Usage:
D25D ( 1HK ),
D30D ( 3AJ ),
D40D ( 2JJ ),
D350D ( 9RF ),
D400D ( 8TF ) Trucks
Description of Change: A new, more secure door stop is used on the above models. The new stop has a fixed length which prevents the door from opening further than originally set. Previously, the door stop consisted of a webbed material and an adjuster. The material had a tendency to stretch and slip through the adjuster. This could increase the length of the webbed material and permit the door to open more than necessary. See Illustration 1.
Adaptable To: The new 8W2257 Door Stop replaces the former 3G1992 Strap (1) and 3G1996 Adjuster (2). See the chart for the quantity and description of the parts required for this change. This change is effective with D25D (1HK116), D30D (3AJ121), D40D (2JJ57), D350D (9RF188), and D400D (8TF153) Trucks. This change is also adaptable to first production if the procedure in this article is used.
Illustration 1. Former door stop arrangement. (1) 3G1992 Strap. (2) 3G1996 Adjuster.
Procedure To Install Fixed Length Door Stop On Earlier Machines
1. Fabricate two plates (A) from 10.0 mm (.39") thick steel with a minimum tensile strength of 1 409 356 kPa (204,551 psi), and a minimum yield strength of 737 454 kPa (107,032 psi). Use the dimensions in Illustration 2.
Illustration 2. Dimensions to fabricate two plates (A).
2. Discard strap (1) and adjuster (2). Remove the existing strap mountings (7 and 8) by flame cutting back to the welds. See the arrows in Illustration 1. Do NOT cut into the back of the cab or the door. Finish grind the areas smooth and flat.
3. Drill two 12.5 mm (.50") holes (B) in the rear of the cab, and one 12.5 mm (.50") hole (C) in the inside of the cab door. These holes will provide clearance for the mounting bolts. See Illustration 3.
Illustration 3. Rear view of cab (left). Inside view of cab door (right). Location of three drilled holes.
4. Position plates (A) so that the tapped holes coincide with the drilled holes in the door and cab. Weld plates (A) in position. See Illustration 4.
Illustration 4. Rear view of cab (left). Inside view of cab door (right). Weld plates (A).
5. Prime and paint the door and cab as required.
6. Complete the installation of the fixed length door stop. See the chart and Illustration 5.
Illustration 5. Location of parts required to finish installation of new door stop.
7. Replace the cab trim.