I-B-15
PARTS-SERVICE
Date: April 20, 1987
Model: R40DH
GRAM
Hoist
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
2008593 Boss 1
2008238 Bearing ring 1
2005296 O-ring 1
2005297 Scraper ring 1
2003299* Mach-free-lift head 1
2008236 Rod seal 1
2008245* Flow restrictor-modified 1
2008237 Hex. head plug BSPP 1
2008242 Sealing washer 1
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.
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.
H6030
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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.
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April 20, 1987
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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.
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April 20, 1987
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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)
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April 20, 1987
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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.