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Attn: Designer of Technical ePublications
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This material is confidential
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3
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Contents ved
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RevisionhControl
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3
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Important
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Introduction
.................................................................................................................................
9
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Vehicles Covered ...............................................................................................................................
Bo
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Information Included
...........................................................................................................................
9
V
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Other Information
9
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PD...............................................................................................................................
p
S
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Utilivan and Truck
Body Differences .........................................................................................
10
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Wall Construction
Types ...........................................................................................................
10
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11
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12
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12
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Ordering Parts ..........................................................................................................................
13
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Filing Warranty Claims
14
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n15
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Reporting Safety Defects
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Canada Only
15
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16
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16
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16
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17
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17
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17
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17
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Truck Body and PDV—Body Service Manual
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More Information ......................................................................................................................
18
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Utilimaster Quick
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18
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Utilimaster Detailed Parts Manual ....................................................................................................
18
v
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Utilimaster
18
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Contact
Utilimaster ...........................................................................................................................
18a
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Safety
19
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e 19
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Towing and Emergency
19
P Repairs .......................................................................................................
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20
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20
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Body Maintenance
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20
B
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20
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20
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Door, Central Locking System (Trademaster
ti Compartments) a............................................................ 21
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Door, General .....................................................................................................................................
21
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22
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Other Body Parts ................................................................................................................................
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Tools and Fasteners .........................................................................................................................
25
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Common Tools .........................................................................................................................................
25
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Fastener Replacement
.............................................................................................................................
26
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26
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27
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28
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28
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29
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31
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Download Files ................................................................................................................................. 18
®
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Truck Body and PDV—Body Service Manual
5
Service Procedures .......................................................................................................................... 32
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Body Mounting
32
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34
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34
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b
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35
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36
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Door, Central LockingB
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37
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37
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38
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Cable Replacement (with Tension
39
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41
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42
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44
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Bottom Panel Replacement
...............................................................................................................
46
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Protective Beam (Load Bar) Assembly
48
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Roller Play Adjustment .......................................................................................................................
48
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Roller Replacement ............................................................................................................................
k
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MSL (“Banana Lock”) Replacement
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ru
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Two-point (Fan-type)sLatch Adjustment .............................................................................................. 50
a
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Pull Strap Replacement
.....................................................................................................................
51
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Door Seal Replacement
.....................................................................................................................
51
Ut
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Drains .......................................................................................................................................................
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54
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54
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Lights ........................................................................................................................................................
55
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Clearance, Identification, iand
55
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Stop/Turn/Tail/Back-upc.......................................................................................................................
56
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License Plate .....................................................................................................................................
57
2
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Cargo .................................................................................................................................................
58
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Mirror ........................................................................................................................................................
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Adjustment
.........................................................................................................................................
59
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......................................................................................................................................
59
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Battery, Disconnecting .............................................................................................................................. 32
6
Truck Body and PDV—Body Service Manual
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Tools andvParts
60
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61
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62
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63
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64 l
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M 64
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64
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64
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Panel, DuraPlate
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65
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65
B
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66
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66
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P
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67
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Self-adhesive Panel (Option C) ..........................................................................................................
68
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Entire Panel Replacement (Option
70
d
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Rear Vision (Back-up) Camera System
78
rp ....................................................................................................
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Operating Instructions ........................................................................................................................
C
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Monitor Controls .................................................................................................................................
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Basic Troubleshooting
79
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Troubleshooting
80
il Flowcharts ...............................................................................................................
bi
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Roof ..........................................................................................................................................................
83
U
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Front 0
(Fiberglass) Cap Replacement .................................................................................................
84
w
pr
a
0
l
2 (Aluminum) Corner Casting Replacementy ................................................................................
n
Front
85
n
t
o
i
o
b
h
i
t
(Aluminum) Radius Replacement .............................................................................................
t 85
c
d
ig Front
a
u
r
r
e
d
y Rear Corner Casting Replacement ....................................................................................................
o 86
it
p
o
p
b
r
i
r
Roof Panel REPAIR ...........................................................................................................................
86
p
h
o
Co
C
Roof Panel REPLACEMENT ..............................................................................................................
86
re
ro
r
p
d
e
Scuff Plate ................................................................................................................................................
88
t
e
n
z
s
o
i
a
Lower Scuff Plate ...............................................................................................................................
88
r
ti
o
c
m
Top “Gator” Plate ................................................................................................................................
88
u
th
ili
d
t
u
d
o
Slats .........................................................................................................................................................
89
U
a
r
e
n
4
v
p
r 90
Switch, Cargo Light
U
0
e
re ..................................................................................................................................
0
s
2
Vents ........................................................................................................................................................
91
d
e
t
e
r
h
z
Side i....................................................................................................................................................
91
s
g
r
t
i
h
Front
92
yr
ho ...................................................................................................................................................
g
i
t
p
r
93
l
au Roof ...................................................................................................................................................
l
Co
n
A
U
Paint ......................................................................................................................................................... 60
®
Truck Body and PDV—Body Service Manual
7
Wiring Diagrams ....................................................................................................................... 94
l
d
a
e
aw
u
l
v
r Diagram ............................................................................................................
y
Connector Locating
95
e
an
b
s
M
Cargo Light
96
d
reWiring ...........................................................................................................................
e
e
t
s
c
i
TaillighttWiring ..................................................................................................................................
97
bi
v
h
i
r
g
e Wiring ...................................................................................
Clearance/Identification/Marker
Light
98 l
ri
oh
a
S
r
lRear
u
l
p
Vision (Back-up) Camera
System Connections ......................................................................
99
y
n
A
d
a
n
o
o
Index ......................................................................................................................................
M 100
B
ti
e
c
—
u
ic
V
d
v
r
ro
e
PD
p
S
d
y
re
d
an
d
e
y
Bo
z
d
i
r
—
o
Bo
V
h
t
k
c
u
PD
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n
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n
Un
it o
a
a
y
r
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o
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p
r
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o
k
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aw
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r
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r
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b
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a
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t
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il
bi
t
i
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n
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o
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r
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a
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er
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ig
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U
Circuit Number Identification and Codes .......................................................................................... 94
8
Truck Body and PDV—Body Service Manual
l
a
u
Introductioned
n
aw
l
a
v
r
y
M Information Included
Vehicles Covered
e
b
s
e
d sections contain informaic
re
This manual includes
service informationvfor
This manual’s various
e
t
r ,
i
ts Metromaster , Trademaster
Utilimaster’s
tion on:
e
b
h
i
• Repair
procedures
and Utilivan
vehicle bodies, knownSgenerically
l
ig
y mounted
r
oh and replacement
r
• Maintenance
(inspection and lubrication) ua
as PDVs
ll (Parcel Delivery Vans)odand
p
n
A
•n Wiring diagrams
(usually)
on cutaway chassis,Bas well as
a
M
Utilimaster’s truck bodies—
mounted (usually)
tio• Warranty claim procedures
e
V
c
on cab chassis.
u • Flat rates (warranty time and laborvicstandards)
PD
d
• Other resources
o
NOTE: Utilivan
and Trademaster
d
r
er
n
p
S
This manual contains drawings and photos to aid
bodies can
a also be mounted on cabre
y
y
in servicing the vehicle, and itdmay include mainchassis,
and Utilimaster truck d
d
o items installed but
e
o
tenance information on some
bodies
can be mounted on cutaway
B
z
i
B The body style is ther
not manufactured by Utilimaster
Corporation.
chassis.
—
k
o
V
c
h
Items such as chassis
t the
D and drive train components
u important factor regarding
r
u
P
or
certain
interior
furnishings
may be covered by
information
in
this
manual,
not
the
T
a
d
n
n
separate manufacturer-supplied
information.
type of chassis it is mounted on.
n
U
io
a
t
Information
provide
here
is
intended
to assist
y
NOTE: Your type of vehicle and ra
d customers and is no way meant to
Utilimaster
installed options determine the po
o
replace
r
B or supercede instructions provided by
relevance of the various sections
o
k
other
C
c suppliers of their products.
aw
of this manual. This service
l
r
u
y
information is generic.teDetails in
Tr All information, specifications, and illustrations
b
s
contained in this manual are based on the
illustrations and procedures
may
a
d latest
e
m
product information available at theittime of
differ from thoseliin your vehicle.
i manufactures
t
publication. However, because ofibUtilimaster’s
Because Utilimaster
U
h
policy of continual product improvement,
the
many customized
vehicle bodies,
o
4
r
w
0
p document is subject
information
contained in this
this manual
0 cannot list and
lachange without
2
n
to
notice.
illustrate
every
possible
part
in
n
y
t
o
i
o
b
h
i
t
every
vehicle. Nevertheless, the
c
d Other Information
ig common
at
u
r
r
most
body options are
e
d
y described here. Use this
o
it
p
o
p
b
See
the
appropriate
body
parts
manual
for
more
r
i
r
o
Co information as a guideline whereritoh
informationep
about ordering replacement
parts.
C
r
applies.
(See thedMore Information section,r surf
p
e
t page on
e
n
Utilimaster’s
Technical Manuals
z
s
o
i
a contact Customer
r
ti
www.utilimaster.com,
and/or
o
c
m
u
thService.)
ili
d
t
u
o
U manual or order the ed
a To download the correct
r
n
4
v
p
r
U
0
e
correct
parts
you
will
need
to
know
whether
you
r
0Metromaster, Trademaster,se
2
have a Utilivan,
d
e
t Truck Body. If you are runcertain,
e
h
z
Aeromaster,
or
ri
tson
ig
see Utilimaster’s
product information
r
o
h
y
h
ig
t
www.utilimaster.com
and the following
two
p
r
u
o
l
a
l
sections.
C
n
A
U
®
®
®
Truck Body and PDV—Body Service Manual
9
Utilivan and Truck
Body Differences
l
d
w
a
e
a
u
l
v
Although Utilimaster
in some areas (e.g.,
r Utilivans and Truck Bodiesanhave many parts in common,
y your
e
subframe, front wall,
rear
structure)
you
will
need
to
know
which
body
model
vehicle has to
b
s
M
e
d
correctly orderrparts. The body model can e
be identified by looking at the
(cargo floor) and its
te subfloor
s the sidewall. The floor of iacTruck Body is built of structural
i
attachment tto
I-beam
crossmembers
b
v
h
i
r
(visibleig
from underneath) and is attached
hfasteners. The Utilivan uses formed-C al
e to the sidewall with two
r
o
S
crossmembers
that attach to the sidewall with a single fastener.r See Illustrations FL–10 and FL–20.
l
u
p
y
n
Al
d
a
n
M
io
Bo
t
e
c
—
u
ic
V
d
v
r
ro
e
PD
p
S
d
y
re
d
an
d
e
y
Bo
z
d
i
r
—
o
Bo
V
h
t
D
k
c
u
P
a
u
FL–10
n
Tr Two Fasteners Attach the Truck
nd theFL–20
One Fastener a
Attaches
Utilivan Floor and Sidewall
UnBody Floor and Sidewall
it o
a
y
r
d
o
Wall Construction Types
o
p
r
B
o types of body construction.
This manual documents the three different
Metromaster and Trademasteraw
C
ck
l
r
u
construction is FRP only. Utilivan
and Truck Body construction
can be any of these types. See Illustrar
e
y
T
b
tion FL–30.
st
a
d
• Aluminum (sheet andmpost) has an aluminum exterior skin joined to steel vertical interior
e studs with
t
i
i
l
buck rivets. The studs
ti might be covered with an optional interior liner.
iba little rougher
• FRP (FiberglassUReinforced Plastic) has no studs or panel seams and the surface has
n
h
o
o
4
i
r
texture than0painted metal.
w
p panels might
atbe
la panels, but no studs.nThe
r
• DuraPlate20has seams at the overlapping steel laminate
y
t
joinedhtogether
with rivets or adhesive.
io
po
b
t
r
c
o
d
ig
Aluminum
FRP
DuraPlate
u
r
e
C
t
d
y
Construction
Construction
Construction
i
p
o
b
er
r
i
t
o
C
ep
oh
as
r
r
p
d
lim
e
i
n
t
iz
io
U
r
t
o
4
c
0
u
th
0
d
u
2
d
a
ro
e
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n
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er
re
ir g
s
d
y
e
re
p
o
ir z
ts
C
o
h
ig
th
r
u
a
ll
FL–30 Aluminum, DuraPlate, and FRP Construction
n
A
U
Aluminum
panel
(outside)
Optional
plywood
liner
Plywood
core
Fiberglass
coating
Fiberglass
coating
Polyethylene plastic
foam core
Galvanized
steel skin
Galvanized
steel skin
Stud
Rivets or
Adhesive
Rivet
(Viewed from top, 0.040
exterior skin and 3/8”
plywood liner option shown)
10
(5/8” panel shown)
(Viewed from top,
6mm panels shown)
Truck Body and PDV—Body Service Manual
l
a
u
Body (or Unit)
ed Serial Numberan
aw
l
v
r Body (or Unit) SerialMNumber is recorded on theyFederal Certification
The 15-digit Utilimaster
e
b(about 11" long and 2" high)
Label. (See Illustrations
LA–5 and LA–10.)ceThis label is a plastic decal
es
d
i
r
that contains
(including the VIN
te and Work Order Number). This
s a variety of manufacturingeinformation
rv
i
t
label should
h be near the hinge, latch, Sor catch on a cab door or door
ibpost. Open the door to see it.
h
l
ir g
y
o
a
r
ll
d
u
p
o
n
A
a
B
n
M
it o
—
V
c
ce
D
u
i
P
rv
od
d
r
e
S
an
ep
y
r
y
d
d
d
o
e
o
LA–5
B
iz Federal Certification
B
r
Label
—
k
V
c
ho
t
D
u
r
u
P
T
a
d
n
n
U
an
tio
a
y
r
d
o
Vehicle Identification Number
(VIN)
o
p
r
B
o Number k
w
The 17-digit chassis Vehicle Identification
C
c
a
l
r
u
(VIN) is the legal identifier for this
e vehicle and is Tr
y
t
b
the number recorded in the license
plate registration.
s
a
d
The VIN appears in one of
several
locations depende
m
t
i
ing on the model:
il
bi
t
i
• The VIN may appear
U on a small metal plate on
h
o
4
the front corner
0 of the dash on the driver’s side. aw
pr
0
You can read
the
VIN
if
you
look
through
the
l
2
n
n
y
t
o
windshield.
(See
Illustration
LA–15.)
i
o
b
h
i
t
c
• In vehicles
d
ig over 10,000 lb. (4,536 kg.) GVWR,
at
u
r
r
e
d
y plate may be mounted near the latch onitthe
the
o
p
o
p
b
r
i
r
driver’s door post or on the edge of the door.
o
Co Open the door to see it. (See Illustration
ep
oh
C
r
r
p
d
LA–10.)
er
t
e
n
s
• The number is also recorded on
o the Federal
iz
i
a
r
t
Certification Label. (See Illustrations
LA–5 and o
c
im
h
u
l
t
i
LA–10.)
d
t
u
d
o
U
a
r
e
n
4
v
p
r
U
0
e
re
0
s
2
d
t
e
re
h
z
ri
ts
ig
r
o
h
y
h
ig
t
p
LA–10 r
u
o
a
llVIN Plate on Door Post
CFederal Certification Label and
n
A
U
Truck Body and PDV—Body Service Manual
11
ts
h
rig
d
e
rv
e
s
re
ce
i
rv
e
S
l
a
u
an
M
d
ti e
ib
h
o
pr
by
w
la
l
a
ll
u
y
n
A
d
a
n
o
M
io
B
t
e
c
Work Order Numbers
—
u
ic
V
d
v
r
D Label, below the ro
On the Federal Certification
LA–15
e
P
p
S
Vehicle
Identification
Number
Plate
on Dash
Body Serial Number,
is the vehicle’s 7-digit Work
d
e
y
r
n
Order Number.
(See
Illustrations
LA–5
and
LA–
d
a
dmay
o
e
y
10.) This number
(without the leadingzW)
B
d (since 1999) on the left-hand
i
r
also be stamped
base
o
—
B Illustration LA–20.) Onhovehicles built
V
rail. k(See
t
D
c 1999, the Body Serial aNumber
u
P
before
was
u
r
d
n
n
stamped
on
the
base
rail.
Either
number
can
be
T
n
U
io
a
t
used to identify the body if it is no longer mounted
y
ra
on the original chassis.
d
o
o
p
r
B
o
C
ck
aw
l
r
u
r
Part Numbers
e
y
t
T
b
s
d
This manual lists some parts aand kit numbers that
e
m
t
i
i
can be ordered directly from
il the Utilimaster
b
t
i
Customer Service Department.
For more compreU
n
h
o
o
4
i
hensive illustrations
and
parts
lists,
see
the
relr
w
0
Illustration
p LA–20 rat
a
0
evant Utilimaster
parts
manual.
(See
the
Technical
l
Work Order ornBody Serial Number
2
y
t
Manuals page
on
www.utilimaster.com
or
contact
io
po
b
h
t
r
c
CustomerigService.)
o
d
u
r
e
C
t
d
y
i
Somepparts or procedures may be dependent on
o
b
er
r
i
t
o
p
h
Front
which
s
C side of the vehicle they are located.roRight
e
a
r
Hand (RH) or Left Hand (LH) is basedpupon the
d
lim
e
position of the driver while facing forward.
i
n
t
iz
ioCurb Side,
U
Right Hand is also sometimes called
r
t
o
4
c
and Left Hand is sometimes called
0
u Road Side.
th
0
d
u
2
d
Rear
a
ro
e
t
n
v
p
h
U
er
(NS–Not Shown)
re
ir g
s
d
y
e
re
p
Illustration LA–25 s
o
ir z
t
C
Vehicle Orientation
o
h
ig
th
r
u
a
ll
n
A
U
12
Truck Body and PDV—Body Service Manual
al
u
an
M
Ordering Parts
ed
aw
l
v
y
How to Orderer
b
s
e
d
ic
refor this vehicle, gather the
To order parts
e
v
t
s
r
i
followinghtinformation:
e
b
i
S
• Model
l
ig and year of vehicle (200x-Customer
y
r
oh
a
r
ll name).
d
u
p
o
n
A• Chassis VIN or Utilimaster
Body
Number
a
B
n
M
it o
(see page 11).
—
V
c
• Complete shippingDaddress.
ce
u
i
P of shipping.
d
• Preferred method
rv
o
d
r
e
• Complete description
of all the necessary
n
p
S
a
parts (seeythe relevant parts manual). re
y
d
d
• Methoddof payment.
o
e
o
B
NOTE:
iz
B Customer Service prefers
r
—
kpayment by Visa, MasterCard,
V
c
ho
t
D
u
Discover,
or
American
Express
r
u
P
T credit cards. Purchase
a Orders
d
n
Returns
n
U established tio
from customers with
an
a
To return parts
y for credit, call the Customer Service
open accounts are also accepted. r
d
o
Department
o for prior authorization. All returns must
p by
Then contact Utilimaster Customer Service
r
B
be shipped prepaid freight. A restocking fee will be
o
w
using one of the following methods:
C
ck to all returns. Special-order parts are not
charged
a
l
r
u
• Email your order to
y
te (See the Cus- Tr returnable.
b
CustSvc@Utilimaster.com.
s
a
d
tomizable Parts OrdermForm section.)
e
t
i
Customizable Parts Order
• Fax your order tot574-862-7637.
il
bi Form
i
• Call 800-237-7806
U (574-862-3219) and ask You can download a customizable
h form template
o
4
for the Parts0Department.
w
prsite
file
from the Utilimaster web
a
0
l
• Mail or express
service
your
order
to
the
2
n template has a n
www.utilimaster.com.oThat
y
t
following
address:
i
o
b header that you can ccustomize
h
t
with your nametiand
g
Corp.
d
ri Utilimaster
rato
te address. Then, toduorder parts, you only have
y
o
Attn: Parts Department
i
p 65528 State Road 19
p
enter the specific
ro information about theorvehicle—
ib
o
p
h
saving retyping
C
e the same address information
o
P.O. Box 585
r
r
repeatedly.
After completing the form
r C informad
Wakarusa, IN 46573-0585p
e
e file can be emailed assant attachment.
tion, zthe
n
U.S.A.
o
i
r form can also be used fora mailing or faxing.
That
ti
o
c
im
h
u
l
t
i
d
t
u
d
o
U
a
r
e
n
4
v
p
r
U
0
e
re
0
s
2 that our
d NOTE: When phoning Utilimaster, be aware
t
e
re
h
z
219
telephone
area
code
changed
to
574
in
January
ri
ts
ig
2002. The 800 numbers were unaffected.
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Truck Body and PDV—Body Service Manual
13
Filing Warranty
l
d Claims
w
a
e
a
u
l
v
•
Any
claim
that
is
not
legible and complete
If a problem on the Utilimaster
body is caused by a n
r
y
e
a
will be returnedbfor completion.
defect in materialssor workmanship during the
M
e
•
All
paint claims
d require pictures, estimates,
r it will be covered by our Limited
warranty period,
e
e
t
s
c
and prior iauthorization.
t
Warranty. Chassis,
engine, tires, and batteryi failures
v
h
ib damage claims also require
•
Shipping
r
are covered
h
e
ir g by the individual manufacturers.
o estimates, and prior authorization. ual
pictures,
S
r
l
l must meet the requirements
Claims
p damage must also be noted on the n
y listed below.
The
A
d
a
n
Failure to meet these requirements
may
result
in
a
o
Delivery Acceptance form. This form M
o
i
t requires the signature of the carrier driver.
denied or delayed claim. B
c
—
ce
u
i
•
Sublet
work
must
have
the
sublet
repair
V
d
Complete a repair order
with the following
v
r
D
o
order
attached
to
the
service
facility’s
repair
r
e
P
information:
p
S
d
order that is being submitted.
• Chassis VIN
ywithin 30 days
re
n or Utilimaster Body Serial
d
•
Claims must be submitted
a
Number (see page 11).
d
y model of vehicle. ze
after the repair is completed.
Bo
• Year and
d
i
r name and
—
• Owner’s
o
Bo and/or service facility’s
V
h
The claim can be mailed,
t
D faxed, emailed, or
kcomplete address.
c
u
P
performed on-line on our web site (assuming all
a
u• Service center representative’s
signature n
d is included).
n
required
information
Tr (or name).
n
U
it o
aclaims should be mailed to:
• Warranty
a
• Date vehicle was repaired.
y
r
d
Utilimaster
o
• Mileage at time of failure.
o
p
r
BAttn: Warranty Department
• Itemized description of the problem,
o
k
including complaint, cause ofCfailure (if
c 65528 State Road 19
aw
l
r
u
P.O. Box 585
e in detail). Tr
known), and correction (describe
y
t
b
s
Wakarusa, IN 46573-0585
• Service center labor rate
and
total
time
of
a
d
U.S.A.
e
m
repair.
t
i
i (if no
il including cost of parts
• Alternately, you can fax yourib
claim
• Total claim amount,
t
U P/Ns), labor, miscellah the aboveon
photographs are involved) with
(include Utilimaster
o
4
r
ti
(The resoluwinformation to 574-862-7637.
0 and sales tax (if applicable).
neous charges,
p
a
a
0
l tion of the received copies
r
2 or repair order number.
n must be accept• Your claim
o
y
t
o
p hard
b able, or you willcbe
h The claim or repair order
ti asked to mail
NOTE:
ryour
g
o
d
copies.)
number
is the number used to
u
ri
e
Cwith the above
t
d
y
i
•
Or
you
can
email
your
claim
r
match
Utilimaster
payment
with
p
roto Warranty@Utilimaster.com.
ib
te
o
information
p
the
work
done.
It
will
be
noted
on
h
s
C
e download a customizable
o
a
r
(You can
Warr
your payment.
m
p
d
i
ranty
Claim
Form
template
from
the
Utili• Utilimaster authorization number
(repairs
e
il
n
t
z
io
costing over $150 U.S. or fortstructural
rimaster web siteUwww.utilimaster.com. The
o
c
has4a header that you can customize
warranty require prior authorization
from
h template
0
u
t
with your0name and address. Then, to file a
d
Utilimaster).
u
2
d
a
ro
claim, tyou only have to enter the specific e
n
v
p
h
U
information
about the vehicle—saving retypOther claim requirements:
er
re
ir g
s
ing
d $150 U.S. or for structural
y the same address information repeatedly.
• Any repairs over
e
re the
p
warranty require
ir z prior authorization from Co After completing the form information,
ts This
file can be emailed as an attachment.
o
h
Utilimaster,
and that number must appear on
ig or faxing.)
th order. Contact the Warranty
form can also be used for mailing
the repair
r
u
a
ll
Department.
n
A
U
14
Truck Body and PDV—Body Service Manual
l
a
u
w
n
ed
a
l
a
v
Claims are paid semimonthly.
Utilimaster genery Utilimaster, be aware
NOTE: When phoning
er tax on claims. If you doe M
ally does not payssales
b
that
our
219
telephone
area code changed to
d
re exemption number on file,vicplease
not have our tax
e
574 in January
s
rask for
it 2002. The 800 numbers
call 800-528-3454
or 574-862-4561 and
t
e
b
h department to obtain the
were unaffected.
i
S number.
the accounting
h
l
ir g
y
o
a
r
l
d
u
l returning any parts, contact
Before
a Utilimaster
p
o
n
A
a
B
n
Warranty representative.
M
it o
—
V
c
ce
D
u
i
d designed specifications. Improper use or roverloading
v
CAUTION: P
Utilimaster vehicles are builtoto
d
r
e
can cause
damage to the equipment and void the warranty.
S
an
ep
y
r
y
d
d
d
o
e
o
B
iz
B WARNING: Unauthorized ralteration
or improper maintenance or repair can result in possible
—
k dangerous driving conditions.
V
c
ho
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u
r
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P
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an
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Reporting Safety Defects
B
o
C
ck
aw
l
r
United States Only
Canada
Only
u
y
te
Tr
b
s
If you believe that your vehicle
If you believe that your Canadian-registered
a has a defect that
d
m
could cause a crash, injury,
or
death,
you
should
vehicle has a defect that could causeitea crash,
i
l
immediately inform thetiNational Highway Traffic
injury, or death, you should immediately
ib inform
U
h
Safety Administration
Transport Canada, in additionoto notifying Utili4 (NHTSA), in addition to
w
0
notifying Utilimaster.
master.
pr
a
0
l
n call 800-333-0510 (orn
y
t 2 similar complaints, it may
o
If NHTSAhreceives
To
contact
Transport
Canada,
i
b
io
t
g
open an iinvestigation,
and if it finds that a safety d 613-993-9851 in the cOttawa region) or write to:at
u
r
r
defectyexists in a group of vehicles, it may orderite
a
Transport Canada
d
o
p and remedy campaign. However, NHTSA
ro Defect Investigation
ib
rp
recall
Motor Vehicle
o
p
h
o
C become involved in individual problems
cannot
PO Box
C
re 8880
ro
p
between you, your dealer, or Utilimaster.
Ottawa,
Ontario, K1G 3J2 er
d
t
e
n
z
s
o
i
a
To contact NHTSA, you may eitherticall the Auto
r
o
c
m
Safety Hotline toll-free at 800-424-9393
(or 202h
ili
du area) or write to: ut
t
366-0123 in the Washington,oD.C.,
d
U
a
r
e
n
NHTSA
4
v
r
0
epTransportation U
U.S. Departmentrof
e
0
s
2
d
400 Seventh Street
t
e
re
h
z
Washington,
ri DC 20590
ts
ig
r
o
h
y
h obtain other information about motor
You can also
ig
t
p
r
u
o
vehicle asafety from the Hotline.
ll
C
n
A
U
Truck Body and PDV—Body Service Manual
15
Flat Rates (Time
l
d and Labor Standards)
w
a
e
a
u
l
v
Allowed time is theraverage or typical time (in hours)
n needed to make a y
e
a
given repair. In some
cases,
because
of
the
complexity
or unpredictable b
s
M
e
r straight time (ST), the actual
nature of the task,
e repair time recorded,itised
s
c
i
used in a warranty
claim. For example, repairing
a translucent panel
in the
t
b
v
h
i
r
roof is straight
roof is allowed 4.0 h
hours.
l
e
ig time, but resealing aScomplete
r
o
a
Warranty
(or numr
ll claims for labor are theynumber of allowed-time hours
u
pof the repair
n
berAof actual straight-time hours)
multiplied by the labor rate
d
a
n
o
facility at which the job wasBdone.
M
io
t
e
c
—
u impartial treatment
These times have been established
to promote fair and
ic
V
d
v
r
D
in the processing of warranty
claims. The policies
and procedures are
ro warranty
e
Pcommunication
p
S
designed to improve
in
processing
claims
and
to
d
y
re repairs.
minimize customer
d
an inconvenience concerning
d
ya repair has been assignedzean allowed time, this does not
Bo
Even though
d
i
r covered under warranty. These —
mean that
o
Boany such repair is automatically
V
h reference only.
D
timeskmay be used as guidelines tand
c
u
P
a
u
r
d
n
n
DESCRIPTION
TIME
DESCRIPTION
TIME
T
n
U
io
a
t
y
ra
d
Door,
Side
Door, Bulkhead
o
o
p
r
B
o
Handle,
Interior Sliding Door—Replace
Stop, Open Position—Replace
0.2
k
w0.2
C
c
a
Handle,
Exterior
Sliding
Door—Replace
0.5
l
r
u
r
e
y
t
Catch, Closed Position—Replace
0.5
T
b
as
Side Roll-up Door—Replace
ST
d
ti e
Side Roll-up Door Spring—Replace
1.0
Door Seal—Replace ilim
1.0
b
t
i
U
n
h
o
o
Latch—Replace 4
0.5
Electrical
i
r
t
w
0
p
a
a
0
l
r
2
n
Light, Cargo Dome—Replace
0.3
o
y
t
o
Door, Roll-up
i
p
b
h
t
r
c
g
o
d
i
Light,
Clearance/Identification—Replace
0.2
u
Roll-up rDoor—Adjust
0.5te
C
d
y
i
r
p
o
b
e
r
i
t
o
Light, Marker—Replace
0.2
Door
C Cable—Replace
ep
oh0.5
as
r
r
p
dStop/Turn/Tail/Back-up—Replace
lim
Light,
0.2
e
i
Door Side Seal—Replace
0.5
n
t
z
o
i
U
r
ti
o
4
c
Light,
License
Plate—Replace
0.2
Door Bottom Seal—Replace u
1.0
h
0
t
0
d
u
o
a
r
ed
t 2 Off/On—Replace
Switch,hCargo
0.5
Door Latch—Replace p
1.0 n
v
U
er
re
ig
r
s
d
y Cargo Light—Replace re 0.5
Harness,
Counterbalance Shaft—Replace
1.5
e
p
o
iz
r
ts
C
Harness, Rear Clearance Lights—Replace
0.5
o
h
Door, Swing
h
g
i
t
u Swing—Replace
lr
a
l
Handle,
Rear
0.3
Harness,
Taillight—Replace
0.5
n
A
U
16
Truck Body and PDV—Body Service Manual
l
a
DESCRIPTION
TIME
u
d
w
n
e
la
a
v
r
Rear
Structure
Floor Assembly
y
M
e
b
s
e
d
Grab Handle—Replace
0.2
re Bolts—Tighten Fastenersvic0.1
Body Mounting
e
t
s
r
i
t Bolts—Replace
Body Mounting
e 0.3
h
ib Post—Reseal
S
Rear Corner
0.5 l
h
ir g
y
o
a
Floor
0.2
r
l Corner Seal, Top—Replaceod
u
l
p
n0.3
License
Plate Bracket—Replace
A
a
B
n
Hardwood Floor—Complete
M
—Replacement 16.0 tio
e
V
c
u Sidewall
ic
PD
Mud Flap Bracket—Replace
0.7 d
v
d
ro
er
E-track—Repair
0.2
n
p
S
a
e
Mud Flap—Replace
0.4
y
r
y
d
d
d
Side Vent—Reseal
0.3
o
e
o
B
z
i
B
—
FrontkWall Assembly
or
Apitong (Wood) Scuff—Replace
1.0
V
c
h
t
D
u
r Roof Cap—Reseal au
Front
1.0
PSlats—Replace
T
Apitong (Wood)
0.4
Front Corner Post—Resealn
0.5 n
d
n
o
U
a
ti
a
y
Baserail—Replace
7.0
r ST
Aluminum Panel—Repair
d
o
o
Aluminum Panel—Replace
p 8.0
r
B
Aluminum
Panel—Repair
ST
o
kAluminum Panel—Replace
w
C
c
la ST
FRP Panel—Repair
ST
r
u
r
e
y
t
FRP Panel—Replace
ST
T
b ST
DuraPlate Panel—Repair
as
d
DuraPlate Panel—Replace
ST
te
im
DuraPlate Panel—Repair
ST
i
l
i
b
t
DuraPlate Panel—Replace
ST
U
hi
FRP
Panel—Repair
ST
o
4
r
w
0
ST
0
laFRP Panel—Replace n p
Mirrors t 2
n
y
o
i
o
b
h
i
t
Reflector Tape—Replace
c
Rear Crosswalk
Mirror—Replace
0.2 d
ig
at 0.1
u
r
r
e
d
y
o
it
RearpCrosswalk
Mirror—Tighten
0.1
o
p
b
r
i
r
o
Co
ep
oh
C
r
r
p
Roof
d
er
t
e
n
s
iz
io
a
Complete Roof—Reseal
4.0
r
t
c
Complete Roof Structure—Replace
ST
im
ho
u
l
t
i
d
t
u
d
o
U
a
r
e
n
Translucent Panel—Repair
ST
4
v
p
r
U
0
Translucent Panel—Replace
ST
e
re
0
s
2
d
t
e
re
h
z
Roof Bows—Tighten
0.2
ri
ts
ig
r
o
h
y
hBracket—Replace
ig
t
p
Cargo Light
0.2
r
u
o
a
ll
C
n
A
U
DESCRIPTION
Truck Body and PDV—Body Service Manual
TIME
17
More Information
l
d
a
w
e
a
u
l
v
n
Download Files
r
y
a
e
b
s
M
e
Many support rdocuments,
including those described
here, are downloadable
d
ce
(as Adobe tAcrobat
PDF files) from our iaward-winning
web site at ite
s
b access
h
rv
www.utilimaster.com.
Click on the Technical
Manuals button, ito
g
e
h
l
i
the download
page. To view the files
r
S you must have the Adobe
o Acrobat
a
r
l
u
l version 4.0 or higher installed
y on your computer. Acrobat
p readers are
Reader
n
d
A
a
n the Adobe web
o
available free for all leading computer
operating systemsoon
M
B
i
t
site (www.adobe.com). —
e
c
u
ic
V
d
v
r
o
Utilimaster Quick
e
PD Reference PartsprGuide
S
d
y
reUtilimaster vehicles in the Utilin replaced parts for most
Easily find commonly
d
a
d
master Quick
e illustrated document includes part Bo
y Reference Parts Guide. zThis
d
i
numbers ofor door hardware, electricalr components, mirrors, vents, mud flaps,
—
o It also includes sealants and repair kits.
roll-upB
door parts, and many otherhparts.
V
t
k
c
u
PD
a
u
r
d
Detailed nParts Manual on
TUtilimaster
n
U
it
amanuals.
a bodies in detailed parts
Find parts specific to Utilimaster PDV and truck
y
r
d
o
o
p
r
B
Utilimaster Glossary of Terms
o
k
w
C
c
a
l
r
u
If you are not familiar with someeof the terminology used
in this manual, you
y
t
Tr and definitions in the
b
can find many Utilimaster andsindustry
associated terms
a
d
Utilimaster Glossary of Terms—Body
Information Guide.
e
m
t
i
il
bi
t
i
U
n
h
Contact Utilimaster
o
o
4
i
r
t
wand its products or p
0
a
Browse our site0for more information about Utilimaster
a
l
r
2 Customer Service by using one of
n
o
contact Utilimaster
the following methods:
y
t
o
i
p
b
h
t
r
• Call 800-237-7806
(or 574-862-3219).
c
g
o
d
i
u
r
C
• Faxyto 574-862-7637.
ti e
d
p
o
b
er
• Email
to
CustSvc@Utilimaster.com.
r
i
t
o
•CMail to the following address:
ep
oh
as
r
r
Utilimaster
p
d
lim
e
i
n
Attn: Customer Service Department
t
iz
io
U
r
t
65528 State Road 19
o
4
c
0
u
P.O. Box 585
th
0
d
u
2
d
Wakarusa, IN 46573-0585
o
a
r
e
t
n
v
p
h
U.S.A.
U
er
re
ir g
s
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re
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NOTE: When phoning Utilimaster,
be aware that
o
ir z
ts
our 219 telephone area codeCchanged to 574 in
o
h
ig
th
January 2002. The 800 numbers were unaffected.
r
u
a
ll
n
A
U
®
18
®
Truck Body and PDV—Body Service Manual
al
u
an
M
Safety Considerations
ed
aw
l
v
r and Warnings
y
Notes, Cautions,
e
b
s
e
d
ic come across NOTES, CAUTIONS,
re the procedures, you will
As you read through
e
v
t
i
ts
and WARNINGS.
Each one is there forera specific purpose.
b
h
i
S
g
h
l
• ri NOTES give you additionalyinformation that will helpro
you to complete the procedure.
a
ll
d
u
p damage the vehicle.
o making an error that could
n
A • CAUTIONS warn youBagainst
a
n
o
M
i
—
t is a risk of personal injury.
• WARNINGS remind
V you to be careful whencthere
ce
D
u
i
d heed when you work on the vehicle’s body.
Below are some basicP
WARNINGS that you should
rv They are
o
d
r
e
not all inclusive, however,
and common sensepmust be used when servicing vehicles. S
an
re
y
dy on the
• Do NOT smoke whileoworking
• Always
wear safety glasses and wear
other
d
d
e
vehicle.
B
proper
ir z steelBo protective equipment (gloves,
—
ktoed shoes, face shields, kneeopads, hearing
• Always removeVrings, watches, hanging
c
h the process.
t
protection)
as
appropriate
to
u
jewelry, and
u
PDloose clothing before working
Tr• Use safety stands and/or
a
d Tie long hair securely behind
on a vehicle.
n wheel blocks on
n
U
i
your
head.
a
whenever you are underneath the vehicle.
at
r
dy familiar with all warning labels.
o
• oBecome
• Be sure that the ignition switch is Off
unless
rp
B
otherwise required by the procedure.
o
• Always maintain firm footing and controlwof
k
C
c tools.
la
• Put the transmission in Parkr and set the
u
r
e
y
t on the vehicle. T • Use only tools that are in good condition,
parking brake before working
b
as
d
and use them only in the appropriate
• Operate engines only
m in well-ventilated areas.
te manner.
i
it li
ib injuries
• Get help when needed tohavoid
• Keep yourselfUand your clothing away from
o
caused by overexertion.
the radiator4fan, belts, and any moving parts
r
w
0
when the0engine is running.
la• Always be aware nof pthe location of other n
2
t contact with hot metal parts, such as by
io trip hazards (e.g., airtio
people and potential
• Avoid
h
t
c cords, tools).
d
ig radiator or exhaust system.
lines, electrical
the
u
r
ra
e
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d
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o
i
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C
Towing
and Emergency Repairs
C
re
ro
r
p
d
e
Problems with the Utilimaster body are
t
e
n unlikely to disable iazvehicle
s
o
enough to make it undrivable. See
chassis operator’sr manual
a
ti the
o
c
m
and the engine service manual
for
emergency
information.
u
th
ili
d
t
u
d
omanual for information
See the chassis operator’s
U
a on towing
r
e
n
4
v
precommends the following:
procedures. Utilimaster
r
U
0
e
re
0
s
2
• A wheel liftdor flatbed equipment is the preferred method of ttowing.
e
re
h
z
i vehicle when possible to reduce stress on theigchassis
• Unloadrthe
ts
r
o
h
y
during
h towing.
ig
t
p
r
u
o
ll if towing.
• a
Be sure to place the transmission in Neutral and fully
C release the parking brake
n
A
U
Truck Body and PDV—Body Service Manual
19
Service Information
l
d
w
a
e
a
u
l
v
Manufacturers’r Recommendations n
y
e
a
b
s
Mprovided by
Safety, application,
d
re and operation instructions
e
e
t
the manufacturer
with
sealants,
adhesives,
cleaners,
access
c
i
t
bi
v
i
sories, andhother equipment should always
supersede
r
l
ig provided by Utilimaster.Se
information
r
oh
a
r
ll
u
p
y
n
A
d
a
n
Body Maintenance Checklist
M
io
Bo
t
e
c
—body is low-maintenance.uHowever,
By design, the Utilimaster
ic
V
d
v
r
Utilimaster recommends
the following items should
be checked every
ro more
e
PDunless
p
S
three to four months,
otherwise
stated.
For
detailed
d
y
re manual.
information, check
d
an the relevant sections ofd the
e
y
Bo
z
d
i
r
—
Pre-Trip
BoInspection (daily) ho
V
t items on the body each day:
k
u
Thecdriver should check the following
PD
a
u
d
n
Tr ! Adjust crosswalk mirrors
n
Un as needed. tio
a
a
y
r
! Inspect operation of rear vision camera
d
o system. See theoRear
p
Vision (Back-up) Camera System
section.
r
B
o
k
C lights.
! Check all exterior and interior
c
aw
l
r
u
y
te and close tightly.Tr
! Check that doors open s
easily
b
a
d
e
m
t
i
il
(every three to four months)
bi
Routine Body Maintenance
t
i
U
n
h
o
o
4
Utilimaster recommends
that
a
technician
do
the
above
pre-trip
ini
r
t
w
p
a
00
spection before2performing
the following body maintenance
la checks:
r
n
o
y
t
o
i
p
b
h
t
r
Bumpers
c
o
d
ig
u
r
e
C
t
d
! yCheck for loose fasteners on the bumperi and brackets.
p
o
b
er
r
i
t
o
C ! Check for damaged or bent components.
ep
oh
as
r
r
p
d
lim
e
i
n
t
iz
io
U
r
t
o
4
c
0
u
th
0
d
u
2
d
a
ro
e
t
n
v
p
h
U
er
re
ir g
s
d
y
e
re
p
o
ir z
ts
C
o
h
ig
th
r
u
a
ll
n
A
U
20
Truck Body and PDV—Body Service Manual
l
a
u
ed See the Door, Centralan
aw
needed.
! Lubricate as v
l
r (Trademaster) section. M
y
Locking System
e
b
s
e
e
d
ic
Door, Generalr
e
v
t
r
i
ts
e
b
h
i
! Check
operation
of
the
locks.
S
Catch
h
l
ig
y
r
o
a
Plate
r
ll! Check interior and exterior
d
handles for
u
p
o
n
A tightness.
a
B
n
o
M
i
—
1/8"
! Check alignment of
V latches and catches. At ct
ce
D
u
i
latch
tongue
needs
to
least 1/8" of the
Kason
P
d
rv
engage the catch
plate. (See Illustrationro
d
e
S Latch
MC–10.)an
ep
y
r
Tongue
y
d
d
d
! Check
for
wear
on
the
bulkhead
catch
plates
o
e
Illustration
B MC–10
ir z
and
Bolatch tongue.
Check Latch Tongue
and Catch Plate for Wear
—
k
o
V
c
h
!
t seals around door
u Inspect and clean rubber
r
u
PD
edges.
T
a
n
nd
Unlock cylinders withtioa light
! Lubricate ABLOY
a
a NUTO
y
oil (such as Exxon Hydraulic oil type
r
d
o
o
68, or equivalent, for the lock cylinders.)
p
r
B
obecome dirty, use k
! If the ABLOY lock cylinders
C
c
aw
l
r
u
ZEP 45 penetrating lubricant
e to clean the Tr
y
t
b
cylinders before applying
the NUTO 68.
s
a
d
e
m
t
i
i
il
b
t
i
NOTE: ThisUservice information
h
o
4
is generic.
Details
in
illustrations
w
0
pr
a
0
and procedures
may
differ
from
l
2
n
n
y
o
thoset in your vehicle. Since doors
i
o
b
h
i
t
c
differ,
d
ig adapt these instructions as
at
u
r
r
e
d
y needed.
o
it
p
o
p
b
r
i
r
o
Co
ep
oh
C
r
r
p
d
er
t
e
n
s
iz
io
a
r
t
c
im
ho
u
l
t
i
d
t
u
d
o
U
a
r
e
n
4
v
p
r
U
0
e
re
0
s
2
d
t
e
re
h
z
ri
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Door, Central Locking System (Trademaster Compartments)
®
®
®
®
®
Truck Body and PDV—Body Service Manual
21
Door, Roll-up
l
d
a
e
aw
u
l
v
rof the door and strap: an
y
Check the condition
e
b
s
M
e
d
! Check rthat the door opens easily and
e
e
t
s
c
i
t tightly.
closes
bi
v
h
i
r
g
l
! riCheck condition of latch. See
oh
a
SeIllustrar
ll tion MC–15, Door, Roll-up—MSL
u
p
y
n
A (“Banana Lock”) Replacement
d
a
section,
o
on
M
i
B
t
and Door, Roll-up—Two-point (Fane
c
— section.
u
ic
type) Latch Adjustment
V
Illustration MC–15v
d
r
Check Roll-Up Door Latch Dead
e Bolt for Wear
PD fasteners or other pro
! Check for loose
S
d
components.
y
re
d
an
d
e
y the condition of the pull-down
! Check
Bouse grease on
z
d
CAUTION: Do NOT
i
o for fraying or wear. or
—get oil on rubber
doors. Do NOT
Bstrap
V
h
seals. Wipe
t centered in
D up any drips immediately.
!k Check that the rear dooruis
c
P
a
u the opening.
d
n
n
Tr
n
o
U
i
a
Lubrication
at
y
Track
r
d
Spring
o
Counterbalance Shaft
Lubricate the following rear roll-up
p
Bo
door parts with a (Utilimaster P/N or
Drum Roller
k
04202540, or equivalent) light oil C
c
aw
l
r
u
r
e
(see Illustration MC–30):
y
t
T
b
s
a
Hinges
d
! Roller drums and
e
m
t
i
shafts—wipe offil
bi
t
i
excess oil (#1,U#3).
n
h
o
o
4
i
r
t
w
0
! Springs—lubricate
p
a
a
0
l
r
2 along
n
both springs
Roller Shaft
y
t
o
i
po
b
theirhentire length to
t
r
c
o
d
ig rusting (#2).
prevent
u
r
e
C
t
d
y
i
p
o
b
er
r
i
!
Hinges
(center
and
t
o
C end)—wipe off
ep
oh
as
r
r
p
excess oil (#5).
d
lim
e
i
n
t
iz
! Rollers (#6, #7).
io
U
r
t
o
4
c
0
u
th
! Latches (NS).
0
d
u
2
d
o
a
e
t
! Clean and lubri- pr
n
v
h
U
cate track (#4).re
er
ir g
s
d
y
e
re
p
o
ir z
ts
C
Roller Bracket
o
h
ig
Illustration MC–30
th
r
u
Lubrication Points on Rear Roll-Up Door ll
a
n
A
U
Inspection
22
Truck Body and PDV—Body Service Manual
Door, Swing
!
ed
al
u
an
M
v (metal)—use ZEP® 45
Handles/latches
r
e lubricant to clean contact e
penetrating
s
e moving parts before applying
pointsrand
ic a
v
r oil type
lightweight
ts ® oil. (Exxon Hydraulic
e
h
gNUTO 68, or equivalent.) S
d
ti e
ib
h
o
pr
by
w
la
l
i
y
a
ll!r Hinges and metal exterioroddoor
u
catches—
n
A lubricate the zerk fittings
a
B with #2 grease at on
M
it
six-month intervals —
(or three-month
V
c
ce
intervals in hot, D
dusty conditions). (See
u
i
P
Illustration MC–35.)
rv
od
d
r
e
Illustration MC–35
S Hinges
an catches (metal)—use ZEP
! Interior door
ep 45
Grease Swing Door
y
r
y lubricant to clean before
d
penetrating
d
d
o
e
o
applying a lightweight oil. (Exxon
B
z
i
B
r
—
kHydraulic oil type NUTO 68,
o or
V
c
h
equivalent.)
(See
Illustration
t MC–40.)
D
u
r
u
P
T ! Rubber door catchesaand latches—cleann
d
n
U fasteners. (See tio
and check for loose
an
a
y
Illustration MC–45.) Do NOT use r
d
o
o
petroleum jelly on rubber door rcatches.
It
p
B
o
will attract dirt and become abrasive
to the
C
ck
aw
fittings.
l
r
u
y
tein this
Tr
b
s
NOTE: The information
a Details may
d
illustration is generic.
e
m
t
i
differ from yourtilvehicle. Use this
bi
i
U a guideline where it
h
information as
o
4
applies. 0
w
Illustration
pr MC–40
a
0
l
LubricatenSwing Door Catches
2
n
y
t
io
o
b
h
i
t
c
d
ig
at
u
r
r
e
d
y
o
it
p
o
p
b
r
i
r
o
Co
ep
oh
C
r
r
p
d
er
t
e
n
s
iz
io
a
r
t
c
im
ho
u
l
t
i
d
t
u
d
o
U
a
r
e
n
4
v
p
r
U
0
e
re
0
s
2
d
t
e
re
h
z
ri
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll MC–45
Illustration
C
n
A
Clean Rubber Catches
U
Truck Body and PDV—Body Service Manual
23
Other Body Parts
!
l
A!l
l
d
e of body mounting ua
Check the alignment
v
r
spacers andetighten mounting bolts after n
a
s 60, and 90 days of operation
the first e30,
M
r six months after that. (Seee
and every
s
ic
t
Illustration
MC–50 and the Body
v
h
g
er
Bolts section.)
riMounting
S
y
Sweep debris from floordsurface.
d
ti e
ib
h
o
pr
by
w
la
l
a
u
an
M
n
io
t
c
ce
u
i
V
d
v
r
D
o
! Check that all
reflective
tape
is
securely
r
e
P
S
attached. d
ep
y
r
n
d
a
d
o
! Clean
rear threshold drains and drain
e
y
B
d (See also the Drainsrsection.)
iz
troughs.
o
—
B
V
ho bolts for
!k Check grab handle mounting
t
D
P
uc tightness. (See also ntheauGrab Handle n
Illustration MC–50
r
d
T
section.)
n Body Mounting Bolts
U
io
a
t
y
ra
! Check mirror mounting bolts for tightness.
d
o
o
(See also the Mirror section.) rp
B
o
C
ck
aw
l
r
u
r
e
y
t
T
b
s
a
d
e
m
t
i
CAUTION: DoilNOT power-wash for the first 90 days. Wash and wax the body periodically
bi to
t
i
preserve the
body
finish,
but
avoid
harsh
cleaning
solutions
and
high-pressure
washes.
U
n
h
o
o
4
i
r
t
w
0
p
a
a
0
l
r
2
n
y
t
o
i
po
b
h
t
r
c
o
d rated under 14,000ulbs
ig CAUTION: Do NOT drive a forklift into a evehicle
r
GVWR.
C
t
d
y
i
p
o
b
er
r
i
t
o
C
ep
oh
as
r
r
p is generic. Details ind illustrations land
im procedures
NOTE: This service information
e
i
n
t
may differ from those in your
manufactures
many
iz
io vehicle. Because Utilimaster
U
r
t
customized vehicle bodies,
o and illustrate04every possible part in
c this manual cannot list
h
u
t
every vehicle. Nevertheless,
the most common body options are
0 described here. Use this
2
d
od where it applies.au
information as a guideline
r
e
t
n
v
p
h
U
er
re
ir g
s
d
y
e
re
p
o
ir z
ts
C
o
h
ig
th
r
u
a
ll
n
A
U
!
24
o
Do NOT wash downBwooden floors since
— to warp.
this can cause wood
Truck Body and PDV—Body Service Manual
al
u
an
M
Tools and Fasteners
d
w
e
a
l
v
Common Tools r
y
e
b
s
e
Below are tools,
including
recommended
brands
and
models,
commonly
used
c
d in vehicle body repairs.
i
re
e
s and flat-blade screwdriver
rvset including Torx bit bit
• Phillips
t
e
h
S open-end wrench set hi
• ig
Metric and standard box-end and
l
y
o
a
r
ll• r Metric and standard socket
d
u
p
o sets
n
A • Torque wrenches (any Bquality
a
n [or N•m] measurements)
sets with in•lb andoft•lb
M
it
—
• 3/8" drill (Dewalt VDW221 recommended) c
ce
D
u
i
P DW231 recommended)
• 1/2" drill (Dewalt
rv
od
d
r
e
• Drill stopan
S
ep
y
r
y set (including 1/4" or F-bit
• Drill d
bit
d
d and 3/16" or #11 bit)
o
e
o
B
• Screw
z
B gun (Dewalt DW281rirecommended)
—
• ckPOP riveter (Emhart PRG
V installation)
ho 540 for both POP rivet and MONOBOLT
t
D
u
(Emhart PRG
u 540 with 1/4" nose assembly—this nose
P assembly consists of Jaws
Tr• Monobolter
a
d
n 1/4" Nose Tip BRN-811)
PRG 540-44, Jaw Pusher
n PRG 740-7A,oand
n
U
i
a
• Huck riveter (Huck 2025-L) with: at
y
r for Hucktainer fasteners
d
! Hucktainer nose assembly 99-3464,
o
o
pfor Magna-Grips/pin-and-collars
! 1/4" nose assembly 99-3204,
r
B
o for Magna-Lockskand Magna-Bulbs
! 1/4" nose assembly 99-3305,
C
c
aw
l
r
u
• Nutsert insert tool (Sioux
y
te 02107TL recommended)
Tr
b
s
• Air hammer with a buck
a riveter attachment (Sioux 270 with 3/16" Ajax rivet set #1620) and
d buck bar
e
m
• Hand punch or an
it
ili air hammer with a punch attachment
b
t
• Disk air sander
U with 220-, 320-, and 600-grit sandpaper
hi
o
4
w
• Saber saw0 (Porter Cable 548)
pr
a
0
l
2 with blade
n
• Die grinder
n
y
t
o
i
o
b
h
i
t
• DVOM
c
d
ig (Digital Voltmeter)
at
u
r
r
e
d
o
• y Terminal tool kit (Snap-On TT600 recommended)
it
p
o
p
b
r
i
r
h
o
Co• Needle-nose pliers
ep
o
C
r
r
• Locking pliers (VISE-GRIP recommended,
9" or 10" [23 or 25 cm] long)
r
p
d
e
t
e
n
• Multigrips pliers (any standard
iz [23 or 25 cm] long) as
io model about 9" or r10"
t
• Tape measure
c
im
ho
u
l
t
i
d
t
• Fine-pointed marker
u
o
U
a
r
ed
n
• Rubber mallet p
4
v
r
U
0
e
e
0
• Razor knife r
s
2
d
t
e
re
• Pry bar or
large
screwdriver
h
z
ri saver
ts
ig
r
• Memory
o
h
y
h
ig
t
p
r
• Caulking
gun
u
o
a
ll
C
• n Safety glasses
A
U
®
®
®
®
®
®
®
®
®
®
®
Truck Body and PDV—Body Service Manual
25
Fastener Replacement
l
a
u
an
M
d
e
rv
e
s
re
BOM® Fastener
Removal
d
Cut it off with
s a die grinder. With a centericepunch, knock out the ite
t
center pin.h The remaining ring may need
v to be drilled out. (See ib
r
g
e
i
Illustration
r FR–5.)
oh
l
Replacement
Al
S
pr
by
w
la
Illustration FR–5
BOM Fastener
l
a
u
an
M
y
d
n
o
io
A BOM fastener should be B
replaced per original specifications.
However, in some
t
c
—
applications it may be able
to be replaced with a Grade
8
bolt,
and
a Grade 8 locknut of
ce
u
i
V
d remember to use flat washers
v
like diameter. If replacing
with a nut and bolt, always
r
D
o
r
e
against all aluminumPsurfaces.
S
d
ep
y
r
n
d
a Brazier-head)
Buck Rivet (Solid
d
o
e
y
B
Removal d
iz
r
o
—
B or 3/16" [5 mm] drill bitho(depending on rivet size) to drill off the V
Use ak #11
t
c
u
PD
head
of
the
rivet,
starting
at
the
dimple
located in the center. After the head
a
u
r off, use a punch to knock
d
n
Tpops
n
Un out the stems. t(See
io Illustration FR–10.)
a
a the rivet head in order
y
NOTE: A center punch can be usedron
to get a
d
o
good start for the drill bit.
o
p
r
B
o 3/16" [5 mm] in kdiameter and of
w
NOTE: Brazier-head buck rivets
C
c
a
l
r
u
varying lengths are used eon a number of locations
r on the body.
y
t
T
b
s
Replacement
Illustration
FR–10
a
dRivet
e
Buck
m
it
Use an air hammer withialibuck-riveter attachment and bucking bar to replace
b
t
i
the rivet. In most applications
a MONOBOLT can also be used to replace a
U
n
h
o
o
4
i
buck rivet. Do NOT
replace
buck
rivets
with
a
POP
rivet.
r
t
w
0
p
a
a
0
l
r
2
n
Buck Rivets Lengths
y
t
o
i
po
b
h
t
r
o
dMetal Thickness Rangeuc
ig
Rivet Length
r
e
C
t
d
y
i to 15/64" [4.8 to 6.0 mm]
p
o
b
7/16" [11.1 mm]
3/16"
er
r
i
t
o
p
C
1/2" [12.7 mm]
oh 1/4" to 19/64" [6.4 to 7.5remm]
as
r
9/16" [14.3 mm]p
5/16" to 23/64" [7.9d
to 9.1 mm]
lim
e
i
n
t
o
iz to 10.7 mm] U
5/8" [15.9 imm]
3/8" to 27.64" r[9.5
t
4
c mm]
3/4" [19.1
7/16" to 17/32"
ho [11.1 to 13.500mm]
u
t
u 21/32" [13.9 to 216.7 mm]
d
7/8"
35/64"ato
od[22.2 mm]
r
e
t
n
For Rivet Diameter 3/16" [4.76
mm], Hole Diameter
0.191"
v
p
h
er
re [4.85 mm], Drill Bit #11 U
ir g
s
d
y
e
re
p
o
ir z
ts
C (S.A.E.) measurements. Utilimaster
NOTE:o This vehicle was designed using English
h
ig but
th metric conversion equivalents as a courtesy if metric tools must be used,
provides
r
u
a
ll
Utilimaster
does not warrant metric values given in this manual.
n
A
U
26
Truck Body and PDV—Body Service Manual
l
a
u
n and is used on
ed has a rubber-coveredahead
aw
l
v
Note: A Hucktainer
r
y
M
panels. se
b
e
d
ic
re
Removal
e
v
t
r
i
ts a center punch (or an air hammer
e
b
1. With
with
a
punch
attachment),
h
i
S from the collar side. (See
l
igknock the stem out of the fastener
Illustration FR–15
y
r
oh
a
r
ll Illustration FR–15.) od
Hucktainer Fastener u
p
n
A
a
B
n
2. If the fastener sections
M
io with a screwdriver.
— don’t fall out, pry them tout
e
V
c
Replacement
D
u
ic
P
d
v
Use a Huck riveterdto replace it. (The rubber-covered
head should be positioned on the exterior
ro
er side.)
n
p
S
a
Locknut
y uses centerre
y
CAUTION: Utilimaster
d
d
d
o which distort the
lock-type locknuts,
Removal o
e
B
z
i
threads
of
the
nut
and bolt. This type,
B
r
—
Remove
with an appropriate open-end
or
box-end
k
should
NOT
be
reused
after disassemo
V
c
h
bly.
Always
replace
the
locknut and
t
wrench.
Dnew.
u
r
u
P
bolt
with
T
a
Replacement
d
n
n
n
o
U
i
a
t
Utilimaster commonly uses center-lock typealocknuts,
which distort
y the threads. These locknuts and the
r
d
bolts should always be discarded and replaced
with
new.
Nylon
insert
nuts and KEPS nuts are reusable.
o
o
p
r
If locknuts are not available, use lock washers
and a thread adhesive
like Loctite. Flange head nuts and
B
o
k
bolts can be used in place of flat washers.
C Always use flat
c washers against aluminum surfaces. law
r
u
r
y
te appropriate value.T(Using
Slowly torque the new bolt to the
a power tool to spin the fastener quickly
b
s
may lower its effectiveness.)a
d
e
m
t
i
il , Magna-Lok , and Hemlok Rivets
bi
t
MONOBOLT , Magna-Bulb
i
U
h
o
4
Removal
r FR–20
w
0
Illustration
p
a
0
l
1. With a2center punch (or an air hammer with a punch
n Magna-Bulb
n
y
t
o
i
o
attachment),
knock
the
stem
out
of
the
fastener.
(See
b
h
i
t
c
d
Illustrations
FR–20 through FR–30.)
ig
at
u
r
r
e
d
y Drill off the head of the rivet using a #11it (or 3/16" [5
o
2.
p
o
p
b
r
i
r
o
Co mm]) or F (or 1/4" [6 mm]) drill rbitoh(depending on rivet rep
C
Illustration FR–25
size). The back stem should fallp off.
d
er
Magna-Lok
t
e
n
NOTE: Be very careful (especially
s
iz
io drillingforoffHemloks)
a
r
t
not to enlarge the hole while
the
o
c
im
l
head. If the hole does u
become enlarged, you th
i
d
t
u
d
o fastener in its place.
will need to put a larger
U
a
r
e
n
4
v
p
r
U
0
Replacement
e
re
0
s
2
drivet gun to replace it.
Use a MONOBOLT
t
e
re
h
z
i may also replace it with a Magna-Lok or ig
ryou
ts
For a Hemlok,
r
o
h
y
Illustration
buck rivet.th
igFR–30
p
r
u
Hemlok
o
a
ll
C
n
A
U
Hucktainer
®
®
®
®
®
Truck Body and PDV—Body Service Manual
®
®
27
Nutsert
d
l
e is a threaded insert that isuacrimped into
NOTE: A nutsert
v
r
place. A nutsert
e need only to be removedanif it is damaged and
s
the threads
M
e cannot be retapped.
by
w
la
d
r
e
e
t
s
c
i
t
bi
v
h
i
Illustration FR–35
r
Cut it off
FR–35.)
h
l
e
igwith a die grinder. (See Illustration
Nutsert
r
o
a
S
r
l
u
Replacement
p
y
n
Al
d
a
n
Using a nutsert insert tool, replace
M
Bo the nutsert with ctio
CAUTION: Do NOT use Loctite thread
e
one meeting original specifications.
Do
NOT
use
—
u
locker on the threads of a nutsert.
ic
V
Loctite thread locker on
the threads of a nutsert. d
v
r
e
PDspecifications or the toolprtoo
S
If a nutsert of original
d
y insert or a nut
re be replaced with another form of threaded
install nutsertsaisn not available, the nutsert may
d
d
o
and bolt. This
Service. If it
eand should be approved by Utilimaster Customer
y depends upon application
B
z
d
i
is to be replaced
with
a
nut
and
bolt,
it
is
important
to
use
flat
washers
on
both
sides
of
the
material.
r
—
o
Bo
V
h
t
k
Pierce-and-Roll
(Self-Piercing) Rivet
c
u
PD
a
u
r hardened steel fastenern(attaching the translucent
d panel
n or aluminum roof
TThis
n
o
U
i
a and
to the roof rails) crimps parts together by driving
at through the top material
y
r
mushrooming out into the bottom part without
d surface.
o penetrating the olower
p
(See Illustration FR–40.)
r
B
o
k
C
Removal
c
aw
l
r
u
r grinder to grind off
edrilled off. Use a 4"Tangle
y
t
The rivet head can be ground or
b
s
d
the rivet head. Or use a solidacarbide or cobalt steel 1/4" [6 mm] drill bit to
e
m
t
i
drill off the head of the rivet,
il starting at the dimple located in the center. Use a
bi FR–40
t
i
Illustration
variable-speed drill, drilling
as
slowly
as
possible
and
periodically
dipping
the
U
n
h
Pierce-and-Roll Rivet
o
o
drill bit in Mer*Lube
829 lubricant (cut 50/50 with water). You do not need to
4
i
r
t
w
0
p
a
drill all the way 0through the rivet—just enough to removelathe head.
r
2
n
y
t
o
i
po areas
b
After the roof
panel is removed, use a 4" angle grinder
to grind down all rivet
stems and rough
h
t
r
c
o
dto not grind off excessumetal.
igare flush with the rail surface. Be careful
until they
r
e
C
t
d
y
i
p
o
b
Replacement
er
r
i
t
o
h
C
epfrom the old rivets.
as Use an air
Drill 3/16" [5 mm] new holes through thero
panel and rails, staggered
r
d a 3/16" diameter
hammer with a buck-riveter attachmentpand bucking bar to install
lim by 1/2" long soft buck
e
i
n
t
rivet (P/N 11600108-0308S). (Seeio
Illustration FR–30.) riz
U
t
o
4
c
Alternately, drill 1/4" [6 mm] new
from the old rivets. Use a
0
u holes through the panel
th and rails, staggered
0
d
u
MONOBOLT rivet gun ando1/4" Magna-Loks (P/Na11400026).
2
d
r
e
t
n
v
p
h
U
Do NOT replace with POP
er
re rivets.
ir g
s
d
y
e
re
p
o
ir z
ts
C
o
h
ig
th
r
u
a
ll
n
A
U
Removal
®
®
28
Truck Body and PDV—Body Service Manual
l
a
u
n
ed
aw
Removal
l
a
v
r
y (With Collar)
M
e
a. From either
side, the rivet can be cut eoff with a die
b
s
ic remaining ring. (See ted
re Punch out the center andvthe
grinder.
r
i
ts
Illustration
FR–45.)
e
b
h
i
S
g
h
l
b.ri Or from the head side, using
the appropriate-size drill bit
y
a
ro (3/
ll 16" [5 mm], 1/4" [6 mm],odor 3/8" [10 mm]), drill offpthe
u
(With Flanged Collar)
n
A head of the pin. PunchBout the center of the remaining
a
n
it o pin.
Illustration FR–45 M
—
Vside, using the appropriate-size
c drill bit
c. Or from the collar
Magna-Grip ce
D
u
d drill out the
(3/16" [5 mm],P1/4" [6 mm], or 3/8" [10 mm]),
vi
r
o
d collar. With a center punch,
r knock out the
e
center of the
n
p
S
center of athe remaining pin.
y
re
y
d
d
d
o
NOTE:
Be extremely careful not
drill
e to overheat the steel pin and collar. UseBlow-RPM
o
z
i
B
speed.
—
k
or
V
c
h
Replacement
t
D
ru
u
P
T
a
Use a Huck rivet gun to replace it.
d
n
n
n
o
U
i
a
t fastener with a Grade 8 bolt of like diameter and a Grade
If a Huck rivet gun is not available, replace a
the
y
r
8 locknut. For additional locking capacity,
use Loctite thread locker.
d
o
o
p against aluminumBsurfaces.
r
NOTE: Flat washers are required
o
C
ck
aw
l
POP Rivet
r
u
y
te
Tr
b
s
Removal
a
d
e
m
Drill off the head of the rivet
using a #11 or 3/16" [5 mm] drill bit.
t
i
il off. (See Illustration FR–50.)
bi
The back stem should tfall
i
U
h FR–50
Illustration
o
4
Replacement
rPOP Rivet
w
0
p
a
0
l
Use a POP rivet
2 gun to replace it.
n
n
y
t
o
i
o
b
h
i
t
T-Nut andgBolt
c
d
i
at
u
r
r
e
d
y
o
it
Removal
p
o
p
b
r
i
r
p nut stationary.
With
h bolt while keeping the
o
Co an appropriate screwdriver, unscrewrothe
e
C
r
(See Illustration FR–55.) Discard the bolt
thread adhesive and r
p and nut. The bolt has
d
a compressible plastic spacer/seal, sonnot attempt to reuse either
the
bolt or the nut. te
e
z
io from the adhesiverior seal is present on a as
After the bolt is removed, if any residue
t
reusable surface, scrape off theuc
residue.
im Illustration FR–55
ho
l
t
i
d
t
u
T-Nut and Bolt d
o
Replacement
U
a
r
n
4
ve
p
r
U bolt. Slowly torque the00new bolt to
While keeping the nutre
stationary, screw in a new
se
the appropriate value.
(Using a power tool to spin the fastener quickly2 may lower the
d
e
t
e seal.)
r
effectiveness ofithe
h
z
s
r
t
ig
r
o
h
y
ig
th
p
r
u
o
a
ll
C
n
A
U
Pin-and-Collar Fastener (Magna-Grip®)
®
®
®
Truck Body and PDV—Body Service Manual
29
Tape, Double-faced Adhesive
l
d
a
e
aw
u
l
v
r
y flat surfaces. Scrape off
With a razor knife,ecut along the length of the tape
an while pulling apart the joined
b
s
M
remnants as much
d
re as possible. Clean with aesolvent.
e
t
s
c
i
t
Replacement
bi
v
h
i
r
e Do NOT remove the tape
igone surface from a fresh roll.
Applyrto
ohpaper until the other surface is in the ual
S
r
l
l position. Once the tape sticks
proper
p be able to reposition it without starting n
y to a surface, you will not
A
d
a
n
over.
o
o
M
i
B
t
c
Tape, Vinyl Barrier
—
ce
u
i
V
d surfaces mate in order to prevent corrosion
v of the
r
D
o
White vinyl tape is used
wherever steel and aluminum
r
e
P
S
surfaces.
d
ep
y
r
n
d
a
Removal
d
o
e
y
B
d off.
iz
Peel or scrape
r
o
—
o
B
V
h
Replacement
t
D
k
u
P
a
uc to mating surfaces from
Apply
a fresh roll.
r
d
n
n
T
n
o
U
ithe
a
t
NOTE: Tape rolls can be ordered with
following
part
numbers:
y mm]-wide roll........P/N 12303706
ra
d
1" [25.4 mm]-wide roll........P/N 12303707
2" [50.8
o
o[101.6 mm]-wide roll......P/N 12605947
3" [76.2 mm]-wide roll........P/Nrp
12303705
4"
B
o
C
ck
aw
l
Thread Adhesive
r
u
r
e
y
t
T
b
Removal
s
a
d
e
m
Bolts with thread adhesive
cannot
be
reused.
After
the
bolt
is
removed,
if
any
residue
from
the
seal is
t
i
il scrape off the residue.
bi
t
present on a reusable surface,
i
U
n
h
o
o
4
i
Replacement
r
t
w
0
p
a
a
0
l
r
Slowly torque 2the new bolt to the appropriate value. (Using
a power tool to spinnthe fastener quickly
y
t
io
po
b
h
may lower the
effectiveness of the seal.)
t
r
c
o
d
ig
u
r
e
C
t
d
TorqueySeal
i
p
o
b
er
r
i
t
o
p nut or across
h across a bolt threadeand
The
s a bolt and washer
C torque seal appears as a small paintedroline
a
r
seam. If the seal line is broken (out of alignment),
the fastener has loosened. m
p
d
ebut
ili it.
n
t
z
NOTE: Torque seal indicates
a
fastener
has
loosened
does
not
prevent
U
ri
tio
o
4
c
Removal
0
u
th
0
d
u
After the bolt is removed, if
a is present ont 2a reusable surface, scrape off the ed
roany residue from the nseal
p
h
residue.
rv
U
e
re
ir g
Replacement
d
y
es
e
r
p
obead of torque seal or paint stick across
iz installation is complete, apply a small
When the fastener
r
ts the new
C
o
h
bolt threads,hnut, head, and/or washer.
ig
t
r
u
a
ll
n
A
U
Removal
30
Truck Body and PDV—Body Service Manual
l
a
u
n
ed
aw
l
a
v
r
y for the process.
M equipment when appropriate
e
b
WARNING:
Always wear proper protective
s
e
d
ic
re
e
v
t
r
i
ts
e
b
h
i
S instructions providedhwith sealants, adhesives, and other
l
ig WARNING: Safety and application
y
r
o by Utilimaster.
a
r
products should alwaysdsupersede information provided
ll
u
p
o
n
A
a
B
n
o
M
i
—
The one-compound polyurethanes
Utilimaster uses are very
V
ct effective sealants. They remain permanently
case well as
D
u
i
elastic (less cracking due
to
shrinkage),
they
can
be
painted,
and
they
require
no
mixing.
They
bond
P
rv
od needed, and they also reduce noise andecorrosion.
seal, thus reducing the
number of mechanical fasteners
d
r
S sealants:
an provide an overviewreofp what to look for when working with polyurethane
The following statements
y
y
d
d Always follow manufacturer’s cautions
d
o
e
1. Manufacturer’s
Recommendations:
o
B and
z
i
B
krecommendations for protective
or equipment, application, and cleanup.V—
c
h
D to 100º F [37º C]. For coldu Conditions: Recommended
2.
application temperatures are 40º [5º C]
ut sealants
P
Tr weather applications,astore
at approximately
70º F [21ºdC] and remove them just prior to
n
n
using. Make sureUjoint is frost-free. tio
an
a
y air, sandblast, or solvent. Remove all
r jet of compressed
3. Surface: Clean the surface with aostrong
d
o dry, free of grease or rust, and of
p surface must be Bclean,
loose particles and old sealant. rThe
o
sound quality.
C
ck
aw
l
r
u
4. Priming: Usually no priming
te is required. Since
Tr substrate type and uniformity can vary,baypretest
s
is recommended. Sealant
a manufacturers have primers when substrates require them. dSince
m
compatibility among
te
i manufacturers is in question, do not mix and match different manufacturers’
i
l
i
primers and sealants.
ib
Ut
h
o seal. Install with
4 Cut the tip of the plastic nozzle to joint
5. Application:
size. Puncture the airtight
r
w
0
p be gunned in the
a hand-20or power-operated caulking gun. For best
laperformance, sealantnshould
n
twhere the joint slot is at the midpoint ofbitsy designed expansiontand
joint
io contraction. Dip a Polyo
h
i
c
stick
ig in a soapy solution to ease spreadingedthe adhesive to seal anyugaps.
at
r
r
d
y
o
it
Limitations:
p
o
p
b
r
i
r
o
Co• For curing, permit sufficient exposure
ep
oh to air.
C
r
r
p
d silicones.
er
t
e
• Do NOT apply over siliconesnor in the presence of curing
s
o
iz
i
a
r
t
• During cure, avoid contact
solvents. m
c with alcohol and alcohol-containing
ho
u
t
ili
d cartridges in the same
t
u
• For best results, useoopen
day.
d
U
a
r
e
n
4
v
p
r
U
0
e
re
0
s
2
NOTE: This
and procedures e
d service information is generic. Details in illustrations
t
e
may differ
manufactures many s r
h
ir z from those in your vehicle. Because Utilimaster
t in
ig
customized
vehicle bodies, this manual cannot list and rillustrate
every possible part
o
h
y
every
th vehicle. Nevertheless, the most common bodypoptions are described here.rigUse this
u
ainformation as a guideline where it applies. Co
ll
n
A
U
Sealant
Truck Body and PDV—Body Service Manual
31
Service Procedures
l
a
aw
u
l
r
y
e
an
b
s
Mor
WARNING:
To avoid accidental shock
d
re to the
e
e
damage
vehicle,
disconnect
the
t
s
c
i
i
t
battery
before servicing an electrical
b
v
h
i
r
Check your chassisl
ig component.
r
oh
a
supplied operation or service
Se informar
ll
u
p
tion for specific recommendations.
y
n
A
d
a
n
o
M
io
B
t
e
c
WARNING: Always
remove
the
(Black)
—first and connect it last. u
ic
Negative cable
V
d
v
r
ro
PD
Illustration BA–20 e
p
S
d
Plugging in a MemoryySaver
1. Make sure
the ignition switch is Off.re
n
d
a
dsaver
o
e
2. You ymay need to plug a memory
B
d 9-volt battery) into the raccessory
iz
(with
o
—
o
Boutlet on the dash. (See Illustration
V
BA–
h
t
D
k
u
P
Check your chassis-supplied
a
uc 20.)
r
d
n
n
operation
or
service
information
for
T
n
U
io
a
t
specific recommendations.
y
ra
d
o
3. Disconnect the Negative (Black)pbattery
Bo
cable(s) first. (See IllustrationorBA–25.)
C
ck
aw
l
r
u
4. Tuck the battery cable away
from
the
r
e
y
t
T
b
terminal to prevent accidental
contact.
s
a
d
e
m
5. When servicing the
vehicle
is
finished,
t
i
il
bi
t
reconnect the cable.
i
U
n
h
Illustration BA–25
o
o
4
i
r
t
Body Mounting0 Bolts
w (Black) Cable Disconnected
Negative
p and TuckedraAway
a
0
l
2 Mounting bolts come in a
n
y
NOTE:
t
o
i
po
b
h
t
r
variety
c
o
d
ig of configurations
u
r
e
C
depending
on
the
application.
t
d
y
i
p
o
b
er
r
i
t
o
Normal
road
vibration
and
the
natural
changing
C
ep
oh
as
r
r
properties of the wood runners between the
Base Rail
m
p
d
i
(Under
Sidewall)
chassis and body may reduce the clamping
force
e
il
n
t
z
Crossmember
on the body mounting bolts.
ri Floor) U
tio
(Under
o
4
c
h
0
u
Therefore, it is important to check
the alignment
t
0
u
2
d
od tighten the
of body mounting spacers rand
a
e
t
Bolts
n
v
p
h
mounting bolts after theefirst 30, 60, and 90 days
U
er
ir g
of operation and everyrsix months after that. (See
s
d
y
Illustrations BM–5ethrough BM–20 and the
re
p
z
o
i
torque chart.) r
ts
C
o
h
ig
th the lower nuts because, in some
Always tighten
r
u
Illustration BM–5
a the top nuts have been welded in place.
ll Bolts
applications,
Base Rail to Crossmember
n
A
U
d
Battery, Disconnecting
ve
32
Truck Body and PDV—Body Service Manual
l
a
u
CAUTION: Check
the alignment of
n
ed spacers
aw
body mounting
and tighten the a
l
v
r bolts after the first 30, 60, M
mounting
e
by
s days of operation and everycsix
e
ande90
d
i
r after that.
months
e
v
t
r
i
Long
ts
Mounting
e
b
h
i
Sill
S
Torque
Description
and
g
Oak
h
l
i
Illustration
y
o
a
ft•lb
N•m
Application
(Wood)
r
ll r
d
u
p
o
rail to
n
ABase
BM–5
24–31
32.6–42.0
a
B
n
crossmember
o
M
i
—
Tie rod with angle
e
ct
BM–10V
45–55
61.0–74.5
c
D
u
bar
i
Chassis
P
Tie rod with Jrv
od
Frame
BM–15
24–35
32.6–47.4
d
r
e
hook
n
p
S
Rail
e
U-bolt with angle a
y
r
y BM–15 45–55 d61.0–74.5
d
bar
d
o
Angle
e
o
5/8 bolt in body
B
Tie
Bars
Bangle BM–20 80–110riz 108.5–149.1
tie-down
—
k
Rod
V
c at chassis
ho
5/8
bolt
t
D
u
r
u
P
Tframe rail for
BM–20 a 90–120
122.0–162.6
d
n
body mounting
n
U
angle
an
tio
a
y
r
d
NOTE: Utilimaster vehicles are o
rp
Bo
designed using English (S.A.E.)omeaIllustration BM–10
C
surements. Utilimaster provides
ck
aw
Tie Rods with Angle Bars
l
r
u
metric conversion equivalents
e as a
Tr
by
st be used,
courtesy if metric toolsamust
d
e
but Utilimaster doesim
not warrant
t
il in this manual.
metric values given
bi
t
i
U
h
o
4
w
0
pr
a
0
l
Long
2
n
n
y
t
o
Sill
i
o
b
h
i
t
c
d Long
ig
at
u
r
r
e
Sill
d
y
o
it
p
o
p
b
r
i
r
p
h
o
Co
e
o
C
r
r
Mounting
Mounting
r
p
d
Rumber
e
Oak
t
e
n
z
s
(Wood) io
a
ri
t
o
c
m
(Body
Tie
Down)
Tie
u
th Mounting Bolt
ili
U Bolt
d
t
u
Rod
Chassis d
o
U
with a
Chassis
r
with J
n
Frame
4
ve
pFrame
Angle
r
U
0
e
Hook
Rail
e
r Rail
Bar
0
s
2
d
e
e
r
(Chassis
ht
ir z
s
FrameigRail)
t
r
o
h
Mounting
Bolt
y
ig
th
p
r
u
o
a
ll
Illustration BM–20
Illustration BM–15
C
n
A
Chassis Frame Rail and Body Tie Down Bolts
J Hook and U Bolt
U
®
Truck Body and PDV—Body Service Manual
33
Bumper, Rear
d
l
Most truck body bumpers
ve are welded in place. To nua
r
replace a bumper, cut
e it off with a torch and weld the
a
s
new bumper in place.
Remove
any
other
applicable
M
re
fasteners andsinstall with new fasteners. ce
d
ti e
ib
h
o
pr
by
w
la
i
t
v
h
r
For bumper
l
e the bolt
ig rubber impact strips, remove
r
a
S
attaching
ll the strip to the bumper.yReplace with a
u
n
new
bolts and
A strip as well as new stainless-steel
d
a
n
nuts. (See Illustration BU–5.)
M
io
Bo
t
e
c
— to a bumper
u
Most PDV bumpers areVbolted
ic
d
v
r
support and have rivets
ro
e
PD attaching lights and splash
p
S
guards. Remove d
the various fasteners to replace
y
reit
the bumper. To
d
anreplace the bumper support,
d
o
may need toybe cut off with a torch and e
the reB
z
d
i
Illustration BU–05
placement
welded into position.
r
—
o
Rubber ImpactVStrip and Fasteners
Bo
h
t
k
c
u
PD
WARNING: When replacing
a bumper,
a
u
d
n bumper to keep it on
always support the
Tr
n
U
i
a
from falling.
at
y
r
d
o
o
p
r
B
CAUTION: Always use new o
bolts and
k
CDo NOT
c
aw
two-way Grade 8 locknuts.
l
r
u
reuse locknuts or bolts
ewhen replacing Tr
y
t
b
bumpers.
s
a
d
e
m
t
i
bi
til
i
Cable RetainmentUTrack
n
h
o
o
4
i
r
t
Removal
w
0
p
a
a
0
l
r
n
o
1. With ta 2Torx bit, unscrew the fasteners. (If
y
o
i
p
b
h
t
r
the
c
g exterior encapsulated T-nut starts to d
o
ispin,
u
r
e
C
hold
it
while
unscrewing
the
bolt.)
t
d
y
i
p
o
b
er
r
i
t
o
2. Remove the track from the sidewall.h
s
C
ep
o
a
r
r
Installation
p
d
lim
e
i
n
t
1. Position the track in place and
o screw in the
iz
i
U
r
t
fasteners with a Torx bit.c(If the exterior
o
4
0
u to spin, hold it
th
encapsulated T-nut starts
0
d
u
2
d
a
while unscrewing the
ro bolt.)
e
t
n
v
p
h
er
2. If a new T-nut riserequired, punch out theU
ir g
s
d pound in the new one
y
old T-nut, and
e
re
p
z
o
i
before screwing
in the bolt.
r
ts
C
o
h
ig
th
Illustration CR–5r
u
a
ll and E-track
Cable Retainment Track (Middle)
n
A
U
34
Truck Body and PDV—Body Service Manual
Decals
al
u
an
M
w
ed
a
l
v
NOTE: Seeralso the Paint section.
y
e
b
s
e
Removal
d
ic
re
e
v
t
r
1. Usetsa heat gun to soften the adhesive
i
e
b
h
i
S
h
l
igunder the decal.
y
r
o
a
r
ll2. With a razor knife, carefully
d
u
peel the edge
p
o
n
A back.
a
B
n
M
it o
—
e
V while manually c
3. Continue to heat evenly
c
D
u
i
pulling the decal
P off.
rv
od
d
r
e
Installation
S
an
ep
y
r
yreapplying decals over fresh
1. Before
d
d paint,
d
o
waito24 hours for nonreflectivezedecals or
B
Bhours for reflective decals.ri
72
—
k
V
c
ho 2319S
t
D
u
2.
Clean
the
surface
with
DuPont
r
u
P
T Cleaner.
a
d
n
n
U
an
tio
3. Align the decal into position.
a
y
r
d
o
4. Smooth the decal from the center
o
p to the
r
B
edges.
o
w
C
ck
a
l
r
u
5. Squeegee the edges to ensure
e a proper
y
t
Tr
b
seal.
s
a
d
e
m
t
i
il
bi
t
i
U
h
o
4
Deflector Plate0
w
pr
a
0
l
2
n
Removal
n
y
t
o
i
o
b
h
i
t
c
1. Remove
the cargo light switch. (See the d
ig
at
u
r
r
e
d
y Switch, Cargo Light section and Illustra-it
o
p
o
p
b
r
i
r
tion
DE–5.)
p
h
o
Co
e
o
C
r
r
2. Remove the fasteners holding the
p plate to
d
er
the sidewall.
t
e
n
s
o
iz
i
a
r
t
3. Remove the plate.
c
im
ho
u
l
t
i
d
t
Installation
u
d
o
U
a
r
e
n
4
v
p holes in the sidewall,U
1. Using the fastener
r
0
e
e
r
0
drill holes in the new deflector plate from
s
2
d
t
the outside.
e
re
h
z
ri
ts
ig
Illustration DE–5 h
2. InsertoHucktainer fasteners into the holes.
r
y and Hucktainer Fasteners oniga Deflector Plate
h
Switch
t
p
r
u
3. Reinstall
the cargo light switch.
o
l
a
l
C
A
Un
Truck Body and PDV—Body Service Manual
35
Door, Bulkhead (Midship/Front Wall) Latch Adjustment
l
d
a
e
aw
u
l
NOTE: Not rall
v door latches are
y
e
an
adjustable.
b
s
M
e
d
e
1. Loosenr the fasteners on the catch. (See
e
t
s
c
i
t
Illustration
DR–5.)
bi
v
h
i
r
l
e align
ig
oh
a
2.l r Position the door latch to properly
S
r
u
p
y
n
Al with the catch.
d
a
n
o
M
io
3. Holding the catch inBthis position, tighten
t
e
c
—
the fasteners.
u
ic
V
d
v
r
4. Open and close
PD the door multiple timesptoro
Se
d
ensure proper
operation. Repeat the e
y
r
n
d
processaif necessary.
d
e
y
Bo
z
d
i
NOTE:
Depending
on
the
door
r
o
— DR–5
o
Bhardware,
Illustration
you may be able
to
make
V
h
t this
k the door close tighter with
Bulkhead Door
c
u
PD Latch (Cargo Side)
a
u
adjustment.
d
n
Tr
n
Un
it o
a
a
y
r
d
o
o
p
r
B
o
k
C
c
aw
l
r
u
r
e
y
t
T
b
s
a
d
e
m
t
i
il
bi
t
i
U
n
h
o
o
4
i
r
t
w
0
p
a
a
0
l
r
2
n
y
t
o
i
po
b
h
t
r
c and procedures
o
d Details in illustrations
ig This service information is generic.
NOTE:
u
r
e
C
t
d
ymay differ from those in your vehicle. Because
i
Utilimaster manufactures
many
p
o
b
er
r
i
t
o
p every possible
h cannot list and illustrate
s part in
C customized vehicle bodies, this manual
ahere.
re are described
ro common body options
every vehicle. Nevertheless, thepmost
Use this
m
d
i
information as a guideline where
e
il
n it applies.
t
z
o
i
U
r
ti
o
4
c
0
u
th
0
d
u
2
d
a
ro
e
t
n
v
p
h
U
er
re
ir g
s
d
y
e
re
p
o
ir z
ts
C
o
h
ig
th
r
u
a
ll
n
A
U
36
Truck Body and PDV—Body Service Manual
l
Door, Central Locking
d System (Trademaster)ua
w
n
e
a
l
a
v
Operation (electric and
r manual systems)
y
M
e
CAUTION:
To close an open
b
s
e
The keyed lock
in
each
compartment
door
handle
e
c
compartment
door, the central
d
i from the
r
e
v
locking
system
must be UNworks in conjunction
with
but
is
independent
t
s
r
i LOCKED! Slamming
t
e
a door
b
dead-bolthcentral locking system. TheSkeyed lock
i
g
closed with the central system
h
l
i
enables
y while the
r its compartment to remaindlocked
o
locked may damage the system. a
r
l
u
p
restl of the compartments are conveniently
unlocked
o
n
A
a
B
n
by the central system.
M
it o
—
V the keyed lock AND thec
To fully open a door, both
ce
D
u
i
P must be unlocked. od
central locking system
rv
d
r
e
S
• For electric
an system operation, pressrethep lock or
y
unlockybutton on the key fob. (See Illustration
d
d
d
o
e
DR–10.)
o
B
iz
B
r
—
• ckFor manual (or override) o
operation,
V
h system
t
D
u
slide
the
locking
lever
toward
the
rear
of truck
r
u
P
T to unlock the compartments
a
and toward the
d
n
n
front to lock them.U
an
tio
a
y
r still
When the central system is locked, a doorowill
d
o
p the handle.
open slightly when you rotate and pullron
B
o
For maximum security, use keys to C
individually
lock
ck
aw
l
r
u
each compartment and place a padlock
around
the
r
y
te
locking lever and through thessupplied
(hasp) hole. T
Illustration DR–10
b
d
Electric System and Key Fob
(See Illustration DR–15.) a
e
m
t
i
il moving with greater
bi
If a locking lever ever tstarts
i
U compartments, clean the lockh
difficulty, open all4the
o
0 lithium grease to the rod 2" on each aw
ing rod, and apply
pr
0
l
2 bushings.
n
side of the plastic
n
y
t
o
i
o
b
h
i
t
c
d
Maintenance
ig (electric system only)
at
u
r
r
e
d
y NOTE: Perform every 12 months in it
o
p
o
p
b
r
i
r
o
Co normal use.
ep
oh
C
r
r
p the cover
d
1. Remove the four screws that holding
er
t
e
n
s
in place and remove the cover.
iz
io
a
r
t
c plate that moves the ho
im
2. On the triangular actuator
u
l
t
i
d
t
locking lever, find the
d
o large pivot bolt at theau
U
r
e
n
base of the triangle
and
two
smaller
rod
pivot
4
v
p
r
U
0
e
re corners. (See Illustration
pins at the outside
0
s
2
DR–15.) ed
t
re
h
z
i these three pivot points with light
DR–15ts
roil
ig ElectricIllustration
3. Lightly
r
o
h Points
System
Lubrication
y
h oil (not penetrating oil) and reinstall
g
machine
i
t
p
r
u cover.
o
l
the
a
l
C
A
Un
Truck Body and PDV—Body Service Manual
37
Door, Roll-up
l
d
a
e
aw
u
l
v
r Read all instructions beforean
WARNING:
y
e
b
starting
repair. Always maintain firm
s
d
footing
re and control of tools. e M
e
t
s
c
i
t
bi
v
h
i
r
l
ig When ordering parts for
NOTE:
r
oh
a
Sofe atherear
r
ll door, specify the serial number
u
p
y
n
A door. (See Illustration DR–25.)
d
a
The
n
M
io
serial number can be found
Bo on a metal
t
e
c
— of the door.
tag attached to the inside
u
ic
V
d
v
r
NOTE: After replacement
of any part,
ro
e
PD
p
S
d
check relevant adjustments and properre
y
n
d
operationaof the door.
d
o
e
y
B
z
d
i
NOTE:
The following instructions
r
— DR–25
Illustration
Boillustrations are generic.hoDoors in
and
V
Typical
Locations
of
Roll-up
Door S/N Plates
t in
D
kparticular vehicles may differ
c
u
P
a
u details. Use these instructions
as a
r
d
n
n
WARNING:
The counterbalance spring
T guide where appropriate.
n
U
io
t
is a
wound under high tension. This highytension spring can cause severe injury
ra
d
o
NOTE: A vehicle may have a hollowo or death.
p or
r
B
core (aluminum or fiberglass) door
o
Installation, repairs, and adjustments w
k
a solid-core (DuraPlate, aluminumC
c
must be made by trained service perla
rwood)
u
clad wood, or plastic-coated
r
sonnel using proper tools and instruce
y
T
b
tions.
st although
door. On hollow-core doors,
a
d
some fasteners extend
Use two heavy-gauge steeltwinding
mall the way
i
i e(See bars
l
i brackets are
with the proper dimensions.
through the door,tmost
b
iNOT USE bentn
Illustration DR–35.) DO
h
fastened ONLY U
to the inner panel.
winding bars, screwdrivers,
or punches
4
io
ro
t
(Some “hollow-core”
doors have
w
0
p
for
spring
winding.
0 with foam, but the
la
ra
interiors filled
2
n
o
y
t are the same.) In those
io
fasteners
b
h
t
rp
c
g
o
d
cases,
u
ri do NOT drill through the
C
te
Cable
d
y
i
r
outside
panel.
Solid-core
doors
have
p
ro
ib
te
o
most fasteners through the entire
p
h
s
Cable
Anchor
C door. When drilling holes in the door,
e
o
a
r
r
Bracket
m
p
be sure to drill only to the appropriate
ed Pin
ili
n
t
Cotter
z
depth. Follow the appropriate
io
U
ri
t
o
4
c
instructions where the differ.
u
th Cable 00
d
u
2
d
a Anchor Pin
ro
e
t
v
WARNING: DopNOT use the rear door n
h
U
pull strap tore
support yourself when
er
ir g
s
entering d
or exiting. The strap can
y
re
p
break z
orepull the door down upon you.
o
i
ts
Use ra grab handle for assistance when
C
o
h
getting
h in and out of the back of the
ig
t
truck.
r
u
Illustration DR–30
a
ll
Cable Anchor
n
A
U
38
Truck Body and PDV—Body Service Manual
Cable Replacement (with Tension on Spring)
al
u
an
M
w
ed
a
l
v
Removal
r
4. Temporarily tape
y the cable to the outside
e
b
s
e
top panel of the door.
NOTE:eIf only one cable is frayed orc
d
i
r
e
v
damaged,
Utilimaster
still
recommends
t
5. From iinside the cargo area, insert the cable
tsboth cables be replaced at ether same
b the cable drum slot. Thread the
h
that
iinto
end
S
h
ir gtime.
y
o into the groove nearest the slot and ual
cable
r
ll
d
p turn the cable drum toward you until alln
A 1. Close the door from theBoinside. Release
a
n
the spring tension from
the cables by fully
M is
it o slack is taken out, making sure the cable
—
V steel winding bar c
following in its proper groove. e
inserting a heavy-gauge
D
u
ic
v
into one of thePspring-winding plug holes.d
NOTE:
The
cable
must
be
wound
r from the
o
d
r
e
(See Illustration
DR–35.)
outermost groove toward S
the inside of the
an
ep
y
r
drum.
NOTE:y If the door has two springs, you
d
d
d
o
willoneed to release the tension eon both
6. Maintaining tension
B on the cable, slide the
iz
B
sides.
r
—
cable drum on the counterbalance shaft
k
o
V and tighten the two
c
h
against the bearing
D
u2. Raise the bar enough toutallow insertion of
r
P the drum.
T a second winding barainto the lower hole,n
setscrews on
d
n
o
and then release the
U tension enough totilet
7. Clamp
anthe counterbalance shaft with a
a
the second bar rest against the top panel
y pliers, handle against the ceiling,
r of
locking
d
o
the door.
oto keep the cables tight. (See Illustration
p
r
B
othe cable
k DR–35.)
3. Loosen the two setscrews on
C
c
aw
l
drum, releasing the cableerdrum from the
u
CAUTION: Protect the roof panelyfrom
t from the cable Tr
shaft, and remove the scable
b
the pliers with a piece of flat stock
a
d
drum.
(plywood or sheet metal). e
m
i
it
l
i from the door bottom
b
t
4. Remove the cable
8. Release the spring tension
U the anchor and cotter
hi by rotating the
panel by removing
o
winding plug just
r far enough to
w spring
04Illustration DR–30.)
pins. (See
p
a
0
l allow removal ofnthe winding bar against n
2
y
t
the top of the door.
io
b
h
io
t
WARNING: Do NOT raise the door with
t
c
g
winding bar in place. Raising the ed
9. Remove the
u clamp and tape, and then
ri the
ra
d
y
o
door at this point can cause injury or it
check the
p damage to equipment.
o operation of the door.rp
b
r
i
o
o
C
NOTE:
ep A properly adjustedCdoor
oh
r
r
p
dshould open easily and, twhen
er
Installation
e
n
sat any
iz stopped, should remain
iobase of the
a
r
1. Mount the new cable at the
t
given
location.
(See
the
Door,
o
c
m
i
h
bottom panel by slipping
the
cable
anchor
u
l
Roll-up—SpringtiWinding
and
t
danchor
pin through the cable
bracket and au
o
Adjustment section.)
U
r
ed
n
4
the eye at the endpof the cable.
v
r
U
0 Make sure the drums are
e
re
0
CAUTION:
s
2 the counterbalance shafte bear2. Insert the cotter
d pin into the cable anchor
against
t
e
r tightpin to secure
the
cable.
h
ings,
the setscrews are properly
ir z
s
igened, and the cables havehtequal tension.
r
o
3. Bring
the
other
cable
end
to
the
top
of
the
y
the counterbalance
assembly
ig to jump
thand thread it over the top of the door
p Rotating
r
door
too far may cause cables
off the
u
o
l
ato the inside.
l
cable drum.
C
n
A
U
Truck Body and PDV—Body Service Manual
39
Winding Bar Dimensions
d
e
rv
e
1/2"
s 127 mm
e
r1/2" 127 mm
Door
Diameter
Diameter Approximate
Manufacturer (Inches) (Millimeters)
Length
Todco
Diamond
Whiting
ts 3/8"
h
ig
r
l
Al
d
n
a
ce
i
rv
e
S
18" or 46 cm
95.2 mm
y
d
Bo
—
V
PDCable Drum
l
a
u
an
M
n
io
t
c
u
od
r
p
re
Spring Winding Plug
by
Locking Pliers
Against Ceiling
d
ti e
ib
h
o
pr
w
la
Protective
Flat Stock
Chalk mark
ce
i
rv
e
S
l
a
u
an
M
y
d
d
e
y
Bo
z
d
i
r
—
o
Bo
V
h
t
k
u
LeftcHand
Right Hand
PD
a
u
(Roadside)
(Curbside)
r
d
n
T
n
Un
it o
a
a
y
r
d
o
Winding Bars (See
o
Cable
p
r
B Dimensions Table)
o
k
C
c
aw
l
r
u
r
e Top Panel
Door
y
t
T
b
s
a
d
e
m
t
i
il
bi
t
i
Uwas den
h
NOTE: This vehicle
o
o
4
i
r
t
w
0 (S.A.E.)
p
signed using English
a
a
0
l
r
2 Utilimaster
n
measurements.
o
y
t
o
i
p
b
Setscrew
h
t
r
provides g
conversion
c
o
d
imetric
u
r
equivalents
as a courtesy, but
e
C
t
d
y does not warrant
i
p
o
Utilimaster
b
er
r
i
t
o
h
s
metric
C values given in this
ep
o
a
r
r
manual.
p
d
Chalk
lim Mark
e
i
n
t
(Compressed Spring)
iz
io
U
r
t
o
4
c
0
u
th
0
d
u
2
d
a
ro
e
t
n
v
p
h
U
er
re
ir g
Rotate Toward the
s
d
y
Ceiling to Compress Spring re
e
p
o
ir z
ts
C
o
h
ig
th
r
Illustration DR–35
u
a
ll
Winding the Counterbalance Spring
n
A
U
Support Bracket
40
Truck Body and PDV—Body Service Manual
l
a
u
ed counterbalanced door an
aw
l
v
NOTE: A properly
r
WARNING:
y The counterbalance spring
M
e
should, when
stopped, remain at any given
is woundbunder high tension. This highs
e
d spring can cause severe injury
location.
tension
ic by
re If the door leaves the floor
e
v
t
or ideath.
r and
itself,
ts the spring is wound too tightly,
e
b
h
i
quarter turns should beSreleased. If
Installation, repairs, and adjustments
h
ir gathefewdoor
o must be made by trained service person-ual
has a tendency tody
drop when
r
ll
p nel using proper tools and instructions.n
o turns should
A stopped, a few more quarter
a
B
n
be added.
Use two heavy-gauge steel winding
bars
M
it o
—
with the proper dimensions. (See
V on the inside, clamp c
ce bent
1. Close the door and,
D
Illustration DR–35.) DO NOT USE
u
i
P shaft with the handleoofd
winding bars, screwdrivers,rv
or punches
the counterbalance
d
r
e
for
spring
winding.
the lockingnpliers against the ceiling top
S
a
e
y
r
keep the
y cables tight. (See Illustration
d
d
d
o
DR–35.)
e
o
B
iz
CAUTION: Rotating the counterbalance
B
r
—
k CAUTION: Protect the roof
assembly too far may cause cables to
o panel from
V
c
h
jump off D
the cable drum.
u
the pliers with a piecetof flat stock
r
u
P
T
(plywood or sheet a
metal).
d
n
n
U
anfor about 10-1/2 turns (for a new
tio
Repeat
a
y or as many needed to adjust). Turns
2. Run a chalk mark the full length of rthe
d
door
o
oare counted by using the chalk marks,
counterbalance spring.
p
r
B
o bar
3. Insert a heavy-gauge steel winding
C
ck which show up as stripes as the springlaisw
r
u
wound.
(see Illustration DR–35 e
for dimensions)
r
y
t
T
b
s
into one of the spring-winding
plug
6. After adjusting the spring tension,
a
d tighten
holes.
e
m
both setscrews on the spring-winding
plug
it
li
i
b
t
and remove the locking pliers
NOTE: If theUdoor has two springs, you
hi from the
counterbalance shaft.ro
will need to4 use this procedure on both
w
pof the door by
sides and
00wind each spring the same
la7. Check the operation
2
n
n
amount.
y
t
io the door.
o
opening and closing
b
h
i
t
t
c
ig the setscrews on the spring- ed
a
4. rLoosen
u
r
8. If furtherdadjustment is needed, repeat
y winding plug.
o
it
p
o
p
Steps
1,
3,
and
4.
Then
raise
the
winding
b
r
i
r
h
bar etopadd spring tension (doorolifts more
Co5. Wind the spring by lifting the bar.roWhile
r
easily) or lower the winding
holding the first bar, place a second
r Cbar to remove
p bar
d
e
t less easily). Then
espring tension (door lifts
in the next hole and lift in thensame
z
s
o
i
r repeat Steps 6 and 7. a
manner after removing thetifirst bar.
o
c
im
h
u
l
t
i
d
t
u
d
o
U
a
r
e
n
4
v
p
r
U
0
e
re
0
s
2
d
t
e
re
h
z
NOTE: This
service
information
is
generic.
Details
in
illustrations
and
procedures
may
ri those in your vehicle. Since doors differ, adapt
ts
ig these instructions as needed.
differ from
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Spring Winding and Adjustment
Truck Body and PDV—Body Service Manual
41
Top Panel Replacement
l
d
a
e
aw some fasteners
CAUTION:vOn hollow-core (some aluminum
and fiberglass) doors, although
u
l
extend e
allr the way through the door, most
brackets are fastened ONLY
y to the inner panel. In those
anpanel.
b
cases,sdo NOT drill through the outside
Solid-core
doors
(DuraPlate,
aluminum-clad wood,
M
d
re
or plastic-coated
wood) have most
fasteners
through
the
entire
door.
When
drilling holes in the
te
s be sure to drill only to theiappropriate
ce
i
door,
depth.
t
h
ib
rv
g
h
l
e
i
o
a
Removal
S
r
ll r
u
p
y
n
A 1. With the door closed, clamp
d
a
the
track
n
o
M
io
below the top panel B
to prevent the door
t
e
c
—
from raising.
u
ic
V
d
v
r
D
2. Drill out thePrivet heads in the center ro
e
p
S
d
hinges on the top panel and the rivetrheads
e
NOTE: This service information
n
dy
on the a
joint roller bracket in the lower
half
d
is generic. Details inoillustrations
y top panel. (See Illustrations
of the
B differ from
ze DR–45
and procedures may
d
i
r
o
—
and
DR–50.)
those in your vehicle.
Since doors
o
B
V
h
t
differ, adapt D
c3.k Punch out the rivets and,
u in at least one of
P these instructions as
a
u
needed.
the hinges, insert a punch
d
n in one of the on
Tr
n
U
i
rivet holes to stabilize the door panel while
a
t
a
y
r
detaching the remaining rivets and bolts.
d
o
o
p
r the
B
4. Using a wrench and socket, remove
o
k
roller brackets and rollers atC
the top of the
c
aw
l
r
u
panel. (See Illustration DR–40.)
r
e
y
t
T
b
s
a lift out the old
5. Remove the punch and
d
e
m
t
i
panel.
il
bi
t
i
U
n
h
o
o
4
i
r
t
w UP
Move roller
0
p
a
a
0
l
r
to
move
panel
IN
2
n
y
t
o
i
po
b
h
t
r
c
o
d
ig
u
r
e
C
t
d
y
i
p
o
b
er
r
i
t
o
C
ep
oh
as
r
r
p
d
lim
e
i
n
t
iz
io
U
r
t
o
4
c
0
u
th
0
d
u
2
d
a
ro
e
t
n
v
p
Move
roller DOWN
h
Uto move paneligOUT
er
re
r
s
d
y
e
re
p
o
ir z
ts
IllustrationC
DR–40
o
h
Sample Top Roller Brackets and Adjustments
ig
th
r
u
a
ll
n
A
U
42
Truck Body and PDV—Body Service Manual
l
a
Adjustment
u
n
eared unable to secure
aw
l
a
v
NOTE: If you
1.
Close
the
door.
r
y
M
the hingesse
with the original type of
b
e
2.
Loosen
the
nuts
slightly on the top roller
d(See Illustration
rivets that
re extend completely throughvic
e
bracket.
DR–40.)
t
s use carriage bolts or rib-er
thetdoor,
i
h carriage bolts to attach them.
ib the top roller brackets so that the
3. Position
S
h
ir gneck
o panel is nearly vertical and seals bothual
top
r
ll (The bolt head must be onothe
dy
p along the top and at the sides.
n
A exterior side of the door,Band the nut
a
n
must be on the interior!)
—
tio NOTE: Moving the roller brackete M
V
c
1. Using a wrench D
and socket, attach the
up moves the panel in (toward the
u
ic
d
v
roller bracketsPand rollers to the top of the
interior);
moving
the
roller
bracket
d
ro
er
new panel nwhile putting the rollers in p
the
down moves the panel outS(toward
a
e
y
tracks.y(See Illustration DR–40.) r
the exterior).
d
d
d
o
ethe panel
2. Lineo up the new top panel with
NOTE: Adjusting B
the panel too
z
i
B
r for a close
—the door to jam
below it (making sure theyoalign
tightly may cause
k
V
c
h
before it latches.
t the hinge holes
u fit at the joint) and (using
r
u
PD
T as a guide) drill all ofathe hinge holes on n
4. Tighten d
n panel:
the bottom of theUnew
n the nuts with a wrench.
it o
a
5. Check
a the
y the operation of the door and
r
2a. For a solid-core door, drill through
d
oreadjust as necessary.
entire panel with an F (or 1/4")
po bit. Tip
r
B
o carriage
the panel toward you to insert
C
ck
aw
bolts through the outside
of the panel.
l
r
u
y
te the bolts and Tr
Install the hinges over
b
s
tighten the nuts. a
d
e
m
t
i
il door, drill through
2b. For a hollow-core
bi
t
i
U panel only with an F (or
h
the interior
o
4
1/4") 0
bit and install Magna-Lok
w
pr
a
0
l
fasteners
2 through the hinges.
n
n
y
t
o
i
o
b
h
i
t
c
ig CAUTION: Do NOT drill through the ed
at
u
r
r
d service informationpo
y outside panel of a hollow core door. it
NOTE:oThis
p
b
r
i
r
is generic.
Details in illustrations
p
h
o
Co
o
C
reprocedures may differr from
and
3. Check the door operation by opening
pr and
d
e
t doors
ethose in your vehicle. sSince
n
closing the door.
z
o
i
as
a
r differ, adapt these instructions
ti door should
o
NOTE: A properly adjusted
c
m
needed.
ustopped, remain at th
ili
open easily and, when
d
t
u
d
U
any given location.ro(See Door, Roll-up—na
e
4
v
p
r
Spring Winding
0
e
reand Adjustment section.)U
0
s
2
4. Also checked
the seal gap on the outside top
t
re
h
z
of the roll-up
ri door and adjust as necessary.
ts
ig
r
o
h
(Seehthe following Adjustment section.)
y
ig
t
p
r
u
o
5. a
If paint repair is necessary, see the Paint
ll
C
n
A
U section.
Installation
Truck Body and PDV—Body Service Manual
43
Intermediate Panel Replacement
l
d
a
e
aw
u
l
v
r closed, clamp the track an
y
1. With the door
e
b
s
M
below the
d
re panel to be replaced (to prevent
e
e
t
the door
from
rising).
s
c
i
t
bi
v
h
i
r
g off the rivet heads in theecenter
2. iDrill
l
r
oh
a
S
r
(See
ll hinges on the panel to beyremoved.
u
p
n
A Illustration DR–45.) d
a
o
on
M
i
B
t
3. Punch out the rivets and, in at least one of
e
c
—
ic
the hinges, insert
a punch into one of the du
V
v
r
D
rivet holes toPstabilize
the door panel while
ro
e
p
S
detachingdthe remaining rivets and bolts.
y
re
n
d
a
d
4. Using
a
wrench
and
socket,
(if
applicable)
y both roller brackets andzerollers of
Bo
d
remove
i
— DR–45
or top of the
Btheo joint roller brackets (aththe
V
Illustration
t
k panel). (See IllustrationuDR–50.)
Sample
c
PD Center Hinges
a
u
d
n of the joint rolleron
Tr 5. Drill off the rivet heads
n
U
i
a
bracket hinges attached to the bottomatof
y
r
d
the panel.
o
o
p
r
B
6. Punch out the rivets and, in at o
least one of
k
C one of the
c
aw
the hinges, insert a punch into
l
r
u
edoor panel while Tr
y
rivet holes to stabilize the
t
b
s
detaching the remaining
a rivets and bolts.
d
e
m
t
i
7. Lift the door panels
il (above the panel to be
bi
t
i
replaced) intoUthe horizontal track and
n
h
o
o
4
i
r
secure them
t
w
0 with a locking pliers clamped
p
a
a
0
l
r
on the horizontal
track.
2
n
o
y
t
o
i
p
b
h
t
r
8. Remove
c
o
ig the punches and lift out the old ed
u
r
panel.
C
Illustration
DR–50
t
d Brackets and Alignment
y
i
Sample Joint Roller
Washers
p
o
b
er
r
i
t
o
p
h
s
C
e
o
a
r
r
m
p
ed
ili
n
t
z
U
ri
tio
o
4
c
h
0
0
du
ut in illustrations
NOTE: This service o
information
is generic.aDetails
and procedures may
2
d
r
e
t
n
differ from those inpyour vehicle. Since doors
differ, adapt
these
instructions
as
needed.
v
h
U
er
re
ir g
s
d
y
e
re
p
o
ir z
ts
C
o
h
ig
th
r
u
a
ll
n
A
U
Removal
44
Truck Body and PDV—Body Service Manual
l
a
u
CAUTION: On
hollow-core (some aluminum and fiberglass) doors, although
some fasteners
n
edway
awthe inner panel. In those
extend allvthe
through the door, mostabrackets
are fastened ONLYlto
r NOT drill through the outsideMpanel. Solid-core doors (DuraPlate,
cases, e
do
aluminum-clad wood,
y
b
s
or plastic-coated
wood) have most fasteners
through the entire door.
When drilling holes in the
e
d
ic
re be sure to drill only to the appropriate
door,
depth.
e
v
t
r
i
ts
e
b
h
i
S
Installation
l
ig
y
r
oh
a
r
ll NOTE: If you are unableotodsecure
u
p 4a. For a solid-core door, drill through the
n
A the hinges with the original
B type of
n
entire panel with an F (or 1/4") bit.a Tip
o
M
i
—
the panel toward you to insert ecarriage
t
rivets that extend completely
through
V
c
c panel.
bolts through the outside of ithe
D bolts or ribu
the door, use carriage
P
d
v
Install the hinges over ther bolts and
neck carriage
d bolts to attach the
ro
e
n
tighten
the
nuts.
p
S
handle. (The
bolt
head
must
be
on
a
e
y
y
the exterior
side of the door, and the r
d
4b. For a hollow-core
door,
drill through
d
d
o only with
nut o
must be on the interior!) ze
the
interior
panel
an F (or
B
i
B
r
—
1/4") bit and install Magna-Lok
1.ckLine up the new panel withothe panel
V
h
fastenersDthrough the hinges.
t align for a
u below it (making sure uthey
r
P
T close fit at the joint) and
a (using the hingen
5. Using a d
wrench and socket, (if applicable)
n
n
holes as a guide) drill
U all of the hinge tholes
io
attacha the roller brackets and rollers to the
a
yof the new panel while putting the
on the bottom of the new panel: r
top
d
o
orollers in the tracks. (See Illustration DR–
p
1a. For a solid-core door, drill rthrough
the
B
o1/4") bit. Tip
k 50.)
w
entire panel with an F (or
C
c
a
l
r
u
the panel toward youeto insert carriage r
NOTE: The roller brackets on the ybottom
t of the panel. T
bolts through the outside
s
of the top panel and on the top ofbthe
a
dpart in
Install the hinges
over the bolts and
e
bottom panel play an important
m
t
i
tighten the nuts.
il
maintaining proper door ialignment
within
bi
t
U
h
the track. (See the Door,
Roll-up—Roller
1b. For a hollow-core
door, drill through
o
4
r
Adjustment section
the interior
panel only with an F (or
p and Illustration
aw Play
00
l
2
DR–50.)
n
1/4")
n
y
t bit and install Magna-Lok
o
i
o
b
h
i
t
6. Remove the cclamps and check the door
d
ig fasteners through the hinges.
at
u
r
r
e
operationdby opening and closing the
y
o door.
it
p
o
p
b
r A properly adjusted door
CAUTION: Do NOT drill through thei
r should
NOTE:
p
h
o
outside panel of a hollow core door.
Co
o
C should
re easily and, when stopped,
open
r
pr
d
e
t (See the
eremain at any given location.
n
z
s
o
i
Door,
Roll-up—Spring
Winding
and
i and clamp
a
r
2. Swing the new panel upright
t
o
Adjustment section.)
im
into position.
h
uc
l
t
i
d
t
o the horizontal tracks. au 7. If a load bar isUinstalled
on the old panel,ed
3. Lower the door from
r
n
4
v
p
remove it 0
and install on the new panel.
r
U
e
e
r panel with the panel
4. Line up the new
0 Roll-up—ProtectivesBeam
See the2Door,
d
e
above it (making
sure
they
align
for
a
t Bar) Assembly section andr Illustra(Load
h
zethe joint) and (using the hinge
close fitriat
g DR–60.
tion
ts
i
r
o
h
holes
yIf paint repair is necessary,
h as a guide) drill all of the hinge holes
ig see the Paint
8.
p
r
onutthe top of the new panel:
o
a
ll
C section.
n
A
U
Truck Body and PDV—Body Service Manual
45
Bottom Panel Replacement
l
d
w
a
e
a
u
l
v
CAUTION:
hollow-core (some aluminum
and fiberglass) doors, although some fasteners
rtheOnway
n brackets
y to the inner panel. In those
e
a
extend all
through the door, most
are fastened ONLY
b
s
M panel. Solid-core doors (DuraPlate,
cases,
through the outside
wood,
d When aluminum-clad
re do NOT drillwood)
e
e
or
plastic-coated
have
most
fasteners
through
the
entire
door.
drilling
holes
in
the
t
s be sure to drill only to the iappropriate
c
i
t
door,
depth.
h
ib
rv
g
h
l
e
i
o
a
Removal
S
r
ll r
u
p
y
n
A 1. Push open the door untildthe
9.
Using
a
wrench
and
socket,
(if
applicable)
a
n
o bottom of the
M of
io remove both roller brackets and rollers
door is about 16" [40Bcm] from the header
t
e
c
— opening.
the joint roller brackets (at the top
at the top of the door
u
ic of the
V
d
v
panel). (See Illustration DR–50.)
r
2. Place a clamp
e
PDin the horizontal tracks, ponro
10. Drill out the rivet heads in S
the joint roller
each side,dbelow the bottom rollers. re
y
n
brackets attached to thedbottom panel.
a
d near
o
3. Placeya clamp on one of the cables,
e
Punch out the rivetsBand, in at least one of
z
d
i
the
r
o eye of the cable.
the hinges, insert—
a punch into one of the
o
B
V
h
rivet holes toDstabilize the door panel while
4.
k Grasping the clamp withutone hand, release
c
P remaining rivets and bolts.
detaching the
a of the door by n
u the cable from the bottom
r
d
n
T
pulling the cotter pin
n the panel from the tracks and
U out of the cable tio
11. Remove
a
anchor pin (or other fastener) and a
y the remainder of the door slightly up
push
r
d
o
removing the anchor pin. (See Illustration
o toward the front of the truck.
and
p
r
B
DR–30.)
o
C
ck12. Place a (fourth) clamp in the track to law
5. Allow the spring to wind the
cable onto
r
u
prevent the door from rolling back down.
r
estops it by
y
t
the drum until the clamp
T
b
s
13. If the new bottom panel does not
contacting the drum. a
d have a
e
m
bottom roller bracket attached,
it drill off the
ili
b
t
i
rivets holding the bottom brackets on the
hbrackets. on
CAUTION: U
Protect the roof from the
old panel and remove rthe
o
4
clamp 0
with a piece of flat stock (plywood
ti
w
p
a
a
0
or sheet metal) if necessary.
l
r
2
n
o
y
t
o
b
h
ti
rp
c
g
o
d
u
ri on the opposite cable.
6.yRepeat
C
te
d
i
r
p
b
ro
te
o
7. Drill out the rivet heads in the centerhi
p
s
C hinges attached to the bottom panel.
e
o (See
a
r
r
m
p
Illustration DR–45.) Punch out the rivets
ed
ili
n
t
z
and, in at least one of the hinges,
insert
a
o
U
ri
tiholes
o
punch into one of the rivet
to
4
c
0
uwhile detaching
th
stabilize the door panel
0
d
u
2
d
a
the remaining rivets
roand bolts.
e
t
n
v
p
h
U
e
Illustration DR–55
er
ir g
8. Using a wrenchr and socket, (if applicable)
s
Sample Bottom Roller Brackets e
droller brackets located at the
y
remove both
e
r
p
o
s
bottom rofizthe bottom panel and remove
t
C
o
h
the rollers.
(See
Illustration
DR–55.)
ig
th
r
u
a
ll
n
A
U
46
Truck Body and PDV—Body Service Manual
l
a
u
ed panel does not have a an
awin the bracket at the top of
l
v
1. If the new bottom
4.
Install
the
rollers
r
e
bottom roller
bracket attached, attach e
theM
the panel, asby
well as any spacer washers on
s
c
d
bottomrebrackets taken from the old ipanel.
the roller shafts. (See Illustration DR–50.)
v
teThe roller brackets on the
s
r
i
t
NOTE:
NOTE:
h If you are unable to secure
iofb the bottom panel and on the
Sofe
h
top
l
ir gthe hinges with the original type
y
o
a
r
ll rivets that extend completely
d
of the top panel play an
u
through
p bottom
o
n
A the door, use carriage bolts
important
part
in
maintaining
a
B or ribn
it o proper door alignment within the M
neck carriage bolts to—attach them.
Vbe on the
c
track. (See the Door, Roll-up—ice
(The bolt head must
D
u
Roller Play Adjustment section
exterior side ofPthe door, and the nut
rv and
od
d
r
e
Illustration DR–50.)
must be onnthe interior!)
S
a
ep
y
r
5. Reconnect each cable d
by drawing it by the
2. Usingdy
a wrench and socket, (if applicable)
d
o
e
o
clamp to the outside
attach the roller brackets and irollers
B of the bottom door
z to the
B
r
panel.
—
kbottom of the new panel while
o putting the
V
c
h
rollers
in
the
tracks.
(See
Illustration
t
D
u
6. Insert the cable
anchor pin through the
r
u
P
T DR–55.)
a
cable eye
d and the cable anchor bracket.
n
n
n
o
(See
Illustration
DR–30.)
U
3. Line up the new bottom panel with the
a
ti
a
y the cable anchor pin with the cotter
r for
panel above it (making sure they align
7. Secure
d
o
opin.
a close fit at the joint) and (using
pthe hinge
r
B
o hinge holes
holes as a guide) drill all of the
C
ck8. Remove the clamps and check the door
aw
on the top of the new panel:
l
r
u
operation by opening and closing the
r
e
y door.
t
T
b
s drill through the
3a. For a solid-core adoor,
NOTE: A properly adjusted door
d should
entire panel with
an F (or 1/4") bit. Tip
e
m
open easily and, when stopped,
it it should
ili you to insert carriage
the panel toward
b
t
remain at any given location.
i (See the
U the outside of the panel.
h
bolts through
Door, Roll-up—SpringoWinding and
r
Install04
the hinges over the bolts and
w
Adjustment section.)p
a
0
l
tighten
2 the nuts.
n
n
y
t
o
9.
If
paint
repair
is
necessary,
see the Paintio
i
b
h
t
t
3b.
For a hollow-core door, drill throughd
c
section.
ig the
a
u
r
r
e
interior panel only with an F (or
t
d
y
o
i
10. See also
the Door, Roll-up—Pull
Strap
p
o
p
b
1/4")
bit
and
install
Magna-Lok
r
i
r
o
Replacement
section.
Co
fasteners through the hinges. oh
ep
C
r
r
p
d
er
t
e
n
s
o the
iz
CAUTION: Do NOT drilltithrough
a
r
outside panel of a hollow
c core door.
im
ho
u
l
t
i
d
t
u
d
o
U
a
r
e
n
4
v
p
r
U
0
e
re
0
s
2
d
t
e
re
h
z
i service information is generic. Details in illustrations
NOTE: This
and procedurestsmay
ig these instructions
r
or those in your vehicle. Since doors differ, adapt
h
differ hfrom
as needed.
y
g
i
t
p
r
u
o
l
a
l
C
A
Un
Installation
Truck Body and PDV—Body Service Manual
47
Protective Beam (Load Bar) Assembly
Roller Play Adjustment
l
d
Removal
a
e
NOTE: The roller
awbrackets on the bottom
u
l
v
r
of the top panel
y and on the top of the
1. Remove thee fasteners.
an
b
s
bottom
panel
play an important part in
d
rethe load bar assembly. e M
2. Remove
maintaining
te proper door alignment within
s
c
i
i
t
the track.
Installationh
ib
rv
h
e
ir g
o that the door has some but not ual
1. Check
S in posi1.
r
ll Place the new load bar assembly
pexcessive side play (1/4" maximum) andnis
y
A tion.
d
a
n
o
centered in opening. There should beM
o
i
t
2. Install new fasteners.B
e not
some slight play so that the door does
c
—
cthree
u
i
V
bind
in
the
track.
Approximately
to
NOTE: If you are unable to secure
d
v
r
D
o
five spacer washers should be
r
e at the
the assemblyPwith the original type
p
S
d
second-from-top joint roller
and the
of fasteners,
y roller
n use carriage bolts or re
d
a
second-from-bottom
joint
on each
rib-neck carriage bolts. (The boltd
o
e
y
side. (See Illustration
B DR–50.)
head
d must be on the exterior rside
iz
o
—
o be on
Bof the door, and the nut must
2. Add or subtractVspacer washers on roller
h
t
k
the interior!)
shafts, if necessary,
c
u
PD to achieve proper play.
a
u
Equal numbers
d of washers should be used
n
Tr 3. Adjust the latches Uonnboth sides.
n
it o
on each
a side to ensure that the door
Latch Adjustment
a
y
r
remains
d centered. (See the Door, Rollo
o
up—Roller
Replacement section for
1. Close the door from the inside. rp
B
o
k removing rollers.)
2. Loosen the bolts on the endsCjust enough
c
aw
l
r
u
to be able to slide the latches
e in and out. Tr
y
t
b
s
(See Illustration DR–60.)
a
d
e
m
t
i
3. Position each latch
so
that
the
metal
il of the catch’s “finger”
bi
t
i
“finger” is in front
U
n
h
o
o
but not touching.
4
i
r
t
w
0
p
a
a
0
l
r
4. Tighten2the bolts.
n
o
y
t
o
i
p
b
h
t
r
5. Raise
c
g and lower the door several times to d
o
i
u
r
e
C
ensure
the
latch
and
catch
do
not
hit
each
t
d
y
i
p
o
b
er
other.
r
i
t
o
C
ep
oh
as
r
r
p
d
lim
e
i
n
t
iz
io
U
r
t
o
4
c
0
u
th
0
d
u
2
d
a
ro
e
t
n
v
p
h
NOTE: This service
er
re information U
ir g
s
d in illustrations
y
is generic. Details
e
re
p
and procedures
o
ir z may differ from
ts
C
those in
your vehicle. Since doors
o
h
ig
th adapt these instructions as
differ,
r
Illustration DR–60
u
l
a
needed.
Protective Beam Latchl and Catch
n
A
U
48
Truck Body and PDV—Body Service Manual
l
a
MSL (“Banana Lock”) Replacement
u
w
n
ed
ano
l
a
v
1. Open the door.
NOTE:
There
is
adjustment on
r
y
M
e
a Master Security
b Lock. If the
s cover is held in place with
e
2. If the roller
e
c
d
handle
becomes
worn to the point
i
r a wrench and socket to remove
e
nuts,suse
v
t
r (See
that the
i door no longer closes
tnuts that secure the roller cover.
e
the
b
h
i
tightly
S DR–55.)
h as it should, replace the
l
igIllustrations DR–40, DR–50,y and
r
o
a
handle.
r
ll If the roller cover is heldoind place by rivets,
u
p
n
A drill out the rivets. B
a
n1. Remove the fasteners holding the handle.
M
it o (See Fastener Replacement section and
—
V
CAUTION: On hollow-core
(some
c
ce
Illustration DR–65.)
D
u
i
aluminum and
fiberglass)
doors,
P
d
rv
althoughd
some fasteners extend all theo
2. Remove the handle.
r
e
way through
the door, most bracketsp
S
an ONLY
e
are fastened
to the inner panel.
y
r
3. Align the holes in the dnew handle with
y cases, do NOT drill through
Indthose
d
those in the door andofasten the handle
edoors
o
the outside panel. Solid-core
B
z
i
B (DuraPlate, aluminum-cladrwood, or
into place.
—
k plastic-coated wood) haveo most
Vare unable to secure
c
h
NOTE: If you
D
u
fasteners through the tentire door.
r
u
P the original type of
T
When drilling holesain the door, be
the lock with
d
n
n
sure to drill only to the appropriate o
rivets,nuse carriage bolts or ribU
i
acarriage bolts to attach the
depth.
t
neck
a
y
r
d
o
handle.
(The bolt head must be on
o
p
3. Remove the roller from the track.
r
B
the
exterior
side of the door, and
o
k
4. Install a new roller in the track.
C
c the nut must be on the interior!) law
r
u
y
te by nuts,
Tr
5. If the roller cover wassheld
b
a on the hinge and
replace the roller cover
d
e
m
t
i
tighten the nuts.ilIf it was held by rivets:
bi
t
i
U
h
5a. For a solid-core
door, insert carriage
o
4
bolts 0
through the outside of the panel.
w
pr
a
0
l
Install
2 the roller cover over the bolts
n
n
y
t
o
i
o
and tighten the nuts.
b
h
i
t
c
i5b.g For a hollow-core door, install the ed
at
u
r
r
d
y
o
it
p
o
p
b
roller
cover
with
Magna-Lok
fasteners.
r
i
r
o
Co
ep
oh
C
r
r
p
d
er
t
e
n
s
iz
io
a
r
t
c
im
ho
u
l
t
i
d
t
u
d
o
U
a
r
e
n
4
v
p
r
0
NOTE: This service
e
re information U
0
s
2
is generic. Details
in illustrations
d
t
e
re
h
and procedures
may
differ
from
z
i
ts
ig
thoseoinr your vehicle. Since doors
r
h
y
h adapt these instructions as
ig
t
differ,
p
r
u
o
DR–65
aneeded.
ll
C Master SecurityIllustration
n
A
(“Banana”)
Locks and Fasteners
U
Roller Replacement
Truck Body and PDV—Body Service Manual
49
Two-point (Fan-type) Latch Adjustment
Latch Plate Rod
l
d
w Cover
a
1. From inside theetruck, close the door
a
l
Stud Base
rv
nu
tightly.
y
e
a
b
s
M
e
2. The fan-type
latch
should
be
in
the
d
r
e
Bolt on it
s latch position (see Illustration
ce
primary
i
t
Stud Base
ib
rvresting on
gh with the latch plate rod
h
l
e
ir DR–70),
o
a
S assembly. If
r
ll the top of the fan of the latch
u
p
y
it might
n
A the latch is not properlydadjusted,
a
n
latch in the secondary oposition (see
M
io
B
t
e
Illustration DR–75).
If
necessary,
c
Fan
—plate so that the latch u
ic Latch
V
reposition the latch
Keps Nut
d
v
r
o
Weld
plate fits snugly
r
e
PD against the fan.
Illustration DR–70 S
d the latch plate is level andrep
Normal Latch and Striker
y Position
n
3. Ensure that
d
a
d
o
square
e
y with the fan. (See Illustration
B
z
d
i
DR–80.)
r
o
—
o
B
V
h
4.
t
k After both latches are checked/adjusted
c
u
PD
according to this procedure,
check that
a
u
d
n smooth and that theon
Tr
latching/unlatchingUis
n
it
a
door seals at the bottom.
a
y
r
d
o
o
p
r
B
o
k
C
c
aw
l
r
u
r
e
y
t
T
b
s
a
d
e
m
t
i
il
bi
t
i
U
n
h
o
o
IllustrationrDR–75
4
i
w Secondary Latch and
0
p Striker Positionrat
a
0
l
2
n
y
t
o
i
po
b
h
t
r
c
o
d
ig
u
r
e
C
t
d
y
i
p
o
b
er
r
i
t
o
C
ep
oh
as
r
r
p
d
lim
e
i
NOTE: This service information
is
n
t
iz
io and
ULevel
r
generic. Details in illustrations
t
o
4
c
procedures may differ u
from those in
0
th
0
Bolt on
d differ,
u
your vehicle. Sinceodoors
2
d
a
Stud
Base
r
e
t
n
adapt these instructions
as needed.
v
p
h
Latch
U
er
re
ir g
Plate
s
d
y
e
re
p
o
ir z
Illustration DR–80
ts
C
o
h
Square Latch Plate with Fan
ig
th
r
u
a
ll
n
A
U
50
Truck Body and PDV—Body Service Manual
l
a
u
d
w
la
ve to order a new pull strap an
NOTE: Be rsure
y
M is
e enough to reach when theedoor
that is long
b
s
d
open but
ic does
re short enough so that the vstrap
e
t
s on the ground when theerdoor is
nottdrag
i
b
h
i
S
l
igclosed.
y
r
oh
a
r
ll NOTE: If you are unableodto secure
u
p
n
A the strap with the original
type
of
a
B
n
M
it o
rivets, use carriage —
bolts or rib-neck
V them. (The
c
carriage bolts toDattach
ce
u
i
bolt head mustPbe on the exterior side od
rv
d
r
e
of the door,nand the nut must be on p
S
a
e
the interior!)
y
r
y
d
d
d
o
e
o
1. Open the door enough to allowz for comfort
B
i track to
B working, then clamp the
r
while
—
k
V
c
ho or closing.
prevent the door from opening
t
D
u
r
u
P
T 2. Drill out the rivets holding
a the pull strap ton
d
n
the bottom panel of
Illustration DR–85
U the roll-up door. (See
io
an
t
Pull Strap
a
Illustration DR–85.)
y
r
d
o
pothe bottom
3. Attach the end of the new straprto
B
panel of the roll-up door withorivets or
C
ck
aw
l
carriage bolts.
r
u
r
y
te
b
4. Remove the clamp ands test the strap while T
athe door.
d
opening and closing
e
m
t
i
il
bi
t
i
Door Seal Replacement
U
h
o
4
Side Seal
w
0
pr
a
0
l
2 roll-up door.
n
1. Opent the
n
y
o
i
o
b
h
i
t
c
2. Drill
ig out the rivets that hold the seal’s ed
at
u
r
r
d
y aluminum extrusion in place. (See it
o
p
o
p
b
r
i
r
Illustration
DR–90.)
o
Co 3. Uncrimp both ends of the seal extrusion.
ep
oh
C
r
r
r
p
d
e
t
e
n
4. Remove the seal from the extrusion.
s
iz
io
a
r
t
5. Cut the new seal to the proper
c length with ho
im
u
l
t
i
bolt cutters.
d
t
u
d
o
U
a
r
e
n
6. Insert the new seal
into
the
extrusion
and
4
v
p
r
U
0
crimp the ends.re
e
0
s
2
t
Illustration DR–90re
edextrusion using aluminum
7. Reattach zthe
h
Side Seal on Roll-Up
ri or stainless-steel sheet-metal
fasteners
ts Door
ig
r
o
h
y
screws.
h
ig
t
p
r
u
o
8. a
Close the door and check the seals.
ll
C
n
A
U
Pull Strap Replacement
Truck Body and PDV—Body Service Manual
51
Top and Bottom Vinyl Seals
d
l
1. Fully open the e
roll-up door and clamp the ua
v
r
track belowethe bottom panel to prevent n
a
s moving.
the doorefrom
M
w
la
Uncrimp Both Ends
of the Bracket to
Remove the Old Seal
by
d
r
e
e
t
s
c
2. Uncrimp
t both ends of the desiredviseal
bi
h
i
r
extrusion.
(See
Illustrations
DR–95
and
g
l
iDR–100.)
r
oh
a
Se
r
ll
u
p
y
n
A 3. Use a locking pliers to extract
d
a
the old seal.
n
o
M
io
B
t
e
4. Slide the new seal—
into the extrusion and
c
u
ic
V
crimp the ends to
secure the seal.
d
v
r
D
ro
e
5. Remove the P
clamp, close the door, andp
S
d
y
re
check the
d
an seal.
d
e
y
Bo
z
d
i
r
—
o
Bo
V
Illustration
h
t
D DR–95
k
Top P
Seal on Roll-up Door
c
u
a
u
d
n
n
Tr
n
U
it o
a
a
y
r
d
o
o
p
r
B
o
k
C
c
aw
l
r
u
r
e
y
t
T
b
s
a
d
e
m
t
i
il
bi
t
i
U
n
h
o
o
4
i
r
t
w
0
p
a
a
0
l
r
2
n
y
t
o
i
po
b
h
t
r
c
o
d
ig
u
r
Illustration
DR–100 C
e
t
d on Bottom of Rear
y
i
Vinyl Seal Crimped
p
o
b
er Roll-Up Door
r
i
t
o
C
ep
oh
as
r
r
p
d
lim
e
i
n
t
iz
io
U
r
t
o
4
c
0
u
th
0
d
u
2
d
a
ro
e
t
n
v
p
h
U Details iniillustrations
NOTE: This service
and procedures may er
g
re information is generic.
r
differ from those
d in your vehicle. Since doors differ,pyadapt these instructions as needed.res
e
o
iz
r
ts
C
o
h
ig
th
r
u
a
ll
n
A
U
52
Truck Body and PDV—Body Service Manual
Drains
Cargo Floor
Cleaning
ed
v
r
e
s
re
Rubber “duck-bill”
or “kazoo”
ts
h
drain valves
g are designed to let y
i
r
the water
l out without allowing od
l
water
A to siphon into the cargo B
area in a negative pressure —
V
condition.
ce
i
rv
e
S
al
u
an
M
d
ti e
ib
h
o
pr
n
it o
c
u
od
r
p
re Illustration DN–5
by
w
la
Gently insert pointed tool
through drain top (from
inside cargo area)
l
a
u
Or squeeze bottomn
a
“lip” edges to release
M
accumulation (from
underneath
cevehicle)
i
rv
e
S
Clean the Duck-bill drains
y
in the rear d
cargo floor corners
o
B
—
V
D
P
D
P
Clean the drains periodically
d not
n
to ensure that they
are
a or dirt and
blocked by debris
y
dCleaning a Duck-bill Drain
d properly.
are able to drain
e
o
iz
B DN–5.)
(See Illustration
r
k
c
ho use a
•u From the interior of the vehicle,
t
u as a pen or small
Tr small pointed tool, such
a
n
nd
screwdriver, to gently
Un poke down through
it o
a
the drain.
a
y
r
d
o
o
• Or from underneath the vehicle,rpsqueeze
B
o to open the
the wide section on the bottom
C
ck
aw
l
“lips” and release any accumulation
that
r
u
e
y
Tr
did not drain normally.st
b
a
d
Replacement
e
m
t
i
il
bi
t
i
1. Remove the fasteners.
U
h
o
4
2. Remove drain
w
0 valve assembly.
pr
a
0
l
2 the new drain valve assembly.
n
n
3. Position
y
t
o
i
o
b
h
i
t
c
d
4. rFasten
ig into place.
at
u
r
e
dIllustration DN–10
y
o
it
p
o
p
b
Vent
r
i
r
o
Vent Drain
o
C
ep
ohdrains
C
r
Side or front vents may have small formed
r
p have not
d
er
to allow water to escape. To ensure they
t
e
n
s
iz
gotten plugged with dirt, run a short
io piece of wire
a
r
t
c
up into the openings. (See Illustration
DN–10.)
im
ho
u
l
t
i
d
t
u
d
o
U
a
r
e
n
4
v
p
r
U
0
e
re
0
s
2
d service information is generic. Details in illustrations
NOTE: This
and procedures e
t
e
r
h
z
may differ
from
those
in
your
vehicle.
Because
Utilimaster
manufactures
many
ir
s
t in
ig
o
h
customized
vehicle bodies, this manual cannot list andyrillustrate every possible part
th vehicle. Nevertheless, the most common bodypoptions are described here.rigUse this
every
u
ainformation as a guideline where it applies. Co
ll
n
A
U
Truck Body and PDV—Body Service Manual
53
E-track
CAUTION: When welding or
l
d
w to a DuraPlate panel,
cutting next
a
e
a
u
l
v
be very careful to not overheat the
y panel (and melting the
er to grind off the weld (if an
DuraPlate
1. Use a die s
grinder
b
plastic
present)rebetween the front corner brace M
and the
d core).
e
e
E-track.
it
ic periodits (See Illustration ET–5.) vStop
b
h
i
r to cool.
g and allow a DuraPlate panel
h
l
e
ically
r
o
a
S
r
ll2. Remove the Hucktainer fasteners.
u
(See the
p
y
n
A Fastener Replacement section.)
d
a
n
o
M
io
B
t
e
3. Remove the E-track.
c
—
u
ic
V
d
v
Installation
r
ro
PD
p
Se
1. Cut the new
E-track to length, notingewhere
d
y
r the holes
the prepunched
holes must align with
d
an
d
o ET–5
e
in they sidewall panels.
Illustration
B
z
d
i
E-track, Fasteners,
r and install
o
— and Welded Front Brace
o
2. BHold the new E-track in position
V
th
k new Hucktainer fasteners.
c
u
PD
a
u
d
n brace and the newoE-n
Tr 3. Reweld the front corner
n
U
i
a CAUTION: Use stainless-steel
track. Weld quickly and stop periodically
at to
y
r
d
allow the panel to cool. You may also
fasteners for all grab handles.
o spray
o
p
water on the exterior DuraPlate surface
to
cool
it.
r
B
o
k
C
c
aw
l
Grab Handle
r
u
r
e
y
t
T
b
s
1. While holding the handle,
remove
the
a
d
stainless-steel Phillips-head
fasteners from
e
m
t
i
the handle. (SeetilIllustration GH–5.)
bi
i
U
n
h
o
o
2. The handle 4should release into your hand.
i
r
t
w
0
p
a
a
0
l
r
3. While holding
the new handle in place,
2
n
y
t
o
i
po
attach
it
using
stainless-steel
fasteners.
b
h
t
r
c
o
d
ig
u
r
e
C
Liftgate
t
d
y
i
r
p
o
b
e
r
i
t
o
IfCthe vehicle is supplied with an optional afterep
oh
as
r
r
market liftgate installation, see the documentation
p
d
lim
supplied by the liftgate manufacturer nfor operation
e
i
t
o
iz
and service information. To ordertireplacement
U
r
o
4
c
liftgate component parts, contact
an
authorized
0
u
th
0
d
liftgate distributor. See information
supplied by u
2
d
ro their web site. na
e
t
the liftgate manufacturer pand/or
v
h
U
See, for example, www.anthonyliftgates.com,
er
re
ir g
s
d www.interlift.net,
y
www.eagleliftgates.com,
e
re
p
www.leymanlift.com,
o
ir z www.maxonlift.com,
ts
C
www.thieman.com,
www.tommygate.com,
o
h
Illustration GH–5
ig Entrance
th (Ultron/Del/Canadian), or
www.liftgate.com
r
u
Grab Handle at Roll-Up
Door
a
ll
www.waltco.com.
n
A
U
Removal
54
Truck Body and PDV—Body Service Manual
Lights
al
u
an
M
d
w Always replace a light
CAUTION:
e
a
l
v
NOTE: Thisr section illustrates lights
with one of the same size,
y and wattage.
e Utilimaster vehicle e
shape,
mountedson
b
d
bodies.reFor chassis-mounted lights,ic
e
v
t
i CAUTION: Many lights have a
refer
tsto the chassis service er
b
h
i
S
h definite top and bottom. Always al
iginformation.
y
r
o
check the position of the light
r
l
Clearance,
Identification, and SidedMarker
l
p
before removing and install rightnu
o
A
a
B
n
side up.
NOTE: Light assemblies that are sealed units io
M
—
must be replaced as
V complete units. Some ct
ce
D
u
i
assemblies have
removable
lenses
and
P
rv
od
replaceable d
bulbs. Some assemblies have
r
e
S
pigtail wires
an spliced to the body wiring,
ep
y
r
y the pigtails to be cut, and
d
requiring
d the new
d
o
e
o
pigtails spliced in. For information
B
iz lights,about
B
r
—
upgrading
to
long-lasting
LED
contact
k
V
c
ho
Utilimaster Customer Service.
t
D
u
r
u
P
T
a
Sealed Assembly
d
n
n
U
io
an
1. Turn off the ignition and all lights. at
y
r
d
o
2. As applicable, remove the screws,pdrill off the
Illustration LI–5
r out of its
Bo Front Clearance
heads of the rivets, or snap the o
unit
Light (Sealed Unit)
k
C
c
aw
holder that attaches the lightr assembly
to the
l
u
y
vehicle. (See Illustrations
teLI–5 through LI-15.)Tr
b
s
a harness at the back of
d
3. Disconnect the electrical
e
m
t
i
the unit.
il
bi
t
i
U
h
4. Attach the 4electrical harness to the back of the
o
w
0 unit.
replacement
pr
a
0
l
2
n
n
y
t
o
5. Align
the
holes
of
the
new
light
unit
and
attach
i
o
b
h
i
t
cIllustration LI–10
to
d
igthe vehicle.
at
u
r
r
e
Rear Identification
Light (Sealed Unit)
d
y Bulb
o
it
Replaceable
p
o
p
b
r
i
r
o
Co 1. Turn off the ignition and all lights.roh
ep
C
r
p the screws
d
er
2. Use a Phillips screwdriver, remove
t
e
n
s
iz
holding the lens on the light
iofixture.
a
r
t
im
ho
ucbulb.
l
3. Remove the lens anddold
t
i
t
u
d
o bulb.
U
a
r
e
4. Insert the replacement
n
4
v
r
U
0
ep
e
r
0
5. Place the lens back on the fixture and secure
s
2
d
t
e
re
with the screws.
h
z
ri
ts
ig
r
o
h
y
h
CAUTION:
To avoid cracking the lens for
ig
t
p
r
u
a replaceable bulb, do not overtighten
o
a the screws.
ll LI–15
Illustration
C
n
A
Side Marker Light on Rear Light Assembly
U
Truck Body and PDV—Body Service Manual
55
Stop/Turn/Tail/Back-up
l
d
w
a
e
a
u
l
v
CAUTION:
r Always replace a light with aone
n of
y
e
the same
size,
shape,
and
wattage.
b
s
M
d
re
e
e
t
s
c
t (Sealed Assembly) vi
Permanent Mount
bi
h
i
r
g
l
e
1. riTurn off the ignition and allSlights.
oh
a
r
ll
u
p
y holding the
n
A2. Drill off the heads of thedrivets
a
n
light unit to the rear B
ofothe vehicle. (See
M
io
t
e
c
Illustration LI–20.)
—
u
ic
V
d
v
r
3. Disconnect theDelectrical harness at the back
ro of
e
P
p
S
the unit. d
y
re
n
d
a
4. Attach the electrical harness to thedback of the
e
y
Bo
z
replacement
unit.
d
i
r
o
—
o
B
V
5. Align the predrilled holesth
of the new light unit
ck and POP-rivet the unitainu place.
PD
u
r
d
n
TGrommet
n
Mount (Sealed Assembly)
Un
it o
a
a
y
r
1. Turn off the ignition and all lights.
Illustration LI–20
d
o
o
p
Stop/Turn/Tail
Light (Permanent Mount)
B
NOTE: Lightly spray the outeror
C with
grommet and marker light surface
ck
aw
l
r
u
soapy water to ease the removal
and
r
e
y
t
T
b
s
installation.
a
d
e
m
t
i
2. Slip a flat-blade screwdriver
under
the
inner
il
bi
t
i
lip of the outside
grommet
to
pry
the
light
unit
U
n
h
o
o
up, so that it4can be pulled out of the grommet.
i
r
t
w
0 LI–25.)
p
a
a
(See Illustration
0
l
r
2
n
o
y
t
o
i
p
b
3. Disconnect
the light from the electrical harness
h
t
r
Insert the
c
o
d
igthe back of the unit.
at
screwdriver u
r
e
C
t
y
i
under the od
p
b
er
4.
Plug
in
the
replacement
light.
r
i
t
o
inside
lip
C 5. Replace the unit by pushing it through
ep
oh the
of the
as
r
r
grommet
p
d
lim
outside (front) of the grommet.n
e
i
t
iz
io
U
r
t
o
4
c
0
CAUTION: The slit on
uthe rear of the grom- th
0
d
met must be pointed
down to allow water tou
2
d
a
ro
e
t
drain.
n
v
p
h
U
er
re
ir g
s
d
y
e
re
p
o
ir z
ts
C
NOTE:o See also the Wiring Diagrams
h
section.
ig
th
r
Illustration LI–25
u
a
ll Mount)
Back-up Light (Grommet
n
A
U
56
Truck Body and PDV—Body Service Manual
Snap-ring Mount Lens (Replaceable Bulb)
ed
v
1. Turn off therignition
and all lights.
e
al
u
an
M
s
esnap
2. Using aeflat-blade
screwdriver, pry the
c
i
r
ringsout. (See Illustration LI–30.)v
d
ti e
ib
h
o
pr
by
w
la
r
t
e
h
3. g
S
l
i Remove the lens and old bulb.
y
r
a
ll 4. Insert the replacement bulb.
d
u
o
n
A
a
B
n
5. Reinsert the lens and
snap ring.
M
it o
—
V Bulb)
c
Screw Mount Lens (Replaceable
ce
D
u
i
P
rv
od
1. Turn off thedignition and all lights.
r
e
S
athen screws holding the lensreonp the
2. Remove
y
y
d
d
light d
fixture. (See Illustration LI–35.)
o
e
o
B
iz
B
r
3. kRemove the lens and old bulb.
—
V
Illustration
LI–30
c
ho
t
D
u
4.
Insert
the
replacement
bulb.
Brake
Light
(Snap-ring
Mount)
r
u
P
T
a
d
n
5. Place the lens back n
on the fixture and secure
n
o
U
i
a
with the screws.
at
y
r
d
o
o
p lens, do
r
B
CAUTION: To avoid cracking
the
o
not overtighten the screws.
C
ck
aw
l
r
u
y
te
Tr
b
s
License Plate
a
d
e
m
t
i
1. Turn off the ignition
il and all lights.
bi
t
i
U holding the lens (or metal
h
2. Remove the
screws
o
4
w
0 the lens) on the light fixture or
cover over
pr
a
0
l
2 off the lens (or sealed unit) from they
n
pinch/pry
n
t
o
i
o
h
i
t
light
fixture. (See Illustrations LI–35 throughb
c
d
ig
at
u
LI–45.)
r
r
e
d
y
o
it
p
o
p
b
r
i
r
3.
Replace
the
bulb
or
sealed
unit.
p
h
o
Co
e
o
C
r
r
4. Place the lens/unit back on the fixture
Illustration LI–35
r
p withbythe
d
eLicense
Stop,
Turn,
Tail,
Back-up, and
Plate Light
snapping into position or securing
t
e
n
z
s
o
i
screws.
a
r
ti
o
c
m
u
th
ili
d
t
u
d
CAUTION: To avoid
o cracking the lens, doa
U
r
e
n
not overtighten
the
screws.
4
v
p
r
U
0
e
re
0
s
2
d
t
e
re
h
z also the Wiring Diagrams
NOTE:riSee
ts
ig
r
o
h
section.
y
h
ig
t
p
r
u
o
a
IllustrationllLI–40
C
n
License Plate LightA(Replaceable Bulb)
U
Truck Body and PDV—Body Service Manual
57
Cargo
l
d
a
e
aw
u
l
v
r Always replace a light with aone
CAUTION:
n of
y
e
the same
size,
shape,
and
wattage.
b
s
M
d
re
e
e
t
s
c
i
t (Sealed Assembly)
bi
Grommet Mount
v
h
i
r
g
l
e
iNOTE:
r
oh
a
The light assembly S
is a sealed
r
ll
u
p
yas a unit.
n
A unit and must be replaced
d
a
n
o
M
io
1. Turn off the ignitionBand all lights.
t
e
c
—
u
ic
NOTE: Lightly V
spray the outer gromd
v
r
met and marker
e
PD light surface with pro
S
d
soapy water to ease the removal andre
y
d
an
installation.
d
o
e
y
B
z
d
i
2. Slip
a flat-blade screwdriver under
r the inner
—
Blipo of the outside grommethtoo pry the light unit
V
Illustration
LI–45
t out of the grommet.
D
k up so that it can be pulled
c
u
License
Plate
Light
(Sealed Unit)
P
a
u (See Illustrations LI–25
r
and
LI–50.)
d
n
T
n
Un
io
a
t
3. On the back of the unit, disconnect the
y
ra
d
o
electrical harness.
o
p
r
B
4. Plug in the replacement light. o
C
ck
aw
l
r
u
5. Replace the unit by pushing
e it through the Tr
t
by
s
outside (front) of the agrommet.
d
e
m
t
Permanent Mount (Sealed lAssembly)
i
i
bi
t
i
1. Turn off the ignition
U and all lights.
n
h
o
o
4
i
r
t
w
0 rivets holding the unit.
p
2. Drill out0the
a
a
l
r
2
n
o
y
t
o
3. On the
back
of
the
unit,
disconnect
the
i
p
b
h
t
r
c Illustration LI–50
oMount)
d
electrical
harness.
ig
u
r
e
Cargo
Light (Grommet
C
t
d
yPlug in the replacement light unit and align
i the
p
o
4.
b
er
r
i
t
o
C unit with the previous mounting holes.
ep
oh
as
r
r
d
5. Use small POP rivets to reattachpthe unit.
lim
e
i
n
t
iz
U
Removable Lens (Replaceable Bulb)tio
r
o
4
c
0
u all lights.
th
1. Turn off the ignition and
0
d
u
2
d
ro the snap-on lens or na
e
t
2. As applicable, prypoff
v
h
remove the screws
er
re holding the light lensUand
ir g
s
d (See Illustration LI–55.)
y
remove theelens.
re
p
z
o
i
ts
3. Replacerthe bulb.
C
o
h
g
iLI–55
th the lens.
4. Reattach
r
u
Illustration
a
ll
Cargo LightA
(Removable Lens)
n
U
58
Truck Body and PDV—Body Service Manual
Mirror
al
u
an
M
w
ed
a
l
v
Adjustment
r
y Crosswalk exterior mirrors
e
WARNING:
b
s
e
are
convex.
mirror’s surface is
To receive maximum
e benefit from the rear mirror,
c
d so youA convex
i
r
e
curved
can
see
more from the
vmirror
have someone
t seat, but it makes
s assist you by loosening the
r
i
t
driver’s
appear
e while
b away than they reallythings
h
mounts and
adjusting the crosswalk mirror
i
farther
are.
While
S
g
h driving, allow plenty of space between
l
you sitriback in the driver’s chair. y
o
a
r
ll
d
u
p the vehicle and other objects.
o
n
ToAadjust a mirror, loosen the nut
until
the
mirror
a
B
n
M
is just loose enough to turn,—
then grab the outside
it o
V pull in the desired c
edge of the mirror and gently
ce
D
u
i
P nut when the mirror is inod
direction. Retighten the
rv
CAUTION: Do NOT reuse two-way
d
r
e
the desired position.
locknuts or bolts; always
S replace with
an
ep
new fasteners.
y
r
dfasteners to mount
Replacementdy
d
o
Use stainless-steel
e
o
B
mirrors.
1. Remove
B the fasteners holdingrizthe mirror.
—
k
V
c
ho to re2
Use new stainless-steel fasteners
t
D
u
r
u
P
T mount mirrors. Do NOT
a reuse two-way n
d
n
locknuts or bolts; always replace with new
U
an
tio
fasteners.
a
y
r
d
o
o
NOTE: Rotate the mirrors as little
p
r
B
as possible for the first 72 hours
o
C
ck
aw
after installation.
l
r
u
y
te
Tr
b
s
a
d
e
m
t
i
il
bi
t
i
U
h
o
4
w
0
pr
a
0
l
2
n
n
y
t
o
i
o
b
h
i
t
c
d
ig
at
u
r
r
e
d
y
o
it
p
o
p
b
r
i
r
This service information ishgeneric. Details in illustrations
and procedureso
Co NOTE:
epmanufactures
o Because Utilimaster
r
may differ from those in your vehicle.
many r C
r
p
d
customized vehicle bodies, this
manual cannot list and
e illustrate every possiblestepart in
n
z
every vehicle. Nevertheless,
io the most common body
a Use this
ri options are described here.
t
o
information as a guideline
im
uc where it applies. th
l
i
d
t
u
d
o
U
a
r
e
n
4
v
p
r
U
0
e
re
0
s
2
d
t
e
re
h
z
ri
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Truck Body and PDV—Body Service Manual
59
Paint
l
d
w
a paint damage on aluminum
NOTE: This procedure
describes how to repair
u
la and
ve
®r
n
as
well
as
FRP
with
a
gelcoat
finish. A
DuraPlate esurfaces of Utilimaster bodies
y
a
b
s
®
differenteprocess is required for FRP with
M a Tedlar finish. See the
d relevant Panel section.
r
e
te
i
h
ib
rv
h
l
e
ir g
o
a
S
r
ll
p body shop do all paint repairs. The nu
WARNING: Utilimasteryrecommends that a professional
A
d
a
n before working on the vehicle.
service technician should
read this entire procedure
o
o
M
i
B
t in a confined area with paint and paint-related
Adequate ventilation is required when working
c
—
ce
chemicals. Always
wear proper protective u
equipment when appropriate to the process. iSafety
V
d chemical products should always supersede
v informaand application
instructions provided with
r
D
o
r
e
P by Utilimaster.
tion provided
S
d
ep
y
r
n
d
a
d
o
Tools and Parts
e
y
B
d
iz
r
o
—
The following
are the tools and items
o used in this procedure:
B
V
h
t
D
k
applications can be done
u with one or more of the following:
P
a
u• cAll
r
d
n
! Blender gun (1.3 to 1.4
fluid
tip
for
gravity-fed
guns;
conventional
guns
n
T ! Cup gun (for application
n use 40–55 PSI at the gun)
U of Dupont 2222S
io Adhesion Promoter)
a
t
a
y required PSI)
! Touch-up gun (see above statement rfor blender gun tips and
d
o
o
p
• Clean white cotton rags
r
B
o
• 320 and 600 grit sand paper
C
ck
aw
l
• Tack cloth
r
u
y
te
Tr
• Masking tape and maskingspaper
b
d
• Dupont 3900S Cleaner a
e
m
t
i
• Dupont 3901S Cleaner
il
bi
t
i
• Dupont 3401S Blender
U
n
h
o
o
• Dupont Imron45000 paint (check with Customer Service for the original paint code)
i
r
t
w
0Activator
p
a
a
0
• Dupont 193S
l
r
2
n
y
• Dupont t8989S Activator
o
i
po
b
h
t
r
• Dupont
c
o
d
ig 8685S Reducer
u
r
e
C
• Dupont
222S
Adhesion
Promoter
t
py strainer
od
bi
er
r
• oPaint
i
t
C• Measuring cup graded in ounces up toro1hcup or 2 cups
ep
as
r
p
• Paint mixing stick
d
im
l
e
i
n
t
• Optional Items:
iz
ioDupont 2505S Activator
U
r
t
! Dupont 2510S Primer and
o
4
c
0
u
! Dupont 359S Paint Additive
th
0
d
u
2
d
! Dupont 2319S Cleaner
a
ro
e
t
n
v
p
h
! Buffing compound
U
er
re
ir g
s
d
y match the original paint and process
e
re and
Although some substitutions
can
be
made,
these
products
p
z
o
i
r for best results of your paint repair.
ts
are recommended
C
o
h
ig
th
r
u
a
ll
n
A
U
ic
NOTE:
ts See also the Decals section.
®
®
®
®
®
®
®
®
®
®
®
®
60
Truck Body and PDV—Body Service Manual
l
a
u
w
n
ed
la
1. If necessary,rv
remove any decals from the a
y
e (see Decals section) and efillM
affected area
b
s
d
in damaged
ic
re areas with body putty as
e
v
t
r
needed
i
ts (see manufacturer’s instructions).
e
b
h
i
body putty to cure and sand
S it
l
igAllow
y
r
oh
a
smooth.
r
ll
d
u
p
n
A 2. Use a clean rag soakedBinoDuPont 3900S
a
n
M
it o
Cleaner to clean the—
repair area and the
V
c
ce
area surroundingDthe repair. Using a
u
i
P rag, wipe off the 3900Sod
second clean dry
rv
d
r
e
n it evaporates. If the 3900S
cleaner before
p
Illustration PA–10S
a
e
y
r
dries before
y it is removed, re-wetdand wipe
Use DuPont 3900S andd3901S Cleaners
d
o
dry.o(See Illustration PA–10.) e
B
z
i
B
—
3. kSand the defective area with
or320-grit sand
V
c
h
t
u paper. (See IllustrationuPA–15.)
r
PD
T NOTE: If necessary, ause a finer (600- n
n
nd
it o
grit) sandpaper toUsmooth the blend area
a
a
y
r
surrounding the repair area.
d
o
o
psoaked in
r
B
4. Repeat cleaning with a clean rag
o sanding
DuPont 3901S Cleaner to remove
C
ck
aw
l
r
u
dust. (See Step 2.)
y
te
Tr
b
s
a bumper, etc.) to
5. Mask all fixtures (lights,
d
e
m
t
i
protect from overspray.
(See
Illustration
il
bi
t
i
PA–20.)
U
Illustration PA–15
h
o
4
Sand
Area
to
Be
Prepared
w
0
pr
a
0
l
CAUTION:
Make
sure
the
area
cleaned
2
n
n
y
ist bigger than the spray area.
o
i
o
b
h
i
t
c
d
ig
at
u
r
r
e
d
y NOTE: Use masking tape and a paper it
o
p
o
p
b
r
i
r
o
Co that cannot be penetrated by paint.
ep
oh
C
r
r
6. Wipe a wide area with the tack p
cloth to
d
er
t
e
n
make sure all areas to be sprayed
s
o are clear
iz
i
a
r
t
of dust and debris. (SeecIllustration
im
ho
u
l
t
PA–25.)
i
d
t
u
d
o
U
a
r
e
7. If the base or substrate
is
exposed
by
n
4
v
p
r
U
0
sanding (or if it
e
reis a replacement part that
0
s
2 Illustration PA–20
d painted), apply DuPont
has never ebeen
t
re
h
z
2510S Primer
and
2505S
Activator.
ri
tsPaper
igProtect with Masking Tape and
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Substrate Preparation
®
Truck Body and PDV—Body Service Manual
61
l
d
a
e
aw
u
l
v
r
y
e
an
b
s
M
d
re
Paint Preparation
e
e
t
s
c
i
t a graduated (9-ounce) measuring
bi
v
h
1. Using
cup,
i
r
g 3 ounces paint (DuPont eImron 5000) to 1
l
ipour
r
oh
a
S
r
ll ounce activator (DuPont 193S).
u
(See
p
y
n
Illustration PA–25
A Illustrations PA–30 anddPA–35.)
a
n
Use Tack Cloth for Final WipeM
io
Bo
t
2. Add 1/8 ounce of—
accelerator (DuPont 8989Suc
ce
i
V
d
v
gallon can) to D
the paint mixture. (See
r
o
r
e
P
Illustration PA–40.)
S
d
ep
y
r
n
3. Using aa paint stick, stir paint mixture
d
d
o
e
y
thoroughly.
B
d
iz
r
o
—
4. BPlace the paint strainer in the
o touch-up gun
V
h
t
D
k
cup
and
pour
the
paint
through
the
strainer.
u
P
a
uc (See Illustration PA–50.)
r
d
n
n
T
n
o
U
iPaint
a
t
NOTE: A drop or two of DuPont 359S
Illustration PA–30
y
ra
Additive may be added if there is aoproblem
d
Three Ounces of Paint
o
p
with “fish eyes” or other contaminant-related
r
B
o
imperfections.
C
ck
aw
l
r
u
r
e
y
5. Assemble the touch-up gun.
t
T
b
s
a to make sure it has
d
6. Check the blender gun
e
m
t
i
sufficient blenderil (DuPont 3401S).
bi
t
i
U
n
h
o
o
4
i
r
t
w
0
p
a
a
0
l
r
2
n
y
t
o
i
po
b
h
t
r
c
o
d
ig
u
r
e
C
t
d Illustrationr PA–35
y
i
p
o
b
r
i
One Ounce
teof Activator
o
p
h
s
C
e
o
a
r
r
m
p
ed
ili
n
t
z
U
ri
tio
o
4
c
0
u
th
0
d
u
2
d
a
ro
e
t
n
v
p
h
U
er
re
ir g
s
d
y
e
re
p
o
ir z
ts
C
o
h
igPA–50
th Illustration PA–40
r
u
Illustration
a Add 1/8 Ounce Accelerator
ll
Use A
Paint Strainer
n
U
CAUTION: Mix paint thoroughly to ensure
proper application and paint performance.
62
Truck Body and PDV—Body Service Manual
l
a
u
d
CAUTION: e
Clear nozzle before spraying. an
aw
l
v
r
y
M
e
b
s
e
d
ic
re
Paint Application
e
v
t
s
r
i
e
b
ht the cup gun with DuPont
i
1. g
Using
222S
S
l
i Adhesion Promoter, do a testy spray
r
oh
a
r
ll away from the vehicle toomake
d suredirected
u
p
the gun
n
A nozzle is clear.
a
B
n
M
it o
—
V Adhesion Promoter acrossc
2. Spray DuPont 222S
ce
D
u
i
P
d
the area to be repaired
and extend to the o
area
rv
d
r
e
surrounding
n the repair to ensure adequate
S
a
ep
adhesion
of
the
new
to
old
paint.
y
r
y
d
d
d
o
3. Air odry for 1 to 2 minutes. ze
B
i
B
r
—
4.ckUsing the touch-up gun containing
DuPont
Illustration
PA–55
V
hospray directed
t
D
u
Imron
5000
Paint,
do
a
test
Apply
Paint
r
u
P
T away from the vehiclea to make sure the touchd
n
n
U
up gun nozzle is clear.
an
tio
a
y
r
d
5. Apply the first coat of paint. (SeeoIllustration
o
p
PA–55.)
r
B
o
ck
aw
6. Air dry for 1 to 2 minutes.r C
l
u
r
y
te
b
7. Using the blender gunswith DuPont 3401S T
a directed away from the
d
Blender, do a test spray
e
m
t
i
l the blender nozzle is
vehicle to maketisure
bi
i
clear.
U
h
o
4
0 coat of blender. (See Illustration aw
pr
8. Apply a0first
l
2
n
PA–60.)
n
y
t
o
i
o
b
h
i
t
PA–60
cIllustration
d
9. rAir
ig dry for 1 to 2 minutes.
at
Apply Blender
u
r
e
d
y Apply a second coat of paint, covering an
o
it area
p
o
p
10.
b
r
i
r
o
Co just beyond the first coat of color.roh
ep
C
r
p
d
11. Air dry for 1 to 2 minutes.
er
t
e
n
s
io extending just riz
a
12. Apply the final coat of blender,
t
c patterns.
im
beyond the previous spray
ho
u
l
t
i
d
t
u
d
obefore removing masking
U
a
13. Air dry 3 to 4 hours
r
e
n
4
v
p
r
materials. (See
0
e
reIllustration PA–65.) U
0
s
2
dis not glossy enough after drying,
14. If the repair
t
e
re
h
z
use buffing
g
ri compound and buff to achieve the
ts
i
r
o
h
desired
y
h appearance.
ig
t
p
Illustration PA–65
r
u
o
15. a
If applicable, see the decal installation proceAir Dry 3 toll4 Hours
C
n
A
U dure in the Decals section.
Truck Body and PDV—Body Service Manual
63
Panel, Aluminum
Gelcoat FRP Surface Repair
l
d
w
Minor damage may beve
hammered out and filled in ua Damage to a small area,lamay be filled in with
r Follow the manufacturer’s
body filler and
y then painted. Follow the
with standard bodyefiller.
an standard
b
s
manufacturer’s instructions for using the body
instructions for using
e the body filler. For painte M
d
r
filler. For paintterepairs, see the Paint section in
repair, see thesPaint section in this manual. c
i
i
t
this manual.ib
v
h
r
For severe
l
e panel
ig or large areas of damage,Sthe
r
ohSurface Repair
a
Tedlar FRP
should
fasteners
r
ll be replaced. Remove the necessary
u
p
y Replacement
n
and
Areplace the panel. See the Fastener
d
a
n
CAUTION: PAINT repairs on Tedlar
section in this manual. See also
io
surfaces should only be attempted M
by a
Bothe appropriate
t
e
c
professional body shop that is familiar
Utilimaster body parts manual
or
contact
Utilimaster
—
u
ic
with Tedlar.
V
d
Customer Service if you
need
assistance.
v
r
ro Damage to a small area may be filled
e in with
PD
p
S
Panel, FRP
d
ywith a Tedlar
re
n
standard body filler and covered
d
a
CAUTION: For FRP repairs, the d
o widths are availpolyvinyl fluoride tape (various
emust be
y
underlying
plywood in the FRP
B
z
d
i
r any gouge able). Contact Utilimaster
Protect from the weather
— Customer Service for
o
Bo dry.
assistance.
V
th
D
k that exposes the plywood.
c
u
P
1.
Following
the
manufacturer’s instructions,
a
u
NOTE: FRP panelsnwill have
d
n
Tr
fill
in
the
small
gouges with body filler.
n
either a Tedlar finish
U or a gelcoat tio
a
y the damaged area smooth. As much
finish. The best way to repair
ra
2. Sand
d
o
minor damage to a panel depends
o possible, avoid sanding the Tedlar
rp
Bas
on the type of finish it has. If o
you
k surface beyond the damaged area. Be asure
w
C
c
do not know what kind of finish
the final tape repair covers all the sanded
l
r
u
r
eUtilimasy
your vehicle has, contact
t
area.
T
b
s
ter Customer Serviceawith the body
d
3. Clean the surface to be repaired.
e
m
serial number. Major
damage
may
t
i
il the entire panel.
bi
t
require replacing
i
4.
Cut
the
tape
to
the
proper
length.
U
n
h
o
o
4
i
r
FRP Panel Replacement
t
5.
w Peel back the leadingp edge of the paper
0
a
a
0
l
r
liner and fold it down,
2a large area, have the vehicle’s
n exposing the
o
For damage to
y
t
o
i
p
adhesive
surface.
b
h
t
r
panel repaired
o
ig at a professional body shop or ed
uc as needed and
replaceyrthe damaged panel.
C
6. Align the d
tape
apply the
ti
r
p
o
b
e
exposed
surface
to
the
panel.
r
i
t
o
Replacing
an FRP sidewall involves supporting
p
h
s
C
e
a from the tape,
the roof while the mechanical fasteners are
r peeling themliner
7. Begin
rorep
d
moved from the top, bottom, and sides of the
smoothing
down
li with a squeegee and
e
i
n
t
z
sidewall, the sidewall is replaced, and
then the
ri feathering toUthe outer edges from the
tio See
o
original-type fasteners are installed.
the
4 go. If wrinkles occur,
c
center as you
h
0
u
t
Fastener Replacement sectiondin this manual. See u
0 pull back the tape, stretch the d
carefully
2
o body parts
a
also the appropriate Utilimaster
r
e
tapet out, and resume a smooth application.
n
v
p
h
r
manual.
U
e
g
r
8.riIf there are trapped air bubbles, usesaepin
d
y
e tape
Utilimaster recommends
e sidewalls be replaced
p to pop them and then smooth outrthe
z
o
i
only at a professional
body shop or at
with the squeegee.
r
ts
C
o
h
Utilimaster’sh Customer Service Department in
ig
t
r
Wakarusa,uIndiana. Contact Utilimaster Customer
afor assistance.
ll
Service
n
A
U
®
64
Truck Body and PDV—Body Service Manual
Panel, DuraPlate®
al
u
an
M
w
ed
a
l
v
WARNING:
r Always wear proper
CAUTION:y When welding or cutting next
e
protective
equipment whenever
to a DuraPlate
b panel, be very careful to
s
e
appropriate
for the process. Safetycand
e
not overheat
the DuraPlate panel (and
d
i
r
e
application
instructions
provided
with
v
t
melting
the
plastic
core).
s
r
i
t
adhesives
should
always
supersede
e
b
h
i
S
h
ir g information provided by Utilimaster.
y
o CAUTION: Read and understand ALL ual
r
ll
d
p adhesive application instructions and n
Introduction
A
a
Bo
n
safety procedures. Effectiveness M
of the
it o
—
Procedures for repairing DuraPlate
body panels
repair can be compromised by e
Vsize of damage.
c
depend on the severity and
D
environmental conditions or poor
u
ic
P
d
v
application.
d in the panel can be pro
Small dents and scratches
er
n
S
a
covered up by cosmetic
repairs by using Options
y areas in
re
y
CAUTION: All damaged
d
A or B.
d
d
DuraPlate shouldo
tested for
e
o
Bthebesteel
z
i
B
delamination
of
skins to the
If the galvanized
steel panel is punctured
or
badly
r
—
k
plastic core.
If
detected,
delaminated
o
dented,
the
steel
skins
in
the
damaged
section
may
V be cut out and replaced
areas should
th core. Over
D
uc delaminated from the uplastic
become
r
(OptionPC), or the panel should be
T
a weakening then
time the delamination may n
spread,
replaced
nd (Option D).
U a delaminated areatio
integrity of the panel. Such
a
a C.
y
r
should be cut out and replaced, using Option
d
o
Do not attempt to hammer
o CAUTION:
All damage should be tested for delamination.
p
r
out a dent in the DuraPlate panel. This
B
o
See the Testing for Delamination section.
can result in delamination of a steel w
C
ck
la
skin to the core. Over time
r
u
Severe damage may require thatethe entire panel
r
y
delamination can spread and weaken
t
T
b
or sidewall be replaced, using
the strength of the panel.
asOption D.
d
te
im
i
l
i
Testing for Delamination
ib
Ut
h
o
If a DuraPlate panel
4 is punctured or severely
r
w
0
p
dented, one or more
0 of the steel skins and the
la
2
n
n
plastic core may
t start to separate. To prevent this by
io
o
h
i
t
delamination
c
ig from spreading and weakening the ed
at
u
r
r
DuraPlate
y panel, the delaminated area should beit
p
od
po
b
cutoout and replaced. All damaged areas should
r
i
r
o
C tested for delamination.
be
ep
oh
C
r
r
p
d
er
With a quarter, begin tapping on the n
damaged area
t
e
s
iz
and continue tapping while moving
iooutward until
a
r
t
c area. (See
you are well away from the damaged
im
ho
u
l
t
i
d
Illustration PL–5.) If there is a noticeable differ- u
Ut
ro over the damagedna
ed
ence in the sound while ptapping
4
v
r
U
0Illustration PL–5
area compared to the undamaged
area, delaminae
re
0
Tap Across Damaged
Area
to
Test
for
Delamination
s
2
d
tion has probably occurred
in that area. The
t
e
re
h
damaged sectionizshould be cut out and replaced
rthe panel should be replaced
ts
ig
(Option C), or
r
o
h
y
ig
(Option D).th
p
r
u
o
a
ll
C
n
A
U
Truck Body and PDV—Body Service Manual
65
Procedure Options Summary
Self-adhesive Patch (Option A)
l Parts and Supplies
d summarizes
a
e
NOTE: This section
aw
u
l
v
r options. They
the variouserepair
y
• Isopropyl alcohol
an
b
s
are listed
in
order
of
severity
of
• Sealant (contact
d Utilimaster Customer Service)
rerepaired and/or difficulty e M
e
damage
t
•
Self-adhesive
s
c
i patch panels (contact Utilimasi
t process. See the subsequent
of hthe
b
v
i Service)
ter Customer
r
g
h
l
e
for detailed instructions.
isections
r
o The largest currently
a
S
r
NOTE:
ll
u
pavailable size of the self-adhesive
y to hammer
n
A
d
CAUTION: Do not attempt
a
n
o
out a dent in the DuraPlate
panel. This
M
io patch panels is 12" x 24".
B
t
e
can result in delamination of a steel
c
—Over time
u Tools Required
ic
skin to the core.
V
d
v
r
delamination
and weaken o
r
e
• Safety glasses and gloves
PDofcanthespread
the strength
panel.
p
S
d
• Metal file or deburring tool y
re
d
an
• Metal snips
d
o
e
y
CAUTION:
All damaged areas
in
B
z
• Rubber mallet
dDuraPlate should be testedrifor
o
—
• Caulk gun
B delamination of the steelhoskins to the
V
t
D
k
plastic core. If detected, delaminated
Procedure
u
P
areas should be cutaout and replaced
uc
r
d
n
n
(Option
C),
or
the
panel
should
be
T
1. File down
n burrs and protruding metal in
UD).
io
a
replaced (Option
t
the y
damaged area.
ra
d
o
o isopropyl alcohol, thoroughly clean
2. With
p
Option A (Minor Damage)
r
B
o
k the area surrounding the damage. Theaarea
w
C
Covering surface dents and scratches
with a
c
cleaned should be larger than the size lof
r
u
r
cosmetic self-adhesive patch. te
y
the patch panel.
T
b
s
a
Option B (Minor Damage)
d and
3. Peel the paper off the patch panel
e
m
t
i
il
Filling in a dent with automotive
body filler and
carefully center it over damaged
bi area.
t
i
Uto match the panel.
painting over the filler
Apply pressure for goodhcontact. (See n
o
4
io
t
Illustration PL–10.) pr
w
0
Option C (Moderate
Damage)
0
la
ra
2
n
o
NOTE: Clipping
the corners
y
Cutting outhatsection of damaged panel and
iatooffa 45-degree
p of
b
t
r
the
patch
panel
c
o
securing iagreplacement panel section with selfd
u
r
e
C
angle
before
applying
may
help
t
d
y patches on both sides. (This is not i
adhesive
p
o
b
er the
prevent
something
catching
r
i
t
considered
a
structural
repair
but
would
prevent
o
p peeling theaspanel back.
C damage caused by delamination.) rThe
edgeeand
oh
further
r
p applid
largest hole that can be covered in a single
4. eCarefully
tap down
lim the edges of the panel
i
n
t
cation is 8" x 20".
iz with a rubberUmallet.
io
r
t
4 protection, apply a thin bead
c
Option D (Severe Damage)
ho 5. For additional
0
u
t
0 around the perimeter of the d
2
of sealant
od area, replace the au
For severe damage over a large
r
e
t
n
v
p
h
panel.
affected panels or sidewall.
r
U
e
e
r
rig
s
d
y
Utilimaster recommends
this procedure be done
e
re
p
only at a professional
o
ir z body shop or at
ts
C
Utilimaster’s Customer
Service Department in
o
h
ig
th
Wakarusa,uIndiana.
Contact Utilimaster Customer
r
a assistance.
ll
Servicenfor
A
U
66
Truck Body and PDV—Body Service Manual
l
a
Body Filler (Option B)
u
w
n
ed
a
l
a
v
r Do not attempt to hammer M Parts and Supplies y
CAUTION:
e
b
out a s
dent in the DuraPlate panel. This
• Isopropyl alcohol
ce
d
can
i
reresult in delamination of a steel
• Sandpaperite
s to the core. Over time erv
skin
t
• Body filler
h delamination can spread and weaken
ib
h
l
ir g the strength of the panel. y S
o
a
Tools Required
r
ll
d
u
p
o
n
A
• nSafety glasses and gloves
a
B
o
M
i
—
•
Metal
file
or
deburring
tool
CAUTION: All damaged areas in
V be tested for
ct • Sander
DuraPlate should
ce
D
u
i
P of the steel skins to the od
delamination
rv
Procedure
d
plastic core.
If detected, delaminated r
e
n be cut out and replaced
p
S
areasashould
e
1.
File
down
burrs
and
protruding
metal in
y
r
(Option
y C), or the panel shoulddbe
d
d
the damaged area and
replaced (Option D).
o then sand the area
e
o
B
z
smooth.
i
B
—
k
or
V
c
h
2. With isopropyl
t
D alcohol, thoroughly clean
u
r
u
P
the
damaged
area.
T
a
d
n
n
U
3. Follow
anthe body filler manufacturer’s
tio
a
y
instructions
for preparation and
r
d
o
oapplication. (See Illustration PL–15.)
p
r
B
o
w
the body filler is completely cured,
C
ck4. After
a
l
r
u
sanded smooth, and cleaned (according to
r
e
y
t
T
the manufacturer’s instructions), b
paint the
s
a
d
damaged area. See the Paint e
section.
m
t
i
il
bi paint
t
NOTE: The standard white
i
U
h is PPG
code for DuraPlate panels
o
4
w 3HW76160 (but codes
0
pr may vary).
a
0
l
2
n
n
y
t
o
i
o
b
h
i
t
c
d
ig
at
u
r
r
e
d
y
o
it
p
o
p
b
r
i
r
o
Co
ep
oh
C
r
r
p
d
er
t
e
n
s
iz
io
a
r
t
c
im
ho
u
l
t
i
d
t
u
d
o
U
a
r
e
n
4
v
p
r
U
0Illustration PL–15
Illustration
e
re PL–10
0
s
2 (Before Final Sanding andePainting)
Apply Self-adhesive
Patch Panel
Body Filler Applied
d
t
e
r
h
ir z
s
t
ig
r
o
h
y
ig
th
p
r
u
o
a
ll
C
n
A
U
Truck Body and PDV—Body Service Manual
67
Self-adhesive Panel (Option C)
l
d
a
e available size
NOTE: The largest
u
v
r
of the self-adhesive
patch panels is
e
an
s
12" x 24".
Allowing
for
a
re 2" overhang, the largest e M
minimum
tsthat can be covered in a vic
hole
h
g application is 8" x 20".er
risingle
w
la
Opening
by" "Size (X)
d
ti e Panel Inset (X – 1/4")
ib
h
o Self-adhesive Panel (X + 4")
pr
Interior Side
(8 x 20 Max.)
l
a
u
y
Exterior Siden
d
(Viewed
from
top)
a
n
M
io
• DuraPlate repair panel (contact
Bo Utilimaster
t
e
c
Customer Service) —
Illustration PL–20
u
ic
V
d
v
Self-adhesive
Panel
and
Cut-out
• Self-adhesive patch
panels
(contact
Utilimasr
ro
e
PD
ter Customer Service)
p
S
d
• Isopropyl alcohol
y
re
n
d
a
d
• Maskingytape
o
e
B
z
d
i
Tools Required
r
o
—
o
B
V
h
• Safety
t
k glasses
c
u
PD
• Drill with drill bit set
a
u
d
n
Tr • Metal snips
n
Un
it o
a
• Metal file or deburring tool
a
y
r
d
o
• Tape measure
o
p
r
B
• Rubber mallet
o
k
• Reciprocating saw
C
c
aw
l
r
u
r
e
y
Damaged Area Removal
t
T
b
s
a
d
Illustration PL–25
1. Measure and markm
off the area of the
e
t
i
Mark
Off
Damaged
Area
and
Cut
Out
damaged panel ttoil be replaced. Apply tape
bi
i
around the area
U to prevent scratching the
n
h
o
o
4
i
r
wall.
t
w
0
p
a
a
0
l
r
2 holes along the edges and cut
n
2. Drill trelief
o
y
o
i
p
b
h
t
r
outg the area with a reciprocating saw. (See
c
o
d
i
u
r
e
Illustration
PL–25.)
C
t
d
y
i
p
o
b
er
r
i
t
o
3. Deburr the edges on the inside and outside
C of the opening.
ep
oh
as
r
r
p
d
lim
e
i
n
t
iz
io
Patch Panel Preparation
U
r
t
o
4
c
0
u selfNOTE: The flange of the
th
0
d
u
2
d
adhesive patch panel
a
ro should
e
t
n
v
p
h
overhang the opening
e by 2" on all U
Illustration PL–30
g
er
r
i
sides. The inset of the panel
r
s
Mark
2"
Inset
on
Adhesive
Side
of
Panel
y
ed LESS than 1/8"
re
should bezNO
p
o
i
ts
smaller r(on each of the four sides)
C
o
h
thanththe opening. (See Illustration
ig
r
u
PL–20.)
a
ll
n
A
U
l
Parts
Al and Supplies
68
S
Truck Body and PDV—Body Service Manual
l
a
1. Using a low-RPM
circular saw or die grinder,ucut
d
a piece of DuraPlate
ve that is 1/8" smaller (onaneach
r
of the fouresides) than the hole opening M
and
s edges.
e
deburr e
the
c
by
w
la
d
i
e
v
t
r of the
i
NOTE:
ts To easily capture the size
e
b
h
i
l
igpatch panel, hold it up nextytoSthe opening
r
oh
a
from the
r
ll and mark around the opening
d
u
p
o
n
and
the
A inside. Measure the opening
a
B
n
Illustration PL–35
marks on the panel.—
Verify that the
M
it o
Inset Panel Set on Self-adhesive Patch Panel
Vmarked panel are 1/4" c
dimensions of the
ce
D
u
i
P height and width of od
less than the overall
v
r
d
r
e
the opening.
(See Illustration PL–20.)p
S
an
e
y
r
2. Thoroughly
of the
y clean the outside perimeter
d
d
d
o
cutout
and the inset panel with isopropyl
alcohol.
e
o
B
iz
B
r
—
kNOTE: Clipping off the corners
o of the
V
c
h
t angle before
D
u patch panel at a 45-degree
r
u
P
T applying may help prevent
a something n
d
n
n
catching the edgeUand peeling the panel
io
a
t
a
back.
y
r
d
o
p panel just far Bo
3. Peel the paper back from the patch
r
othe edges. (See k
enough to mark 2" back from
C
c
aw
Illustration PL–40
l
r
Illustration PL–30.)
u
Apply Self-adhesive Patch Panely
te
Tr
b
s
4. Peel the paper off thea patch panel and carefully
d
set the inset panelim
in place. Apply pressure for
te
i
l
i
b
good contact. (See
Illustration PL–35.)
Ut
hi
NOTE: This o
procedure
Patch Panel Installation
w
04
describes applying
the
pr
a
0
l
1. Carefully
set the panel assembly in the opening
2
self-adhesive
panel to the
n
tthe outside. Apply pressure around the b2"y
io first and then tion
from
inset tpanel
h
c it to the sidewall. ra
d
ig
perimeter.
(See Illustration PL–40.)
adhering
u
r
e
t
d
y
o
i
Alternately,
you can apply
p
o
p
b
2.
Thoroughly
clean
the
inset
panel
and
surrounding
r
i
r
self-adhesive panel
o to
Co 2" perimeter on the inside of the rvehicle
ep the
oh with
C
r
the
sidewall
first
and
then
r
isopropyl alcohol.
p
d
e
place the inset panel
t into
e
n
z
s
i
3. Peel the paper off a secondiopatch panel and
the hole in the
a sidewall
t interior side of the or
c
m
carefully center it over the
(and
against
i the selfu for good contact. th
l
i
inset panel. Apply pressure
d
t panel).
adhesive
u
d
o
U
a
r
e
(See Illustration PL–40.)
n
4
v
p
r
U with a
0
e
re the edges of the panels
0
4. Carefully tap down
s
2
d Do NOT compress the panels
t
rubber mallet.
e
re
h
z
inside the
ri 2" perimeter.
ts
ig
r
o
h
y
ig
5. Forth
additional protection, apply a thin bead of
p
r
u
o
asealant around the perimeter of the panels.
ll
C
n
A
U
r
Truck Body and PDV—Body Service Manual
69
Entire Panel Replacement (Option D)
d
l
a
u
an
M
e a large area, replace the
For severe damage over
v
r
affected panels. e
w
la
WARNING: Always wear proper
protective equipment whenever
appropriate for the process. Safety and
application instructions provided with
adhesives and sealants should always
supersede information provided by
Utilimaster.
y
b
s
d
See the Fastener
re Replacement section. e
e
t
s
c
trecommends this procedurevbei done at a
Utilimaster
bi
h
i
r
h
l
e Customer
ig body shop or at Utilimaster’s
professional
r
o
a
S
r
l
u
Service
Department in Wakarusa,yIndiana. Contact
p
n
Al
d assistance.
a
Utilimaster
Customer Serviceofor
n
M
io
B
t
e
“Bonded panels” means the
individual
DuraPlate
c
—other with adhesive and u
ic
V
panels are fastened to each
d
v
r
only have mechanical
ro
e
PDfasteners through the rails
p
S
d
and posts. (See Illustrations PL–80 and PL–95.)
y
re to
d
an means the panels are fastened
“Riveted panels”
d
e For
y rivets instead of adhesive.
each otherdwith
Bo
z
i
rRemoval and
o see the Riveted Panel
—
riveted panels,
o
B
V
h
Riveted
t For bonded
k Panel Installation sections.
Illustration
c
u
PD PL–45
panels,
see the following Bonded
Panel Removal
a
u
Removing
r Bonded Panel Installation
d Floor Plank Fasteners
n
Tand
n
Un sections.
it o
a
a
y
Parts and Supplies
r
d
o
o
• DuraPlate panel (contact UtilimasterrpCustomer
B
o
k
w
Service)
C
c
a
l
r
u
• Isopropyl alcohol
r
e
y
t
T
b
• Appropriate fasteners for rails,
castings,
and
s
aUtilimaster Customer
d
posts as needed (contact
e
m
t
i
Service)
il
bi
t
i
• Sealant (contact Utilimaster
Customer Service)
U
n
h
o
o
4
i
r
• Foam Tape (P/N
t
w
0 12301025)
p
a
a
0
l
r
• Two-part methacrylate
adhesive
for
bonded
2
n PL–50
y
t
o
Illustration
panel (contact
Utilimaster
Customer
Service)
i
po
b
h
t
r
Removing Floor c
Plank and Front Floor
o Cap
• Rivets
igfor riveted panel (contact Utilimaster ed
u
r
C
d
y
Customer
Service)
it
p
o
b
er
r
i
t
o
Tools
C Required
ep
oh
as
r
r
p
• Safety glasses, gloves, and ear protection
d
lim
e
i
n
t
• Drill with drill bit set
iz
io
U
r
t
• Step ladder
o
4
c
0
u
th
• Pry bar
0
d
u
2
d
• Scraper
a
ro
e
t
n
v
p
h
• Caulk guns
U
e
g
er
r
i
r
• Air tools for removing
and
installing
fasteners
s
dbars, spacer blocks, and other
y
e
re
p
• Bar clamps, load
z
o
i
Illustration PL–55
r
ts
braces for bonded
panel
C
o
h
Removing Panel Fasteners
• Windshield
ig
th removal tool (CP-838 equivalent)
r
u
• MONOBOLT
rivet
gun
or
air
hammer
with
a
ll
n
A
buck
rivet attachment for riveted panel
U
70
Truck Body and PDV—Body Service Manual
l
a
u
edand parking the truck on aan
aw
l
v
1. After unloading
r
y
M
e
level surface,
remove E-track, slats, scuff
b
s
e
e deflector plate, cable retainment
d
plates,rvent,
ic
e
v
t
r item
track,
i
ts roll-up door track, or any eother
b
h
i
will interfere with the panel
S removal.
l
igthat
y
r
oh
a
(See
relevant
sections
in
this
manual.)
r
ll
d
u
p
o any decals at the
n
A 2. On the damaged panel,Bcut
a
n
M
Illustration PL–60
it o
—
seam between the panels.
Also, cut the
Vperimeter of the panel at c Cutting Adhesive in Seam with Windshield Removal
ce Tool
sealant around the
D
u
i
P casting.
the rail, post, and
rv
od
d
r
e
S
an 3 through 5 and the rep
NOTE: Steps
y
y in this section describe
d
illustrations
d
d
o
e
o
a vehicle with hardwood flooriz
B
B
r
—
kplanks that run the length ofo the
V
c
tha plywood
D
u body. For a vehicle with
r
u
P
T floor instead of planks,
a you will need n
d
n
to remove the plywood
U section(s) tio
an
next to the damaged panel instead ofa
y
r
d
o
a floor plank.
o
p
r
B
3. If a rear floor cap is present (ito protects the
Cthreshold),
ck
aw
floor planks at the rear door
l
r
u
y
Illustration PL–65
tethe cap.
remove the fasteners and
Tr
b
s
Leveling Old Adhesive
a in the outer floor
d
4. Remove the fasteners
e
m
t
i
ilfloor cap inside the front
plank (and front
bi
t
i
U side as the damaged
h
post) on the same
o
4
panel. (See
w
0 Illustration PL–45.)
pr
a
0
l
2 the floor plank. (See Illustration y
n
n
5. Remove
t
o
i
o
b
h
i
t
t
PL–50.
c
g Depending on the orientation of thed
iplank
a
u
r
r
e
lap joint, you may need to loosenior
t
d
y
o
p
o
p
b
remove
the
adjacent
plank
as
well.)
r
i
r
o
Co 6. On the exterior and interior, markrotheh
ep
C
r
p panel
d
er
location of the edges of the damaged
t
e
n
s
o (to help with riz
on the other panels and/or ipost
a
t
o
proper alignment of the c
new panel during
im
h
u
l
t
i
installation).
d
t
u
d
o
U
a
r
e
n
4
v
p
7. Remove all the fasteners
holding the U
r
0
e
re panel to the applicable
0
damaged DuraPlate
s
2
d rail, front/rear post, and/or
t
roof rail, base
e
re
h
z
corner casting.
(See Illustration PL–55.)
ri
Illustration PL–70 ts
ig
r
o
h Side)
y Applying Foam Tape (InteriorigSeam
h
t
p
r
u CAUTION: If removing multiple panels,
o
l
a
l
the
roof
must
be
supported.
C
A
Un
Bonded Panel Removal
Truck Body and PDV—Body Service Manual
71
8. Continue removing fasteners about three
d
feet beyond theedamaged
panel at the base al
and roof railsrv(to allow the adjacent panelnu
a
to flex). (See
se Illustration PL–65.)
by
w
la
M
e
d
r
e
e
9. Placesa pry bar or other object between
the
t
c
t and the base rail to providevia few
bi
panel
h
i
r
g of clearance. (See Illustration
l
iinches
r
oh
a
Se
r
ll PL–65.)
u
p
y
n
A
d
a
n
10. Use a windshield removal
M
Bo tool to cut the ctio
e
adhesive bond on—
the interior and exterior
u
ic
V
sides of the DuraPlate
seam. (See
d
v
Illustration PL–75
r
ro
e Side)
Removing Tape Backing (Exterior Seam
Illustration PL–60.)
PD
p
S
d
y
re
11. Remove
d
anthe damaged panel (fromdinside
the vehicle).
e
y
Bo
z
d
i
r
o
—
12.BCarefully
use the knife tool oand/or scraper
V
h
k to remove the high spotsutof adhesive and
c
PD
a
tape
from
the
seam
of
the
adjacent
panel.
u
d
n
Tr
n
Be careful not to remove
Un any paint fromtio
a
a
the DuraPlate. (See Illustration PL–65.)
y
r
d
o posts,
Also clean off old sealant from rails,
o
p
r with
B
and castings. Wipe surfaces clean
o
k
C
isopropyl alcohol.
c
aw
l
r
u
r
e
y
t
T
Bonded Panel Installation
b
s
a
d
e
m
t
CAUTION: Read
and
understand
ALL
i
l
bi
adhesive andtisealant application
i
Uand safety procedures.
h Down on
instructions
Seam Cross-section Looking
o
4
r
Effectiveness
of
the
repair
can
be
ti
w
0 by environmental
p
a
a
0
compromised
l
r
2
n
o
conditions
or poor application. Follow
y
t
o
b
h
adhesive
and sealant manufacturer’s
ti
rp
c
g
o
d
instructions and
Foam
u
DuraPlate
Adhesive/Sealant
ri application
e
C
recommendations for cure time. Safetyit
d
y
Tape
r
Panel
Bead
p
o
b
e
and
application
instructions
provided
by
r
i
t
s
manufacturers always supersedesh
Co
ep IllustrationaPL–80
o
r
r
information provided by Utilimaster.
Applying Tape and Adhesive
m (Bonded Repair)
p
d
i
l
or
Sealant
(Riveted
Repair)
e
i
n
t
z
o
i
U
r
NOTE: After removing thetibonded
o
4
c
0
u fasten
panel, if desired, you may
th
0
d
u
2
d
the replacement panel
o with rivets
a
r
e
t
n
v
p
h
instead of adhesive as described in
U
e
er
ir g
Steps 2 throughr 8. (See the Panel,
s
d
y
DuraPlate—Riveted
Panel Instale
re
p
z
o
i
lation section.)
r
ts
C
o
h
ig
th
r
u
a
ll
n
A
U
72
Truck Body and PDV—Body Service Manual
l
a
1. Test fit the new dDuraPlate panel. (If
u
necessary, cut
veto the correct length and an
r
width and ecut the front top edge of the new
M
e
panel toes
fit under the front roof casting.
ic
r the panel lap is correctly oriented
v
Be sure
s
r
e
before
ht cutting.)
S
d
ti e
ib
h
o
pr
by
w
la
Bar
l
ig
y holes in the
a
Clamp
ll 2.r Using the applicable fastener
d
u
o
n
post,
and/or
A roof rail, base rail, front/rear
a
B
n
corner casting as a template,
drill holes
M
it o
—
V four corners of the
c
through each of D
the
ce
u
i
P holes are for help od
new panel. (These
Spacer
v
r
d
Block
r
e
locating the
n correct panel position and
S
ep
inserting athe four anchor fasteners as
y
r
yas possible in Steps 6 through
d
quickly
d 10.)
d
o
e
o
B
z bars,
B fit the panel, bar clamps,riload
3. Test
—
kbraces, and spacer blocks. o(See
V
c
h
D
u Illustrations PL–85 andutPL–95.)
r
After the
P
T
a
d
adhesive is applied,na consistent, even on
an
ti
pressure will needUto be applied
a
y
rof the
immediately along the entire length
d
o
o
p time
seam for at least 30 minutes or rthe
B
o
recommended by the adhesive
w
Illustration PL–85
C
ck
a
l
r
manufacturer.) Be sure that
you can
u
Clamped in Position (Exterior)
e
y
Tr
position them all againstas quickly as
b
a 7.
d
possible in Steps 6 and
e
m
t
i
il the panel, apply foam
bi
4. After pulling back
t
i
U
h
tape (P/N 12301025)
on the interior and
o
4
r
w
0 of the seam (both sides) and
exterior0edge
pVertical
a
l
2 the backer paper. (See
n Brace
remove
n
y
t
o
Load
i
o
b
h
i
t
Illustrations
PL–70 through PL–80.)
Bars
c
d
ig
at
u
r
r
e
d
y NOTE: If a middle panel or
o
it
p
o
p
b
r
i
multiple
panels
are
replaced,
r
o
Co repair one seam at a time and roh
ep
C
r
allow to cure thoroughly (wait p
at
d
er
t
e
n
least double the normal cure
s
o time)
iz
i
a
r
t
before repairing the nextcseam.
im
ho
u
l
t
i
d
t
u
CAUTION: The adhesive
sets very
U
a
ro understand
ed
quickly. Readpand
ALL
n
4
v
r
0
adhesive application
instructions andU
e
re
0
Illustration
PL–90
safety procedures. Effectiveness of the
s
2
d be compromised by
Braced tin Position with Load Bars (Interior)
repair can
e
re
h
z
environmental
conditions or inadequate
ri
ts
ig
r
application.
If the procedure is not
o
h
y
h
performed
correctly, after the adhesive
ig
t
p
r
u
o
is
fully
cured,
you
will
need
to
remove
a the panel and start over.
ll
C
n
A
U
Truck Body and PDV—Body Service Manual
73
9. After the exterior side is clamped, place a
5. Assemble two adhesive cartridges in two
l
d
vertical (wood or metal)
separate applicators—but
do not open the a
w brace and three
e
a
u
l
v
load bars securely against the interior side
cartridge seal
r until everything else is an
y
e
of the seam.bThe vertical brace must be
ready. You
will
need
two
short
tubes
per
s
M
e (one for each side). Two
d of the panel and sturdy
the full height
lapped rseam
e
e
t
s
c
i to evenly distribute the pressure
enough
people
t will need to quickly applyvithe
b
h
i
r
against
simultaneously on the
g
h the full length of the bonded seam. al
e interior
iadhesive
r
o
S
r Illustration PL–90.) The DuraPlate u
l and exterior of the panel. yAfter the
p(See
panel
must be flat and not bowed.
only four to
Al adhesive is applied youdhave
an
n
o
o
five minutes to position
M
B the panel, brace cti
CAUTION: The exterior spacer block
e
it, fasten the four—predrilled anchor
u
icalign
and interior vertical brace must
holes, and wipeVup any excess adhesive! d
v
with
but
not
cover
the
edge
of
the
r
e
Have all necessary
PD personnel and pro
seam where excess adhesive
may
S the wood to
d(tools, fasteners, panel, etc.)
e
squeeze out (and bonding
materials
y
r
n
the panel).
ready a
before continuing!
d
od
y
B
ze
d
i
r
o
—
CAUTION: The adhesive o
sets very
10. Wipe up any adhesive that squeezes out
B quickly. You will have NOT
V
MORE
h
t
with a clean disposable
rag (before it
D
k
THAN FOUR TO FIVEuMINUTES to
c
P
cures). d
a 10. If the n
u
perform Steps 6 through
n
Tr
n panel is anchored in position at
o
panel is movedU
or repositioned after the
i
a
11.
After
the
t
adhesive’s “open” time, you will need
a
yfour corners and braced, continue
rand
the
to remove the panel and adhesive
d
o
o the applicable fastener holes in the
start over. HAVE ALL NECESSARY
p
using
r
B
PERSONNEL AND MATERIALS
(TOOLS,
o
k roof rail, base rail, front/rear post, and/or
C
FASTENERS, PANEL, ETC.)
READY
c
aw
l
corner
casting
as
a
template,
drill
the
r
u
BEFORE CONTINUING!
r
e
y
t
T
remaining holes through the new panel.
b
s
adown to the point
da
6. Cut the two tube tips
e
NOTE: If you will be installing
m
t
i
il has mixed as it is being
where the adhesive
second panel, install all four
bi
t
i
U adhesive beads should be
h panel on
pushed out. The
anchor fasteners in theofirst
4
i
r
at least 1/4"
w (Step 7)—but then install
0 wide as they are applied. (See
only the at
p
a
0
l first half of the fasteners
Illustration
2 PL–80.) Apply the adhesive
n nearest or
y
t
o
p
on both
b
the seam just completed
(Step r12).
h sides of the seam and quickly
ti
c
g
o
d
move
When the adhesive
is fully C
cured
u
ri the panel into position. Remove the
te
d
y
i
pry
bar
between
the
panel
and
the
base
(wait at o
least double theernormal
p
b
r
i
ttwo anchor
o
rail.
cure time),
remove the
p
h
s
C
e
o
a that will join
r at the seam
fasteners
7. In the four corner anchor holes,pr
m
d the next panel.
ewith
ili
n
immediately insert and then secure
new
t
z
i
U the new Utilimasterr12.
Utilimaster-approved fasteners
tio that are
Continue 4
installing
o
c
0 fasteners that are equal to or
equal to or superior to the
u original
th approved
0
d
u
2 to the original fasteners. Do noted
fasteners. Do not reuse
superior
ro old fasteners. Dona
t
p
not use POP rivets.
h old fasteners. Do not use POP rivets.
reuse
rv
U
e
re
ir g
8. Place a bar clamp
d and spacer block on the
13.
y Allow at least 30 minutes (or adhesive
es
e
r
p
exterior of
o manufacturer’s recommendation),
iz the seam. (See Illustration
s before
r
t
C
PL–85.)
removing the braces.
h
ho
g
i
t
u
14. Place the floor plank (or
l rplywood section)
a
l
in position and install
Athe fasteners.
Un
74
Truck Body and PDV—Body Service Manual
15. Place the front corner
d cover in position
e
and install the
v fasteners.
al
u
an
M
NOTE: “Bonded panels” means
the individual DuraPlate
panels
aw
l
r
are fastened to
y each other with
e floor cap (if present) in e
16. Place thesrear
b
adhesive
and
d only have mechanical
re and install the fasteners. vic
position
e
fasteners
s
r
it through the rails and
t
e
b
17. Reinstall
E-track,
slats,
vent,
deflector
posts.
h
i (See Illustrations PL–80
S door
h
l
ir gplate, cable retainment track,y roll-up
and
o PL–95.) “Riveted panels”
a
r
ll track, or other items removed
d
u
at the
p means the panels are fastened to
o
n
A beginning.
B
n each other with (buck or Hemlok) a
it o rivets instead of adhesive. Buck M
—
V the perimeter of the c
18. Apply sealant around
ce
D
u
rivets are solid; Hemlok rivets have
i
P and front corner od
rails, posts, castings,
v
r
a stem through the center. For
d
r
e
cover.
S
riveted panels, see the Riveted
an
ep
y
r
Panel Removal and Riveted
y
CAUTION:
When welding or cutting next
d Panel
d
d
o
to a DuraPlate panel, be very careful
Installation sections
B on the followze (andto
Bonot overheat the DuraPlateripanel
ing pages. For —
bonded panels, see
k melting the plastic core).o
V Removal and
c
the Bonded Panel
th
D
u
r
u
Bonded Panel
P Installation sections
T 19. Install new decals as aneeded. See the n
d
on
the
preceding
pages.
n
Decals section. U
it o
an
a
r
po
r
o
C
er
t
as
m
it li
U
4
0
0
2Bonded
Seam
t
h
ig
r
y
p
Co
n
it o
uc
d
o
r
p
re
ck
u
Tr
d
te
i
ib
h
o
pr
Stem
by
y
d
Bo
w
la
Hemlok
Riveted
Seam
ed
z
ri
o
th
u
a
n
U
by
n
it o
c
u
od
r
p
re
w
la
d
ti e
ib
h
o
r
Buck
p
er
t
as
m
it li
U
n
it o
ra
o
rp
o
C
Riveted
Seam
ed
4
v
r
0
e
0
s
2
d Hemlok
t
Buck re
e
h
z
Rivet
Rivetts
ri
ig
r
o
h
y
h
g
i
t
p
r
u
o
l
Illustration PL–95
a
l
C
Fastening/Bonding DuraPlate Seams (Cross-section Looking Down) A
Un
Truck Body and PDV—Body Service Manual
75
Riveted Panel Removal
d
l
a
e instructions and
NOTE: Read all
u
v
r
have all documents
and materials
e
an
s
needed before
attempting
this
M
re
e
repair!
s
c
4. Remove the fasteners in the outer floor
w
plank (and front floor
la cap inside the front
post) on the same
y side as the damaged
b
panel. (SeedIllustration PL–45.)
e
5. Removeitthe floor plank. (See Illustration
i
t
ib Depending on the orientation of
PL–50.
gh For riveted panels, inerv
h
ir NOTE:
o plank lap joint, you may need to loosenual
Salso
the
r
ll addition to this manual, see
por remove the adjacent plank as well.) n
y
A the “Shiplap DuraPlatedPanel
a
n
o
Change” section in the
Wabash
o
M
i
BRepair
t 6. On the exterior and interior, mark the
National DuraPlate
c
—
ce panel
location of the edges of the damaged
u
i
Manual. It canVbe downloaded
d
v (to help
r
D
on the adjacent panels and/or post
o
from www.wabashnational.com/
r
e
P
with proper alignment of the
S new panel
d
products/features/duraplate.htm
ep
y
r
n
during installation).
d
or fromafollowing the links on the d
o
e
y
Technical
Manuals page of theiz
B holding the
7. Remove all the fasteners
d
r
o
—
Utilimaster
web site
damaged DuraPlate panel to the applicable
B(www.utilimaster.com). ho
V
t
roof rail, baseDrail, front/rear post, and/or
k
u
P (See Illustration PL–55.)
corner casting.
a
uc1. After unloading and parking
the truck on a n
r
d
n
T
n removing fasteners at least one
U E-track, slats, scufftio
level surface, remove
a
8. Continue
ybeyond the damaged panel at the base
ra
plates, vent, deflector plate, cable retainment
foot
d
o
o roof rails (to allow the adjacent panel
track, roll-up door track, or any other
p item
and
r
B
that will interfere with the paneloremoval.
k to flex). (See Illustration PL–65.) aw
C
c
(See relevant sections in thisr manual.)
l
u 9. Remove the buck or Hemlok rivets along
r
e
y
t any decals at T
b to the
scut
2. On the damaged panel,
the seam holding the damaged panel
a
d
the seam between panels.
adjacent panel. See Illustration
m Also, cut the
i
itePL–95 and
l
it perimeter of the panel at
sealant around the
the Fastener Replacement section.
b
i
U casting.
n
h
the rail, post, and
o
o
4
10. Place a pry bar or other robject
between tthe
i
w panel and the base railpto provide a fewa inches
0
NOTE: 0
Steps 3 through 5 and the
a
l
r
2 referenced in this
n
o
illustrations
y
t
of clearance. (See
Illustration
PL–65.)
o
b
h describe a vehicle with
ti
rp
section
c
g
o
d
11. Use a windshield
to cut the
u removal tool
ri
C
hardwood
floor planks that run the
te
d
y
i
r and exterior
sealant and
p length of the body. For a vehicle ib
o tape on the tinterior
e
r
o
sides of
seam between
s the panels. (See
C with a plywood floor instead of roh
ep the PL–60.)
aAlternately,
r
Illustration
you can
planks, you would need to remove
m
p
d
i
use
e a hammer and
il wedge (see the “Shiplap
the plywood section(s) next tonthe
t
z
o
i
DuraPlate
Panel
U Change—Breaking the
r
damaged panel instead of tai floor
o
4
c
h Panel Sealant
0 Bonds” section in the Wabash
u you
plank. With riveted panels,
t
0
d
National
u
2 DuraPlate Repair Manual). ed
might not need to remove
o the floor
a
r
t
n
h the damaged panel (from insidervthe
plank or plywoodpsection if you
12. Remove
U
e
g
e
r
i
have sufficient clearance to remove
rvehicle).
s
d
y
the panel. e
rethe
p
13. Clean off old sealant and tape from
o
ir z
ts as rails,
C remaining adjacent panel as well
3. If a rear
floor cap is present (it protects the
o
h
g
floorthplanks at the rear door threshold),
posts, and castings. Wiperisurfaces clean
u
a
remove
the fasteners and the cap.
with isopropyl alcohol.ll
n
A
U
76
Truck Body and PDV—Body Service Manual
Riveted Panel Installation
ed
al
u
an
M
1. Test fit the new
rv DuraPlate panel. If
e
necessary,
cut to the correct length ande
es cut the front top edge of the
width rand
ic new
v
r
panel
ts to fit under the front roof ecasting.
h
sure the panel lap is correctly
S oriented
igBe
y
r
before
cutting.
l
d
8. Continue drillingaw
and riveting along the
l
seam betweenythe 12" intervals done in
b
Step 7.
d
e
t
9. Wipe up
any sealant that squeezes out with
bi disposable rag before it cures.
i
a clean
h
l
o
a
r
10.
p Using the fastener holes in the roof rail,nu
o
Al 2. Using the applicable fastener
B holes in the
n base rail, front/rear post, and/or cornera
o
M
—
casting as a template, drill the remaining
roof rail, base rail, front/rear
post, and/or
ti
e
V
c
holes through the replacement panel.
corner casting asDa template, drill holes
u
ic
P
d
v
through each of the four corners of the o
NOTE: If you will be installing
dpanel. (These holes are for
r
er a
n
replacement
p
S
second panel, install all four
a the correct panel position
y
re and
help locating
y
anchor fasteners in thedfirst panel
d
d
o
inserting
the four anchor fasteners.)
e
o
(Step 6)—but then B
install only the
z
i
B
first half of the fasteners
nearest
—
3. kAfter pulling back the panel,
orapply foam
V
c
h
the seam justDcompleted (Step 11).
u tape (P/N 12301025) onutthe interior and
r
P to install the next
When ready
T exterior edge of the seam
a (both sides) andn
d
n
panel, n
remove the two anchor
remove the backerUpaper. (See Illustrations
io
a
t
fasteners
PL–70 through PL–80.)
a
y at that seam.
r
d
11. oContinue installing the new Utilimaster4. Apply beads of sealant along both
posides of
r
B approved fasteners that are equal to or
o
the seam. The beads should be
at least 1/
k
w
C(See
c superior to the original fasteners. Dolanot
4" wide as they are applied.
r
u
y rivets.
reuse old fasteners. Do not use POP
Illustration PL–80.) ste
Tr
b
a
d section)
12. Place the floor plank (or plywood
5. Carefully place thempanel in position (and
e
t
i
l between the panel and
in position and install the fasteners.
remove the prytibar
bi
i
h
the base rail).UThe seam must fit flush and
13. Place the front cornerro
cover in position and
4
tight together.
w
p
00
la install the fasteners.
2
n
NOTE:
y 14. Place the rear floor
t If the seam is not tight and
o cap (if present) in ion
i
b
h
t
flush,
drill shavings may lodge in
cinstall the fasteners. rat
d
position and
itheg sealant
u
r
e
and obstruct the final fit it
d
y
o
p
o
p
15. Reinstall
E-track, slats, vent, deflector
b
of
the
seam.
r
i
r
o door
plate,
Co 6. In the four corner anchor holes, install
epcable retainment track,Croll-up
oh new
r
r
track,
or other items removed
r at the
pthat are
d
e
Utilimaster-approved fasteners
t
e
n
s
iz beginning.
equal to or superior to the original
it o
a
r
o 16. Apply sealant around
fasteners. Do not reuse c
old fasteners. Do
im the perimeter of the
h
u
l
t
i
rails, posts, castings,
not use POP rivets. d
t and front corner d
u
o
U
a
cover.
4
ve
prthe adjacent panel asUan
7. Using the holes in
r
0
e
0 When welding or cutting
template, drillrholes and fasten rivets in
CAUTION:
se next
2
d
e
to
a
DuraPlate
panel,
be
very
careful
t
pairs at 12"e intervals along the seam (to
r (andto
h
z
not
overheat
the
DuraPlate
panel
preventripuckering of the panel and drill
igmelting the plastic core).hts
r
o
shavings
y
h accumulating in the seam). (See
ig
t
p
r
u
the
Fastener Replacement section.)
17.
Install
new
decals
as
needed.
See the
o
a
C Decals section. All
n
U
Truck Body and PDV—Body Service Manual
77
Rear Vision (Back-up) Camera System
l
d
a
e
aw
u
l
v
r
y systems/models
e
an Vision system. Other camera
b
NOTE: These
instructions refer to a Safety
s
M identical, manner. d
re in a similar, but not necessarily
may operate
e
te
s
c
i
i
t
When the h
vehicle ignition key is turned to
ib power is supplied to the monitor.
rvthe Accessory or On position,
h
e
ir g
o by pushing the Power button (in). (Seeual
r
Withllpower supplied to the monitor,Sthe screen can be turned On
y The screen will displaypa picture of the area behind the vehicle then
theAMonitor Controls section below.)
d
a
n
o
o
entire time the vehicle is operated.
M
i
B
t
c
—
cescreen
i
When the Power buttonVis in the S/By position (out),uthe monitor is placed in Stand By mode (the
dHowever, (if the vehicle has the appropriate
v wiring
r
o
is normally blank andDthe LED is not illuminated).
r
e
P
S By. While
option) when the d
engine is running, placing the
eptransmission in Reverse overrides the Stand
y
r
n
the transmission
glow, and the screen will display a picture.
d
a is in Reverse, the LED will
d
o
e
y
B of the monitor’s
For safe operation,
the entire back edge
d
iz of the bumper must be visible at the bottom
r
o
—
screen.BIf it is not, loosen the screws
o on the camera and adjust the camera forVthe best view. Tighten the
h
t
screws
ck and recheck the screen.au
PD
u
r
n
operating temperature
Fdor –25° C to +50° C.)
T(Typical
n
Un range of the system
it o is –13° F to +122°
a
a
y
r
Monitor Controls
d
o
o
p
r
B
o
k
C
c
aw
l
r
u
r
e
y
t
T
b
s
a
d
e
m
t
i
il
bi
t
i
U
n
h
1. Power LED 4
o
o
i
r
tand
w is in the On or Accessory
0 green whenever the vehicle ignitionaswitch
p
This LED glows
position
a
0
l
r
2 Power switch is in the On position (pushed
n the Poweroswitch is
the monitor’s
in). Alternately,owhen
y
t
i
p engine
b monitor will displaycta picture) whenrthe
h (Stand By), the LED will glow (and the
set togS/By
o
d
u
ri and the transmission is put in Reverse.
isyrunning
C
te
d
i
r
p Switch
2. Power
ro
ib
teto turn the screen
o
p
h
s
Press
the
Power
switch
in
to
turn
the
monitor
On.
Press
the
power
switch
again
(out)
C
o
a
re position m
Off (Stand By). (Putting the vehicle p
inrreverse overrides the Standby
and turns on the screen.)
ed
ili
3. Camera Audio/Video Selector n
t
z
o
U
ri
The button should be out (Ca)tito select the camera input.
o
4
c
4. Camera Selector
0
u
th
0
d
u
The button should normally
be
out
(Ca1)
to
select
the
camera
input
2 Ca1. (If the camera has been ed
o
a
r
t
n other way.) h
attached to the otherpinput, push the button the
v
r
U
e
g
e
r
i
5. Day/Night Switch
d normally be in the out position (DAY).
yr At night or in a tunnel, depressrethes
This switch should
e
p
iz the picture brightness (NIG). Co
switch to reduce
r
ts
o
h
6. Contrast
Control
h
ig picture
tthe
Adjust
contrast control for the desired overall best picture. Turn clockwise tol rincrease
u
a and counterclockwise to decrease.
l
contrast
n
A
U
Operating Instructions
S/BY
POWER
ON
CA
AV
CAMERA
CA1
CA2
DAY
NIG
CONTRAST
1
2
3
4
5
6
BRIGHT
VOLUME
MIN
MAX
7
8
9
78
10
11 12 13
Truck Body and PDV—Body Service Manual
l
a
7. Brightness Control
u
d
n picture or display brightness.
e control for the best overall
Adjust the brightness
aw Turn clockwise to
l
a
v
r brightness and counterclockwise
increase picture
y
M to decrease.
e
b
s
e
8. Volume Control
d
ic sound level. Turn clockwise
re
e
v
Adjuststhe volume control for the desired
to increase and counterclockt
r
i
t
e
b
wisehto decrease.
i
h
l
ir g Power Connector y S
9. Monitor
o
a
r
ll This connector supplies power
d
o to the monitor when thepengine is on.
nu
A
a
n
M
it o
cDescription
ceTool
Value
u
i
1
Black: Ground
rv
od
d
r
e
Green:
2
DVOM
p R(reverse) gear power (optional) (10 - 26 VDC)S
an 3
e
y
r
(10 - 26 VDC)
Red: Positive power
3
DVOM
y
d
d
d
o
o Input Connector ize
10. Camera
B
B
r
—
Two
k mini-DIN type connectorso provide the video camera inputs, but onlyV Ca1 is normally used on
c
Utilimaster
vehicles. The monitor
supplies power to the camera.
th
u
r
u
PD
T
a
n
Camera Input
ndConnector
Un
it o
a
aNo.
Pin
Descriptiony
Value
Tool
2
3
r
d
12
VDC
Power Supply
DVOM
4
1
o
po 12
35 decibel
Audio Input
Tone Generator
r
B
o
3
Groundk
C
cInput
aw
1.0V p-p
l
4
Oscilloscope
Video
r
u
y
te
Tr NOTE: See also the Wiring Diagrams
b
s
section.
11. & 12. VCR Jacks
a
d
te
(Not used on Utilimaster
im vehicles.)
i
l
i
t
13. Normal/Mirror Option
ib
U
h
When the switch
be reversed. When the
oswitch is in NOR4 is in MIRROR position, the picture will
r
w
0
p
MAL position,
0 the picture will be displayed normally.
la
2
n
n
y
t
io
o
Basic Troubleshooting
b
h
i
t
c
d Monitor Screen is White
ig
at
u
r
e
Monitor rScreen is Black
d
y
o
it
p
o
p
b
r
i
r
• Be sure the
• Make sure the monitor’s Power switch h
is On
p Camera Audio/Video Selector
o
Co(not just in Stand By) and the vehicle’s
e
o
switch
is
set to Ca (button is out)Cand the
ignir
r
p the
d Selector Switch is set
Camera
tion is turned to On or Accessory. If
erto the correct
t
e
n
input
monitor’s green LED power indicator
is not
iz (normally Ca1). as
io
r
t
knobs for
illuminated, see Flowchart A.
o• Check Contrast and Brightness
c
m
i
h
u
l
t
i
proper adjustment. t
• Be sure the Camera Audio/Video
Selector
d
u • Check
d
o
U switch for the appropria
the Day/Night
switch is set to Ca (button
is
out)
and
the
r
e
n
4
v
r
ate setting. 0
Camera Selector Switch
ep is set to the correctU
e
r
0
s
•
See
Flowchart
C.
input (normallydCa1).
2
t
e
re
• Check Contrast
and
Brightness
knobs
for
h
z
ri
NOTE:
ig These instructions referhttos a
proper adjustment.
r
o
y Vision system. Other icamera
h Day/Night switch for the appropriSafety
g
• Check tthe
p
r
u
o
systems/models
may
work
in
a
l similar,
ate setting.
a
l
C
n
A manner.
but not necessarily identical,
• See
U Flowchart A.
B
—
V Pin No.
D
2
P
1
Truck Body and PDV—Body Service Manual
Monitor Power Connector
79
Troubleshooting Flowcharts
l
a
aw
u
l
y
Monitor IPower
an
b
M
Pin No.
Description
Value
Tool
d
e
e
t
1
Black: Ground
s
c
i
i Green: R(reverse) gear powerb(optional)
t
h
2rv
(10 - 26 VDC)
DVOM
i
h
l
e
ir gStart
Red: Positive power
(10 - 26 VDC)
DVOM
o
a
S3
r
ll
u
p
y
n
A Monitor
d
a
n
M
io1
Bo
screen is black
2
t
e
c
—
u
ic
V
d
v
3
r
ro
e
PD
p
S
d
y
re
n
d
a
Are
Camera
Audio/Video
d
Is monitor y
power
e YES Selector, Camera Selector, YESBo
YES
z
d
switch AND
ignition
i
Day/Night, Brightness, and
Is LED illuminated?
See Flowchart B
r
o
—
Contrast switches/knobs
turned
on?
o
B
V
set correctly?
th
k
c
u
PD
a
u
NO
d
n
NO
Tr NO
n
Un
it o
a
Check power and ground
a
Turn on power
Adjust controls
y
r
NOTE: These
connections to theo
switch and/or
d
appropriately
monitor p
o
ignition
instructions refer to
r
B
o
a Safety Vision w
k
C
c
system. Otherla
r
u
r
e
y
t
T in-line 3-AMP fuse in
camera systems/
Check
b
s
a connections YES monitor power harness (inside
Are
d opermodels may
e
m
t
overhead
shelf)
and
ignition
good?
i
ate ini a similar, but
il
t
fuse at fuse block
ibnecessarily n
not
U
h
4
io
roidentical, manner.
t
w
0
NO
NO
p
0
la
ra
2
n
o
y
t
Make proper
io
b
h
t
rp
connections
c
g
o
d
both fuses in
uYES
ri
Replace
C
te Are
y
i
monitor
good condition? d
r
p sure the monitor’s Power switch is ib
• Make
ro
te
o
p
h
s
On
(not
just
in
Stand
By)
and
the
vehicle’s
C
o
a
re
ignition is turned to On or Accessory.pr
m
NO
ed
ili
• If the monitor’s green LED power nindicator is
t
z
U
ri
not illuminated, check power/ground
tio connecIdentify cause of 4
o
c
tions and harness in-line fuse.
u
th blown fuse 00
d
u
NOTE: See also thed
• Be sure the Camera Audio/Video
Selector
switch
2
o
a
r
t
Wiring Diagramsve
n
is set to Ca (button is out)
p and the Camera Selector
h
r
U
e
g
section.
e
r
i
Switch is set to the correct
input (normally Ca1).
r
s
Replace
d Brightness knobs for proper
y fuse
• Check Contrast eand
re
p
z
o
i
adjustment. r
ts
C
o
h
• Check thehDay/Night
switch for the appropriate
ig
r
setting.ut
a
ll
• See n
Flowchart
B.
A
U
d
e
rv
e
s
re
Flowchart A: If Monitor’s Screen is Black
80
Truck Body and PDV—Body Service Manual
Flowchart B: If Monitor has Power but No Picture
Start
Monitor has
power but no
picture
ts
h
rig
ed
v
r
e
s
re
l
l
Check
A DIN
connector on
back of
monitor
d
n
a
dy
o
B
—
V
D
P
ce
i
rv
e
S
al
u
an
M Pin No.
1
2
3
4
n
it o
c
u
od
r
p
re
w
a
l
Camera Input Connector
y Value
Descriptionb
12 VDC
Power Supplyd
35 decibel
Audio Input
ti e
Groundb
iInput
1.0V p-p
Video
h
o
r
p
2
1
3
Tool
DVOM
Tone Generator
l
a
u
n
a
M
Oscilloscope
ce
i
rv
e
S
4
y
d
d
NOTE:
These instructions
e
Boto a Safety Vision
ir z
refer
—
k
o
system. Other camera
V
c
h
t
D
u
Unplug the camera
u
P systems/models may work
TrNO
a
from n
the cable and
in a similar, but not necesd
n
n
o
check
the
voltage
IsUcamera
Plug
YES
sarily identical, manner.
a
tati terminal 1 on
plugged in
a
connector
y
r the cable
d
NOTE: See also the
properly?
o
into monitor
o
p
r
Wiring Diagrams section.
B
o
NO
k
C
c
aw
l
r
u
y
Is correct
te
Plug camera
Trvoltage YES Replace the
b
s
present at
into a
cable
d
camera
terminal 1
e
m
properly
t
i
on the cable?
il
bi
t
i
U
h
o
4
NO
w
0
pr
a
0
l
2
n
n
y
t
o
Unplug
DIN
connector
i
o
b
h
i
t
t
Is correct
c voltage YES Replace
at the monitor
d and
ig
a
the
u
r
r
e
present at
check
CheckyDIN connector on back of the
t for correct
d
o
i
cable
p
1
voltage at
ro on terminal
monitor:
ibterminal
rp
o
p
the
monitor?
h
o
1
on
C• Is connector plugged in properly? ro
re
the monitor
rC
• If so, check cable connection at thep
d
e
t
e
n
camera.
NO
z
s
o
i
a
r unplug
ti and still no picture,
• If the camera is connected properly
o
c
m
Replace
the
uand check the voltage atthterminal 1
the camera from the cable
ili
d
t
monitor
u
d
o
on the cable:
U
a
r
e
n
4
v
! If correct voltagepis not present at terminal
U 1 on the cable, 00
e
er
r
unplug DIN connector at the monitor and check for correct 2
s
d
t
re
voltage atze
terminal 1 on the monitor.
h
ri voltage is present at terminal 1 on the monitor,rig
ts
! If correct
o
h
y
then
hreplace the cable.
ig
t
p
r
! Ifucorrect voltage is not present at terminal 1 on theomonia
ll
C
n
tor, then replace the monitor.
A
U
yYES
d
Bo
Is connector
plugged in
properly?
Check cable
connection at
camera
Truck Body and PDV—Body Service Manual
81
Flowchart C: If Monitor’s Screen is White
d
e
Start
rv
e
s
2
Monitor re
1
screen is s
twhite
h
ig
r
l
Al
3
ce
i
rv
e
S
l
a
u
an Pin No.
M4
1
2
3
4
w
la
Camera Input Connector
Description
d
ti e
ib
h
o
pr
Power Supply
Audio Input
Ground
Video Input
by
Value
12 VDC
35 decibel
Tool
DVOM
Tone Generator
l
a
u
y
• Be sure the Camera Audio/Video Selector switch is set
n
Check the Camera
d
a
n
Audio/Video Selector,
o
to Ca (button
M is
io is out) and the Camera Selector Switch
Camera Selector,
B
t
set to
c the correct input (normally Ca1).
Day/Night, Brightness,
—
ce
u
i
and Contrast
V
•
Check
Contrast
and
Brightness
knobs
for
proper
d
v
switches/knobs
r
D
o
adjustment.
r
e
P
S
d
setting.
ep• Check the Day/Night switch for the appropriate
y
r
n
d
a
•
Check
for
obvious
cable
damage.
d
e
y
• Check the continuity of the cable
Boat terminals 2 and 4.
z
d
i
r
othey
—
• If the continuity cannot be confirmed
on circuits 2 and /
Are
YES
Check o
for
B
V
h
adjusted
or 4, then replace the cable.
obvious
t cable
k properly?
c
u
PD temporarily install a
damage
• If there is a short in the camera,
a
u
d
n
Tr
n
Un
it o known good camera.
a
• If there is a shortyin the monitor, temporarily install a
a
r
NO
d
o
known good o
monitor.
p
r
B
Make proper
o
k
w
YES
adjustments
Any obvious
C
Replaceccable
a
l
r
u
damage?
r
e
y
t
T
b
s
a
d
e
m
t
i
il NO
bi
t
i
U
n
h
o
o
4
i
r
Check continuity
t
w
0
p
a
of the cable at
a
0
l
r
2
terminals 2 and 4
n
y
t
o
i
po
b
h
t
r
c
o
d
ig
u
r
e
C
t
d
y
i
p
o
b
er
r
i
t
o
h
C
ep
oYES
as
r
r
Replace camerad
Continuity? p
lim
e
i
n
t
iz
io
U
r
t
o
4
c
0
u
th
0
d
u
NO
2
d
a
ro
e
t
n
v
p
h These instructions refer to a r
NOTE:
U
g
re Replace cable
i
Safety
r Vision system. Other camera ese
d
y
e
r
psystems/models may work in a similar,
o
ir z
s
t
C but not necessarily identical, manner.
o
h
ig
th
NOTE: See also the Wiring rDiagrams
u
a
ll
section.
n
A
U
82
1.0V p-p
Oscilloscope
Truck Body and PDV—Body Service Manual
Roof
l
l
A
ed
v
r
e
s
re
Front
s Wrap Roof
tAlumi
h
Sealing Tape
ir g
Front
Corner
Casting
Double-sided
Butyl Tape
Front
Radius
d
n
a
dy
o
B
—
V
D
P
ce
i
rv
e
S
al
u
an
M
n
it o
c
u
od
r
p
re
d
ti e
ib
h
o
pr
Angle
Metal
by
w
la
Roof
Panel
l
a
u
n
a
M
ceRoof Bow
i
rv
e
S
Roof Bow
y
Tape
d
d
o
e
B
Roof
ir z
—
Perimeter
V
ho
Tape
t
D
u
P
a
d
n
n
Rear Roof Rail
n
o
Bow
U
i
a
t
Side
a
y
r
Roof
Clearance and ID Lights
d
o
o
Rail
rp
B
Light
o
k
C Backer
c
aw
l
r
u
CargoTr
y
te
Rear Corner
b
(Not Shown: Fiberglass Front s
Light
a
Casting
d
Cap in Place of Front Radius
e
m
t
i
and Front Corner Castings)
il
bi
t
i
Illustration RO–5
U
h
o
4
Roof Assembly
w
0
pr
a
0
l
2
n
n
y
t
o
i
o
b
h
i
t
c
d
ig
at
u
r
r
e
y CAUTION: Removal and replacement ioft the roof could result inodroof leaks. If a vehicle requires
o
p
p
b
r
i
r
major roof or structural repair, check
with Utilimaster for a recommendation
the
pbody shop. on returning
hdamage
o
Co
e
vehicle to Utilimaster or repairing
at a professional
o
r
rC
pr
d
e
t
e
n
z
s
o
i
a
r
ti
o
c
m
u
th
ili
d
t
u
d
o
a Details in illustrationsUand procedures
r
e
n
NOTE: This service
information
is
generic.
4
v
p
r
0
e
re those in your vehicle. UBecause Utilimaster manufactures
may differ from
many
0
s
2 every possible part in e
customizeded
vehicle bodies, this manual cannot list and illustrate
t
r
h
ir z Nevertheless, the most common body options
every vehicle.
are
described
here.
Use
this
s
t
ig
r
o
h
information
as
a
guideline
where
it
applies.
y
ig
th
p
r
u
o
a
ll
C
n
A
U
y
d
AerocapBo
(Only)k
Roof c
u Rail Front
r
Plug
T
Roof
Truck Body and PDV—Body Service Manual
83
Front (Fiberglass) Cap Replacement
NOTE: Some vehicles have a onel
d
piece fiberglassefront roof cap
w
a Removal
a
u
l
v
(Illustration rRO–10). Others have
y all clearance and
1. On the cap, remove
an
a separatesealuminum front radius
b
M
identification
d lights for reuse. See the
and tworealuminum corner castings e
e
t
Lights—Clearance,
Identification, and
s
c
i
(Illustration
RO–15). See the i
t
b
v
h
SideiMarker section.
r
Front (Fiberglass) Cap
g
e
irelevant
r
oh the roof sealing tape over the ual
S
r
2. Remove
ll Replacement, Front (Aluminum)
pfront roof cap and roof panel seam. n
y
A Corner Casting Replacement,
d
a
n
o
o
and/or Front (Aluminum)
Radius
M
i
B
t 3. Remove the fasteners holding the front
e cap
c
Replacement sections.
—
c
u
i
to the roof and wall sections. (See
V
d
v the
r
D
o
Fastener
Replacement
section.)
r
e
P
y
d
Bo
d
n
a
ed
z
ri
o
th
u
a
n
U
p
re
S
4. Using a razor knife, cut the
dy sealant and
tape around the cap. oPull off the cap.
B
—
V
k
1. Scrape off oldDsealant and tape and clean
Psurfaces with isopropyl
the bonding
uc
r
d
n
T
n
alcohol.
io
a
t
y For the new cap, drill new holes
ra
NOTE:
d
o
o the old cap as a model (if possible)
p
using
r
B
o
k or mark and drill hole locations from testC
c
aw
l
r
mounting
the
cap
on
the
vehicle.
u
r
e
y
t
T
b
s
2.
Place
double-sided
butyl
tape
along
top
a
d
edge of the roof panel.
te
imRO–10
Illustration
i
l
i
b
FiberglasstFront Roof Cap
iposition and n
3. Carefully place the cap in
U
h
4
fasten in place.
io
ro
t
w
0
p
a
0
la4. Apply “Alumi Wrap”
rtape
2
n
roof
sealing
o
y
t
o
b
h
where the frontticap and the roof
rp panel
c
g
o
d
overlap. u
ri
C
te
d
y
i
r
p
ro
ib
5. Apply polyurethane
sealant
te around the
o
p
h
s
C
e perimeter ofa the cap. (See the
exterior
o
r
r
p
Sealant
d section.)ilim
e
n
t removed from the original
iz Install the lights
6.
it o
U
r
c
ho cap. 004
u
t
u 7. After2an eight-hour waiting period, water-d
od
a
r
e
t
n
v
p
h
test
the
roof.
With
doors
closed
tightly,
r
U
e
g the roof and the top of the sidee
r
rispray
d
y
es
e
r
p
structures
near
the
affected
area
with
o water. Check for leaks. (Reseal
iz
r
ts and retest
C
o
h
if any leaks appear.)
ig
th Illustration RO–15
r
u
a
ll
Aluminum Front Corner Casting and Radius
n
A
U
84
Installation
Truck Body and PDV—Body Service Manual
l
a
Front (Aluminum) Radius Replacement
u
n
ed has a front
aw has a front
l
a
v
NOTE: If the
vehicle
NOTE:
If
the
vehicle
y
er
roof cap s(Illustration
RO–10), see e M
roof cap (Illustration
RO–10), see
b
e
c
d
the Front
(Fiberglass)
Cap
Rethe
Front
(Fiberglass)
Cap Rei
r
e
v
t
r
placement
placement
i section.
ts section.
e
b
h
i
S
Removal
Removal h
l
ig
y
r
o
a
r
ll 1. Remove the clearance light
d
1.p Remove any identification lights on the nu
o for reuse. See
A the Lights—Clearance,BIdentification,
a
n radius for reuse. See the Lights—Clearance,
and
o
M
i
—
Side Marker section.
Identification, and Side Marker section.
V
ct
ce
D
u
i
P
2. Remove the fasteners
holding the castingod
2. Remove the tape over the front
rv radius and
d
r
e
to the frontnradius, walls, and roof. (See
roof panel seam.
p
S
a
e
the Fastener
Replacement
section.)
y
r
y
3. Remove one of the castings.
(See the
d
d around
d
o
e
o
Roof—Front
Corner
(Aluminum)
Casting
3. Using
a utility knife, cut the sealant
B
z
i
B
Replacement section.)
—
kthe casting. Pull off the casting.
or
V
c
h
Dfasteners holding the front
u
Installation
4. Remove the
ut
P
Tr
a
radius todthe other casting, roof, and wall
1. Scrape off the old sealant
n and clean theon
U
sections.
an (See the Fastener Replacement
ti
bonding surface with isopropyl alcohol.
a
y
section.)
r
d
o
NOTE: For the new casting, drill
new
o
p
5.B Using a razor knife, cut the sealant and
holes using the old casting asoarmodel (if
possible) or mark and drill C
hole locations
ck tape around the radius. Pull off the radius.
aw
l
r
u
e
from test-mounting the tcasting.
y
Tr Installation
b
s
d clean the
2. Apply polyurethane asealant along the
1. Scrape off old sealant and tapeeand
m
t
i
i alcohol.
bonding surfaceilwhere the casting will
bonding surfaces with isopropyl
b
t
i
mate with theUfront radius, roof, and walls.
h drill new
NOTE: For the new radius,
o
4
(See the Sealant
section.)
r as a model (if
w holes using the old pradius
0
a
0
l
3. Fasten2the casting into place.
possible) or marknand drill hole locations n
y
t
io the radius on the tio
b
h
t
from test-mounting
c
4. Apply
ig polyurethane sealant around the ed
vehicle. u
r
ra
t
exterior perimeter of the corner casting.i
d
y
o
p (See the Sealant section.)
ro
ib
2. Place double-sided
butyl tape along
rp top
o
p
h
o
C
edge
re of the roof panel. r C
rofrom
5. Install the clearance light removed
p
the original casting.
3.ed
Carefully place the radius
tein position and
n
z
s
ioperiod, watera
ri fasten in place.
t
6. After an eight-hour waiting
o
c
m
u tightly closed, th 4. Reinstall the corner
test the roof. With allddoors
ili casting. (See the
t
u
d
o top of the side
spray the roof andrthe
Roof—Front Corner
U (Aluminum) Casting
a
e
n
4
v
p affected area with U
structures near e
the
Replacement
r
0 section.)
e
r
0
water. Check
for
leaks.
(Reseal
and
retest
s
2 Wrap” roof sealing etape where
dappear.)
5. Applyt “Alumi
e
r overlap.
if any leaks
h radius and the roof panel
thegfront
ir z
s
t
i
r
o
h
y
6. Apply polyurethane sealant
g around the
th
p exterior perimeter of theriradius.
u
o
(See the
a
C Sealant section.) All
n
U
Front (Aluminum) Corner Casting Replacement
Truck Body and PDV—Body Service Manual
85
7. Install any identification lights removed
from the original
edradius.
CAUTION: Removal and replacement
l
wcould result in roof
a
of roof sections
a
u
l
v
leaks. If a vehicle requires major roof
r
n
8. After an eight-hour
waiting period, watery repair, check with
e
a
or structural
b
s
test the roof.
M
Utilimaster
a recommendation on
e With doors closed tightly,
d theforvehicle
r
e
e
returning
to Utilimaster or
spraysthe roof and the top of the side
t
c
i
i
t
repairing
damage
at
a
professional
b shop.
structures
near the affected arearvwith
h
i
body
g
l
e and retest
iwater. Check for leaks. (Reseal
oh
a
r
ll r if any leaks appear.) y S
u
p
n
A
d
a
n
Roof
M
Rear Corner Casting Replacement
io Panel REPAIR
Bo
t
e
c
—
u Quick and easy translucent fiberglass repair
Removal
ic kits
V
d
v
are
available
for
permanently
repairing
small
tears
r
D
e
1. Remove the P
fasteners holding the castingro
and punctures. These kits, such asSKemlite
drails. (See the Fastener Reep
to the roof
y work in a
r
SunPatch repair kit (P/N 01900680),
n
d
a section.)
placement
d
o do not require the
wide range of temperatures and
e
y
B
z
d
i
mixing of resins. (See also the Utilimaster Quick
2. Using
a utility knife, cut the sealant
around
r
—
o
Btheo casting.
Reference Parts Guide.)
V
h
t
k
c
u
PD
3. Pull off the casting. a
u
r
d
n Roof Panel REPLACEMENT
TInstallation
n
Un
it o
a If the roof panel is translucent
a
NOTE:
y
r
d , Utilimaster recommends the use
1. Scrape off the old sealant and clean
o the
Kemlite
o
p
bonding surface with isopropyl ralcohol.
Bof a patch kit such as SunPatch (P/N
o
k
Cdrill new
c 01900680) where possible. See the Roof
aw
NOTE: For the new casting,
l
r
u
e as a model (if Tr
Panel Repair section.
y
t
holes using the old casting
b
s
a locations from testpossible) or mark hole
d the
NOTE: A heat gun may help break
e
m
t
mounting the casting.
i
i
adhesive bond holding the translucent
il
brails.
t
i
panel
to
the
roof
bows
and
U sealant along the
n
h
2. Apply polyurethane
o
o
4
i
r
bonding surface
t
Removal
w
0 where the casting will
p
a
a
0
l
r
mate with
2 the roof rails. (See the Sealant
n the front radius
o and
1. Remove the tapeoover
y
t
i
p
section.)
b
h
t
r
roof panel seam.
c
g
o
d
i
u
r
e
C
3. yFasten the casting into place.
ti
d pop rivets securing
2. Removeothe
the panel
r
p
b
e
r
i
t
polyurethane sealant around the
to thepfront radius and
h
s the heads of the
Co4. Apply
e
o
a
exterior perimeter of the corner casting.
pierce-and-roll
rivets securing the roof
r
pr
d
panel
to
the
roof
limrails. (See the Fastener
e
i
n
5. After an eight-hour waiting period,
watert
iz Replacement
iotightly closed,
U section.)
r
test the roof. With all doors
t
o
4
c
spray the roof and the top
u of the side
th 3. Remove00the angle metal above the rails.
d
u
2
structures near the affected
area with
d
a
ro
e
4. Cuttthe double-sided tape between the roof
v
water. Check for pleaks. (Reseal and retestn
U
gh and the front radius, roof bows,erand
re
ir panel
if any leaks appear.)
d
y rails with a razor knife.
es
e
r
p
o NOTE: If adhesive was used ton
iz Always follow the
s the roof
WARNING:
r
C
o
manufacturer’s
cautions and recomh
bows and rails, a heat gungmay help break
h
i
mendations
for protective equipment,
t
the adhesive bond holding
uapplication, and cleanup.
l r the roof panel.
a
l
A
Un
®
™
®
™
86
Truck Body and PDV—Body Service Manual
l
a
5. Remove the panel
(some prying and
u
d
additional cutting
ve of tape may be required an
r
to break the
e panel loose from the roofe M
s
bows and
e rails).
c
8. Lay down the new roof panel.
w
a
l
NOTE: As you are lowering the panel,
make sure you
by can reach (from the interior
d the peeled-off paper on
i
r
or the exterior)
e
v
t
s outer edge of the rail useear marker
6. Ontthe
everybitape strip.
h
i
S reference
h
ir gto mark each rivet location (for
9.
Carefully
lay down the new roof panel, al
y on top).
o
r
ll after a new angle metal isodplaced
u
p inserting the front edge under (the tape of
n
A 7. Use a 4" angle grinderBto grind down all
n the) front radius, and then carefully a
o
M
i
—
t
rivet stems until they
are flush with the rail
remove the paper strip on the tapee
V
c
D to not grind off excessdu
surface. Be careful
(between the radius and the roof).
ic
P
v
metal.
d
ro
er
10. Carefully pull out all the remaining
tape
n
p
S
a rails, front radius, and roof
e
8. Scrape the
paper.
y
r
y
d
bowsdto remove the old tape.
d
o the perimeter (by
11. Apply pressure around
e
o
B
z
i
B the tape areas with isopropyl
9. Clean
alcohol
hand or preferably
with a roller) to firmly
r
—
k
o
Vto the roof.
adhere the tape
th
D
uc and allow to dry.
r
u
Pangle metals over the panel
T
Installation
a
12. Place new
d
n
n
n over the rails.
ends aand
U and trim as required.
1. Test fit the new panel
tio
a
y 3/16" (for buck rivets) or 1/4" (for
r
13. Drill
d
o
2. Remove the panel.
oMagna-Loks) holes through the new angle
p
r
B
3. Apply double-sided butyl tapeoalong the
and panel staggered from the oldw
C
ck metals
bottom of the front radiusrwhere the roof
la
rivets.
(See the Fastener Replacement
u
r
e
y
panel will overlap. Onstthe side facing
T
section.)
b
a
down, leave the paper strip on for now.
d
14. Fasten the panel in position iwith
te buck
im tape (P/N
it ladhesive
4. Apply 1/2"-wide
rivets or Magna-Loks. ib
h
12605933) onUall the roof bows. On the side
o
4
15.
Using
the
holes
in
the
front
radius as a
r
facing up,0leave the paper strip on for now.
w template, drill holespthrough
a
0
the front of
l
2 In older trucks that used
n
n
NOTE:
y
t
o
the
roof
panel.
i
o
b
h
i
t
t
polyurethane
sealant instead of
c to the front radius with
g
d
itape
a
16.
Fasten
the
panel
u
r
r
e
t
d (See the Fastener Replacement
y along the tops of the roof
o
i
POP rivets.
p
o
p
b
bows
and
rails,
you
may
choose
to
r
i
r
section.)
o
Co use sealant in those places, but roh
ep
C
r
tape is easier and cleaner to p
17. d
Apply Alumi Wrap roof sealing
er tape where
t
e
n
install. (See the Sealant section.)
sroof panel overlap.
iz the front radius and the
io
a
r
t
o 18. Apply a bead of sealant
c tape (P/N
5. Apply the 1"-wide adhesive
im around the exterior
h
u
l
t
i
12605927) around the
roof perimeter on u
d
perimeter of thetpanel. Ensure there are no
d
o rails. On the side a
U
r
e
the side and rear roof
voids
in
the
sealant.
n
4
v
p
r
U
0
facing up, leave
e
rethe paper strip on for now.
0
19.
After
an
eight-hour
waiting
period,
waters
2
d an inch (a few centimeters)
t
6. Peel off about
e
re tightly,
test
the
roof. With all doors closed
h
z
s side
of the tape
ri paper at each tape end of the
spray
ig the roof and the top ofhtthe
r
o
roofhperimeter.
ystructures with water. Check
ig for leaks.
t
p
r
u
o
(Reseal
and
retest
if
any
l leaks appear.)
l
7. a
Peel off about an inch (a few centimeters) of
C
n
A
U the tape paper at each end of the roof bows.
Truck Body and PDV—Body Service Manual
87
Scuff Plate
l
a
aw
Top “Gator” Plate
u
l
y
an Removal
Removal
b
M
d
e
1. Removetethe fasteners at the front and rear
1. Remove
the
fasteners
holding
the
lower
s
c
i (See Illustration SC–10 and
t plate to the sidewall. (Seevi
of the
bplate.
scuff
h
i
r
g
l
the
e
iIllustration
SC–5 and the Fastener
r
ohFastener Replacement section.)
a
r
ll Replacement section.) y S
u
2.pUse a utility knife to cut the double-sidedn
A
d
a
n
2. Remove the scuff plate.
M
io tape between the plate and the sidewall.
Bo
t
e
c
—
Installation
u 3. Pull and/or gently pry the platevoff
ic the
V
d
sidewall.
r
D the plate to length as ro
1. Measure andPcut
e
p
S
needed. d
4. Clean remnants of the tape
y off the sidewall.
re
n
d
a
d scuff
Installation
2. Fromy the exterior, drill holes in the
e
Bo
z
d
i
plate
from
the
exterior,
using
the
fastener
r
o
1. Measure and cut—
the plate to length.
o
Bholes
in the sidewall as a template.
V
h
t
D paper strip on for now,
k
2. Leaving thePtop
c
u
3.
Insert
fasteners
into
the
holes.
a
u
apply double-sided
tape to the top and
d
n
Tr
n
Un
bottom
parts
of
the
plate.
it o
a
a
y
r
3. If dnecessary, position the plate and mark
o
o
p
where rivets protrude.
r
B
o
C
ck4. Lay the plate down.
aw
l
r
u
r
e
y areas.
t
T
b
5. Cut and remove the tape from the rivet
s
a
d
e
m
6.
Remove
the
paper
strips
from
all
the tape.
t
i
il
bi
t
i
7. Carefully position the plate
U
h and press iton
o
4
r
ti
w against the sidewall.p
0
a
a
0
l 8. From the exterior,ndrill holes in the
r scuff
2
o
y
t
o
b
h
tifastener holesorinp the
plate, using the
c
g
d
Illustration SC–5
ri Lower Scuff
sidewall as u
a template.
C
te
d
y
Plate (and Fasteners)
i
r
p
ro
ib
9. Insertpfasteners
into theteholes.
o
h
C
e
o
as
r
r
p
d
lim
e
i
n
t
iz
io
U
r
t
o
4
c
0
u
th
0
d
u
2
d
a
ro
e
t
n
v
p
h
U
er
re
ir g
s
d
y
e
re
p
o
ir z
ts
C
o
h
ig
th
r
u
Illustration SC–10
a
ll
“Gator” Scuff
Plate
n
A
U
d
e
rv
e
s
re
Lower Scuff Plate
88
Truck Body and PDV—Body Service Manual
Slats
al
u
an
M
ed
aw
l
v
r
y
e
b
s
e
1. Remove
the
fasteners
securing
the
slat
to
d
re (See Illustration SL–5vicand
e
the sidewall.
t
s
r
i
tFastener
the
Removal section.) e
b
h
i
l
igRemove the slat and save it yforSuse as a
r
oh
a
2.
r
ll
d
u
p
n
A possible template. Bo
a
n
M
it o
Installation
—
V
c
ce
D
u
i
1a. For mounting to
a
vertical
support,
you
P
rv
od
may be abledto use the old slat as a
r
e
S
template atondrill holes in the new slat.ep
y
r
y
d
d
1b. If not,dhold the new slat in position
o
e
o
B
slightly
iz position
B above or below the old
r
—
kand drill new holes throughothe slat and
V
c
th
D
u vertical support.
Illustration
SL–5
r
u
P and Vertical
T
a
Slats, Fasteners,
Supports
d
n
n
CAUTION: UseUa drill stop and take io
an
t
care not to accidentally drill holes into
a
y
r
d
the sidewall.
o
o
p
r
B
oto the
1c. If the slat is mounted directly
C
ck
aw
l
r
u
sidewall with spacers, you
e may be able to Tr
y
t
b
s
use the holes in the sidewall
as
a
template.
a
d
Brace the new slatm
in position and drill
e
t
i
l
holes (from thetioutside)
in the new slat.
bi
i
U
h
o
2. Attach the 4fasteners.
w
0
pr
a
0
l
2
n
n
y
t
o
i
o
b
h
i
t
c
d
ig
at
u
r
r
e
d
y
o
it
p
o
p
b
r
i
r
o
Co
ep
oh
C
r
r
p
d
er
t
e
n
s
iz
io
a
r
t
c
im
ho
u
l
t
i
d
t
u
d
o
U
a
r
e
n
4
v
p
r
U
0
e
re
0
s
2
d
t
e
re
h
z
ri
ts
ig
r
o
h
y
h
ig
t
p
r
u
o
a
ll
C
n
A
U
Removal
Truck Body and PDV—Body Service Manual
89
Switch, Cargo Light
l
d
w
a
e
a
u
l
v
CAUTION:
On
three-way
switches
the
Switch Body
Actuator
r
n
y
order inewhich the wires connect to thea
b
sis very important. Failure to M
switch
e
d
Actuator snaps
Detach
r
reconnect properly will cause the e
threee
onto Switch Body
Harness
t
s
c
i
i
t
hway switch system to fail. rv
ib
g
h
l
e
ir
o
a
S
r
ll NOTE: The cargo light typically
u
p Squeeze tabs to release
n
A can be turned on with ordywithout
a
n switch body from Bracket or Bezel
M
io
Bo
the key in the ignition.
t
e
c
Illustration SW–5
—
u
ic
Removal
V
Switch Components
d
v
r
ro
e
PDNegative (Black) terminal
1. Disconnect the
p
S
d
of the battery.
y
re
n (See Battery, Disconnecting
d
a
d
section.)
e
y
Bo
z
d
i
r at the back
2. Identify
and tag the connectors
—
o
Bofothe switch
V
h
bodies so that
t they can be
k
c
u
PD
reconnected
in
the
same
order.
a
u
d
n
Tr 3. Detach the electrical
n
Unharness from the back
it o
a
a
y
of the switch body.
r
d
o
o
p
4. Squeeze the top and bottom of the
r switch
B
o
k
w
body (or remove screws as necessary)
to
C
c
a
l
r
u
remove it from the panel.e (See
y
t
Tr
b
Illustrations SW–5 andsSW–10.)
a
d
e
m
t
5. Pop off the actuator
(if
separate).
i
i
il
Illustration SW–10 ib
t
Installation
U
n
h
Cargo Light Switch
o
o
4
i
r
t
w
0
1. Snap the0actuator
onto the new switch
p
a
a
l
r
n
body t(if2necessary).
y
o
i
po
b
h
t
r
c
2. Attach
o
ig the wiring harness connectors in theed
u
r
C
t
d
ysame locations as on the old switch. i
p
o
b
er
r
i
t
o
h
s
C 3. Reattach the switch to the panel orroplate.
ep This serviceainformation
r
NOTE:
is
m
p
4. Reconnect the battery.
d
i
generic.
Detailsilin illustrations and
e
n
t differ from those in
z
o
i
procedures
may
it
5. Test the function of the switch.
U
r
4 Because Utilimaster
c
ho your vehicle.
0
u
t
0 many customized
manufactures
u
2
d
od
a
r
e
t
vehicle
bodies,
this
manual
cannot
n
v
p
h
U
list
re
ir g and illustrate every possible partser
d
yin every vehicle. Nevertheless, there
e
p
o most common body options arets
iz
r
C
described here. Use this information
h
ho
g
i
t
as
a
guideline
where
it
applies.
u
lr
a
l
A
Un
90
Truck Body and PDV—Body Service Manual
Vents
Side
ed
v
r
e
s
re
al
u
an
M
w
la
by
e
d
ic
e
v
t
r
i
NOTE:
ts If a scuff plate covers any
e
b
h
i
S
remove the scuff plate
l
igfasteners,
y
r
oh
a
r
ll first.
d
u
p
o
n
A NOTE: Vents may be mounted
a
B
n
o
M
i
—
from the inside or V
outside.
e
ct
c
D
u
i
1. Remove all thePfasteners securing the vent.d
v
r
o
d
r
e
(See Illustrations
VE–5 through VE–15
S
Illustration VE–5
an Replacement section.)
ep
and the Fastener
y
r
Louvered Butterfly SidedVent (Outside Mounted)
y
d
d
o
2. Remove
the vent.
e
o
B
z
i
B
r applicable)
—
3. kRemove any excess sealanto(if
V
c
h
u from vent mounting area.t
PD
Tr 4. If sealant was present,auclean contacting n
d
n
n
o
U
i
a
surfaces with isopropyl alcohol.
at
y
r
d
o
Installation
o
p
r
B
o sealant
1. If applicable, apply polyurethane
C
ck
aw
between the contacting surfaces.
l
r
u
y
te and the panel Tr
b
s
2. Align the hole in the vent
a
d
opening.
e
m
t
i
il
bi
t
i
3. Fasten into position.
U
h
o
4
r VE–10
4. From the 0exterior, apply a bead of sealant
w
Illustration
p
a
0
l
Louvered Butterfly
to the joint
2 between the vent and the wall y
n Side Vent Interior View n
t
o
i
(if applicable).
b
h
io
t
t
c
g
d
u
ri
ra
te
d
y
o
i
p
ro
ib
rp
o
p
h
o
C
o
re
rC
NOTE: This service information
pr is
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e
t
e
n and
generic. Details in illustrations
z
s
o
i
a
r
ti those in
procedures may differ from
o
c
m
your vehicle. Because u
Utilimaster
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ili
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u
d
manufactures manyro
customized
U
a
e
n
4
v
vehicle bodies, this
r
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ep manual cannot U
e
r
0
list and illustrate every possible part
s
2
d Nevertheless, the
t
e
re
in every vehicle.
h
z
ri body options are
most common
ts
ig
r
o
h
y
described
h here. Use this information
ig
t
p
r
u
as
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guideline
where
it
applies.
o
Illustration
l VE–15
a
l
C
Two-Way Hingeless Side
n
A Vent (Outside Mounted)
U
Removal
Truck Body and PDV—Body Service Manual
91
Front
l
d
a
e
aw
u
l
v
r of the vehicle, removean
y
e
1. From the interior
b
s
Mand
the screws
d
re holding the plate to the wall
e
e
t
remove
the
plate.
(See
Illustration
VE–
s
c
i
t
bi
v
h
i
25.)
r
l
ig
r
oh
a
Se remove
r
ll From the exterior of the vehicle,
2.
u
p
n
A the fasteners that attach dthey vent and
a
n
M
io
remove the vent assembly.
Bo (See
t
e
c
Illustration VE–20—and Fastener
u
ic
V
d
v
Replacement section.)
r
D
ro
e
P
p
S
Installation
d
y
re
n
d
a
1. From the interior of the vehicle, insert
the
d
e
y through the plate and sidewall.
Bo
z
screws
d
i
r
o
—
o
B
V
2. While the screws are heldhin position from
t place the
k the interior, from the exterior
c
u
PD
a
u
dIllustration VE–20
n the screws. (Seeon
foam rubber spacer over
Tr
n
U
i
a Butterfly Vent (Exterior View)
Illustration VE–30.)
Front
at
y
r
d
o
3. Place the wire screen over the screws.
o
p
r
B
o
4. Turn the screws into the holes
of
the
vent
k
C
c
aw
l
r
cover.
u
r
e
y
t
T
b
s
5. Rivet the vent cover to
the
wall
using
the
a
d
e
existing holes. im
t
il
bi
t
i
NOTE: See also
the
Drains
section
U
n
h
o
o
4
i
for cleaning
information.
r
t
w
0
p
a
a
0
l
r
2
n
y
t
o
i
po
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i
p
o
b
er
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i
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o
C
ep
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as
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r
p
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Illustration
lim VE–25
e
i
n
t
Vent (Interior View)
iz Front Butterfly
io
U
r
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4
c
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0
u
t
0
u
2
d
od
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er
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C
o
h
ig
th Illustration VE–30
r
u
Front
Vent
Assembly
Parts
a
ll
n
A
U
Removal
92
Truck Body and PDV—Body Service Manual
Roof
al
u
an
M
ed
aw
l
v
r
y
e
b
1. From thesexterior of the vehicle, removeethe
d
ic
re that attach the roof vent tovthe
fasteners
e
t
r
i
ts plate. (See the Fastener Replacement
backer
e
b
h
i
S
l
igsection and Illustration VE–35.)
y
r
oh
a
r
ll 2. Gently cut the sealant around
d
u
p
the
o
n
A circumference of the vent
a
B before removing on
M
i
—
the vent from the roof.
V
ct
ce
D
u
i
P sealant from the ventod
3. Remove any excess
rv
d
r
e
mounting area.
S
an
ep
y
r
y roof surface with alcohol.
IllustrationdVE–35
4. Cleandthe
d
o View)
Roof Vent (Exterior
e
o
B
z
5. From
the
interior,
remove
screws
securing
i
B
—
k
or Illustration
the
interior baffle plate. (See
V
c
h
u VE–40.)
ut
PD
Tr
a
n
Installation
nd
Un
it o
a
1. On the outside of the vehicle, applyra
y
d
polyurethane sealant around thepo
Bo
circumference of the roof ventorflange.
C in the roof
ck
aw
l
r
2. Align the vent with the holes
u
y
te
Tr
and the vent backing plate.
b
s
a
d
e
3. Refasten the ventim
to the roof.
t
i
il
b
t
i
4. From the exterior,
U apply a bead of sealant
h
o
4
to the joint
between
the
vent
and
the
roof.
r
w
0
p
a
0
l
Illustration
2 interior, reattach the baffle plate y
n VE–40
5. From the
n
t
o
Roof
Vent
(Interior View)
i
o
b
h
i
t
with
screws.
c
d
ig
at
u
r
r
e
d
y
o
it
p
o
p
b
r
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o
Co
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4
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r
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re
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s
2
d service information is generic. Details in illustrations
NOTE: This
and procedures e
t
e
r
h
z
may differ
from
those
in
your
vehicle.
Because
Utilimaster
manufactures
many
ir
s
t in
ig
o
h
customized
vehicle bodies, this manual cannot list andyrillustrate every possible part
th vehicle. Nevertheless, the most common bodypoptions are described here.rigUse this
every
u
ainformation as a guideline where it applies. Co
ll
n
A
U
Removal
Truck Body and PDV—Body Service Manual
93
Wiring Diagrams
l
d
w
a
e
a
u
l
v
Circuit Numberr Identification and Codes
y
e
an
b
s
M
d
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e
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c
i
t
WIRE CODE:
SYMBOL
bi CODE:
v
h
i
r
l
ig
500 rBK
CONNECTOR
oh
a
Se
r
ll
SYMBOL
u
p
y
n
A
WIRE COLOR d
a
n
MTO
io
CIRCUIT NUMBER
Bo
t
CONTINUE
e
c
—
ANOTHER
u
ic SHEET
V
d
v
r
ro
e
PD
p
S
CONTINUED
FROM
d
e
y
r
n
ANOTHER
SHEET
d
WIRE COLOR aCODE:
d
o
e
y
LG - LIGHT
B
BK - BLACK
d
izGREEN
r
o
—
RD - RED
BR -B
BROWN
o
SPLICE
V
h
t
D
YL - YELLOW
k
DG
- DARK GREEN
u
P
a
uc
r
d
n
n
T
n
U
io
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ra
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TYPICAL
CIRCUIT
o
DESCRIPTION
k
COLOR
NUMBER
C
c
aw
l
r
u
r
e RED
y
t
T
150
BATTERY POWER
b
s
a
d
e
m
t
i
220
DARK
GREEN
CARGO
LIGHTS
il
bi
t
i
U
n
h
230
BROWN
TAIL/RUNNING LIGHTS
o
o
4
i
r
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w
0
p
a
a
0
l
r
DARK GREEN
2 232
REAR RIGHT TURN
n LIGHTS o
y
t
o
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b
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r
c
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o
234
RED
d
STOP LIGHTS
u
ri
C
te
d
y
i
r
p
236
LIGHT GREEN
ro UP LIGHTSte
BACK
ib
o
p
h
s
C
e
o
a
r
r
238
YELLOW
REAR LEFT TURN
m LIGHTS
p
d
i
l
e
i
n
t
iz
500
GROUND
it o BLACK
U
r
4
c
ho
0
u
t
0
u
2
d
od
a
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n
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er
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NOTE: These
Details in these diagrams may
o
ir z wiring diagrams are a genericCsample.
ts
differ o
from those in your vehicle. Because Utilimaster manufactures many customized
h
ig
th bodies, this manual cannot list and illustrate every possible wiring configuration
vehicle
r
u
a every vehicle. Use this information as a guideline where it applies.
ll
for
n
A
U
Codes and Circuit Number ID - Diagram Generic58301003a1-3 Sheet 1/3
94
Truck Body and PDV—Body Service Manual
Connector Locating
d Diagram
l
l
A
ts
h
rig
ve
r
e
s
re
dy
o
B
—
V
D
P
ce
i
rv
e
S
al
u
an
M
ROOF HARNESS
INTERMEDIATE
SIDE MARKER
(TYPICALLY 16' OR LONGER)
d
n
a
d
ti e
ib
h
o
pr
SIDE MARKER
LIGHT
n
it o
c
u
od
r
p
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by
w
la
CLEARANCE
LIGHT
I.D.
LIGHTS
l
a
u
n
a
M
CLEARANCE
LIGHT
ce
i
rv
e
S
CARGO
LIGHT
SIDE MARKER
LIGHT
CARGO
LIGHT
y
d
d
e
Bo
ir z
—
k
o
V
c
h
u
ut
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a
n
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Un
it o
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aw
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s
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NOTE: These
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t
e
r
h
differ from
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ir z those in your vehicle. Because Utilimaster manufactures
s
t
ig possible wiring configuration
vehicle
bodies, this manual cannot list and illustrate every
r
o
h
y
h vehicle. Use this information as a guidelinep where it applies.
ig
fortevery
r
u
o
a
ll
C
n
A
U
y
d
Bo
CARGO
LIGHT
CARGO
LIGHT
SWITCH
CARGO
LIGHT
CLEARANCE
LIGHT
TAILLIGHTS
I.D. LIGHTS
(PDV)
CLEARANCE
LIGHT
CHASSIS
HARNESS
CARGO
LIGHT
FUSE
POWER HARNESS
Connector Location, International - Diagram Generic58301003a4 Sheet 4
Truck Body and PDV—Body Service Manual
95
96
CARGO
LIGHT
n
io
t
c
u
od
r
p
re
CARGO
LIGHT
CARGO
LIGHT
l
a
u
an
M
NOTE: These wiring diagrams are a generic
sample. Details in these diagrams may differ
from those in your vehicle. Because Utilimaster
manufactures many customized vehicle bodies, this
manual cannot list and illustrate every possible
wiring configuration for every vehicle. Use this
information as a guideline where it applies.
NOTE: Some vehicles have a separate Ground wire
(500 BK). Others are grounded at the mountings
and have no separate dedicated Ground wire.
ce
i
rv
e
S
500 BK
220 DB
y
d
Bo
—
V
PD
LOCATED IN
BATTERY BOX
150 RD
d
n
a
CARGO LIGHT
SWITCH
CARGO
LIGHT
l
Al
ts
h
rig
d
e
rv
e
s
re
500 BK
150 RD
10 AMP
IN-LINE
FUSE
CARGO
LIGHT
y
d
d
e
y
Bo
z
d
i
r
—
o
Bo
V
h
t
k
c
u
PD
a
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d
n
Tr
n
Un
it o
a
a
y
r
d
o
o
p
r
B
o
k
C
c
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3-WAY
CARGO LIGHT
SWITCHES
Cargo Light Wiring
d
ti e
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o
pr
by
ce
i
rv
e
S
Cargo Lamps - Diagram Generic58301003a6 Sheet 6
CARGO
LIGHT
w
la
l
a
u
an
M
Truck Body and PDV—Body Service Manual
d
n
a
dy
o
B
—
V
D
P
n
it o
c
u
od
r
p
re
RIGHT
SIDE MARKER
LIGHT
d
ti e
ib
h
o
pr
by
w
la
RIGHT
STOP/TAIL
LIGHT
RIGHT
TURN
LIGHT
RIGHT
BACK-UP
LIGHT
LICENSE
PLATE
LIGHT
LEFT
TURN
LIGHT
LEFT
BACK-UP
LIGHT
ce
i
rv
e
S
al
u
an
M
Taillamps - Diagram Generic58301003a7 Sheet 7
l
l
A
ts
h
rig
ed
v
r
e
s
re
LEFT
STOP/TAIL
LIGHT
LEFT
SIDE MARKER
LIGHT
Taillight Wiring
ce
i
rv
e
S
l
a
u
n
a
M
234 RD
232 DG
230 BR
500 BK
500 BK
500 BK
230 BR
230 BR
236 LG
500 BK
232 DG
234 RD
500 BK
236 LG
230 BR
234 RD
232 DG
238 YL
Truck Body and PDV—Body Service Manual
500 BK
236 LG
500 BK
230 BR
236 LG
500 BK
238 YL
500 BK
230 BR
230 BR
234 RD
500 BK
500 BK
236 LG
234 RD
500 BK
230 BR
238 YL
y
d
d
e
Bo
ir z
—
k
o
V
c
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ut
PD
Tr
a
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it o
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2
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r
r
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n
NOTE: These
s wiring diagrams
iz
io
a
r
t
are
a
generic
sample. Details in
o
c
m
i
h
these diagrams
may differ from
t
il
du
t
u
o
thoseUin your vehicle. Becauseed
a
r
n
4
v
p
Utilimaster
manufactures many
r
U
0
e
r
0customized vehicle bodies,sethis
2
d
t manual cannot list andreillustrate
e
h
z
ri
ts
ig every possible wiring
r
o
h
y
configuration for
h
ig every vehicle.
t
p
r
u
Use
this
information
as a
o
l
a
l
C
n
guideline where
A it applies.
U
y
d
Bo
97
98
230 BR
500 BK
230 BR
500 BK
REAR SIDE MARKER
LIGHT
Clearance/Marker Lights - Diagram Generic58301003a8 Sheet 8
230 BR
230 BR
500 BK
500 BK
d
ti e
ib
h
o
pr
by
500 BK
230 BR
n
io
t
c
u
od
r
p
re
NOTE: Vehicles with LED lights have a separate
Ground wire (500 BK). Vehicles with incandescent
lights typically are grounded at the mountings and
have no separate dedicated Ground wire.
y
d
Bo
—
V
PD
ce
i
rv
e
S
INTERMEDIATE
SIDE MARKER LIGHT
(TYPICALLY 16' OR LONGER)
REAR CLEARANCE/I.D. LIGHTS
l
a
u
an
M
500 BK
d
e
rv
e
s
re
230 BR
d
n
a
NOTE: These wiring diagrams are a generic
sample. Details in these diagrams may differ
from those in your vehicle. Because Utilimaster
manufactures many customized vehicle bodies, this
manual cannot list and illustrate every possible
wiring configuration for every vehicle. Use this
information as a guideline where it applies.
REAR SIDE MARKER
LIGHT
l
Al
ts
h
rig
500 BK
230 BR
y
d
d
e
y
Bo
z
d
i
r
—
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Bo
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Rear Vision (Back-up)
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REVERSE SIGNAL
International mounts the back-up monitor in the dash.
Freightliner provides wiring for the back-up camera system in a
three-way Packard connector located under dash to the left of
the fuse panel. Utilimaster connects to this point and routes the
back-up monitor cable to the center of the cab.
Rear Vision - Diagram 58301003a9 Sheet 9
Truck Body and PDV—Body Service Manual
99
D
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Decals 24, 35
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Truck Body and PDV—Body Service Manual
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MONOBOLT 27
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B Glossary of Terms 18
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Par
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Number:: 03102101-VY04EN
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