REHS9540-07

November 2021

Step 1 - 7 Step 8 - 14 Step 15 - 17

A 230-1224 A C 1P-4584 F AG 8T-4195 J
E G H J K C E BC
B 8T-0568 E 8T-4223 BN 6D-4244
C
D
1P-4584
8T-4184
H
BC
8T-4139
8T-4192
BT
BU
8T-4121
8T-4186 CJ CK
Special

(Dimensions: 56 inches x 35 inches)

E 8T-4223 B C D E BD 228-4473 BV 8T-4133 AG BN BT BV
F 230-1223 B C D E CH 7X-7729
Instruction

REHS9540-07
E H BD
G 228-3357 CJ 220-0239
H 8T-5041 CK 228-7090
BN BU BV CH
J 8T-4139 A 797 and 797B Off-Highway Truck
F
Procedure to Install the Hydraulic Upgrade Kit

AG BN BT BV Serial #:
5YW1-UP
JSM1-UP
E 8T-4223 A E 8T-4223 F AP 9X-8257 J AP AT BS CL CM CN
H 8T-4139 H 8T-4139 E H BE BF AT 8T-4140

42 Page,
K 194-344 BE 228-3356 AZ 8T-4193
E H N P E H BH
N 228-3353 BF 5P-9371 BS 8T-4196
P 8T-4194 BG 8T-5041 BZ 6V-5101 AP AT CP NOTE: This document is for reference purposes only.
BH 194-3440 CL 8T-9527 Refer to REHS9541 for Safety Information, and
CM 7X-7729 Additional Instructions.
E BG
CN 8T-3490
CP 5S-9134 AP AZ BZ CR
Retain L M
CR 192-3478
L 329-5526 x2 Adapeter As CS 192-3479
M 6V-9170 x2 Nut-Bulkhead
E H K AP AZ CP CS
© 2013 Caterpillar, All Rights Reserved Printed in U.S.A.

E 8T-4223 B A 230-1224 W 214-7568 K

F
H 8T-4139 R S T B 8T-0568 E P AH BJ CK 228-7090
W 214-7568 E H C 1P-4584 CU 228-7089
D 8T-4184
U V W G B
E 8T-4223
F 230-1223 Retain
F A
U W CT CU
P 8T-4194 U 6V-3965 Adapter
Retain AH 8T-4244 L M
R 5P-7464 Clip-Half Slot CT 7X-2459 Adapter
BJ 228-3352 CK
S 5P-7465 Clip-Half Tang E D
T 6V-7359 Gromm et F B C D E
U 6V-3965 Adapt er Retain
V 6V-0852 Cap L 329-5526 x2 Adapeter As A B C D E
M 6V-9170 x2 Nut-Bulkhead
C
B 8T-0568 B B 8T-0568
D E X Y Z G
D 8T-4184 D 8T-4184
E 8T-4223 E 8T-4223
X 293-6088 Y 235-2481
D E Y Z BK
Y 235-2481 Z 8T-4190
Z 8T-4190 AC 8T-3957
AB 293-6029 BK 342-0733
AC 8T-3957 BL 293-6028

AD Unclip lines B AB AC
AD
B AC BL

D 8T-4184 C BR 313-5128 H R S
E AE AF AG BM J H
E 8T-4223 AM AN AP AR BS 8T-4196 U V
AE 9X-2646 AS BT 8T-4121
AF 9X-2647 BU 8T-4186 BW
AG 8T-4195 BV 8T-4133
AH 8T-4244 BW 228-7091 K
AJ 157-6285 Retain
AK 8T-4985 R 5P-7464 Clip BN
AL 194-3435 D E AE AF AH S 5P-7465 Clip
AM 163-1977 U 6V-3965 Adapter
AN 8T-7338 BP
V 6V-0852 Cap
AP 9X-8257 Unclip AJ AK AL
BM 6V-1249 Grommet
AR 235-2482 Brake BN 6D-4244 Clip BR BS BT BU BV
AS 192-5665 BP 5D-0718 Clip
C 1P-4585 AP 9X-8257
D-E H CA AP BB CD CE
E 8T-4223 AT 8T-4140 C
A
H 8T-4139 BA BB AP AZ AZ 8T-4193
AP 9X-8257 BB 6V-1197 CB CC
AT 8T-4140 BX 192-3480 AT AP BZ
AU 194-3006 AP AW AX AZ BY 192-3477
AV 124-1859 BZ 6V-5101 H
E H AY AP AZ BX BZ
AW 6V-5040 CD 7X-2555 B
AX 6V-5039 C AP AT CE 8T-4132 D
AY 9X-6400
AZ 8T-4193 Retain
BA 228-4421 CA 156-5744 Clamp
BB 6V-1197 CB 6V-4356 Clip AP AZ BY BZ
AU AV
CC 6V-4357 Clip
Retain E 8T-4223
E J
AA 151-8062 Bracket As AH 8T-4244 CF E R S AH BM CG
BS 8T-4196
Reference: BT 8T4121
Refer to AA BV 8T-4133 F
REHS9541 CG 8T-4194 BN BP BS BT BV
Step 1 of
Fabricated
Retain J K
Parts
R 5P-7464 Clip
S 5P-7465 Clip
BM 6V-1249 Grommet G
BN 6D-4244 Clip
BP 5D-0718 Clip E
CF 156-5745 Clamp
 Step 1 - 7 Step 8 - 14 Step 15 - 20
1 388-0810 (1) Plate A 18 8T-4223 (5) Washer C 5 235-2482 (1) G
(Dimensions: 56 inches x 35 inches)

Plate R S T 18 28 55
2 388-0811 (1) 28 8T-4184 (1) Bolt 6 8T-4140 (4) Bolt
3 387-3158 (1) Tube As 1 2 4 5 36 235-2481 (1) O-Ring 7 9X-8257 (4) Washer 5 6 7 36
4 8T-0439 (4) Bolt 38 8T-4910 (4) Bolt 18 8T-4223 (4) Washer
REHS9540-07

5 235-2482 (2) Seal 28 8T-4184 (4) Bolt

6 8T-4140 (4) Bolt Reuse 29 8T-0568 (1) Seal 18 28
7 9X-8257 (4) Washer R 5P-7464 Clip 36 235-2481 (2) Seal
8 6V-5052 (1) Seal S 5P-7465 Clip 52 452-6656 (1) Plate
T 6V-7359 Grommets 53 8T-3957 (4) Bolt
54 9S-8004 (1) Plug As
55 452-6654 (1) Tube As 52
3 6 7 8 18 36 38 57 374-8227 (1) Plate 57 58
54
58 383-1184 (1) Adapter

9 5P-1296 (1) Hose As A D-E 6 8T-4140 (4) Bolt G

42 Page,

10 387-3159 (1) Tube As AS 10 7 9X-8257 (4) Washer 26 83 84

11 9X-2201 (4) Clamp 18 8T-4223 (8) Washer
17 8T-4194 (1) Bolt 26 214-7568 (1) O-Ring
12 375-3193 (1) Clip
18 8T-4223 (4) Washer 39 28 8T-4184 (4) Bolt
13 375-3192 (1) Clip
20 8T-4139 (4) Bolt 29 8T-0568 (2) O-Ring 53
14 8T-4195 (1) Bolt 30 1P-4584 (2) Flange
39 387-3160 (1) Tube As
15 5P-1075 (1) Washer 53 8T-3957 (4) Bolt
40 156-5744 (4) Clip 17 18 41 88 78 1P-4585 (2) Flange
41 6V-4356 (1) Clip 83 6V-3965 (2) Adapter 6 7 78
12 13 14 15 Clip 18 20 40
88 6V-4357 (1) 84 6V-0852 (2) Cap
AS 192-5665 Control Gp
Brake Lubrication 18 28
9 11 18 28 29 30
GP onto
52 452-6656 Plate As

B 6 8T-4140 (8) Bolt D 6 8T-4140 (12) Bolt H 6 7 43 59

16 383-8878 (1) Plate As 6 7 42 43 44 40 63 64
7 9X-8257 (16) Washer
18 8T-4223 (10) Washer 7 9X-8257 (8) Washer 26 214-7568 (1) O-Ring
19 329-3356 (4) Nut 31 6V-8001 (1) O-Ring 40 156-5744 (2) Half Clamp
21 383-8883 (1) Plate 42 598-1122 (1) Hose As 43 6V-1197 (1) Seal 26 83 84
18 21 48 56 8T-4193 (4) Bolt 6 7 60 61
38 8T-4910 (4 Bolt 43 6V-1197 (1) O-Ring
48 8T-4183 (2) Bolt 44 1P-7016 (2) Flange 59 444-4950 (1) Tube As
60 444-4947 (1) Tube As 67 68 69
78 1P-4585 (2) Flange 61 6V-5101 (3) 6 7 61 70
O-Ring
Reuse 16 18 19 38 63 8T-4196 (2) Bolt
L 329-5526 Adapter As 64 7X-7729 (4) Washer
67 383-4257 (1) Adapter
M 6V-9170 Bulkhead 68 383-4256 (1) Plate
L M
69 8T-4944 (4) Bolt
6 7 31 78 70 5S-9134 (1) O-Ring
83 6V-3965 (1) Adapter 7 56 61
84 6V-0852 (1) Cap
G C
18 8T-4223 (8) Washer B 18 20 22 23 24 25 26 6 8T-4140 (4) Bolt E 14 8T-4195 (3) Bolt H 62 F B
82 79 14 65 66 85 86
20 8T-4139 (4) Bolt 7 9X-8257 (4) Washer 62 448-3454 (1) Hose As
22 383-8876 (1) Tube As 8 6V-5052 (1) O-Ring 65 444-4950 (3) Nut
23 5P-9371 (1) Seal 45 598-1123 (1) Tube As 45 66 8T-4195 (6) Washer
24 8T-5041 (4) Bolt 79 446-9532 (1) Hose As E D
25 9S-4191 (1) Plug Reuse 82 446-9531 (1) Hose As
26 214-7568 (1) Seal AA 151-0862 Plate 85 5D-0718 (3) Clip
From the 86 8J-8197 (3) Clip
A
14 65 66 85 86
Procedure 6 7 8

AA
14 65 66 85 86

18 20 18 8T-4233 (10) Washer 6 8T-4140 (8) Bolt J 6 7 71 73 6 7 70 72

6 8T-4140 (4) Bolt B F 18 19 38 46 9X-8257 (16) Washer
19 329-3356 (4) Nut 7
7 9X-8257 (4) Washer 26 214-7568 (1) O-Ring
18 8T-4223 (8) Washer 38 8T-4910 (2) Bolt 56 8T-4193 (8) Bolt
20 8T-4139 (4) Bolt 46 383-8879 (1) Plate As 61 6V-5101 (1) Seal
47 383-8885 (1) Plate 63 8T-4196 (2) Bolt
27 508-8374 (1) Hose As Washer 63 64 87 26 83 84
64 7X-7729 (2)
28 8T-4184 (4) Bolt 48 8T-4183 (2) Bolt 67 383-4257 (1) Adapter
29 8T-0568 (1) O-Ring 68 383-4256 (1) Plate J H
30 1P-4584 (2) Flange Resue 18 47 48 69 8T-4944 (4) Bolt 7 56 61
31 6V-8001 (1) O-Ring L 329-5526 Adapter As L M 70 5S-9134 (3) O-Ring
6 7 27 31 78
77 508-8375 (1) Hose As M 6V-9170 Nut-Bulkhead 71 521-4543 (1) Tube As
72 Tube As 7 56 70
78 1P-4585 (2) Flange 444-4951 (1)
73 8T-9527 (1) Seal
83 6V-3965 (1) Adapter
18 28 29 30 77 84 6V-0852 (1) Cap
67 68 69 70
87 156-5745 (2) Half Clamp
18 8T-4223 (4) Washer C 18 8T-4223 (12) Washer F J
18 20 49 14 65 66 86 80
26 214-7568 (2) Seal 20 8T-4139 (8) Bolt 14 8T-4195 (4) Bolt 76
35 36
29 8T-0568 (1) O-Ring 49 383-8877 (1) Tube As 18 20 65 444-4950 (4) Nut
32 388-1416 (1) Plate As 23 5P-9371 (8) Seal 66 8T-4195 (8) Washer
33 095-0673 (4) Bolt 24 8T-5041 (4) Bolt 76 446-4953 (1) Hose As
18 20
18 34 80 446-9532 (1) Hose As A B
34 8T-6868 (4) Bolt 25 244-3712 (1) Plug As Hose As
81 444-4949 (1)
35 388-1417 (1) Tube As
85 8J-8197 (4) Clip
36 235-2481 (2) O-Ring 81
18 23 24 25 86 5D-0718 (3) Clip
83 6V-3965 (2) Adapter 14 65 66 85 86
84 6V-0852 (2) Cap H
26 83 84 14 65 66 85 86
D C

29 32 33 14 65 66 85 86

6 8T-4140 (4) Bolt C 6 8T-4140 (4) Bolt F 18 28 29 30 50

7 9X-8257 (4) Washer 7 9X-8257 (4) Washer
18 28 29 30
18 8T-4223 (4) Washer 18 8T-4223 (4) Washer
28 8T-4184 (4) Bolt 28 8T-4184 (4) Bolt 6 7 31 51 78
29 8T-0568 (2) O-Ring 29 8T-0568 (1) Seal
30 1P-4584 (2) Flange 30 1P-4584 (2) Flange F
31 6V-8001 (1) O-Ring 31 6V-8001 (1) O-Ring
37 436-6639 (1) Adapter 50 508-8376 (1) Hose As
78 1P-4585 (2) Flange 51 512-9527 (1) Hose As
78 1P-4585 (2) Flange
J

G
6 7 29 31 37 78 E