24M Motor Grader Assembly Instruction (Split Shipping Configuration){7000, 7960} Caterpillar

24M Motor Grader Assembly Instruction (Split Shipping Configuration){7000, 7960}

Usage:

24M B9K

Motor Grader:: 24M (S/N: B9K1-UP)

Introduction

This special instruction contains the necessary procedures and information for the assembly of the 24M Motor Grader in the split shipping configuration.

Note: The illustrations in this publication are for illustrative purposes.

The suggested tools and equipment should be present before assembly. If the recommended tools and equipment are not present, assembly will be more difficult and more time will be necessary to complete the assembly.

Do not perform any procedures until you read the information that is contained in this manual. Do not order any parts until you have read the information and you understand the information that is contained in this manual.

Prepare the machine for use after you complete the assembly. Use the Parts Manual and the Service Manual with this instruction.

ReferenceService Manual, RENR9060, "24M (S/N: B9K1-UP) Motor Grader"

ReferenceParts Manual, SEBP4105, "24M (S/N: B9K1-UP) Motor Grader"

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Do not attempt to assemble this machine until you read and you understand the assembly instructions.

Improper assembly procedures could result in injury or death.

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NOTICE

Do not allow any dirt or foreign material to get into the hydraulic system during assembly, connection of lines, when components are filled with fluid, or during any maintenance operation.

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NOTICE

Clean all surfaces and remove burrs from all areas where parts are to be installed. Chase all tapped holes used for mounting purposes. Remove the paint from all contacting surfaces. This is necessary for a good solid joint.

Parts List

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Table 1
Required Parts for Installation of the 252-0981 Articulating Hitch Gp ⁽¹⁾
Qty	Part Number	Description
1	271-1421	Pin
1	117-2026	Shim Pack
1	117-2025	Shim Pack
4	8T-4193	Bolt
4	9X-8257	Washer

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Required parts are shipped inside the cab.

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Table 2
Required Parts for Installation of the 8X-8994 Platform Mounting Gp ⁽¹⁾
Qty	Part Number	Description
12	137-6617	Mount As
4	125-6875	Washer
4	2J-8937	Pin
4	4F-0255	Pin
4	3B-4626	Cotter Pin
6	137-6627	Sleeve
2	8C-8478	Bolt
10	8T-4123	Washer
6	9W-6584	Washer
2	140-8465	Plate
4	7X-2488	Bolt
6	8T-4131	Nut

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Required parts are shipped inside the cab.

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Table 3
Required Parts for Installation of the 253-3993 Air Cleaner Gp ⁽¹⁾
Qty	Part Number	Description
2	245-3816	Air Cleaner Cap

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Required parts are shipped inside the cab.

Approximate Weights

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Personal injury or death can result from lifting a heavy assembly.
The heavy assembly can fall if using an incorrect hoist to lift the load.

Be sure the hoist has the correct capacity to lift a heavy assembly. Approximate weight of the assembly is given below.

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Personal injury or death can result from improper lifting or blocking.
When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.

Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

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Table 4
Item	Specification
Front half of the Chassis	22680 kg (50000 lb)
Rear half of the Chassis	24960 kg (55000 lb)
Cab Assembly	2265 kg (5000 lb)
Ripper Assembly	2500 kg (5500 lb)
Moldboard Assembly	3172.5 kg (7000 lb)
Tire Assembly	977 kg (2150 lb)

Torque Specifications

Tighten the eight bolts that secure the upper hitch pin to a torque of 530 ± 70 N·m (390 ± 52 lb ft).

Tighten one air conditioning line to a torque of 49 + 0 - 1 N·m (36 + 0 - 0.74 lb ft).

Tighten one air conditioning line to a torque of 62 + 0 - 1 N·m (46 + 0 - 0.74 lb ft).

Torque all other bolts according to standard torque values.

Specifications for Cables, Chains, and Lifting Devices

Use approved cables, chains, and lifting devices in order to lift components. Refer to the manufacturer's literature in order to determine the application when you select cables, chains, and lifting devices. When you lift a component, the lift angle is critical. Refer to the Illustration that follows in order to see the effect of the lift angle on the working load limit.

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Illustration 1	g00629745
Lift angles for lifting slings. (A) The load capacity is 100 percent of the working load limit for the sling. (B) The load capacity is 86 percent of the working load limit for the sling. (C) The load capacity is 70 percent of the working load limit for the sling. (D) The load capacity is 50 percent of the working load limit for the sling.

Necessary Lifting Capacity

Two lifting devices with a lifting capacity of 36280 kg (80000 lb) are required in order to remove the front section and the rear section of the machine from the trailers.

Required Tooling

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Table 5
Qty	Part Number	Description
As Required	-	Wood Blocks
As Required	-	Suitable Spreader Bars
As Required	-	Equipment for Installing the Tires
Numerous	-	Cables Chains Hooks Shackles
2	-	Fabricated Tooling ⁽¹⁾
1	1U-7542	Ram
1	1U-9204	Lever Puller Hoist
2	1U-9755	Hydraulic Jack

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^( 1 )

Fabricate two M16 X 2 THD rods that are 305 mm (12 inch) in length.

Rollover Protective Structure (ROPS)

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Personal injury or death can result when voiding this certification.
Structural damage, an overturn, modification, alteration, or improper repair can impair the ROPS structure's protection capability thereby voiding this certification.
Do not weld on or drill holes in the structure.
To avoid possible weakening of this ROPS, consult a Caterpillar dealer before altering this ROPS in any way. The protection offered by this ROPS will be impaired if it has been subjected to structural damage.

Consult a Caterpillar dealer to determine this structure's limitations without voiding its certification.

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Illustration 2	g01705233

The ROPS is a protective structure that is located above the operator's compartment. The ROPS is secured to the machine.

In order to avoid weakening the ROPS, consult a Caterpillar dealer before you perform the following tasks: adding weight, welding, cutting and drilling holes.

Do not weld any brackets or do not drill any holes in the ROPS. See your Caterpillar dealer for mounting guidelines.

Shipping Configuration

Three tractor-trailers will be required for the delivery of the 24M Motor Grader to the location of assembly.

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Illustration 3	g01709584
Typical view of shipping configuration

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Illustration 4	g01709583
Typical view of shipping configuration

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Illustration 5	g01709582
Typical view of shipping configuration

One tractor-trailer will carry the front section (A) of the Motor Grader.
The second tractor-trailer will carry the rear section (B) of the Motor Grader.
The third tractor-trailer will carry the following components: cab (C), moldboard assembly (D), ripper assembly (E), six rims (F) and shipping container (G) .

Selecting A Site and Unloading

A smooth, level site is needed for assembly. The site should be approximately 18.2 × 18.2 m (60 × 60 ft). This allows adequate space for connecting the front frame to the rear frame, the installation of the cab, the assembly of the wheel assemblies to the axle spindles and the moldboard assembly.

Chassis Lifting Points

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Illustration 6	g01305966
View of the correct lifting position for the front of the 24M Motor Grader Right side of machine is shown.

The front of the 24M Motor Grader must be lifted at the proper location. Use a suitable strap and a suitable lifting device. The front section of the 24M Motor Grader weighs approximately 22680 kg (50000 lb).

Note: Attach a lifting device to the front of the machine in order to assist in stabilizing the front section.

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Illustration 7	g01705733
View of the correct lifting position for the rear of the 24M Motor Grader Left side of machine is shown.

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Illustration 8	g01705734
View of the correct lifting positions for the rear section of the 24M Motor Grader Right side of machine is shown.

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Illustration 9	g01155378
Typical view of the top articulation hitch

The rear section of the 24M Motor Grader must be lifted with a suitable spreader bar. Chains that are suitable for the task must be attached to the two attachment hooks. Attach a suitable lifting device to the top articulation hitch pin. The rear section of the 24M Motor Grader weighs approximately 24960 kg (55000 lb).

Note: Use a piece of rubber in order to protect the articulation hitch pin from being damaged. Place a thick board between the lifting device and the articulation hitch in order to protect the frame from being damaged.

Cleaning

If necessary, clean shipping grease from all the hydraulic cylinder rods before you begin operation of the machine or operation of the implements.

Note: The grease is easily removed if the air temperature is warm.

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Illustration 10	g01705493
The view of the mounting areas for the blade wear strips.

Clean the mounting areas for the blade wear strips.

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Illustration 11	g01705678
View of the mounting location for the precleaner assemblies and on the location for the exhaust extension

Remove the tape from the mounting location for the precleaner assemblies. Remove the tape from the mounting location for the exhaust extension.

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Illustration 12	g01705693
View of the front axle

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Illustration 13	g01705695
View of the rear axle

If necessary, clean the grease from the axle mounting for the front and clean the grease from the axle mounting for the rear before you begin the procedure for the wheel assembly.

If necessary, remove the wrapping that was used for shipping from the cylinders.

Assembly Sequence

This general list of major components is given as a suggestion for the assembly sequence for the 24M Motor Grader.

Unload the rear section of the machine.

Unload the front section of the machine.

Connect the front section of the machine to the rear section of the machine.

Connect the articulation cylinders.

Route the hoses and the wiring harnesses for the chassis.

Install the cab.

Route the hoses and the wiring harnesses for the cab.

Install the wheel assemblies.

Install the rear step groups.

Install the front step groups.

Install the exhaust extension.

Install the air cleaner caps.

Install the link assembly.

Install the ripper assembly.

Install the moldboard assembly.

Install any optional equipment.

24M Assembly Tips

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Before service work is begun, park the machine on a hard level surface. Block the wheels of the machine so unexpected movement will not occur. Unexpected movement of the machine can cause personal injury or death.

Block the 24M Motor Grader to the proper height on a level, smooth area for assembly after removal from the trailers.
Note: If necessary, place a plate on the ground for stability before you build the blocking that is required for the chassis.

Use a lever puller in order to level the ripper assembly before the assembly is positioned to the rear frame.

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Illustration 14	g01306187
View of the moldboard assembly that is being supported for assembly on the right side of the 24M Motor Grader

Note: There should be approximately 9 m (30 ft) on the right side of the machine for assembly of the moldboard assembly.

The blade assembly can only be installed on the right side of the machine. The mount for the yoke for the sideshift cylinder is located on the right side of the blade assembly.

Removing the Rear Section of the Machine

In order to remove the rear section of the chassis from the trailer, remove all of the hold-downs that were used for shipping.

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Illustration 15	g01155375
Typical view of lifting the rear section of the machine with spreader bar (1)

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Illustration 16	g01155417
Typical view of the rear section of the machine that is blocked

Use proper lifting devices in order to remove the rear section of the chassis from the trailer. Place the rear section of the chassis on proper blocking.
Note: Refer to ""Chassis Lifting Points" " in this manual for the proper lifting procedure.
Note: The blocking that is used for the rear section of the machine should be 1118 mm (44 inch) tall. The blocking should be 1320 mm (52 inch) wide. The blocking should be 1219 mm (48 inch) long. The blocking should be placed under both the front and the rear of both the tandem housings.
Note: Remove all straps that were used to secure any cylinders, hoses, etc during shipping.

Removing the Front Section of the Machine

In order to remove the front section of the chassis from the trailer, remove all of the hold-downs that were used for shipping.

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Illustration 17	g01707109
View of the front section of the machine that is being lifted

Use proper lifting devices in order to remove the front section of the chassis from the trailer. Place the front section of the chassis on proper blocking.
Note: Refer to ""Chassis Lifting Points" " in this manual for the proper lifting procedure.
Note: The blocking that is used for the front of the machine should be 1118 mm (44 inch) tall. The blocking should be 203 mm (8 inch) wide. The blocking should be 406 mm (16 inch) long.
Note: Remove all straps that were used to secure any cylinders, hoses, etc during shipping.

Connect the Front Section to the Rear Section

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Table 6
Required Parts for Installation of the 252-0981 Articulating Hitch Gp ⁽¹⁾
Item	Qty	Part Number	Description
1	1	271-1421	Pin
2	1	117-2026	Shim Pack
3	1	117-2025	Shim Pack
4	4	8T-4193	Bolt
5	4	9X-8257	Washer

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^( 1 )

Required parts are shipped inside the cab.

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Illustration 18	g01707133
View of the upper hitch pin

Remove three bolts (A) and three washers (B) in order to remove plate (C). Retain all parts.
Note: Plate (C) is removed in order to gain access to the upper hitch pin.

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Illustration 19	g01707333
Bottom view of the upper hitch pin

Remove four bolts (D) and four washers (E) in order to remove plate (F). Retain all parts.

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Illustration 20	g01707201

Remove eight bolts (G) and eight washers (H). Retain all parts.

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Illustration 21	g01707214

Remove pin (J). Pin (J) weighs approximately 40 kg (88 lb). Retain all parts.

Remove spacer (K). Retain all parts.

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Illustration 22	g01707522
View of the lower hitch pin

Remove four bolts (L), four washers (M) and four spacers (N) in order to remove plate (P). Retain all parts.

Clean pin (J) and pin (1). Clean the bores for the upper and the lower hitch pins.
Note: Pin (1) weighs approximately 20 kg (44 lb).

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Illustration 23	g01707247
Typical view of the rear section of the machine that is being leveled

Place a level on the top of the articulation hitch.

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Illustration 24	g01707248
Typical view of the rear section of the machine that is leveled

Use two hydraulic jacks in order to level the articulation hitch.

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Illustration 25	g01707638

Install tooling (AA). Locate tooling (AA) in two holes that are directly in-line.
Note: Tooling (AA) was fabricated in the ""Required Tooling" " section.

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Illustration 26	g01707997
Rear view of the front section of the machine

Remove eight bolts (R) and eight washers (S) in order to remove guard (T). Use a suitable lifting device in order to remove guard (T). Guard (T) weighs approximately 40 kg (88 lb). Retain all parts.

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Illustration 27	g01707654

Install spacer (K) to the front section of the machine. Spacer (K) was removed in Step 5.

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Illustration 28	g01707677

Use a suitable lifting device in order to position the front section of the machine to the rear section of the machine.
Note: Refer to ""Chassis Lifting Points" " in this manual for the proper lifting procedure.

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Illustration 29	g01707680
Typical view of the front section of the machine that is positioned with the rear section of the machine

Use a straight edge in order to ensure that the pin bore is lined up correctly.

Lower the temperature of pin (J) to −75° C (−103° F) prior to installation. Pin (J) was removed in Step 4.

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Illustration 30	g01707913

Position pin (J) for installation. Align the holes of pin (J) with tooling (AA) .

Install pin (J) .

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Illustration 31	g01708077

Install plate (F) with four bolts (D) and four washers (E) that were removed in Step 2. Tighten four bolts (D) to a torque of 460 ± 60 N·m (340 ± 45 lb ft).

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Illustration 32	g01708114

Measure the gap between plate (F) and pin (J). Measure the gap through the small hole that is located in plate (F) .

Remove four bolts (D) and four washers (E) in order to remove plate (F). Retain all parts.

Select the correct number of shims (2) in order to fill the gap that was measured in Step 19. Install shims (2) .

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Illustration 33	g01708173

Install plate (F) with four bolts (D) and four washers (E) that were removed in Step 20. Tighten four bolts (D) to a torque of 530 ± 70 N·m (390 ± 52 lb ft).

Remove tooling (AA) .

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Illustration 34	g01708313

Measure the gap between plate (U) and the frame.

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Illustration 35	g01708414

Remove four bolts (V) and four washers (W) in order to remove plate (U). Retain all parts.

Select the correct number of shims (3) in order to fill the gap that was measured in Step 24. Install shims (3) between plate (U) and the frame.

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Illustration 36	g01708416

Install plate (U) with four bolts (V) and four washers (W) that were removed in Step 25. Tighten bolts (V) to a torque of 530 ± 70 N·m (390 ± 52 lb ft).

Install eight bolts (G) and eight washers (H) that were removed in Step 3.

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Illustration 37	g01709574

Install plate (C) with three bolts (A) and three washes (B) that were removed in Step 1.

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Illustration 38	g01709013
Bottom view of the lower hitch pin

Install plate (P) with four bolts (L), four washers (M), and four spacers (N) that were removed in Step 6.

Lower the temperature of pin (1) to −75° C (−103° F) prior to installation.

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Illustration 39	g01708973

Install tooling (AA). Locate tooling (AA) in two holes that are directly in-line.
Note: Tooling (AA) was fabricated in the ""Required Tooling" " section.

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Illustration 40	g01709533

Place pin (1) for installation. Align the holes of plate (P) with tooling (AA) .

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Illustration 41	g01709534
View of pin (1) that is completely installed

Use a 1U-7542 Ram to press pin (1) into position.
Note: Tooling (BB) can be found in the ""Required Tooling" " section.

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Illustration 42	g01709535

Remove tooling (AA) from pin (1) .

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Illustration 43	g01709553

Install four bolts (4) and four washers (5) in order to secure pin (1) in position.

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Illustration 44	g01709555

Connect the articulation lock.
Note: The locking link must be installed in order to prevent movement of the chassis.

Connect the Articulation Cylinders

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Illustration 45	g01710294
View of the left hand articulation cylinder

Disconnect grease line (A) from fitting (B) .

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Illustration 46	g01710334

Remove bolt (C), washer (D), spacer (E), washer (F), and nut (G). Retain all parts.

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Illustration 47	g01710338

Remove pin (H). Remove shims (J) and shims (K). Retain all parts.
Note: Shim (J) is 1.6 mm (0.063 inch) thick.
Note: Shim (K) is 3 mm (0.12 inch) thick.

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Illustration 48	g01710415

Position cylinder (L) to the front section of the machine. Install pin (H) that was removed in Step 3.

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Illustration 49	g01710417

Place shims (J) below cylinder (L) until the cylinder is level. Fill any gap above cylinder (L) with shims (K). Shims (J) and shims (K) were removed in Step 3.

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Illustration 50	g01710476

Install bolt (C), washer (D), spacer (E), washer (F), and nut (G). These parts were removed in Step 2.

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Illustration 51	g01710478

Install grease line (A) that was removed in Step 1 to fitting (B) .

Repeat Step 1 through Step 7 for the other side of the machine.

Install the Hoses and the Wiring Harnesses for the Chassis

Note: All hoses are identified by an attached metal tag that is marked with the corresponding part number.

Note: Prior to shipping, all required clips, clamps, and brackets are installed to the chassis in the correct corresponding location.

Install the Wiring Harness for the Chassis

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Illustration 52	g01713034

Remove seven bolts (A), seven washers (B), plate (C), and guard (D). Retain all parts.

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Illustration 53	g01713035

Remove all shipping plugs and caps. Discard all parts.

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Illustration 54	g01714279

Remove bolt (E), two washers (F), nut (G), and clip (H). Retain all parts.

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Illustration 55	g01714280

Install harness (J) .
Note: Each connection on harness (J) will only fit in one plug in one orientation. Ensure that the harness is installed correctly before securing the harness in place.

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Illustration 56	g01714314

Secure harness (J) in place with bolt (E), two washers (F), nut (G), and clip (H). Bolt (E), two washers (F), nut (G), and clip (H) were removed in Step 3.

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Illustration 57	g01714319

Install seven bolts (A), seven washers (B), plate (C), and guard (D). Bolts (A), washers (B), plate (C), and guard (D) were removed in Step 1.

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Illustration 58	g01714381

Remove bolt (K) and washer (L). Retain all parts.

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Illustration 59	g01714384

Connect ground cable (M) with bolt (K) and washer (L). Bolt (K) and washer (L) were removed in Step 7.

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Illustration 60	g01714434

Remove two bolts (N) and two washers (P). Retain all parts.

Remove two straps from two links (R) .

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Illustration 61	g01714435

Install two links (R) with two bolts (N) and two washers (P). Bolts (N) and washers (P) were removed in Step 9.
Note: Do not adjust two links (R). Two links (R) are correctly adjusted during production.

Install the Hoses for the Chassis

Install the Hoses for the Right Hand Side of the Front Section of the Chassis

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Illustration 62	g01715495
View of the right hand side of the machine Objects have been removed for clarity.

Remove two bolts (S), two washers (T), plate (U), and block (V). Retain all parts.

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Illustration 63	g01715514
Objects have been removed for clarity.

Remove two bolts (W), two washers (X), and block (Y). Retain all parts.

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Illustration 64	g01715533
Objects have been removed for clarity. (1) 307-3240 Hose As

Position hose (1) to block (Z) .

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Illustration 65	g01715534
Objects have been removed for clarity. (2) 307-8791 Hose As

Position hose (2) to block (Z) .

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Illustration 66	g01715536
Objects have been removed for clarity. (3) 268-0243 Heater Lines Gp

Position hose (3) to block (Z) .

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Illustration 67	g01715693
Objects have been removed for clarity. (4) 286-1329 Hose As

Position hose (4) to block (Z) .

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Illustration 68	g01715734
Objects have been removed for clarity.

Install two bolts (W), two washers (X), and block (Y). Two bolts (W), two washers (X), and block (Y) were removed in Step 2.

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Illustration 69	g01715736
Objects have been removed for clarity. (5) 286-3476 Hose As

Position hose (5) to block (Y) .

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Illustration 70	g01715737
Objects have been removed for clarity. (6) 307-8785 Hose As

Position hose (6) to block (Y) .

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Illustration 71	g01715739
Objects have been removed for clarity. (7) 268-0243 Heater Lines Gp

Position hose (7) to block (Y) .

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Illustration 72	g01715740
Objects have been removed for clarity.

Install two bolts (S), two washers (T), plate (U), and block (V). Two bolts (S), two washers (T), plate (U), and block (V) were removed in Step 1.

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Illustration 73	g01715878
Objects have been removed for clarity.

Remove two bolts (AA), two washers (BB), plate (CC), and block (DD). Retain all parts.

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Illustration 74	g01715884
Objects have been removed for clarity.

Remove two bolts (EE), two washers (FF), and block (GG). Retain all parts.

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Illustration 75	g01715887
Objects have been removed for clarity.

Position hose (1) to block (HH) .

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Illustration 76	g01715892
Objects have been removed for clarity.

Position hose (2) to block (HH) .

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Illustration 77	g01715893
Objects have been removed for clarity.

Position hose (3) to block (HH) .

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Illustration 78	g01715894
Objects have been removed for clarity.

Install two bolts (EE), two washers (FF), and block (GG). Two bolts (EE), two washers (FF), and block (GG) were removed in Step 13.

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Illustration 79	g01715895
Objects have been removed for clarity.

Position hose (5) to block (GG) .

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Illustration 80	g01715896
Objects have been removed for clarity.

Position hose (6) to block (GG) .

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Illustration 81	g01715897
Objects have been removed for clarity.

Position hose (7) to block (GG) .

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Illustration 82	g01715898
Objects have been removed for clarity.

Install two bolts (AA), two washers (BB), plate (CC), and block (DD). Two bolts (AA), two washers (BB), plate (CC), and block (DD) were removed in Step 12.

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Illustration 83	g01716016
Objects have been removed for clarity.

Remove two bolts (JJ), two washers (KK), and two clamps (LL). Retain all parts.

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Illustration 84	g01716018
Objects have been removed for clarity.

Secure hose (4) to the frame with two bolts (JJ), two washers (KK), and two clamps (LL). Two bolts (JJ), two washers (KK), and two clamps (LL) were removed in Step 22.

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Illustration 85	g01716019
Objects have been removed for clarity.

Remove bolt (MM), washer (NN), and clamp (PP). Remove bolt (RR), washer (SS), and clamp (TT). Remove bolt (UU), washer (VV), and two clamps (WW). Remove bolt (XX), washer (YY), and two clamps (ZZ). Retain all parts.

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Illustration 86	g01716076
Objects have been removed for clarity.

Secure hose (2) to the frame with bolt (MM), washer (NN), and clamp (PP). Bolt (MM), washer (NN), and clamp (PP) were removed in Step 24.

Secure hose (6) to the frame with bolt (RR), washer (SS), and clamp (TT). Bolt (RR), washer (SS), and clamp (TT) were removed in Step 24.

Secure hose (1), hose (3), hose (5), and hose (7) to the frame with bolt (UU), washer (VV), and two clamps (WW). Bolt (UU), washer (VV), and two clamps (WW) were removed in Step 24.

Secure hose (2) and hose (6) to the frame with bolt (XX), washer (YY), and two clamps (ZZ). Bolt (XX), washer (YY), and two clamps (ZZ) were removed in Step 24.

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Illustration 87	g01716120
Objects have been removed for clarity.

Remove two bolts (AB), two washers (AC), plate (AD), and block (AE). Retain all parts.

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Illustration 88	g01716294
Objects have been removed for clarity.

Secure hose (5) to the frame with two bolts (AB), two washers (AC), plate (AD), and block (AE). Two bolts (AB), two washers (AC), plate (AD), and block (AE) were removed in Step 29.

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Illustration 89	g01716295
Objects have been removed for clarity.

Remove two bolts (AF), two washers (AG), plate (AH), and block (AJ). Retain all parts.

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Illustration 90	g01716297
Objects have been removed for clarity.

Secure hose (1) to the frame with two bolts (AF), two washers (AG), plate (AH), and block (AJ). Two bolts (AF), two washers (AG), plate (AH), and block (AJ) were removed in Step 31.

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Illustration 91	g01716334
Objects have been removed for clarity.

Remove any shipping plugs or caps from hose (1) and port (AK). Discard all parts.

Connect hose (1) to port (AK) .

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Illustration 92	g01716350
Objects have been removed for clarity. (8) 307-3236 Hose As

Remove any shipping plugs or caps from hose (8) and port (AL) .

Connect hose (8) to port (AL) .

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Illustration 93	g01716359
Objects have been removed for clarity.

Remove any shipping plugs or caps from hose (6) and port (AM) .

Connect hose (6) to port (AM) .

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Illustration 94	g01716358
Objects have been removed for clarity.

Remove any shipping plugs or caps from hose (2) and port (AN) .

Connect hose (2) to port (AN) .

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Illustration 95	g01716356
Objects have been removed for clarity.

Remove any shipping plugs or caps from hose (4) and port (AP) .

Connect hose (4) to port (AP) .

Install the Hoses for the Left Hand Side of the Front Section of the Chassis

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Illustration 96	g01716758
View of the left hand side of the machine Objects have been removed for clarity.

Remove two bolts (AR), two washers (AS), plate (AT), and block (AU). Retain all parts.

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Illustration 97	g01716759
Objects have been removed for clarity.

Remove two bolts (AV), two washers (AW), and block (AX). Retain all parts.

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Illustration 98	g01716837
Objects have been removed for clarity. (9) 307-8795 Hose As

Position hose (9) to block (AY) .

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Illustration 99	g01716839
Objects have been removed for clarity. (10) 280-1453 Hose As

Position hose (10) to block (AY) .

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Illustration 100	g01716840
Objects have been removed for clarity. (11) 307-8792 Hose As

Position hose (11) to block (AY) .

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Illustration 101	g01716841
Objects have been removed for clarity. (12) 307-8786 Hose As

Position hose (12) to block (AY) .

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Illustration 102	g01716843
Objects have been removed for clarity. (13) 275-8363 Hose As

Position hose (13) to block (AY) .

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Illustration 103	g01717154
Objects have been removed for clarity.

Install two bolts (AV), two washers (AW), and block (AX). Two bolts (AV), two washers (AW), and block (AX) were removed in Step 2.

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Illustration 104	g01717173
Objects have been removed for clarity. (14) 310-5578 Hose As

Position hose (14) to block (AX) .

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Illustration 105	g01717176
Objects have been removed for clarity. (15) 307-3241 Hose As

Position hose (15) to block (AX) .

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Illustration 106	g01717177
Objects have been removed for clarity. (16) 315-5717 Hose As

Position hose (16) to block (AX) .

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Illustration 107	g01717178
Objects have been removed for clarity. (17) 273-1757 Hose As

Position hose (17) to block (AX) .

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Illustration 108	g01717395
Objects have been removed for clarity.

Install two bolts (AR), two washers (AS), plate (AT), and block (AU). Two bolts (AR), two washers (AS), plate (AT), and block (AU) were removed in Step 1.

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Illustration 109	g01717398
Objects have been removed for clarity.

Remove bolt (BA), washer (BC), and two clamps (BD). Retain all parts.

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Illustration 110	g01717702
Objects have been removed for clarity.

Secure hose (9) and hose (14) to the frame with bolt (BA), washer (BC), and two clamps (BD). Bolt (BA), washer (BC), and two clamps (BD) were removed in Step 14.

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Illustration 111	g01717707
Objects have been removed for clarity.

Remove two bolts (BE), two washers (BF), plate (BG), and block (BH). Retain all parts.

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Illustration 112	g01717401
Objects have been removed for clarity.

Remove two bolts (BJ), two washers (BK), and block (BL). Retain all parts.

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Illustration 113	g01717400
Objects have been removed for clarity.

Position hose (10) to block (BM) .

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Illustration 114	g01717413
Objects have been removed for clarity.

Position hose (11) to block (BM) .

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Illustration 115	g01717414
Objects have been removed for clarity.

Position hose (12) to block (BM) .

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Illustration 116	g01717415
Objects have been removed for clarity.

Install two bolts (BJ), two washers (BK), and block (BL). Two bolts (BJ), two washers (BK), and plate (BL) were removed in Step 17.

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Illustration 117	g01717419
Objects have been removed for clarity.

Position hose (15) to block (BL) .

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Illustration 118	g01717418
Objects have been removed for clarity.

Position hose (16) to block (BL) .

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Illustration 119	g01717417
Objects have been removed for clarity.

Position hose (17) to block (BL) .

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Illustration 120	g01717426
Objects have been removed for clarity.

Install two bolts (BE), two washers (BF), plate (BG), and block (BH). Two bolts (BE), two washers (BF), plate (BG), and block (BH) were removed in Step 16.

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Illustration 121	g01718674
Objects have been removed for clarity.

Remove bolt (BM), washer (BN), and clamp (BP ). Retain all parts.

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Illustration 122	g01718678
Objects have been removed for clarity.

Secure hose (13) to the frame with bolt (BM), washer (BN), and clamp (BP). Bolt (BM), washer (BN), and clamp (BP) were removed in Step 26.

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Illustration 123	g01718683
Objects have been removed for clarity.

Remove any shipping plugs or caps from hose (12), hose (13), hose (17), port (BR), port (BS), and port (BT). Discard all parts.

Connect hose (12) to port (BT) .

Connect hose (13) to port (BR) .

Connect hose (17) to port (BS) .

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Illustration 124	g01718694
Objects have been removed for clarity.

Remove two bolts (BU), two washers (BV), three clamps (BW), and spacer (BX). Retain all parts.

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Illustration 125	g01718695
Objects have been removed for clarity.

Secure hose (10) and hose (15) to the frame with bolt (BU), washer (BV), and clamp (BW). Bolt (BU), washer (BV), and clamp (BW) were removed in Step 32.

Secure hose (111) and hose (16) to the frame with bolt (BU), washer (BV), two clamps (BW), and spacer (BX). Bolt (BU), washer (BV), two clamps (BW), and spacer (BX) were removed in Step 32.

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Illustration 126	g01718813
Objects have been removed for clarity.

Remove any shipping plugs or caps from hose (16) and port (BY). Discard all parts.

Connect hose (16) to port (BY) .

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Illustration 127	g01718817
Objects have been removed for clarity.

Remove bolt (BZ), washer (CA), and two clamps (CB). Retain all parts.

Secure hose (9) and hose (14) to the frame with bolt (BZ), washer (CA), and two clamps (CB) that were removed in Step 37.

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Illustration 128	g01718864
Objects have been removed for clarity.

Remove two bolts (CD), two washers (CE), plate (CF), and block (CG). Retain all parts.

Secure hose (15) to the frame with two bolts (CD), two washers (CE), plate (CF), and block (CG). Two bolts (CD), two washers (CE), plate (CF), and block (CG) were removed in Step 39.

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Illustration 129	g01718871
Objects have been removed for clarity.

Remove two bolts (CH), two washers (CJ), plate (CK), and block (CL). Retain all parts.

Secure hose (10) to the frame with two bolts (CH), two washers (CJ), plate (CK), and block (CL). Two bolts (CH), two washers (CJ), plate (CK), and block (CL) were removed in Step 41.

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Illustration 130	g01718841
Objects have been removed for clarity. (18) 307-3238 Hose As (19) 307-3237 Hose As

Remove any shipping plugs or caps from hose (10) , hose (18), hose (19), port (CM), port (CN), and port (CP). Discard all parts.

Connect hose (10) to port (CM) .

Connect hose (18) to port (CN) .

Connect hose (19) to port (CP) .

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Illustration 131	g01718842
Objects have been removed for clarity.

Remove any shipping plugs or caps from hose (11) and port (CR). Discard all parts.

Connect hose (11) to port (CR) .

Install the Lines for the Articulation Cylinders

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Illustration 132	g01718936
View of the right hand articulation cylinder Objects have been removed for clarity.

Remove any shipping plugs or caps from hose (20), hose (21), port (CS), and port (CT). Discard all parts.

Remove one bolt (CU), two washers (CV), spacer (CW), clamp (CX), and nut (CZ). Retain all parts.

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Illustration 133	g01718953
Objects have been removed for clarity. (20) 298-4730 Hose As (21) 186-3471 Hose As

Connect hose (20) to port (CS) .

Connect hose (21) to port (CT) .

Secure hose (21) to the cylinder with bolt (CU), two washers (CV), spacer (CW), clamp (CX), and nut (CZ). Bolt (CU), two washers (CV), spacer (CW), clamp (CX), and nut (CZ) were removed in Step 2.

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Illustration 134	g01718975
View of the left hand articulation cylinder Objects have been removed for clarity. (22) 307-8793 Hose As (23) 9R-6698 Hose As

Repeat Step 1 through Step 5 for the other side of the machine.

Install the Cab

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Table 7
Required Parts for Installation of the 8X-8994 Platform Mounting Gp ⁽¹⁾
Item	Qty	Part Number	Description
1	12	137-6617	Mount As
2	4	125-6875	Washer
3	4	2J-8937	Pin
4	4	4F-0255	Pin
5	4	3B-4626	Cotter Pin
6	6	137-6627	Sleeve
7	2	8C-8478	Bolt
8	10	8T-4123	Washer
9	6	9W-6584	Washer
10	2	140-8465	Plate
11	4	7X-2488	Bolt
12	6	8T-4131	Nut

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^( 1 )

Required parts are shipped inside the cab.

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Illustration 135	g01710733
View of the lifting points for cab assembly (A)

Attach a suitable lifting device to cab assembly (A). Cab assembly (A) weighs approximately 2265 kg (5000 lb).
Note: The rear section of the cab assembly is heavier than the front section of the cab assembly. Adjust the chains accordingly in order to keep the cab assembly level.

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Illustration 136	g01710815

Remove four bolts (B), eight washers (C), and four nuts (D) in order to remove cab assembly (A) from the shipping stand. Discard all parts.

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Illustration 137	g01710875

Remove four bolts (E) and four washers (F) in order to remove cover (G). Retain all parts.

Repeat Step 3 for the other side of the machine.

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Illustration 138	g01710957

Position six mount assemblies (1) to the chassis. Position four washers (2) on top of the four rear mount assemblies (1) .

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Illustration 139	g01710975

Position cab assembly (A) to the chassis.

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Illustration 140	g01713015

Secure cab assembly (A) to the chassis with four pins (3) .

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Illustration 141	g01713016

Install four pins (4) and four cotter pins (5) into four pins (3) .

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Illustration 142	g01713017
View of the front cab mount

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Illustration 143	g01713018

Install mount (1), sleeve (6), washer (9), washer (8), and plate (10) on bolt (7). Repeat for the other front cab mount.

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Illustration 144	g01713019
View of rear cab mount

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Illustration 145	g01713020

Install mount (1), sleeve (6), washer (9), two washers (8), and nut (12) on bolt (11). Repeat for the three remaining rear cab mounts.
Note: Four bolts (11) are installed from the inside of the cab. The floor mat must be removed in order to install bolts (11) .

Install the Hoses and the Wiring Harnesses for the Cab

Note: All hoses are identified by an attached metal tag that is marked with the corresponding part number.

Install the Brake Lines for the Cab

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Illustration 146	g01713042

Remove five caps from cab assembly (A). Remove five plugs. Discard all parts.

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Illustration 147	g01713044
Objects have been removed for clarity.

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Illustration 148	g01713047
Objects have been removed for clarity. (1) 233-9522 Hose As (2) 307-3241 Hose As (3) 286-3474 Hose As (4) 286-3476 Hose As (5) 279-8972 Hose As

Connect hose (1) to port (B) .

Connect hose (2) to port (C) .

Connect hose (3) to port (D) .

Connect hose (4) to port (E) .

Connect hose (5) to port (F) .

Install the Wiring Harness for the Cab

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Illustration 149	g01713038

Remove all shipping caps and plugs from the bottom of cab assembly (A). Discard all parts.

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Illustration 150	g01713039

Remove all shipping caps and plugs from harness (G). Discard all parts.

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Illustration 151	g01713040

Install harness (G) .
Note: Each connection on harness (G) will only fit in one plug in one orientation. Ensure that the harness is installed correctly before securing the harness in place.

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Illustration 152	g01713257

Remove clip (H), bolt (J), and washer (K). Retain all parts.

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Illustration 153	g01713261

Secure harness (G) to cab assembly (A) with clip (H), bolt (J), and washer (K). Clip (H), bolt (J), and washer (K) were removed in Step 4.

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Illustration 154	g01713273

Remove clip (L), bolt (M), and washer (N). Retain all parts.

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Illustration 155	g01713275

Secure harness (G) to cab assembly (A) with clip (L), bolt (M), and washer (N). Clip (L), bolt (M), and washer (N) were removed in Step 6.

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Illustration 156	g01713293
Objects have been removed for clarity.

Install four connectors from harness (G) to cab assembly (A) .

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Illustration 157	g01713315
Objects have been removed for clarity.

Remove bolt (P) and washer (R). Retain all parts.

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Illustration 158	g01713313
Objects have been removed for clarity.

Install two ground cables to cab assembly (A) with bolt (P) and washer (R) that were removed in Step 9.

Install the Heater Lines for the Cab

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Illustration 159	g01713373

Remove all shipping plugs and caps. Discard all parts.

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Illustration 160	g01713376
Objects have been removed for clarity.

Install hose (S) and hose (T) to cab assembly (A) .

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Illustration 161	g01713434
Objects have been removed for clarity.

Secure hose (S) and hose (T) in place with two clamps (U) .

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Illustration 162	g01713378

Open shut off valves (V) .
Note: Shut off valves (V) are located on the left rear of the engine.

Install the Air Conditioning Lines for the Cab

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Illustration 163	g01713455

Remove all shipping plugs and caps. Discard all parts.

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Illustration 164	g01713473
Objects have been removed for clarity.

Install hose (W) and hose (X) to cab assembly (A) .
Note: Tighten hose (W) to a torque of 49 + 0 - 1 N·m (36 + 0 - 0.74 lb ft).
Note: Tighten hose (X) to a torque of 62 + 0 - 1 N·m (46 + 0 - 0.74 lb ft).

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Illustration 165	g01713514
Objects have been removed for clarity.

Install two hoses (Y) to cab assembly (A) .

Install the Lines for the Window Washer Fluid for the Cab

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Illustration 166	g01713357
Objects have been removed for clarity.

Install two hoses (Z) to cab assembly (A) .

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Illustration 167	g01713935

Install cover (AA) with four bolts (BB) and four washers (CC). Cover (AA), four bolts (BB), and four washers (CC) were removed in Step 3 of the ""Install the Cab" " section of this document.

Repeat Step 2 for the other side of the machine.

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Illustration 168	g01713936

Install guard (DD) with eight bolts (EE) and eight washers (FF). Cover (DD), eight bolts (EE), and eight washers (FF) were removed in Step 11 of the ""Connect the Front Section to the Rear Section" " section of this document.

Install the Wheel Assemblies

ReferenceRefer to Special Instruction, REHS3286, "24M Motor Grader Assembly Instruction" for the proper installation procedure of the wheel assemblies.

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Illustration 169	g01713581
Front view of the front axle

Note: After the six wheel assemblies are installed, remove the two blocks and one bolt. The two blocks and one bolt are used to secure the front axle during shipping.

Install the Rear Steps

ReferenceRefer to Special Instruction, REHS3286, "24M Motor Grader Assembly Instruction" for the proper installation procedure of the rear steps.

Install the Front Steps

ReferenceRefer to Special Instruction, REHS3286, "24M Motor Grader Assembly Instruction" for the proper installation procedure of the front steps.

Install the Exhaust Extension

ReferenceRefer to Special Instruction, REHS3286, "24M Motor Grader Assembly Instruction" for the proper installation procedure of the exhaust extension.

Install the Air Cleaner Caps

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Table 8
Required Parts for Installation of the 253-3993 Air Cleaner Gp ⁽¹⁾
Item	Qty	Part Number	Description
1	2	245-3816	Air Cleaner Cap

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^( 1 )

Required parts are shipped inside the cab.

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Illustration 170	g01713021

Ensure that all tape is removed.

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Illustration 171	g01713022

Install two air cleaner caps (1) with the hardware that is provided.

Install the Link Assembly

ReferenceRefer to Special Instruction, REHS3286, "24M Motor Grader Assembly Instruction" for the proper installation procedure of the link assembly.

Install the Ripper Arrangement

ReferenceRefer to Special Instruction, REHS3286, "24M Motor Grader Assembly Instruction" for the proper installation procedure of the ripper arrangement.

Install the Moldboard Assembly

ReferenceRefer to Special Instruction, REHS3286, "24M Motor Grader Assembly Instruction" for the proper installation procedure of the moldboard assembly.

Install any Optional Equipment

ReferenceRefer to Special Instruction, REHS3286, "24M Motor Grader Assembly Instruction" for the proper installation procedure of any optional equipment.