We reserve the right to make changes in design or add improvements without incur-
ring the obligation to make such changes in equipment previously manufactured.

PARTS-SERVICE

GRAM

H6030

SUBJECT: FREELIFT CYLINDER CONVERSION

The freelift cylinder on the production R40DH is now of the displacement type, which improves the
operating characteristics of the freelift. A modification kit, P/N 2008244 is available for converting the
existing piston type cylinder to the displacement type and this gram, (see attached pages) details the changes
to be made for this conversion.

PARTS REQUIRED:

Part No.

Description

Quantity

INTERCHANGEABILITY:

* P/N 2003299 can be machined from the existing head freelift, P/N 2005288.

P/N 2008245 can be machined from the existing flow restrictor,

P/N 6553311.

PARTS STOCK:

Used up

EFFECTIVE SERIAL NUMBER:

This gram applies to trucks with serial numbers up to B176K-1570G.

I-B-15

Date: April 20, 1987

Model: R40DH

Hoist

2008593
2008238
2005296
2005297
2003299*
2008236
2008245*
2008237
2008242

Boss
Bearing ring
O-ring
Scraper ring
Mach-free-lift head
Rod seal
Flow restrictor-modified
Hex. head plug BSPP
Sealing washer

1
1
1
1
1
1
1
1
1

I-B-15
April 20, 1987
Page 2

INSTRUCTIONS FOR CYLINDER CONVERSION

A. Modification of freelift shell weldment (refer to Figures 1 and 2)

1. Remove the breather, P/N 2005291 from the existing breather port.

2. Grind down the breather pipe, P/N 2005292, ensuring a flat surface exists on the shell tube and that

the shell tube wall thickness is not reduced to less than 5mm.

3. Weld on the boss, P/N 2008593, on the flat surface.

4. Remove all debris (and sharp edges) from the cylinder bore and flush out with a suitable degreaser.

B. Piston and freelift head modification (refer to Figures 2 and 3)

1. Remove the existing head freelift, P/N 2005288, from the shell tube.

2. Remove the piston seal, P/N 2005208 from existing piston weldment and replace with the bearing

ring, P/N 2008238.

3. Fit a new o-ring, P/N 2005296 and a new scraper ring, P/N 2005297 to the mach-freelift head,

P/N 2003299 which replaces the head freelift, P/N 2005288. (Note: P/N 2003299, the
mach-freelift head can be generated from P/N 2005288. See Figure 4 for details.)

4. Add the rod seal, P/N 2008Z36 to the mach-freelift head.

5. Fit the flow restrictor - modified, P/N 2008245 to the inlet plug. (Note: The modified flow

restrictor, P/N 2008245 can be generated from the existing flow restrictor, P/N 6553311; see
Figure 5 for details.)

6. Fit the BSPP Hex. head plug, P/N 2008237 and the sealing washer, P/N 2008242 to the boss.

I-B-15
April 20, 1987
Page 3

ITEM QTY

PART NO

DESCRIPTION

1

1

2005285

SHELL TUBE

2

1

2005282

INLET PLUG F.L. CYL

6

1

2008593

BOSS

Figure 1 - Conversion of free-lift shell: weld boss, P/N 2008593 to shell.

I-B-15
April 20, 1987
Page 4

ITEM QTY

PART NO.

DESCRIPTION

1

1

2005290

WLDMT - F.L. SHELL

2

1

2005289

WLDMT - PISTON

5

1

2005206

PISTON SEAL

7

1

2005286

HEAD - FREE LIFT

Figure 2 - Free-lift cylinder (existing)

ITEM QTY

PART NO.

DESCRIPTION

1

1

2008243

WLDMT - F.L. SHELL - MODIFIED

2

1

2005789

WLDMT - PISTON

3

1

12963

SNAP RING R# 156162

4

1

2005260

WASHER

5

1

2008234

BEARING RINGS

6

1

2005296

O-RING R# 2005295

7

1

2003299

MACH-FREE-LIFT HEAD

8

1

2005297

SCRAPER RING

9

1

2006237

HEX, HEAD PLUG BSPP R# 2006117

10

1

2006242

SEALING WASHER

11

1

2006236

ROD SEAL

FIGURE 3 - Free-lift cylinder (modified)

I-B-15
April 20, 1987
Page 5

FIGURE 4 -

Conversion of head-free lift, P/N 2005288 to mach-free-lift head, P/N 2003299: machine
groove ‘A’ as shown.

SECTION A - A

CONE DETAIL

SCALE: NONE

MC RESTRICTOR CONE WITH TWO 8.5 mm FLATS AS SHOWN

FIGURE 5 - Conversion of existing flow restrictor, P/N 6553311 to flow restrictor - modified, P/N

2008245: machine flats as shown.