CONTROL G 4D5800 - Caterpillar

Introduction
This Special Instruction gives a procedure for installing oil baffles in the 6WD transfer gearbox to prevent overheating. The baffles are installed in the bottom of the gearbox to keep the oil away from the gears. This Special Instruction applies to D250B and D300B Articulated Trucks with 5U-6200, 7U-2283 and 7U-1371 Transfer Gearbox Groups only. The baffles should not be installed on machines with the 7U-7448 Transfer Gearbox Group. The 7U-7448 Transfer Gearbox Group has a larger oil capacity and overheating is not a problem.Do not perform any procedure outlined in this publication, or order any parts, until you read and understand the information contained in this Special Instruction.Necessary Parts
* Six 4B-1280 Screws* Fabricated baffle.Fabricating The Baffle
Illustration 1.
Dimensions for plate (1).
Illustration 2.
Dimensions for plate (2).1. Fabricate plate (1) and plate (2) from using the dimensions in Illustrations 1 and 2. Plates 1 and 2 should be fabricated from 3.0 mm (.12 in) thick mild steel.
Illustration 3.
Dimensions for plate (3).2. Fabricate plate (3) from 1.5 mm (.06 in) thick mild steel.
Illustration 4.
Baffle assembly (4).3. Fabricate baffle assembly (4) by welding plate (3) to plate (1) as shown in Illustration 4. Use a 1.5 mm (.06 in) fillet intermittent weld at Location (X). The intermittent weld should have a 7.0 mm (.28 in) long weld bead with 7.0 mm (.28 in) spaces between each weld.Gear Case Modification
1. Remove the transfer gearbox (splitter box) from the machine.2. Disassemble the transfer gearbox and inspect all parts. Pay special attention to the condition of the bearings. Replace any parts that show signs of excessive heat or wear.
Illustration 1.
Dimensions for additional holes in the gear case. Inner half is shown.3. Drill and tap three holes in each half of the gear case using the dimensions given in Illustration 1.2. Remove any debris and clean the gear case halves.Baffle Installation.
Baffle installation.1. Apply 9S-3263 or 4C-4030 Threadlock to the threads of the 4B-1280 Screws (5). Install baffle (4) in the inner half of the gear case using three 4B-1280 Screws.2. Install fabricated plate (2) in the outer half of the gear case using three 4B-1280 Screws (5).3. After the screws (5) have been tightened, use a chisel, punch or other suitable tool to push gear case material into the slots of the screws (5) as shown at location (B). This will help prevent the screws from coming loose.4. Install the lower gear and bearings in the transfer gear box and loosely assembly the transfer gearbox halves.5. Turn the gear to make sure it does not come in contact with the baffle. If the gear contacts the baffle, make adjustments to the baffle to provide clearance.6. After checking to make sure there is clearance between the baffle and lower gear, apply 6V-6640 Sealant to the joint for the transfer gearbox halves and completely assemble the transfer gearbox. Be sure to use new bolts and nuts when joining the transfer gearbox halves. When assembling the 7U-2283 and 7U-1371 Transfer Gearbox Groups, tighten the bolts using the torque/turn method.