Caterpillar AP-200
Maintenance schedule, common problems & OEM parts breakdown
The Caterpillar AP-200 is a compact, tracked asphalt paver built roughly from 1985 to 1988 under the 6AD serial prefix. It runs a small 2-cylinder air-cooled diesel engine rated around 26 kW (35 hp) gross, roughly 1,626 cc, mechanically governed with no electronic engine controls. Operating weight with screed is about 4,080 kg (8,995 lb). The base screed pours a strip about 0.9 m (3 ft) wide and extends to roughly 3.7-4.3 m (12-14 ft) with bolt-on screed and auger extensions, fed by dual independent augers and heated electrically. It rides on rubber-padded steel crawler tracks about 380 mm (15 in) wide. No documented one-to-one successor exists for this exact prefix and generation; it sits in Caterpillar's earlier compact paver lineup, ahead of the larger, electronically controlled paver families that came later.
Documentation on this machine is thin given its age, and even its engine identity is not fully settled in surviving records: some sources tie it to a Deutz F2L511, others to a Hatz 2M40, both small air-cooled 2-cylinder diesels of similar output, so confirm the actual engine off the data plate before ordering engine parts. Little changed publicly documented within the run itself beyond configuration options for screed width and auger reach. In today's used and parts market, the AP-200 shows up mainly on small driveway, parking-lot, and utility patching jobs where its simplicity is the selling point: no ECM, no fault codes, and only mechanical alarm switches to watch. That same age and simplicity means parts sourcing is thin and buyers should verify engine branding and serial range before ordering engine-specific components.
Below: full specifications, fluids & capacities, the factory service schedule, common service parts, verified fault codes, what owners discuss, attachment guidance, the complete assembly directory, and a serial-number reference. Complete parts lists with full OEM part numbers, exploded diagrams, quantities, and fitment data are available free in Heavy Parts AI.
Caterpillar AP-200 specifications
Engine
| Engine model | Deutz F2L511 |
| Gross power | 35 hp (26.1 kW) |
| Displacement | 1,626 cc (99.2 cu in) |
| Cylinders | 2, air-cooled diesel |
| Emissions tier | Not applicable — pre-emissions-era mechanical air-cooled diesel, no certified tier |
Weights
| Operating weight (with screed, standard configuration) | 4,080 kg (8,995 lb) |
| Shipping weight | Not published — not documented for this model |
Dimensions
| Length with screed | 2.44–2.47 m (8 ft – 8 ft 1 in) |
| Transport width | 3.0–3.02 m (9 ft 10 in – 9 ft 11 in) |
| Transport height | 1.73–1.74 m (5 ft 8 in – 5 ft 9 in) |
| Width with hopper open | 3.66–3.69 m (12 ft – 12 ft 1 in) |
| Track length on ground | 0.76 m (2 ft 6 in) |
| Track width | 38.1 cm (15 in) |
| Ground clearance | Not documented |
Performance
| Standard paving width | 0.91 m (3 ft), varies by screed configuration |
| Maximum paving width | 3.69 m (12 ft 1 in) |
| Maximum paving speed | 54 m/min (177 ft/min) |
| Travel speed | Not documented for this model — verify with dealer or O&M manual |
| Gradeability | Not published |
Service capacities (summary)
| Fuel tank | 19.7 L (5.2 gal) |
| Hydraulic system | 68.1 L (18 gal) |
| Engine oil | Not documented |
| Cooling system | Not applicable — air-cooled engine, no liquid cooling circuit |
Values vary by configuration, region, and serial range — confirm against your machine before planning transport or lifts.
AP-200 fluids & capacities
| System | Capacity | Recommended fluid |
|---|---|---|
| Engine crankcase (with filter) | Not documented in public sources for this model; engine is a small 2-cylinder air-cooled diesel (approx. 1.6-1.8 L displacement, 26 kW / 35 hp class) rather than a Cat-branded engine block | Not confirmed for this exact machine; Caterpillar's standard OMM guidance for non-Cat sourced small diesels of this era specifies a commercial heavy-duty diesel engine oil meeting API CD/CE or Cat DEO equivalent, graded by ambient temperature (for example SAE 15W-40 in moderate climates, lighter grades such as 10W or 10W-30 in cold climates) - verify against the data plate and dealer parts lookup |
| Cooling system | Not applicable - engine is air-cooled, no liquid coolant system | Not applicable (air-cooled engine) |
| Fuel tank | 19.7 L (5.2 US gal) | No. 2-D diesel fuel (or equivalent ultra-low-sulfur diesel for the applicable emissions era); use winter-blend or treated fuel below freezing to prevent fuel waxing |
| Hydraulic system (tank and circuit) | 68.1 L (18 US gal) | Not confirmed by name for this model; consistent with Caterpillar's standard hydraulic-system guidance of that era, expect Cat HYDO (or TDTO as an accepted alternate) graded by climate - heavier grade in hot climates, lighter grade in cold climates - verify grade against the machine's own lubricant chart |
| Track drive / final drive gearboxes (each, tracked crawler undercarriage) | Not documented in public sources for this model | Not documented; Caterpillar final-drive compartments of this class typically call for Cat TDTO (Transmission/Drive Train Oil) graded by climate - verify against the OMM lubrication chart |
| Transmission / powertrain compartment | No separate transmission compartment documented - propel and screed functions on this class of compact paver are hydrostatically driven through the hydraulic system rather than a discrete gearbox reservoir | Not applicable as a separate fill point; see hydraulic system |
| Grease (all fittings - undercarriage, track tensioners, screed, auger/conveyor linkage) | Spec only - no fill quantity applies | Not confirmed by name for this model; Caterpillar's general-purpose lubrication standard for machines of this class is Cat Multipurpose Grease (or Cat Advanced 3Moly Grease for higher-load pivot points) - verify against the OMM lubrication chart for exact fitting-by-fitting grade |
Capacities are refill values from factory literature — always fill to the dipstick/sight gauge, not the number.
Caterpillar AP-200 maintenance schedule
| Service interval | Tasks |
|---|---|
| Every 50 h |
|
| Every 250 h |
|
| Every 500 h |
|
| Every 1,000 h |
|
| Every 2,000 h |
|
| Every 3,000 h |
|
Servicing the AP-200 beyond the schedule
Predictive Maintenance and Fluid Analysis
The AP-200 has no ECM or fault-code system, so predictive care depends on manual inspection and fluid sampling. Pull periodic oil samples from the small air-cooled diesel to catch wear metal trends early, and sample hydraulic fluid from the 68.1 L (18 gal) system that drives the auger, conveyor, and screed functions. Watch the fuel tank sump for water intrusion in the 19.7 L (5.2 gal) tank, and test the mechanical alarm switches for oil pressure, cylinder head temperature, and charging regularly since they are the only warning system on this machine.
Corrective and Common Repairs
Expect wear on the 380 mm (15 in) rubber-padded crawler tracks and their rollers and idlers under constant asphalt exposure. Auger and conveyor bearings and drive chains take a beating from grit ingestion if lubrication schedules slip. Electric screed heat elements and thermostats commonly fail on machines this age and cause uneven mat temperature. Mechanical governor linkage on the air-cooled diesel wears and drifts out of adjustment, and hydraulic hoses routed near the heated screed are prone to heat-cycling failure.
Overhaul and Rebuild Points
Major rebuild points center on the crawler undercarriage (rollers, idlers, and drive sprockets), the hydraulic pump and track drive motors, and the auger gearboxes, all of which see heavy cyclic load in paving service. The air-cooled 2-cylinder diesel's top end, cylinder heads and valve train, runs hotter thermal cycles than a liquid-cooled engine and should get a compression check at major overhaul intervals since there is no electronic diagnostic trail to flag internal wear early.
Seasonal and Environmental Servicing
In cold weather, the mechanically governed diesel is harder to start and cold-thickened hydraulic fluid slows auger and screed response, so warm the machine and check hose fittings for cold cracking before loading it. In hot weather, keep the air-cooled engine's cooling fins and shrouding free of asphalt dust and debris, since airflow is its only cooling path, and watch the cylinder head temperature switch closely during peak summer paving. Before off-season storage, drain the fuel tank sump and protect the rubber track pads from UV and temperature cracking.
AP-200 fault codes & troubleshooting
| Code | Meaning | Likely cause | What to do |
|---|---|---|---|
| Oil pressure warning light / buzzer | Engine oil pressure alarm switch has opened, indicating low or lost oil pressure at the Deutz F2L511 engine | Low oil level, failed oil pump, worn bearings, or a faulty pressure alarm switch | Stop engine immediately, check oil level and condition, test the alarm switch before restarting |
| Engine (cylinder head) high-temperature warning light / buzzer | Air-cooled cylinder head temperature alarm switch has tripped on the F2L511 | Blocked cooling air shrouding or fins, debris in the cooling fan intake, low engine oil (oil also carries heat on this air-cooled design), or an overload condition | Stop engine, clear cooling fins and shrouding of dirt and asphalt debris, check oil level, let engine cool before restart |
| Charging system (alternator/generator) warning light | Battery is not receiving charge from the engine-driven alternator | Broken or slipping fan/alternator belt, failed alternator or regulator, loose or corroded wiring | Check belt tension and condition first, then test alternator output and battery connections |
| Fuel shutoff / no-start safety lockout | Fuel solenoid has been de-energized by one of the mechanical alarm switches (oil pressure or temperature), cutting fuel to the injection pump | A genuine low-oil-pressure or over-temperature condition, or a faulty alarm switch falsely tripping the shutoff | Investigate and clear the oil pressure or temperature fault before attempting to bypass or reset the fuel solenoid |
Codes and remedies are general guidance for this model family — always confirm with diagnostic tooling and your dealer before major repairs.
AP-200 attachments & work tools
Screed and paving width range
Base screed pours a narrow strip around 0.9 m (3 ft) and extends mechanically to roughly 3.7 m (12 ft), with some period listings citing up to about 4.3 m (14 ft) once bolt-on extensions are fitted. Exact top width varies by configuration and which extension set is installed.
Bolt-on screed extensions
Extra paving width comes from bolt-on screed extension plates that mate to the main screed frame rather than a quick-attach coupler. Matching auger extensions are needed alongside screed extensions so material feed reaches the widened strike-off plates evenly.
Screed heating
This model is factory-fitted with an electrical screed heating system to bring the screed plates to working temperature before paving starts, rather than a torch/propane setup. Heat-up time and control detail are not documented for this exact serial range; verify with your dealer.
Hopper, conveyor and auger feed system
A rear hopper feeds asphalt mix through an under-chassis conveyor to left and right augers ahead of the screed; the two augers can be run independently to balance material flow across the paving width. Hopper capacity in published specs is not listed for this model.
Track undercarriage
Standard configuration runs on rubber-padded steel crawler tracks about 380 mm (15 in) wide per side, sized for a compact self-propelled paver rather than a wheeled unit. No factory wheel-paver variant is documented for this model.
Power unit for hydraulic work-tool drive
An air-cooled two-cylinder diesel (rated about 26 kW / 35 hp) drives the hydraulic system that powers the conveyor, augers, screed vibration/tamper function, and travel; total hydraulic reservoir capacity is around 68 L (18 US gal). This is a mechanical, pre-electronic power unit with no ECM-based work-tool programming.
Mounting and coupler system
Work-tool additions on this class of paver (screed extensions, auger extensions, strike-off plates) attach by bolted flange connections built into the screed and auger shafts, not by a hydraulic quick-coupler as used on excavators or loaders.
Factory guarding and operator configuration
Standard build includes a 12V electrical system with a 50-amp alternator supporting lighting and screed heat controls, and an operator's platform at the rear of the machine. Detailed factory options (canopy, additional lighting, edger/safety-edge kits) are not confirmed for this specific model in available records; verify with your dealer for serial-specific option lists.
All AP-200 assemblies by section
Every catalogued assembly group for the Caterpillar AP-200. Open an assembly to preview the parts inside — full OEM part numbers are available in Heavy Parts AI.
Engine Installation
7x9813 Power Gp-Part 2 Of 3
| 7X***13 | Power Group | 1 |
7x9813 Power Gp-Part 1 Of 3
| 7X***13 | Power Group | 1 |
7x9813 Power Gp
| 7X***13 | Power Group | 1 |
7x9813 Power Gp-Part 3 Of 3
| 7X***13 | Power Group | 1 |
Frame
773951 Cap As-Filler Breather
| 07***51 | Cap As-Filler Breather | 1 |
780354 Cylinder As
| 07***54 | Cylinder As-Lift-Screed | 1 |
982012 Cylinder Gp
| 09***12 | Cylinder Group | 1 |
780355 Cylinder Gp-Door
| 07***55 | Cylinder Group-Door | 1 |
7x9810 Structure Gp-Part 3 Of 4
| 7X***10 | Structure Group | 1 |
7x9810 Structure Gp-Part 4 Of 4
| 7X***10 | Structure Group | 1 |
7x9810 Structure Gp-Part 2 Of 4
| 7X***10 | Structure Group | 1 |
7x9810 Structure Gp-Part 1 Of 4
| 7X***10 | Structure Group | 1 |
Fuel System
869953 Lines Gp-Spray Down
| 08***53 | Lines Group-Spray Down | 1 |
7r5551 Lines Gp-Spray Down
| 7R***51 | Lines Group-Spray Down | 1 |
7r5550 Tank Gp
| 7R***50 | Tank & Burner Group-Screed | 1 |
Hydraulic System
869942 Control Gp-Valve Bank
| 08***42 | Control Group-Valve | 1 |
869948 Drive Gp
| 08***48 | Drive Group | 1 |
869955 Guard As-Hose
| 08***55 | Guard As-Hose | 1 |
| 08***56 | Guard, Hose (12 X 36 X 1/8) | 1 |
| 5E***31 | Guard-Hose (1/2" Los Press) | 1 |
869950 Hydraulic Gp-Auger Drive
| 08***50 | Lines Group-Auger Drive | 1 |
869944 Hydraulic Gp-Hopper Lift
| 08***44 | Lines Group-Hopper Lift | 1 |
869946 Hydraulic Gp-Material Door Lift
| 08***46 | Lines Group-Material Door Lift | 1 |
869954 Hydraulic Gp-Pressure
| 08***54 | Lines Group-Pressure | 1 |
869952 Hydraulic Gp-Propane
| 08***52 | Lines Group-Propane | 1 |
869943 Hydraulic Gp-Return & Case Drain
| 08***43 | Lines Group-Return & Case Drain | 1 |
817905 Hydraulic Gp-Screed Elevation
| 08***05 | Lines Group-Screed Elevation | 1 |
869949 Hydraulic Gp-Vibrator Drive
| 08***49 | Lines Group-Vibratory Drive | 1 |
869951 Hydraulic Gp-Wing Extension
| 08***51 | Lines Group-Wing Extension | 1 |
822634 Valve As
| 08***34 | Valve As | 1 |
869355 Valve Gp
| 08***55 | Valve Group | 1 |
869362 Valve Gp
| 08***62 | Valve Group | 1 |
869363 Valve Gp
| 08***63 | Valve Group | 1 |
926137 Valve Gp-Control
| 09***37 | Valve Group-Control | 1 |
Power Train
869941 Control Gp-Throttle
| 08***41 | Control Group-Throttle | 1 |
777189 Motor Gp
| 07***89 | Motor Group | 1 |
822624 Hub As-Planetary
| 08***24 | Planetary Group | 1 |
982324 Pump
779439 Pump Gp-Dual Propel-Part 2 Of 2*R
| 07***39 | Pump Group-Dual Propel | 1 |
779439 Pump Gp-Dual Propel-Part 1 Of 2*R
| 07***39 | Pump Group-Dual Propel | 1 |
773622 Track As
| 07***22 | Track As | 1 |
7x9849 Track & Frame Gp-Lh
| 7X***49 | Track As-Lh | 1 |
7x9850 Track & Frame Gp-Rh
| 7X***50 | Track As-Rh | 1 |
7x9814 Track Drive Gp
| 7X***14 | Track Drive Group | 1 |
Screed
1c4320 Actuator As
| 1C***20 | Actuator As; S/N 6ad147-Up | 1 |
7x9811 Auger Gp
| 7X***11 | Auger Group | 1 |
819431 Cylinder As
| 08***31 | Cylinder As-Hydraulic | 1 |
776064 Jack As
| 07***64 | Jack As | 1 |
9n7315 Kit-Screed Jack
| 1C***20 | Actuator As; S/N 6ad147-Up | 2 |
| 9N***15 | Kit-Screed Jack | 1 |
| 9N***87 | Harness | 2 |
982340 Motor Gp
| 09***40 | Motor Group-Hydraulic | 1 |
780381 Motor Gp
| 07***81 | Motor Group-Hydraulic; S/N 6ad1-264 | 1 |
8c0099 Plate Gp-Screed Cut Off
| 8C***99 | Plate Group-Screed Cutoff | 1 |
7r6732 Screed Cut Off Plate Gp
| 7R***32 | Plate Group-Screed Cutoff | 1 |
7x9812 Screed Gp-Part 1 Of 3
| 7X***12 | Screed Group | 1 |
7x9812 Screed Gp-Part 3 Of 3
| 7X***12 | Screed Group | 1 |
7x9812 Screed Gp-Part 2 Of3
| 7X***12 | Screed Group | 1 |
7x9812 Screed Gp-Part 2 0f 3
| 7X***12 | Screed Group | 1 |
822635 Valve Gp
| 08***35 | Valve Group | 1 |
822633 Valve Gp-Screed Vibrating
| 08***33 | Valve Group-Selector | 1 |
Service Equipment And Supplies
Hardware Chart-Part 2 Of 2
| 7H***00 | Chart-Hardware | 1 |
Hardware Chart-Part 1 Of 2
| 7H***00 | Chart-Hardware | 1 |
0-Ring Chart
| 7R***00 | Chart-O-Ring | 1 |
7r5549 Film Gp
| 7R***49 | Film Group | 1 |
7x9818 Finish Gp-Part 1 Of 2
| 07***84 | Mixer; (Air) | 2 |
| 07***34 | Film-Caution | 1 |
| 07***14 | Regulator | 1 |
7r6712 Finish Gp
| 7R***49 | Film Group | 1 |
| 7R***50 | Tank & Burner Group-Screed | 1 |
| 7R***51 | Lines Group-Spray Down | 1 |
7x9818 Finish Gp-Part 2 Of 2
| 00***33 | Tee-Pipe | 1 |
| 07***58 | Trim, Molding 1/8" | 1 |
| 07***97 | Valve; (Torch) | 2 |
7r6716 Kit-Engine Mount
| 7R***16 | Kit-Engine Mount | 1 |
817904 Kit-Muffler
| 07***96 | Muffler | 1 |
| 07***72 | Clamp | 1 |
| 07***35 | Gasket | 1 |
8c0100 Seat Gp-Dual Operators
| 8C***00 | Seat Group-Dual Operators | 1 |
7x9820 Shipping Gp
| 5P***00 | Key Total 2 Pieces Per Unit; (Literature Compartment) | 1 |
| 5P***01 | Padlock (Use 5p***00 Key) | 1 |
| 6V***74 | Cover-Padlock (Not Part Of This Group) | 1 |
Starting And Electrical System
7r0040 Box As-Control
| 7R***40 | Box As-Control | 1 |
869290 Box As-Control
| 08***90 | Box As-Control | 1 |
7x9817 Electrical Gp
| 7X***17 | Electrical Group | 1 |
7x8284 Kit-Neutral Start
| 7X***84 | Kit-Neutral Start | 1 |
9g7641 Switch Gp-Start
| 9G***41 | Switch Group-Start; -Engine, Key-Vims Service | 1 |
Steering
869940 Control Gp-Steering
| 08***40 | Control Group-Steering | 1 |
AP-200 serial number reference
On the AP-200, the PIN/serial plate is a riveted metal tag mounted on the paver's main frame near the operator's station (tractor unit), not on the screed. The plate reads as a 3-character prefix (identifies the model/build series) followed by a sequential unit number; for this model the prefix is 6AD, e.g. 6AD00512.
| Prefix | Identifies | Notes |
|---|---|---|
| 6AD | AP-200 asphalt paver (base/only known series) | Only serial prefix documented for the AP-200 track paver. Parts and operation/maintenance literature is issued as 6AD1-and-up with no separate lower- or upper-bound cutoff found, consistent with a single production run. Engine fitment is not reliably documented for this prefix - do not assume a specific engine without checking the data plate. Plant/region code is not documented. Used-equipment listings place production in the mid-to-late 1980s (a 1988-built unit is documented), but treat exact build year as approximate and confirm against the full PIN. The later AP-200B is a separate model with its own distinct serial prefix, not part of this range. |
Frequently asked questions
What engine does the Caterpillar AP-200 use?
A small air-cooled 2-cylinder diesel rated about 26 kW (35 hp) gross, roughly 1,626 cc, mechanically governed with no electronic controls. Documentation varies on branding, with some sources pointing to a Deutz F2L511 and others to a Hatz 2M40; both are air-cooled 2-cylinder diesels of similar output, so confirm the exact engine from the machine's data plate before ordering engine parts.
What is the operating weight of the Caterpillar AP-200?
About 4,080 kg (8,995 lb) with the screed attached, in its base compact-paver configuration.
What replaced the Caterpillar AP-200?
No direct, documented one-to-one successor exists for this exact prefix and generation. Caterpillar's later paver lines moved to larger, electronically controlled machines, but no confirmed successor model carries the AP-200's lineage forward. Verify current cross-reference options with your dealer.
What AP-200 owners discuss
What causes overheating on the AP-200's Deutz F2L511 engine, and how do owners keep it in check?
Why is the AP-200 hard to start in cold weather, and what do operators do about it?
The engine surges or hunts at idle - what's usually wrong?
The paver's Deutz engine won't run, or dies right after starting - what should be checked first?
What wears out first on the feeder system (auger and conveyor)?
What about the screed and undercarriage - anything specific to watch on this class of paver?
What should a buyer check before purchasing a used AP-200?
Compiled from owner and technician discussions across the industry — experiences vary by serial range and machine history.
Need a specific AP-200 part?
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