

TP10

LH Conveyor Reverse

F-4

TP11

LH Auger Forward

E-3

TP12

LH Auger Reverse

E-3

TP13

RH Auger Forward

E-2

TP14

RH Auger Reverse

F-2

TP15

RH Conveyor Forward

F-1

TP16

RH Conveyor Reverse

E-1

TP17

Tamper Pump

B-5

TP18

Apron Fold

C-3

TP19

Auxiliary System Pressure

C-5

TP20

Propel Shift Pressure

A-6

TP21

Truck Hitch

C-4

TP22

Hyd. Oil SOS

B-2

TP23

LH G/S Pressure Reducing

C-6

TP24

RH G/S Pressure Reducing

C-5

TP25

Brake Pressure

B-6

TP26

Steering Pressure

C-7

TP27

FWA/Steer/Aux. Supply

C-7

TP28

FWA Reduced Pressure

C-8

TP29

Fan Pump

C-1

2010 Caterpillar, All Rights Reserved

FLUID POWER SYMBOLS

BASIC COMPONENT SYMBOLS

MAIN AUX.

PUMP or MOTOR

SPRING
(ADJUSTABLE)

VARIABILITY

CONTROL VALVES

SPRING

FLUID CONDITIONER

PRESSURE
COMPENSATION

LINE RESTRICTION
(VARIABLE)

TWO POSITION

2-SECTION PUMP

HYDRAULIC
PNEUMATIC
ENERGY TRIANGLES

ATTACHMENT

LINE RESTRICTION

VALVE PORTS

TWO-WAY

THREE POSITION

PUMP: VARIABLE and

PRESSURE COMPENSATED

VARIABLE and PRESSURE

COMPENSATED

VALVES

VALVE ENVELOPES

ONE POSITION

LINE RESTRICTION
(FIXED)

RESTRICTION

FOUR-WAY

THREE-WAY

CONTROL VALVES

CHECK VALVES

AB

AB

P T
NORMAL POSITION

P T
SHIFTED POSITION

INFINITE POSITION

SHUTTLE

SPRING
LOADED

BASIC
SYMBOL

PILOT
CONTROLLED

FLUID STORAGE RESERVOIRS

VENTED

RETURN ABOVE FLUID LEVEL

PRESSURIZED

RETURN BELOW FLUID LEVEL

MEASUREMENT

PRESSURE

TEMPERATURE

ROTATING SHAFTS

FLOW

UNIDIRECTIONAL

BIDIRECTIONAL

COMBINATION CONTROLS

SOLENOID

SOLENOID
or MANUAL

SOLENOID and
PILOT or MANUAL

SOLENOID
and PILOT

SERVO

DETENT

THERMAL

MANUAL CONTROL SYMBOLS

MANUAL SHUTOFF

PUSH-PULL LEVER

RELEASED PRESSURE

EXTERNAL RETURN

SPRING LOADED

HYDRAULIC PUMPS
VARIABLE DISPLACEMENT
NON-COMPENSATED

LINES CROSSING

LINES JOINING

FIXED
DISPLACEMENT

VARIABLE DISPLACEMENT
NON-COMPENSATED

UNIDIRECTIONAL

BIDIRECTIONAL

BIDIRECTIONAL

SPRING

REMOTE SUPPLY PRESSURE

INTERNAL
SUPPLY PRESSURE

COMPLETE

HYDRAULIC AND PNEUMATIC CYLINDERS

SINGLE ACTING

DOUBLE ACTING

INTERNAL PASSAGEWAYS

HYDRAULIC MOTORS

UNIDIRECTIONAL

2010 Caterpillar, All Rights Reserved

PEDAL

SIMPLIFIED

CROSSING AND JOINING LINES

GAS CHARGED

PUSH BUTTON

PILOT CONTROL SYMBOLS

INTERNAL RETURN

ACCUMULATORS

FIXED
DISPLACEMENT

GENERAL MANUAL

INFINITE
POSITIONING

FLOW IN ONE
DIRECTION

THREE
POSITION

PARALLEL
FLOW

CROSS
FLOW

TWO
POSITION

FLOW ALLOWED IN
EITHER DIRECTION

ELECTRICAL SYMBOLS
Hydraulic Symbols (Electrical)

G
Transducer
(Fluid)

Transducer
(Gas / Air)

Pressure Switch
(Adjustable)

Pressure Switch

Generator

Electric Motor

Electrical Wire

Temperature Switch

Electrical Symbols (Electrical)

Pressure
Symbol

Temperature
Symbol

Level
Symbol

Flow
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
Identification

Wire Color

325-AG135 PK-14
325-PK

Circuit Identification
Number

Wire Color

Wire Gauge

Previous Standard
Wire Color

Wire

325-PK-14
B
Circuit Number
Identification

Wire Gauge

2010 Caterpillar, All Rights Reserved

(EXAMPLE VALVE)

(29) MOTOR GP PROPEL, LEFT

269-0530

L1

(30) MOTOR GP PROPEL, RIGHT

269-0530

BRAKE

L2

L1

BRAKE

L2

ALT B
B

M4

min.
disp.

min.
disp.

M4

L2

LEFT
CONVEYOR
MOTOR

M5

(55) VALVE GP STEERING, LEFT

285-4848

GEAR SHIFT

M5

M3

STEERING VALVES
L

TP1

TP4

TP3

L3

MB

M5

TP2

TP10

(56) VALVE GP STEERING, RIGHT

285-4848

M1

M2

L2

M4 M3

M5

M4

LEFT CONVEYOR
PUMP

C1

X2

M4

M5

RIGHT AUGER PUMP

L1

M5

LEFT PROPEL PUMP

LOWER LEFT PUMP STACK

TP15

MC
C

RIGHT CONVEYOR
PUMP

MA

TP11

MD

C1

C2

RIGHT CONVEYOR / AUGER

UPPER RIGHT PUMP STACK

(35) PUMP GP MATERIAL FEED, LEFT

269-0533

C1

C2

(36) PUMP GP MATERIAL FEED, RIGHT

269-0533

L1

L2

M4

C1

C2

C2

LEFT CONVEYOR / AUGER

UPPER LEFT PUMP STACK

X1

L1

L2

MD
E

TP7
M4

L2

TP16

MA

TP9

M3

M5

M4 M3

TP13

M3
X1

M5

M2

L3

MB

LEFT AUGER PUMP

TP8

TP12

(34) PUMP GP PROPEL, RIGHT

339-3533

ALT B

TP14

(33) PUMP GP PROPEL, LEFT

339-3533

ALT B

MC

L1

L1

TP5

B
M1

RIGHT
CONVEYOR
MOTOR

L3

L2

ALT A

ALT A

L2

L3

TP6

GEAR SHIFT

M3

L1

RIGHT
AUGER
MOTOR
A

L2

(20) MOTOR GP CONVEYOR, RIGHT

230-9384

(18) MOTOR GP AUGER, RIGHT

190-8789

LEFT
AUGER
MOTOR
L3

ALT A

ALT B

L1

(19) MOTOR GP CONVEYOR, LEFT

230-9384

L1

ALT A

(11) CYLINDER GP - STEERING

337-4016

(17) MOTOR GP AUGER, LEFT

190-8789

L3

RIGHT PROPEL PUMP

LOWER RIGHT PUMP STACK

X2

(31) PUMP GP AUXILARY

230-9385
S

L1

L2

(1) COOLER AS - OIL

312-4616

M2
B

(45) VALVE GP COOLER BYPASS

324-3255
(51) VALVE GP PRIORITY,
STEERING
346-9505
(49) VALVE GP FLOW DIVIDER
FWA
326-6532

TP28

(5) CYLINDER GP GRADE CONTROL,

LEFT
342-9378

C2

TP26
P1

P3

T1

T3

C1

(52) VALVE GP SOLENOID

GRADE CONTROL,
LEFT
219-3005

STEERING
PRIORITY
VALVE

HL1

PR

T2

(53) VALVE GP SOLENOID

GRADE CONTROL,
RIGHT
219-3005

C1

HL1

B
T

P
G2

RIGHT

(23) MOTOR GP FWA

294-2887

(14) HITCH GP - OSC

195-3182

TRUCK HITCH
(OPTIONAL SYSTEM)

(50) VALVE GP CONTROL

HITCH
230-9160

TP19

(16) MANIFOLD REAR RETURN

107-0003

F
T

(42) VALVE GP CONTROL

2-BANK
270-3549
C1

C2

D
H
C

C1

(43) VALVE GP CHECK,FWA

145-8983

TP21

(25) MOTOR GP FWA, RIGHT

294-2887

C2

F
G

TP29

(21) MOTOR GP - FAN

344-7828

(15) MANIFOLD FRONT RETURN

107-0003
G

#1

FAN CIRCUIT

#2

(38) PUMP & VALVE GP BRAKE, MANUAL RELEASE

193-8539

(32) PUMP GP HYDRAULIC FAN

327-8106

TP18

L.SHIFT

R.BRAKE

(26) MOTOR GP FWA

294-2887

H
C

TP24

TP22

R.SHIFT

REAR

B
L

LEFT
L

A
FRONT

(10) CYLINDER GP SCREED LIFT,

RIGHT
270-2436

AL1

(24) MOTOR GP FWA

294-2887

AL2

BRK

G1

FDS
#4

SCD3

SCD1

SCD2

#9

G2
ASSIST
#7

#3

#1

#2

LOWER
#5

LEFT PROPEL CHARGE PUMP AND CIRCUIT

RIGHT GRADE AND HOPPER HOIST CIRCUIT
RIGHT PROPEL PUMP AND CIRCUIT
TAMPER CIRCUIT
SHIFTING CIRCUIT
LEFT AND RIGHT TRACK TAKE-UP CIRCUITS
SUPPLY LINES

LEFT AUGER PUMP AND CIRCUIT

B2

(39) STRAINER
SUCTION
1G-7663

TRUCK HITCH CIRCUIT

AUGER HOIST AND SCREED HOIST CURCUIT
RIGHT CONVEYOR PUMP AND CIRCUIT
DRAINS, RETURN LINES
RIGHT AUGER PUMP AND CIRCUIT

SEE SCREED
HYD SCHEMATICS
FOR DETAILS

AUXILIARY PUMP OUTPUT AND VENTILATION CIRCUIT

(13) FILTER ELEMENT AS OIL, HYDRAULIC TANK

255-1193

HAND BRAKE PUMP AND CIRCUIT

LEFT CONVEYOR PUMP AND CIRCUIT
APRON FOLD CIRCUIT
LEFT GRADE AND HOPPER HOIST CIRCUIT

OIL CONNECTING LINES

BRAKE COOLING MOTOR, PUMP AND CIRCUITS

STEERING (FWA) CIRCUIT

L2

L1

(54) VALVE GP SOLENOID, SCREED

VIBRATION CONTROL
346-9504

LINE PATTERNS

#8
P1

Pressure Line

T1

Pilot / Load Sensing Pressure

Drain / Return Lines

(44) VALVE GP CONTROL

MAIN AUXILIARY
269-0535

#6

RIGHT PROPEL CHARGE PUMP AND CIRCUITS

(40) STRAINER
SUCTION
250-2783

#2

B1

SCREED EXTENDERS AND

OTHER SCREED FUNCTIONS

LIFT

#1

COLOR LEGEND

LEFT PROPEL PUMP AND CIRCUIT

MB

P1

SEE SCREED HYD

SCHEMATICS FOR DETAILS

(37) PUMP GP TAMPER

348-8146

TP20

(27) MOTOR GP FWA

294-2887

AUX

FRONT

REAR

(4) CYLINDER GP
AUGER, LH
194-7259

(9) CYLINDER GP SCREED LIFT,

LEFT
270-2436

(41) TANK AS HYDRAULIC

324-3253

#3

TP17

(3) CYLINDER GP AUGER, RH

194-7260

(12) FILTER GP TANK

176-9415

TAMPER CIRCUIT

TP25

FWA CIRCUIT
(OPTIONAL SYSTEM)
4WD OPTION SHOWN

F
G

L.BRAKE
A

CD2

APRON FOLD CIRCUIT

(OPTIONAL SYSTEM)
(2) CYLINDER GP HYDRAULIC
(APRON FOLD)
270-3560

(47) VALVE GP COUNTERBALANCE

HOPPER HOIST,
GRADE CONTROL,
RIGHT
292-9094

HL2

PL

(22) MOTOR GP FWA, LEFT

294-2887

C2

TP23

FWA CIRCUIT
(OPTIONAL SYSTEM)
2WD OPTION SHOWN

(46) VALVE GP COUNTERBALANCE

HOPPER HOIST/
GRADE CONTROL, LEFT
292-9094

HL2

G2
CD2

(8) CYLINDER GP
HOPPER HOIST,
RIGHT
275-0895

G1

(6) CYLINDER GP GRADE CONTROL,

RIGHT
342-9378

(7) CYLINDER GP
HOPPER HOIST,
LEFT
275-0895

FWA FLOW
DIVIDER VALVE
(OPTIONAL)

TC

TP27

G3

FC

(48) VALVE GP FLOW CONTROL

VENTLATION
332-6609

Component Group

(28) MOTOR GP PAVER

VENTILATION
266-9833

CALLOUTS
Taps (Pressure, Sampling, Sensor - by letter)

YY

RET

Callout Number

(Machine Location from

Component LocationsTable)

IN
OUT

(52) VALVE GP - CONTROL

138-1234
Part Number

AP500E AND BG500E ASPHALT PAVER HYDRAULIC SYSTEM

MEDIA NUMBER KENR9566
PART NUMBER: 321-2456, CHANGE: 01, VERSION: -

Component
Name

Components are shown installed on a fully operable machine with the key and engine off, transmission shifter
in neutral and with parking brake set.
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.

FRONT RIGHT VIEW

37

TP
18

28

42
TP
22

21

33
15

52
7

47

49

53

51

6
TP
29

40

39

26
8

11
27
25

22

24

23

2
2010 Caterpillar, All Rights Reserved

TP
24

14

31
43

46

50

41

36

VIEW ALL CALLOUTS

13

12

32

55

56

TP
21

35

34

REAR LEFT VIEW

VIEW ALL CALLOUTS

TP
19
TP
23

48
45
30
TP
28

TP
26

20

TP
27

5
TP
25

44
10

38
29
3

19
54

TP
20

2010 Caterpillar, All Rights Reserved

16

17

18

TAP PANEL
VIEW ALL CALLOUTS

TP
16

TP
10

TP
3

TP
1

TP
13

TP
15

TP
11

TP
9

TP
6

TP
4
TP
2

TP
8
TP
7
2010 Caterpillar, All Rights Reserved

TP
5
TP
17

TP
14
TP
12