Installing the 342-2683 Machine Enclosure Seal Kit (DEBRIS BARRIER){7000} Caterpillar

Installing the 342-2683 Machine Enclosure Seal Kit (DEBRIS BARRIER){7000}

Usage:

256C DWS

Compact Track Loader:: 279C (S/N: MBT1-UP)
Multi Terrain Loader:: 277C (S/N: JWF1-UP)
Skid Steer Loader:: 246C (S/N: JAY1-UP); 256C (S/N: DWS1-UP)

Introduction

ReferenceOperation and Maintenance, SEBU8019, "246C, 256C, 262C, and 272C Skid Steer Loaders"

ReferenceOperation and Maintenance, SEBU8020, "277C, 287C, and 297C Multi Terrain Loaders"

ReferenceOperation and Maintenance, SEBU8407, "279C, 289C, and 299C Compact Track Loaders"

This Special Instruction provides the information needed for installing the 342-2683 Machine Enclosure Seal Kit (DEBRIS BARRIER) on the machines above. The kit contains seals, covers, and brushes designed to cover the openings that exist between the frame and the body of the machines. These components prevent wood chips and other materials from entering the engine compartment and the lower frame.

Caterpillar requires the use of the 312-1024 Engine Enclosure Kit and the 272-3062 Debris Guard Kit with the 342-2683 Machine Enclosure Seal Kit (DEBRIS BARRIER) for proper function of the machine systems. Refer to Table 1 for the proper debris guard kit.

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Table 1
Debris Guard Kits
Part Number	Sales Model	Prefix	Serial Number
272-3062	277C	S/N:JWF	S/N:1-1713
272-3062	246C	S/N:JAY	S/N:1-2576
272-3062	256C	S/N:DWS	S/N:1-1304
280-8392	277C	S/N:JWF	S/N:1714-Up
280-8392	246C	S/N:JAY	S/N:2577-Up
280-8392	256C	S/N:DWS	1305-Up

The cover assemblies that are provided in this kit are fabricated from a material that is polyester. The polyester is coated with vinyl. The cover assemblies utilize hook and loop fasteners. Double-sided tape attaches the hook and loop fasteners to the machine. After the adhesive on the tape has cured, you can remove the cover assemblies and you can reinstall the cover assemblies, as needed.

Note: Some of the components in this kit utilize adhesive strips and adhesive backing as the means for attaching the component. The mounting surface for these components should be clean and free of grease to ensure proper adhesion. Use a cleaning solvent or a standard degreaser in order to remove grease and oil from the surface. Then, wipe the mounting surface with alcohol and allow the surface to dry completely before applying the adhesive.

Note: The adhesive in this kit will take 24 hours in order to cure. Once the adhesive is correctly placed on the mounting surface, the adhesive must not be disturbed for 24 hours.

Do not perform any procedure outlined in this publication until you read the information and understand the information contained in this document.

Parts Information

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Illustration 1	g02069253

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Table 2
Parts List
Item	Quantity	Part Number	Description
1	36	3E-8020	Screw
2	12	5P-4116	Hard Washer
3	1	5P-7482	Seal ⁽¹⁾ ⁽²⁾ ⁽³⁾
4	14	6V-7357	Bolt
5	72	6V-7743	Locknut
6	8	6V-9189	Locknut
7	88	8T-4205	Hard Washer
8	4	8T-7547	Bolt
9	14	9X-2045	Screw
10	1	125-3518	Seal ⁽⁴⁾
11	4	127-2170	Screw
12	1	132-8502	Seal ⁽⁵⁾
13	1	5P-0805	Seal ⁽⁶⁾
14	1	308-7536	Cover As
15	1	309-1926	Bracket As
16	1	309-1927	Bracket As
17	4	309-1936	Brush Guard As
18	1	309-2477	Hood As
19	1	342-7192	Plate As
20	1	342-7193	Plate As
21	2	343-3127	Plate ⁽⁷⁾
22	1	346-3588	Plate
23	1	347-4590	Gasket
24	1	347-4591	Gasket
25	1	347-4593	Plate
26	1	347-4595	Plate
27	1	347-7277	Plate
28	2	348-6918	Plate As
29	1	348-6919	Plate As
30	1	348-6920	Plate As
31	2	348-6921	Plate
32	1	348-6926	Plate As
33	1	348-6927	Plate As
34	1	348-7304	Gasket
35	1	348-7305	Plate
36	1	349-4237	Gasket
37	1	349-4238	Gasket
38	1	349-4239	Gasket
39	1	349-4240	Plate
40	1	349-4241	Plate
41	1	349-4242	Plate
42	1	349-4243	Plate
43	4	349-4403	Brush Guard As
44	2	349-8724	Brush Assembly
45	1	349-9133	Plate ⁽⁸⁾
46	2	352-8700	Plate

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^( 1 )	Nonserviceable item
^( 2 )	Order 5P-7483 Seal for service
^( 3 )	80 cm (31.5 inch)
^( 4 )	50 cm (20.0 inch)
^( 5 )	193 cm (76.0 inch)
^( 6 )	17 dm (66.9 inch)
^( 7 )	Use on the 277C Multi Terrain Loader and the 279C Compact Track Loader only
^( 8 )	Use on machines without HVAC only

Installation Instructions

Installing the 5P-7482 Seal

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Illustration 2	g02069713
Profile of the 5P-7482 Seal

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Illustration 3	g02069737

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Illustration 4	g02069773
Detail A

Install 5P-7482 Seal onto the bottom edge of the plate (47) .

Installing the 132-8502 Seal

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Illustration 5	g02069893
Profile of the 132-8502 Seal

Cut two lengths of seal (12) per the lengths that are specified in Table 3.
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Table 3
132-8502 Seal

Item Length

12A
1065 mm (41.9 inch)

12B
865 mm (34.1 inch)

Table 3
132-8502 Seal
Item	Length
12A	1065 mm (41.9 inch)
12B	865 mm (34.1 inch)

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Illustration 6	g02069942
Left side view from the front of the machine (48) Plate (49) Plate

Leave the cab tilted downward. Mark the top edge of plate (49) that corresponds to the front edge of the plate (48) for the canopy. See Illustration 6.
Mark plate (50) on the right side of the machine in the same manner.

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Illustration 7	g02069953
Left side view from the front of the machine (12A) 1065 mm (41.93 inch) length of 132-8502 Seal (49) Plate

Tilt the cab upward. Make sure that the cab support lever is ENGAGED.
Refer to Operation and Maintenance, "Cab Tilting".
Install seal (12A) onto the inside edge of the plate, as shown. See Illustration 7.
Use a rubber mallet to fully seat the seal against the edge of the plate.
Note: Start installing the seal at your marked location on the top edge of plate (49) .

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Illustration 8	g02070014
Right side view at the front of the machine (12B) 865 mm (34.06 inch) length of 132-8502 Seal (50) Plate

Install seal (12B) on the inside edge of plate (50), as shown. See Illustration 8.
Use a rubber mallet to fully seat the seal against the edge of the plate.
Note: Start installing the seal at your marked location on the top edge of plate (50) .

Installing the 343-3127 Plate

Note: This segment applies to the 277C Multi Terrain Loader and 279C Compact Track Loader only.

Tilt the cab upward. Make sure that the cab support lever is ENGAGED.
Refer to Operation and Maintenance, "Cab Tilting".

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Illustration 9	g02070613

Place 343-3127 Plate (21) onto the long side of the opening in the top of machine frame (51) .

Mark the location of the bolt hole on the top of the frame.

Drill a 8.0 mm (0.315 inch) hole in the top of the frame.

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Illustration 10	g02070636

Secure 343-3127 Plate (21) to frame (51) with 6V-7357 Bolt (4), 6V-7743 Locknut (5), and two 8T-4205 Hard Washers (7). Tighten 6V-7743 Locknut (5) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

Repeat Step 2 through Step 5 for the opposite side of the machine.

Installing 342-7192 Plate As and 342-7193 Plate As

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Illustration 11	g02070759

Remove two screws (53) from the machine in order to remove duct (52). Retain two screws (53) and duct (52) .

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Illustration 12	g02070797

Remove two screws (53) from the machine in order to remove duct (52). Retain two screws (53) and duct (52) .

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Illustration 13	g02070914

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Illustration 14	g02071077
342-7192 Plate As

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Illustration 15	g02071133
View B

Locate 342-7192 Plate As (19) at the location that is shown in Illustration 15. Locate the tab that is shown in Illustration 14 on the bottom edge of the cab.

Mark the hole locations that are in 342-7192 Plate As (19) on the machine.

Drill three 8.0 mm (0.315 inch) holes into the machine.

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Illustration 16	g02071216

Secure 342-7192 Plate As (19) to the machine with three 6V-7743 Locknuts (5), three 8T-4205 Hard Washers (7), and three 9X-2045 Screws (9). Tighten three 6V-7743 Locknuts (5) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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Illustration 17	g02071274

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Illustration 18	g02071276
342-7193 Plate As

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Illustration 19	g02071416

Locate 342-7193 Plate As (20) at the location that is shown in Illustration 19. Locate the tab that is shown in Illustration 18 on the bottom edge of the cab.

Mark the hole locations that are in 342-7193 Plate As (20) on the machine.

Drill three 8.0 mm (0.315 inch) holes into the machine.

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Illustration 20	g02071275

Secure 342-7193 Plate As (20) to the machine with three 6V-7743 Locknuts (5), three 8T-4205 Hard Washers (7), and three 9X-2045 Screws (9). Tighten three 6V-7743 Locknuts (5) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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Illustration 21	g02071476

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Illustration 22	g02071513

Remove harness (54) from horn (57). Loosen nut (56). Turn horn (57) so that the connector is pointed to the outside of the machine and angled downward at a 45 degree angle.

Tighten nut (56) to a torque of 18 ± 2 N·m (13 ± 1 lb ft).

Route harness (54) on the inside of plate (55). Connect harness (54) to horn (57) .

Installing the 125-3518 Seal

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Illustration 23	g02069795
Profile of the 125-3518 Seal

Cut two lengths of 125-3518 Seal (10) per the lengths that are specified in Table 4.
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Table 4
125-3518 Seal

Item Length

10A
25 cm (10 inch)

10B
25 cm (10 inch)

Table 4
125-3518 Seal
Item	Length
10A	25 cm (10 inch)
10B	25 cm (10 inch)

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Illustration 24	g02069798
(10A) 125-3518 Seal

Note: Ensure that the mounting surface is clean and free of grease before you install this seal.

Install seal (10A). Install the seal by removing the protective paper strip from the adhesive and by pressing the insulation in position. Start by placing the end of the seal against the firewall. Then, follow the contour of the frame forward, as shown. See Illustration 24.

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Illustration 25	g02069799
(10B) 125-3518 Seal

Note: Ensure that the mounting surface is clean and free of grease before you install this seal.

Install seal (10B). Install the seal by removing the protective paper strip from the adhesive and by pressing the insulation in position. Start by placing the end of the seal against the firewall. Then, follow the contour of the frame forward, as shown. See Illustration 25.

Install 346-3588 Plate and 347-7277 Plate

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Illustration 26	g02071975

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Illustration 27	g02071978
View E

Remove three screws (58), three washers (59), and three nuts (60) from the machine. Discard three screws (58), three washers (59), and three nuts (60) .
Note: Proceed to Step 6 for machines that have HVAC.

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Illustration 28	g02072093

Place 349-9133 Plate (45) onto 346-3588 Plate (22) .

Mark the location of the two slots that are in 349-9133 Plate (45) onto 346-3588 Plate (22) .

Drill two 8.0 mm (0.315 inch) holes into 346-3588 Plate (22) .

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Illustration 29	g02072133

Secure 349-9133 Plate (45) onto 346-3588 Plate (22) with two 6V-7743 Locknuts (5), four 8T-4205 Hard Washers (7), and two 9X-2045 Screws (9). Tighten two 6V-7743 Locknuts (5) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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Illustration 30	g02072140

Secure 349-8724 Brush Assembly (44) onto 346-3588 Plate (22) with two 5P-4116 Hard Washers (2), two 6V-9189 Locknuts (6) and two 127-2170 Screws (11). Tighten two 6V-9189 Locknuts (6) to a torque of 15 ± 3 N·m (11 ± 2 lb ft).

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Illustration 31	g02072163

Secure 346-3588 Plate (22) to the machine with three 6V-7743 Locknuts (5), three 8T-4205 Hard Washers (7), and three 9X-2045 Screws (9). Tighten three 6V-7743 Locknuts (5) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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Illustration 32	g02072214

Secure 349-8724 Brush Assembly (44) to 347-7277 Plate (27) with two 5P-4116 Hard Washers (2), two 6V-9189 Locknuts (6), and two 127-2170 Screws (11). Tighten two 6V-9189 Locknuts (6) to a torque of 15 ± 3 N·m (11 ± 2 lb ft).

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Illustration 33	g02072335

Secure 347-7277 Plate (27) to the machine with three 6V-7743 Locknuts (5), three 8T-4205 Hard Washers (7), and three 9X-2045 Screws (9). Tighten three 6V-7743 Locknuts (5) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

Lower the cab and tighten the bolts for the ROPS. Refer to Operations and Maintenance Manual, "Cab Tilting, Tilting the Cab Downward".

Installing the Protection for the Lift Cylinder Tower on the Left Side of the Machine

Raise the lift arms and engage the brace for the lift arm. Refer to Operations and Maintenance Manual, "Loader Lift Arm Brace Operation, Engage the Lift Arm Brace".

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Illustration 34	g02072374

Secure two 6V-7357 Bolts (4) and two 8T-4205 Hard Washers (7) onto 348-6918 Plate As (28). Hand tighten two 6V-7357 Bolts (4) .

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Illustration 35	g02072693

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Illustration 36	g02072495
View F The outer plate for the tower assembly has been removed for clarity.

Secure 348-6918 Plate As (28) onto plate (61). Tighten two 6V-7357 Bolts (4) to a torque of 6 ± 1 N·m (53 ± 9 lb in). Make sure that the tab on 348-6918 Plate As (28) is in contact with plate (61) .

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Illustration 37	g02072613

Secure two 6V-7357 Bolts (4) and 8T-4205 Hard Washers (7) onto 348-6920 Plate As (30). Hand tighten two 6V-7357 Bolts (4) .

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Illustration 38	g02072756

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Illustration 39	g02072793
View G The outer plate for the tower assembly has been removed for clarity.

Secure 348-6920 Plate As (30) onto plate (62). Make sure that the tab on 348-6920 Plate As (30) is in contact with plate (62). Tighten two 6V-7357 Bolts (4) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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Illustration 40	g02072837

Secure two 6V-7357 Bolts (4) and two 8T-4205 Hard Washers (7) onto 348-6919 Plate As (29). Hand tighten two 6V-7357 Bolts (4) .

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Illustration 41	g02072853

Secure two 349-4403 Brush Guard As (43) to 348-6919 Plate As (29) with four 6V-7743 Locknuts (5) and four 8T-4205 Hard Washers (7). Tighten four 6V-7743 Locknuts (5) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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Illustration 42	g02073174
The outer plate for the tower assembly has been removed for clarity.

Secure 348-6919 Plate As (29) to plate (62). Make sure that the tab on 348-6919 Plate As (29) is in contact with plate (62). Make sure that the slots on 348-6919 Plate As (29) are over the studs on 348-6920 Plate As (30). Tighten two 6V-7357 Bolts (4) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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Illustration 43	g02073175
The outer plate for the tower assembly has been removed for clarity.

Secure 352-8700 Plate (46) onto the studs that are located on 348-6920 Plate As (30) with two 6V-7743 Locknuts (5) and two 8T-4205 Hard Washers (7). Tighten two 6V-7743 Locknuts (5) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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Illustration 44	g02073176
The outer plate for the tower assembly has been removed for clarity.

Secure 348-6921 Plate (31) to the studs on 348-6918 Plate As (28) and the studs on 348-6920 Plate As (30) with four 6V-7743 Locknuts (5) and four 8T-4205 Hard Washers (7). Tighten four 6V-7743 Locknuts (5) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

Installing the Protection for the Lift Cylinder Tower on the Right Side of the Machine

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Illustration 45	g02073458

Secure two 6V-7357 Bolts (4) and two 8T-4205 Hard Washers (7) onto 348-6918 Plate As (28). Hand tighten two 6V-7357 Bolts (4) .

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Illustration 46	g02072554

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Illustration 47	g02073436
View H The outer plate for the tower assembly has been removed for clarity.

Secure 348-6918 Plate As (28) onto plate (63). Tighten two 6V-7357 Bolts (4) to a torque of 6 ± 1 N·m (53 ± 9 lb in). Make sure that the tab on 348-6918 Plate As (28) is in contact with plate (63) .

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Illustration 48	g02073495

Secure two 6V-7357 Bolts (4) and two 8T-4205 Hard Washers (7) onto 348-6927 Plate As (33). Hand tighten two 6V-7357 Bolts (4) .

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Illustration 49	g02073756

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Illustration 50	g02073757
View J The outer plate for the tower assembly has been removed for clarity.

Secure 348-6927 Plate As (33) onto plate (64). Make sure that the tab on 348-6927 Plate As (33) is in contact with plate (64). Tighten two 6V-7357 Bolts (4) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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Illustration 51	g02073801

Secure two 6V-7357 Bolts (4) and two 8T-4205 Hard Washers (7) onto 348-6926 Plate As (32). Hand tighten two 6V-7357 Bolts (4) .

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Illustration 52	g02073914

Secure two 349-4403 Brush Guard As (43) to 348-6926 Plate As (32) with four 6V-7743 Locknuts (5) and four 8T-4205 Hard Washers (7). Tighten four 6V-7743 Locknuts (5) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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Illustration 53	g02073975
The outer plate for the tower assembly has been removed for clarity.

Secure 348-6926 Plate As (32) to plate (65). Make sure that the tab on 348-6926 Plate As (32) is in contact with plate (65). Make sure that the slots on 348-6926 Plate As (32) are over the studs on 348-6927 Plate As (33). Tighten two 6V-7357 Bolts (4) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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Illustration 54	g02074493
The outer plate for the tower assembly has been removed for clarity.

Secure 352-8700 Plate (46) onto the studs that are located on 348-6927 Plate As (33) with two 6V-7743 Locknuts (5) and two 8T-4205 Hard Washers (7). Tighten two 6V-7743 Locknuts (5) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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Illustration 55	g02074537
The outer plate for the tower assembly has been removed for clarity.

Secure 348-6921 Plate (31) to the studs on 348-6918 Plate As (28) and the studs on 348-6927 Plate As (33) with four 6V-7743 Locknuts (5) and four 8T-4205 Hard Washers (7). Tighten four 6V-7743 Locknuts (5) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

Installing the 309-1936 Brush Guard As and the 308-7537 Cover As

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Illustration 56	g02074695
Profile of the 5P-0805 Seal (13)

Cut two 809 ± 5 mm (32 ± 0.2 inch) lengths of 5P-0805 Seal (13) .

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Illustration 57	g02074696

Install one 809 ± 5 mm (32 ± 0.2 inch) length of 5P-0805 Seal (13) on the bottom of 309-1926 Bracket As (15) and 309-1927 Bracket As (16) .

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Illustration 58	g02074697

Place 309-1927 Bracket As (16) on the top plate of the right tower, as shown. See Illustration 58.
Mark the location of the two mounting holes onto the top plate of the tower. Then, remove 309-1927 Bracket As (16) .
Note: The 309-1926 Bracket As (15) is used on the top plate of the left tower.

Drill two 6.7 mm (0.270 inch) holes into the plate. Then, tap both of the holes with a M8 x 1.25 THD tap.

Again, place bracket (19) on the top plate of the right tower. See Illustration 58.

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Illustration 59	g02074698

Place 309-1936 Brush Guard As (17) over 309-1927 Bracket As (16). Align the mounting holes with the holes that were drilled and tapped in the top plate of the tower. Secure 309-1936 Brush Guard As (17) and 309-1927 Bracket As (16) to the tower plate with two 8T-7547 Bolts (8) and two 5P-4116 Hard Washers (2) .
Tighten two 8T-7547 Bolts (8) to a torque of 15 ± 3 N·m (11 ± 2 lb ft).

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Illustration 60	g02074700
(8) 309-1936 Brush Guard As (15) 5P-4116 Hard Washer (18) 6V-9189 Locknut

Place 309-1936 Brush Guard As (17) onto the studs on 309-1927 Bracket As (16). Secure 309-1936 Brush Guard As (17) to 309-1927 Bracket As (16) with two 6V-9189 Locknuts (6) and two 5P-4116 Hard Washers (2) .
Tighten two 6V-9189 Locknuts (6) to a torque of 15 ± 3 N·m (11 ± 2 lb ft).

Repeat Step 3 through Step 7 in order to install the 309-1936 Brush Guard As and the 309-1926 Cover As on the left tower.

Installing the 308-7536 Cover As

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Illustration 61	g02075333
Shape of the 308-7536 Cover As (14)

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Illustration 62	g02075334
Pictorial view of the 308-7536 Cover As (14)

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Illustration 63	g02075353
(14) 308-7536 Cover As

Note: Ensure that the mounting surface is clean and free of grease before you install this cover.

Install 308-7536 Cover As (14). Place the cover on the machine in the position that is shown in Illustration 63.
Remove the protective paper strip from the tape strip on edge (D) and press the tape strip in position. Repeat this task for the tape strip on edges (B), edges (A), and edge (C) .
Note: Do not remove the protective paper strip from more than one tape strip at a time in order to avoid contamination of the adhesive.

Installing the 309-2477 Hood As

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Illustration 64	g02075440

Position 309-2477 Hood As (18) on the radiator guard (65) over the muffler exhaust pipe. Align the front and side edges of 309-2477 Hood As (18) with the front and side edges of the radiator guard (65). Refer to Illustration 64.

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Illustration 65	g02075442

Mark the location of the four mounting holes in 309-2477 Hood As (18) onto the radiator guard (65). Remove 309-2477 Hood As (18). Then, drill four 8.0 mm (0.315 inch) holes into the radiator guard (65) .

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Illustration 66	g02075573

Secure 309-2477 Hood As (18) to the radiator guard (65) with four 6V-7357 Bolts (4), eight 8T-4205 Hard Washers (7), and four 6V-7743 Locknuts (5) .
Tighten four 6V-7357 Bolts (4) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

Installing the Cooling Pack Seals

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Illustration 67	g02075693

Position 347-4595 Plate (26) on the left side of radiator guard (65). Align the outer edge of 347-4595 Plate (26) with the side of radiator guard (65) and the rear edge of 347-4595 Plate (26) with the rear edge of 309-2477 Hood As (18) .

Mark the position of the four mounting holes that are located in 347-4595 Plate (26) on radiator guard (65). Remove 347-4595 Plate (26). Drill four 8.0 mm (0.315 inch) holes into the radiator guard (65) .

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Illustration 68	g02076193

Position 347-4593 Plate (25) on the right side of radiator guard (65). Align the outer edge of 347-4593 Plate (25) with the side of radiator guard (65). Then align with the rear edge of 347-4593 Plate (25) with the rear edge of radiator guard (65) .

Mark the position of the four mounting holes that are located in 347-4593 Plate (25) on radiator guard (65). Remove 347-4593 Plate (25). Drill four 8.0 mm (0.315 inch) holes into radiator guard (65) .

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Illustration 69	g02076235

Clamp 347-4593 Plate (25) and 347-4595 Plate (26) into position on radiator guard (65). Position 348-7305 Plate (35) onto radiator guard (65). Align the rear edge of 348-7305 Plate (35) with the bottom of 347-4593 Plate (25) and 347-4595 Plate (26) .

Mark the position of the four mounting holes that are located in 348-7305 Plate (35) on radiator guard (65). Remove the three plates. Drill four 8.0 mm (0.315 inch) holes into radiator guard (65) .

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Illustration 70	g02076316

Install 347-4593 Plate (25), 347-4595 Plate (26), 348-7305 Plate (35), 347-4590 Gasket (23), 347-4591 Gasket (24), and 348-7304 Gasket (34) with 12 3E-8020 Screws (1), 12 6V-7743 Locknuts (5), and 12 8T-4205 Hard Washers (7). Tighten 12 3E-8020 Screw (1) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

Installing the Rear Door Seals

Note: Proper function of the cooling system and the machine enclosure seal kit, requires use of 312-1024 Engine Enclosure Kit or an equivalent modified rear door. Refer to Special Instruction, REHS4079, "Installing the 312-1024 Engine Enclosure Kit".

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Illustration 71	g02076388

Open door (66) at the rear of the machine. Remove bolt (72), washer (73), and nut (74) from filter (75). Retain bolt (72), washer (73), and nut (74). Remove two wires (71) from filter (75) .

Remove two nuts (69) and two bolts (70) from bracket (68). Retain two nuts (69) and two bolts (70). Remove hose (67) from bracket (68) .

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Illustration 72	g02076713

Remove four bolts (76), four washers (77), and four nuts (78) from bracket (80). Retain four bolts (76), four washers (77), and four nuts (78). Remove coolant recovery bottle (79) from bracket (80). Support coolant recovery bottle (79) .

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Illustration 73	g02076773

Remove three bolts (72) and three washers (73) from bracket (81). Retain three bolts (72) and three washers (73). Remove filter (75) from bracket (81). Support filter (75) .

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Illustration 74	g02076934

Support door (66). Remove two bolts (82) from door (66). Retain two bolts (82). Remove door (66). Place door (66) on a flat surface.

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Illustration 75	g02077004

Align 349-4241 Plate (40) along the edge of door (66). Align 349-4241 Plate (40) along the bottom of door (66). Clamp 349-4241 Plate (40) in place. Bend the top section of 349-4241 Plate (40) so that 349-4241 Plate (40) contacts door (66). Clamp 349-4241 Plate (40) into place.

Mark the location of the nine mounting holes that are located in 349-4241 Plate (40) onto door (66). Remove 349-4241 Plate (40) from door (66). Drill nine 8.0 mm (0.315 inch) holes into door (66) .

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Illustration 76	g02077077

Align 349-4243 Plate (42) along the edge of door (66). Align 349-4243 Plate (42) along the bottom of door (66). Clamp 349-4243 Plate (42) in place. Bend the top section of 349-4243 Plate (42) so that 349-4243 Plate (42) contacts door (66). Clamp 349-4243 Plate (42) into place.

Mark the location of the three mounting holes that are located in 349-4243 Plate (42) onto door (66). Remove 349-4243 Plate (42) from door (66). Drill three 8.0 mm (0.315 inch) holes into door (66) .

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Illustration 77	g02077158

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Illustration 78	g02077136
Area K (A) 146 mm (5.748 inch)

Measure 146 mm (5.748 inch) from the top hole in 349-4243 Plate (42) toward the top of the door (66) and mark the location. Place 349-4242 Plate (41) in the location that is shown in Illustration 78. Make sure that the center of the location hole in 349-4242 Plate (41) is 146 mm (5.748 inch) from the center of the location hole in 349-4243 Plate (42). Also make sure that 349-4242 Plate (41) is flush with the edge of door (66) .

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Illustration 79	g02077635

Clamp 349-4242 Plate (41) into place on door (66). Bend the top edge of 349-4242 Plate (41) so that 349-4242 Plate (41) is in contact with door (66). Mark the location of the three mounting holes in 349-4242 Plate (41) onto the door. Drill three 8.0 mm (0.315 inch) holes into door (66) .

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Illustration 80	g02077656

Install 349-4241 Plate (40) and 349-4237 Gasket (36) with eight 3E-8020 Screws (1), eight 6V-7743 Locknuts (5), and eight 8T-4205 Hard Washers (7). Tighten 12 3E-8020 Screws (1) to a torque of 6 ± 1 N·m (4.4 ± 0.7 lb ft). Do not put the hardware in the bottom hole.

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Illustration 81	g02077960

Install 349-4242 Plate (41), 349-4243 Plate (42), and 349-4238 Gasket (37) with five 3E-8020 Screws (1), five 6V-7743 Locknuts (5), and five 8T-4205 Hard Washers (7). Tighten five 3E-8020 Screws (1) to a torque of 6 ± 1 N·m (4.4 ± 0.7 lb ft). Do not put the hardware in the bottom hole.

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Illustration 82	g02078293

Align the bottom edge of 349-4240 Plate (39) with the bottom edge of door (66). Secure one end of 349-4240 Plate (39) to door (66) and 349-4241 Plate (40) with 3E-8020 Screw (1), 6V-7743 Locknut (5), and 8T-4205 Hard Washer (7). Bend 349-4240 Plate (39) so that 349-4240 Plate (39) contacts door (66). Secure other end of 349-4240 Plate (39) to door (66) and 349-4243 Plate (42) with 3E-8020 Screw (1), 6V-7743 Locknut (5), and 8T-4205 Hard Washer (7) .

Mark the location of five mounting holes that are located in 349-4240 Plate (39) onto door (66). Remove 349-4240 Plate (39) from door (66). Drill five 8.0 mm (0.315 inch) holes into door (66) .

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Illustration 83	g02078394

Secure 349-4240 Plate (39) and 349-4239 Gasket (38) to door (66) with seven 3E-8020 Screws (1), seven 6V-7743 Locknuts (5), and seven 8T-4205 Hard Washers (7). Tighten seven 3E-8020 Screws (1) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

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Illustration 84	g02078473

Use a suitable lifting device in order to install door (66). Place door (66) in place at the rear of the machine and install two bolts (82) .

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Illustration 85	g02078513

Secure wire (71) to the machine with bolt (72), washer (73), and nut (74). Secure filter (75) onto bracket (81) with three bolts (72) and three washers (73) .