PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE AUXILIARY MANIFOLD ON CERTAIN AP-1000D AND AP-1055D ASPHALT PAVERS Caterpillar

PROBLEM

AFFECTED PRODUCT

PARTS NEEDED

ACTION REQUIRED

OWNER NOTIFICATION

SERVICE CLAIM ALLOWANCES

PARTS DISPOSITION

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
        (2-Rework Procedure)
        (3-Part Request Form For Auxiliary Manifold)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

Dear Caterpillar Product Owner:

The auxiliary manifold needs to be replaced on the products listed below. The existing manifold may be missing a check valve which could allow the screed to move under certain conditions. Unexpected screed movement could result in personal injury or death.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated January 16, 2006 when scheduling this service. You will not be charged for the service performed.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Identification #(s)

Attached to January 16, 2006 Service Letter

The auxiliary valve manifold is located on the inside of the machine's back plate. These instructions apply to machine serial numbers FAC00200-208, A6P00100, and EAD00100.

1. Park the paver on level ground and lower the screed onto the ground. Remove pressure from the hydraulic lines connecting the tractor and the screed.

2. Put the machine in park, turn the engine off, and turn off the main power at the center console.

3. Remove the screed from the tractor (KENR 5048, "Screed - Remove and Install"). Separate the tractor and screed to access the cover plate for the auxiliary manifold.

4. Remove the cover plate on the tractor back plate. This will allow access to the connections at the bottom of the auxiliary manifold. The auger may have to be raised or lowered to remove the cover plate.

5. Prior to disassembly of any components, label each hydraulic hose and corresponding manifold port with the same number. For example, label the hose going into ALI port item "1" and also write "1" on the manifold at port ALI. Do this step for all hoses that connect to the manifold.

6. Disconnect all hoses from the manifold and remove the manifold from the machine's back plate by unthreading the four mounting bolts.

7. Referring to print 230-9603, remove all fittings from old manifold and place these items onto the new manifold. Replace ALL seal-o-rings on the fittings prior to fit-up on new manifold.

8. Remove the hose assembly 242-8929 and the screed assist pressure gage 8T-0855 from the old manifold and place these on the new manifold.

9. The port identities are stamped on the aluminum manifold housing. Viewing the old and new manifolds side by side, label the ports on the new manifold with the same numbers that were on the old manifold. This will be the easiest way to properly reconnect the hoses to the correct ports/fittings.

10. Mount the new manifold to the machine's back plate and reconnect all hoses according to the corresponding hose/port labels (match the labels).

11. Dispose of the old manifold. This manifold is incorrectly designed and cannot be modified to work as intended.

12. Re-attach the cover plate on the back of the paver.

13. Re-connect the screed to the tractor.

14. Verify that all auxiliary functions operate as expected.

Dealer Code: ______

Date ordered: __________

Ordered by: ____________________

Phone #: ____________________

Machine serial number: ________________

Ship to: __________________

__________________

__________________

Attn: __________________

Please indicate the quantity of each part required and fax this form to 763-493-7690. Parts will ship at no charge. Parts will ship ground transportation. For shipping or tracking information call Rita in Customer service at 763-493-7668.