- 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"
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. |
NOTICE |
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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. |
NOTICE |
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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
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     |
( 1 ) | Required parts are shipped inside the cab. |
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     |
( 1 ) | Required parts are shipped inside the cab. |
Required Parts for Installation of the 253-3993 Air Cleaner Gp (1)     | ||
Qty     | Part Number     | Description     |
2     | 245-3816     | Air Cleaner Cap     |
( 1 ) | Required parts are shipped inside the cab. |
Approximate Weights
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. |
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. |
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.
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
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     |
( 1 ) | Fabricate two M16 X 2 THD rods that are 305 mm (12 inch) in length. |
Rollover Protective Structure (ROPS)
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. |
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.
Illustration 3 | g01709584 |
Typical view of shipping configuration |
Illustration 4 | g01709583 |
Typical view of shipping configuration |
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
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.
Illustration 7 | g01705733 |
View of the correct lifting position for the rear of the 24M Motor Grader Left side of machine is shown. |
Illustration 8 | g01705734 |
View of the correct lifting positions for the rear section of the 24M Motor Grader Right side of machine is shown. |
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.
Illustration 10 | g01705493 |
The view of the mounting areas for the blade wear strips. |
Clean the mounting areas for the blade wear strips.
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.
Illustration 12 | g01705693 |
View of the front axle |
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
- 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.
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. |
- Use a lever puller in order to level the ripper assembly before the assembly is positioned to the rear frame.
- 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.
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.
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.
- 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.
Illustration 15 | g01155375 |
Typical view of lifting the rear section of the machine with spreader bar (1) |
Illustration 16 | g01155417 |
Typical view of the rear section of the machine that is blocked |
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.
- 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.
Illustration 17 | g01707109 |
View of the front section of the machine that is being lifted |
Connect the Front Section to the Rear Section
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     |
( 1 ) | Required parts are shipped inside the cab. |
- 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.
Illustration 18 | g01707133 |
View of the upper hitch pin |
- Remove four bolts (D) and four washers (E) in order to remove plate (F). Retain all parts.
Illustration 19 | g01707333 |
Bottom view of the upper hitch pin |
- Remove eight bolts (G) and eight washers (H). Retain all parts.
Illustration 20 | g01707201 |
- Remove pin (J). Pin (J) weighs approximately 40 kg (88 lb). Retain all parts.
Illustration 21 | g01707214 |
- Remove spacer (K). Retain all parts.
- Remove four bolts (L), four washers (M) and four spacers (N) in order to remove plate (P). Retain all parts.
Illustration 22 | g01707522 |
View of the lower hitch pin |
- 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).
- Place a level on the top of the articulation hitch.
Illustration 23 | g01707247 |
Typical view of the rear section of the machine that is being leveled |
- Use two hydraulic jacks in order to level the articulation hitch.
Illustration 24 | g01707248 |
Typical view of the rear section of the machine that is leveled |
- Install tooling (AA). Locate tooling (AA) in two holes that are directly in-line.
Note: Tooling (AA) was fabricated in the ""Required Tooling" " section.
Illustration 25 | g01707638 |
- 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.
Illustration 26 | g01707997 |
Rear view of the front section of the machine |
- Install spacer (K) to the front section of the machine. Spacer (K) was removed in Step 5.
Illustration 27 | g01707654 |
- 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.
Illustration 28 | g01707677 |
- Use a straight edge in order to ensure that the pin bore is lined up correctly.
Illustration 29 | g01707680 |
Typical view of the front section of the machine that is positioned with the rear section of the machine |
- Lower the temperature of pin (J) to −75° C (−103° F) prior to installation. Pin (J) was removed in Step 4.
- Position pin (J) for installation. Align the holes of pin (J) with tooling (AA) .
Illustration 30 | g01707913 |
- Install pin (J) .
- 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).
Illustration 31 | g01708077 |
- Measure the gap between plate (F) and pin (J). Measure the gap through the small hole that is located in plate (F) .
Illustration 32 | g01708114 |
- 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) .
- 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).
Illustration 33 | g01708173 |
- Remove tooling (AA) .
- Measure the gap between plate (U) and the frame.
Illustration 34 | g01708313 |
- Remove four bolts (V) and four washers (W) in order to remove plate (U). Retain all parts.
Illustration 35 | g01708414 |
- 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.
- 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).
Illustration 36 | g01708416 |
- Install eight bolts (G) and eight washers (H) that were removed in Step 3.
- Install plate (C) with three bolts (A) and three washes (B) that were removed in Step 1.
Illustration 37 | g01709574 |
- Install plate (P) with four bolts (L), four washers (M), and four spacers (N) that were removed in Step 6.
Illustration 38 | g01709013 |
Bottom view of the lower hitch pin |
- Lower the temperature of pin (1) to −75° C (−103° F) prior to installation.
- Install tooling (AA). Locate tooling (AA) in two holes that are directly in-line.
Note: Tooling (AA) was fabricated in the ""Required Tooling" " section.
Illustration 39 | g01708973 |
- Place pin (1) for installation. Align the holes of plate (P) with tooling (AA) .
Illustration 40 | g01709533 |
- Use a 1U-7542 Ram to press pin (1) into position.
Note: Tooling (BB) can be found in the ""Required Tooling" " section.
Illustration 41 | g01709534 |
View of pin (1) that is completely installed |
- Remove tooling (AA) from pin (1) .
Illustration 42 | g01709535 |
- Install four bolts (4) and four washers (5) in order to secure pin (1) in position.
Illustration 43 | g01709553 |
- Connect the articulation lock.
Note: The locking link must be installed in order to prevent movement of the chassis.
Illustration 44 | g01709555 |
Connect the Articulation Cylinders
- Disconnect grease line (A) from fitting (B) .
Illustration 45 | g01710294 |
View of the left hand articulation cylinder |
- Remove bolt (C), washer (D), spacer (E), washer (F), and nut (G). Retain all parts.
Illustration 46 | g01710334 |
- 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.
Illustration 47 | g01710338 |
- Position cylinder (L) to the front section of the machine. Install pin (H) that was removed in Step 3.
Illustration 48 | g01710415 |
- 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.
Illustration 49 | g01710417 |
- Install bolt (C), washer (D), spacer (E), washer (F), and nut (G). These parts were removed in Step 2.
Illustration 50 | g01710476 |
- Install grease line (A) that was removed in Step 1 to fitting (B) .
Illustration 51 | g01710478 |
- 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
- Remove seven bolts (A), seven washers (B), plate (C), and guard (D). Retain all parts.
Illustration 52 | g01713034 |
- Remove all shipping plugs and caps. Discard all parts.
Illustration 53 | g01713035 |
- Remove bolt (E), two washers (F), nut (G), and clip (H). Retain all parts.
Illustration 54 | g01714279 |
- 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.
Illustration 55 | g01714280 |
- 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.
Illustration 56 | g01714314 |
- 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.
Illustration 57 | g01714319 |
- Remove bolt (K) and washer (L). Retain all parts.
Illustration 58 | g01714381 |
- Connect ground cable (M) with bolt (K) and washer (L). Bolt (K) and washer (L) were removed in Step 7.
Illustration 59 | g01714384 |
- Remove two bolts (N) and two washers (P). Retain all parts.
Illustration 60 | g01714434 |
- Remove two straps from two links (R) .
- 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.
Illustration 61 | g01714435 |
Install the Hoses for the Chassis
Install the Hoses for the Right Hand Side of the Front Section of the Chassis
- Remove two bolts (S), two washers (T), plate (U), and block (V). Retain all parts.
Illustration 62 | g01715495 |
View of the right hand side of the machine Objects have been removed for clarity. |
- Remove two bolts (W), two washers (X), and block (Y). Retain all parts.
Illustration 63 | g01715514 |
Objects have been removed for clarity. |
- Position hose (1) to block (Z) .
Illustration 64 | g01715533 |
Objects have been removed for clarity. (1) 307-3240 Hose As |
- Position hose (2) to block (Z) .
Illustration 65 | g01715534 |
Objects have been removed for clarity. (2) 307-8791 Hose As |
- Position hose (3) to block (Z) .
Illustration 66 | g01715536 |
Objects have been removed for clarity. (3) 268-0243 Heater Lines Gp |
- Position hose (4) to block (Z) .
Illustration 67 | g01715693 |
Objects have been removed for clarity. (4) 286-1329 Hose As |
- Install two bolts (W), two washers (X), and block (Y). Two bolts (W), two washers (X), and block (Y) were removed in Step 2.
Illustration 68 | g01715734 |
Objects have been removed for clarity. |
- Position hose (5) to block (Y) .
Illustration 69 | g01715736 |
Objects have been removed for clarity. (5) 286-3476 Hose As |
- Position hose (6) to block (Y) .
Illustration 70 | g01715737 |
Objects have been removed for clarity. (6) 307-8785 Hose As |
- Position hose (7) to block (Y) .
Illustration 71 | g01715739 |
Objects have been removed for clarity. (7) 268-0243 Heater Lines Gp |
- 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.
Illustration 72 | g01715740 |
Objects have been removed for clarity. |
- Remove two bolts (AA), two washers (BB), plate (CC), and block (DD). Retain all parts.
Illustration 73 | g01715878 |
Objects have been removed for clarity. |
- Remove two bolts (EE), two washers (FF), and block (GG). Retain all parts.
Illustration 74 | g01715884 |
Objects have been removed for clarity. |
- Position hose (1) to block (HH) .
Illustration 75 | g01715887 |
Objects have been removed for clarity. |
- Position hose (2) to block (HH) .
Illustration 76 | g01715892 |
Objects have been removed for clarity. |
- Position hose (3) to block (HH) .
Illustration 77 | g01715893 |
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.
Illustration 78 | g01715894 |
Objects have been removed for clarity. |
- Position hose (5) to block (GG) .
Illustration 79 | g01715895 |
Objects have been removed for clarity. |
- Position hose (6) to block (GG) .
Illustration 80 | g01715896 |
Objects have been removed for clarity. |
- Position hose (7) to block (GG) .
Illustration 81 | g01715897 |
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.
Illustration 82 | g01715898 |
Objects have been removed for clarity. |
- Remove two bolts (JJ), two washers (KK), and two clamps (LL). Retain all parts.
Illustration 83 | g01716016 |
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.
Illustration 84 | g01716018 |
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.
Illustration 85 | g01716019 |
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.
Illustration 86 | g01716076 |
Objects have been removed for clarity. |
- 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.
- Remove two bolts (AB), two washers (AC), plate (AD), and block (AE). Retain all parts.
Illustration 87 | g01716120 |
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.
Illustration 88 | g01716294 |
Objects have been removed for clarity. |
- Remove two bolts (AF), two washers (AG), plate (AH), and block (AJ). Retain all parts.
Illustration 89 | g01716295 |
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.
Illustration 90 | g01716297 |
Objects have been removed for clarity. |
- Remove any shipping plugs or caps from hose (1) and port (AK). Discard all parts.
Illustration 91 | g01716334 |
Objects have been removed for clarity. |
- Connect hose (1) to port (AK) .
- Remove any shipping plugs or caps from hose (8) and port (AL) .
Illustration 92 | g01716350 |
Objects have been removed for clarity. (8) 307-3236 Hose As |
- Connect hose (8) to port (AL) .
- Remove any shipping plugs or caps from hose (6) and port (AM) .
Illustration 93 | g01716359 |
Objects have been removed for clarity. |
- Connect hose (6) to port (AM) .
- Remove any shipping plugs or caps from hose (2) and port (AN) .
Illustration 94 | g01716358 |
Objects have been removed for clarity. |
- Connect hose (2) to port (AN) .
- Remove any shipping plugs or caps from hose (4) and port (AP) .
Illustration 95 | g01716356 |
Objects have been removed for clarity. |
- Connect hose (4) to port (AP) .
Install the Hoses for the Left Hand Side of the Front Section of the Chassis
- Remove two bolts (AR), two washers (AS), plate (AT), and block (AU). Retain all parts.
Illustration 96 | g01716758 |
View of the left hand side of the machine Objects have been removed for clarity. |
- Remove two bolts (AV), two washers (AW), and block (AX). Retain all parts.
Illustration 97 | g01716759 |
Objects have been removed for clarity. |
- Position hose (9) to block (AY) .
Illustration 98 | g01716837 |
Objects have been removed for clarity. (9) 307-8795 Hose As |
- Position hose (10) to block (AY) .
Illustration 99 | g01716839 |
Objects have been removed for clarity. (10) 280-1453 Hose As |
- Position hose (11) to block (AY) .
Illustration 100 | g01716840 |
Objects have been removed for clarity. (11) 307-8792 Hose As |
- Position hose (12) to block (AY) .
Illustration 101 | g01716841 |
Objects have been removed for clarity. (12) 307-8786 Hose As |
- Position hose (13) to block (AY) .
Illustration 102 | g01716843 |
Objects have been removed for clarity. (13) 275-8363 Hose As |
- Install two bolts (AV), two washers (AW), and block (AX). Two bolts (AV), two washers (AW), and block (AX) were removed in Step 2.
Illustration 103 | g01717154 |
Objects have been removed for clarity. |
- Position hose (14) to block (AX) .
Illustration 104 | g01717173 |
Objects have been removed for clarity. (14) 310-5578 Hose As |
- Position hose (15) to block (AX) .
Illustration 105 | g01717176 |
Objects have been removed for clarity. (15) 307-3241 Hose As |
- Position hose (16) to block (AX) .
Illustration 106 | g01717177 |
Objects have been removed for clarity. (16) 315-5717 Hose As |
- Position hose (17) to block (AX) .
Illustration 107 | g01717178 |
Objects have been removed for clarity. (17) 273-1757 Hose As |
- 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.
Illustration 108 | g01717395 |
Objects have been removed for clarity. |
- Remove bolt (BA), washer (BC), and two clamps (BD). Retain all parts.
Illustration 109 | g01717398 |
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.
Illustration 110 | g01717702 |
Objects have been removed for clarity. |
- Remove two bolts (BE), two washers (BF), plate (BG), and block (BH). Retain all parts.
Illustration 111 | g01717707 |
Objects have been removed for clarity. |
- Remove two bolts (BJ), two washers (BK), and block (BL). Retain all parts.
Illustration 112 | g01717401 |
Objects have been removed for clarity. |
- Position hose (10) to block (BM) .
Illustration 113 | g01717400 |
Objects have been removed for clarity. |
- Position hose (11) to block (BM) .
Illustration 114 | g01717413 |
Objects have been removed for clarity. |
- Position hose (12) to block (BM) .
Illustration 115 | g01717414 |
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.
Illustration 116 | g01717415 |
Objects have been removed for clarity. |
- Position hose (15) to block (BL) .
Illustration 117 | g01717419 |
Objects have been removed for clarity. |
- Position hose (16) to block (BL) .
Illustration 118 | g01717418 |
Objects have been removed for clarity. |
- Position hose (17) to block (BL) .
Illustration 119 | g01717417 |
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.
Illustration 120 | g01717426 |
Objects have been removed for clarity. |
- Remove bolt (BM), washer (BN), and clamp (BP ). Retain all parts.
Illustration 121 | g01718674 |
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.
Illustration 122 | g01718678 |
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.
Illustration 123 | g01718683 |
Objects have been removed for clarity. |
- Connect hose (12) to port (BT) .
- Connect hose (13) to port (BR) .
- Connect hose (17) to port (BS) .
- Remove two bolts (BU), two washers (BV), three clamps (BW), and spacer (BX). Retain all parts.
Illustration 124 | g01718694 |
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.
Illustration 125 | g01718695 |
Objects have been removed for clarity. |
- 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.
- Remove any shipping plugs or caps from hose (16) and port (BY). Discard all parts.
Illustration 126 | g01718813 |
Objects have been removed for clarity. |
- Connect hose (16) to port (BY) .
- Remove bolt (BZ), washer (CA), and two clamps (CB). Retain all parts.
Illustration 127 | g01718817 |
Objects have been removed for clarity. |
- Secure hose (9) and hose (14) to the frame with bolt (BZ), washer (CA), and two clamps (CB) that were removed in Step 37.
- Remove two bolts (CD), two washers (CE), plate (CF), and block (CG). Retain all parts.
Illustration 128 | g01718864 |
Objects have been removed for clarity. |
- 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.
- Remove two bolts (CH), two washers (CJ), plate (CK), and block (CL). Retain all parts.
Illustration 129 | g01718871 |
Objects have been removed for clarity. |
- 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.
- Remove any shipping plugs or caps from hose (10) , hose (18), hose (19), port (CM), port (CN), and port (CP). Discard all parts.
Illustration 130 | g01718841 |
Objects have been removed for clarity. (18) 307-3238 Hose As (19) 307-3237 Hose As |
- Connect hose (10) to port (CM) .
- Connect hose (18) to port (CN) .
- Connect hose (19) to port (CP) .
- Remove any shipping plugs or caps from hose (11) and port (CR). Discard all parts.
Illustration 131 | g01718842 |
Objects have been removed for clarity. |
- Connect hose (11) to port (CR) .
Install the Lines for the Articulation Cylinders
- Remove any shipping plugs or caps from hose (20), hose (21), port (CS), and port (CT). Discard all parts.
Illustration 132 | g01718936 |
View of the right hand articulation cylinder Objects have been removed for clarity. |
- Remove one bolt (CU), two washers (CV), spacer (CW), clamp (CX), and nut (CZ). Retain all parts.
- Connect hose (20) to port (CS) .
Illustration 133 | g01718953 |
Objects have been removed for clarity. (20) 298-4730 Hose As (21) 186-3471 Hose As |
- 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.
- Repeat Step 1 through Step 5 for the other side of the machine.
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 |
Install the Cab
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     |
( 1 ) | Required parts are shipped inside the cab. |
- 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.
Illustration 135 | g01710733 |
View of the lifting points for cab assembly (A) |
- 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.
Illustration 136 | g01710815 |
- Remove four bolts (E) and four washers (F) in order to remove cover (G). Retain all parts.
Illustration 137 | g01710875 |
- Repeat Step 3 for the other side of the machine.
- Position six mount assemblies (1) to the chassis. Position four washers (2) on top of the four rear mount assemblies (1) .
Illustration 138 | g01710957 |
- Position cab assembly (A) to the chassis.
Illustration 139 | g01710975 |
- Secure cab assembly (A) to the chassis with four pins (3) .
Illustration 140 | g01713015 |
- Install four pins (4) and four cotter pins (5) into four pins (3) .
Illustration 141 | g01713016 |
- Install mount (1), sleeve (6), washer (9), washer (8), and plate (10) on bolt (7). Repeat for the other front cab mount.
Illustration 142 | g01713017 |
View of the front cab mount |
Illustration 143 | g01713018 |
- 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) .
Illustration 144 | g01713019 |
View of rear cab mount |
Illustration 145 | g01713020 |
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
- Remove five caps from cab assembly (A). Remove five plugs. Discard all parts.
Illustration 146 | g01713042 |
- Connect hose (1) to port (B) .
Illustration 147 | g01713044 |
Objects have been removed for clarity. |
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 (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
- Remove all shipping caps and plugs from the bottom of cab assembly (A). Discard all parts.
Illustration 149 | g01713038 |
- Remove all shipping caps and plugs from harness (G). Discard all parts.
Illustration 150 | g01713039 |
- 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.
Illustration 151 | g01713040 |
- Remove clip (H), bolt (J), and washer (K). Retain all parts.
Illustration 152 | g01713257 |
- 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.
Illustration 153 | g01713261 |
- Remove clip (L), bolt (M), and washer (N). Retain all parts.
Illustration 154 | g01713273 |
- 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.
Illustration 155 | g01713275 |
- Install four connectors from harness (G) to cab assembly (A) .
Illustration 156 | g01713293 |
Objects have been removed for clarity. |
- Remove bolt (P) and washer (R). Retain all parts.
Illustration 157 | g01713315 |
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.
Illustration 158 | g01713313 |
Objects have been removed for clarity. |
Install the Heater Lines for the Cab
- Remove all shipping plugs and caps. Discard all parts.
Illustration 159 | g01713373 |
- Install hose (S) and hose (T) to cab assembly (A) .
Illustration 160 | g01713376 |
Objects have been removed for clarity. |
- Secure hose (S) and hose (T) in place with two clamps (U) .
Illustration 161 | g01713434 |
Objects have been removed for clarity. |
- Open shut off valves (V) .
Note: Shut off valves (V) are located on the left rear of the engine.
Illustration 162 | g01713378 |
Install the Air Conditioning Lines for the Cab
- Remove all shipping plugs and caps. Discard all parts.
Illustration 163 | g01713455 |
- 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).
Illustration 164 | g01713473 |
Objects have been removed for clarity. |
- Install two hoses (Y) to cab assembly (A) .
Illustration 165 | g01713514 |
Objects have been removed for clarity. |
Install the Lines for the Window Washer Fluid for the Cab
- Install two hoses (Z) to cab assembly (A) .
Illustration 166 | g01713357 |
Objects have been removed for clarity. |
- 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.
Illustration 167 | g01713935 |
- Repeat Step 2 for the other side of the machine.
- 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.
Illustration 168 | g01713936 |
Install the Wheel Assemblies
ReferenceRefer to Special Instruction, REHS3286, "24M Motor Grader Assembly Instruction" for the proper installation procedure of the wheel assemblies.
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
Required Parts for Installation of the 253-3993 Air Cleaner Gp (1)     | |||
Item     | Qty     | Part Number     | Description     |
1     | 2     | 245-3816     | Air Cleaner Cap     |
( 1 ) | Required parts are shipped inside the cab. |
- Ensure that all tape is removed.
Illustration 170 | g01713021 |
- Install two air cleaner caps (1) with the hardware that is provided.
Illustration 171 | g01713022 |
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.