Morgan Olson 2016-2018 USPS 2 Ton, Service Maintenance Manual

Page 1: ... S Nottawa Street Sturgis MI 49091 Phone 800 233 4823 Fax 616 659 0499 www morganolson com www morganolsonparts com UNITED STATES POSTAL SERVICE 2 TON DELIVERY TRUCK SERVICE MAINTENANCE MANUAL P N 43004536 ...

Page 2: ...organ Olson 1801 S Nottawa Sturgis MI 49091 1 800 477 8287 Customer Service Fleet Warranty For Parts Ordering 1 800 233 4823 1 616 659 0499 Fax Service Parts Contents CONTENTS INTRODUCTION 2 3 1 BODY TIE DOWNS 4 2 DOORS Side Doors 5 9 Bulkhead Door 10 Rear Door 11 17 3 GAS SPRING 18 4 HEATER Motor Fan Plenum 19 Troubleshooting 20 31 5 HOOD 32 6 LAMPS 33 7 BODY PANEL REPLACEMENT AND RIVETS 34 8 WIN...

Page 3: ... truck is fastened to bolsters that extend the length of the floor The lower flanges of the bolsters are mounted to the chassis frame rails Both sets of fasteners are torqued to specifications All cab and body tie downs should be checked after 3 months and annually Side Door Side Door For smooth operation the locking mechanism should be oiled every 3 months or as needed Grease should also be added...

Page 4: ...ed simply by sliding into a mated part To remove simply pull straight out from the top of the door or door frame Install by feeding into the mated part and sliding into place Handle Mechanism Removal 1 To remove the door handles simply remove the 4 mounting screws Pay special attention to spacer locations You can then remove the inside and outside handles Remember when installing the handles posit...

Page 5: ... strike adjust the upper track for uni form lateral placement of the door in the forward post seal Snug the forward bolt of the upper door track 5 With the door open and engaged in the rear strike the rear portion of the upper and low er tracks can be adjusted laterally to ensure proper alignment with the rear striker 6 When the door is positioned tighten a few of the fasteners in the upper and lo...

Page 6: ...checking the lifting mechanism cables and the door strap for fraying 3 Perform a visual inspection monthly checking for damaged parts replace immediately to prevent wear and fatigue on other components 4 Refer to Trans global Door Company instructions for proper rear door spring adjustment and or replacement Rear Door Bulkhead Door NOTE Where grease is required use a lithium based 1 The latch shou...

Page 7: ...SCRIPTION 1 47106737 Bearing Assembly 2 47106738 Side Seal Snap In Style 75 5 3 47106739 1 Head Protector Yellow 4 47106740 Lock Catch 5 47106741 Latch Guard Angle LH CS 6 47106742 Latch Guard Angle RH RS 7 47106743 5 16 x 1 Hex Head Bolt grade 5 8 47106744 5 16 Kep Nut 9 47106745 1 4 20 x 1 3 4 Hex Head Bolt 25C175HCS5Z 10 47106746 1 4 Kep Nut 11 47106747 Vertical Track Assembly 47106270 Curbside...

Page 8: ... 6 25mm 6 47106722 1 4 20 x 1 Carriage Bolt Stainless Steel 7 47106723 1 4 Nylok Nut 8 47106724 1 4 x 5 8 SS Semi Tubular Rivet 9 47106725 1 4 x 3 4 SS Semi Tubular Rivet 10 47106726 1 4 x 7 8 SS Semi Tubular Rivet 11 47106727 Cable 95 7 x 19 SS 1 4 Metal Eye Each 12 47106728 12 Pull Strap Looped W Black Retainer 13 47106729 D Ring Handle 2 PT Lock 14 47106732 25 Composite Top Panel Complete 13 5 ...

Page 9: ... 47106705 3 Stud Bottom Fixture Assembly Complete 5 47106707 1 Steel Roller 6 47106708 Top Cam Catch 7 47106710 Top Closure Assembly Complete 8 47106711 Top Closure Slide Only 9 47106712 Center Control Complete 10 47106714 Latch Base Center 80 Off D Ring Best Cylinder 11 47106715 Aluminum Cable Cover 68 375 Length 7 5mm Comp 12 47106716 Two Point End Latch Assembly Curbside 13 47106717 Two Point E...

Page 10: ...ly Morgan Olson OEM replace ment parts Gas Spring Heater Motor and Fan Replacement 1 The heater is mounted to the right hand dash panel 2 With the power to the motor off disconnect the motor leads 3 Remove motor mounting screws Remove the motor and the impeller wheel 4 Take out the set screw to remove the impeller wheel squirrel cage 5 For installation reverse the sequence Plenum Replacement 1 Det...

Page 11: ...ted all air is discharged through the dash louvers With this setting air is discharged through the dash louvers and onto the floorboard This is the ideal mode for rapid warm up in cold weather This mode will direct all air to the floorboard This mode is most frequently selected when heating is required When this mode is selected air is discharged onto the floorboard and onto the wind shield This m...

Page 12: ... Blower Motor Resistor wire connector from the resistor Check for electrical continuity between terminal 1 and 2 If an open circuit exists between 1 and 2 the thermal limiter has blown and it will be necessary to replace the resistor Note A failed resistor is often the results of a problem with the blower motor Make sure that the blower motor is fully operable and is not bound in any sort of way b...

Page 13: ...tor failure is suspected the first step is to confirm that the electrical connections at the servo motors are delivering the correct signal to the motors With the ignition switch turned to Accessory unplug each of the servo connectors and test according to the information in the Electrical Connection To Plenum Servo Mo tors Diagram If the electrical check is in agreement with the Diagram and if th...

Page 14: ...ty Repair as required A C system not providing cool air POSSIBLE CAUSE 1 Loss of refrigerant CORRECTIVE ACTION Verify the presence of 1 75 pounds of refrigerant R134a If the AC system is either partially low or completely empty a search will be required for leakage Replace and repair as required POSSIBLE CAUSE 2 Compressor not engaged CORRECTIVE ACTION Confirm that the system is fully charged With...

Page 15: ... 2016 2018 Models CONFIDENTIAL NOT FOR DISTRIBUTION CONFIDENTIAL NOT FOR DISTRIBUTION CONFIDENTIAL NOT FOR DISTRIBUTION CONFIDENTIAL NOT FOR DISTRIBUTION Consult the following Refrigerant System Evaluation chart below for a list of refrigerant related symptoms and their recommended resolution ...

Page 16: ...ssembly 1 Ea 21 47008706 KNOB 2 Ea 22 47008735 KNOB 1 Ea 23 47008707 Decal 1 Ea 24 47008708 Light panel 1 Ea 25 47008709 CONTROL SUB PANEL 1 Ea 26 47008700 BLOWER SWITCH 1 Ea 27 47008710 POTENTIOMETER SWITCH 2 Ea 28 47008711 HARNESS illumination W BULBS 1 Ea 29 47008712 HARNESS blower motor 1 Ea 30 555001721 DEFROST DUCT CURBSIDE metal 1 Ea 31 555001722 DEFROST DUCT ROADSIDE metal 1 Ea 32 09308040...

Page 17: ...e hinge install in reverse order Hood Stop Adjustment 1 The stops that support the hood should be adjusted if the hood ever comes into contact with the cab skirts The stop bracket is slotted to allow for vertical adjustment Adjust brackets so that hood seats evenly and does not come into contact with cab skirts HOOD Headlight Replacement 1 Remove screws and trim from around headlight 2 Remove head...

Page 18: ...ut to 28 diameter and use a 25 bolt and nut otherwise continue to the next step 4 Rivet the parts using a 25 rivet The correct length rivet will measure 25 38 beyond the material being joined NOTE As the vehicle ages it is not uncommon for some rivets to loosen This can often be detected by a black ring aluminum oxide around the head of the rivet If this happens replace the rivet See Re Riveting B...

Page 19: ...ension of the lift gate to enable this person to troubleshoot and correct all normal problems that may be encountered Failure to follow the installation instructions adjustments and mounting dimensions may result in improper and unsafe operation of the lift gate Unauthorized alterations of the lift gate can cause an undesirable and dangerous condition OWNER S MANUAL The Waltco Owner s Manual is in...

Page 20: ...for transit See the Owner s Manual for details Take care to retain cargo during transit for lift gate Platforms which function as the tailgate or door of the cargo area Small objects can fall through the space between the vehicle and the folded Platform A Lock Out device or Shut Off Switch should always be used to prevent unauthorized use of lift gate For lift gates with Runners never use lift gat...

Page 21: ... rate Replacement warranty parts can be obtained by contacting Waltco s Parts Department Parts must be returned for inspection when requested Exclusions Waltco s warranty does not include reimbursement for service calls vehicle rental towing travel time fabrication of parts available from WALTCO damage from misuse or abuse negligence accidents alteration loss of income or overtime expense oil or n...

Page 22: ...or when contacting Waltco for service or warranty questions DATE OF MANUFACTURE Month Year Page 8 Chapter 3 Operation Instructions TO OPEN PLATFORM Drop In Design Manual Close Use switch to raise platform up out of travel plates Pull platform open to horizontal position Never force platform open Keep hands away from pinch points Ref Operation Decal 80101577 GR02961 Page 9 TO STORE PLATFORM Drop In...

Page 23: ...in this manual contact your nearest Waltco Distributor WALTCO MDL SERIES LIFTGATE PREVENTIVE MAINTENANCE CHECKLIST PM Interval 6 Months or 3000 Cycles Date ______________ Vehicle No __________ Mechanic _________________ Liftgate S N ____________ Model ______________ Check appropriate box below for each step 6 Month Liftgate PM Procedures 1 OK Repair Required Corrected Check for apparent damage to ...

Page 24: ...ter 3 Operations Instructions Check all power cables ground cables and connections Clean and tighten all loose connections Replace any damaged or corroded wires or connectors PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE PLATFORM ADJUSTMENT Unfold and raise platform to bed level and check for 1 If platform travels more than above the top of the crossbeam box and lift gate is not an Above Floor mod...

Page 25: ...following fluids Waltco All Season Hyd Oil Part 85803867 Shell Tellus S2 V 15 Mobil DTE 10 Excell 15 Brake Fluid Power steering fluid Automatic Transmission Fluid ATF A good quality SAE 10W motor oil may also be used in temperatures above 32 F Rev 06 Breather Cap Page 14 PREVENTIVE MAINTENANCE Chapter 4 Preventive Maintenance There is no speed adjustment on this liftgate Lowering speed is controll...

Page 26: ...ous place near con trols Locate one on curb side platform 1600 Capacity Decal 80100252 2000 Capacity Decal 80100253 3000 Capacity Decal 80100257 2 Caution Decal 4 75089296 Locate one in a conspicuous place near con trols Locate one in a conspicuous place on driver side of vehicle 3 Protective Cover Decal 2 75089282 Locate one on hydraulic cylinder Locate on back of crossbeam box 4 Cab Shut Off Dec...

Page 27: ...NS Lubricate lifting chains including sections in crossbeam box rails runner assemblies with machine oil or motor oil Lubricate latch inside rails crossbeam box and platform hinges with machine oil or mo tor oil Lubricate driver and passenger side tracks Suggested Minimum Lubrication Schedule days Monthly Cycles Light Duty Medium Duty Heavy Duty 250 45 30 21 250 350 30 21 14 350 400 21 14 7 450 Co...

Page 28: ...1371241 2 Rail Cover 13 7500012 1 4 External Tooth Lock Washer 1 4 14 75086874 4 Screw 1 4 20 X 5 8 Type F MAIN FRAME ASSEMBLY ITEM PART NUMBER QTY DESCRIPTION 1 70430695 Hydraulic Pump Unit 14 reservoir Non Thermal Switch A 70092312 1 Motor 12V B 43016835 1 Reservoir 14 C 70092355 1 Relief Valve D 80001065 1 Motor Solenoid E 70092503 1 Valve 2 way 2 pos w Coil F 75083364 1 Elbow 90 JICM x 6 SAE G...

Page 29: ...latform Forked Runner STD 5 75085188 4 Lock Nut 3 8 16 Center lock 6 43016701 2 Wear Pad Front Forked 6 7 43016602 1 Wear Pad Back Forked Runner 8 75086709 8 Screw 10 32x3 8 FHSCS 9 43020006 1 Chain Anchor Block MDL 12 10 80000419 1 Roller Chain Master Link 50 Chain MDL 12 11 75085994 2 Screw 5 16 18x1 FHSCS Black Oxide RUNNER ASSEMBLY ITEM PART NUMBER QTY DESCRIPTION 91371110 ENTIRE PLATFORM ASSE...

Page 30: ...500010 22 2 HEX BOLT 3 8 16X2 GR 8 13 75086218 2 HEX BOLT 3 8 16X1 1 4 LG GR 8 14 75085168 4 HOG RING SS 1 BLUNT 14 GA 15 75089294 1 HANDLE GRIP 3 4 DIA RUBBER 16 7500010 6 1 HEX BOLT 3 8 16X1 LG GR 8 DECK ASSEMBLY ITEM PART NUMBER QTY DESCRIPTION 1 90995801 1 Cylinder Assembly Complete MDL 10 A 90995850 1 Cylinder Assembly MDL 10 B 43020013 1 Sprocket 13T 50 Chain 80002232 Kit 13T Sprocket with P...

Page 31: ...___________________________ THEN INCLUDE THE FOLLOWING INFORMATION 4 PART NUMBERS 5 DESCRIPTION 6 QUANTITY REQUIRED ________________________________________________________________ MAIL E MAIL OR PHONE YOUR REQUEST TO Waltco Truck Equipment Co 285 Northeast Avenue Tallmadge OH 44278 1 800 411 5685 FAX 1 800 411 5684 E MAIL parts waltco com ALL PARTS ARE F O B FROM THE SHIPPING FACTORY ____________...

Page 32: ...reen when the vehicle shifts into reverse This monitor allows the driver to see obstructions behind the vehicle for added convenience and safety The camera has an advanced CCD image sensor able to process excellent views under dark and light conditions A 120 diagonal field of vision yields superb coverage behind the vehicle and complies with the latest U S DOT guidelines when installed properly DI...

Page 33: ... the camera will compromise the waterproof seal WARNING 5 Color Monitor Backup Camera System User Manual 4 MONITOR BUTTONS i NOTE The monitor buttons do not function while the vehicle is in reverse The vehicle must be running and in park neutral drive to use the buttons It is recommended that the buttons are ONLY used in park neutral POWER ON OFF Powers on the monitor and displays the Camera 1 cha...

Page 34: ...oosing auto will allow the monitor to brighten and dim according to the amount of ambient light in the cabin SCALE Press to toggle the scale grid ON or OFF If ON the scale grid will appear when the driver shifts the vehicle into reverse in order to assist with distance perception ADJUST SCALE Press or to begin adjusting the dimensions of the scale grid Press to switch between the vertical features...

Page 35: ...t the angle camera as needed to achieve the desired rear view image It is highly recommended that the image transmitted by the camera shows the rear bumper and area behind the vehicle See Figure 4 MONITOR KIT INSTALLATION 8 5 Color Monitor Backup Camera System User Manual Camera mounted in suggested location Mount camera assembly high and centered Position of camera Typical monitor image of view f...

Page 36: ... 0 6 lbs Dimensions W x H x D 3 x 2 x 2 SYSTEM TECHNICAL SPECIFICATIONS STSM214 Monitor Includes STSM214 PHAR STSA1004 STSU1004 STSC141 Camera Includes Sunshade and Mounting Hardware 26 Heavy Duty w Twist Lock Connectors STSH214 Extension Harness Included in Kit Screen size diagonal 5 Maximum No of cameras 1 Input Screen ratio 16 9 Contrast ratio 500 1 Video Input Composite 1 V p p 20 75 Ohms Vide...

Page 37: ...ew the rearward scene Adjust the lookdown mirror head so as to provide the driver a view in front of the bumper and to the right of the front right wheel Each rearview mirror head is 4 way hand adjustable up down left right MORGAN OLSON Rearview Mirror System DRIVER MANUAL 6647RSSPH 6647LSSPH 2 3 Heated Flat Mirror Head 1 Exterior left hand rear view mirror assembly Including 1 Heated flat head 1 ...

Page 38: ...gram below for details use wrenches compatible with 5 16 fasteners and apply tightening torque accordingly Wear components are the same between LH and RH assemblies except upper mounting bases WEAR COMPONENT REPLACEMENT 4 5 MORGAN OLSON Rearview Mirror System DRIVER MANUAL 6647RSSPH 6647LSSPH OPERATING HEATED MIRRORS Each rear view mirror head has a heating element behind the glass to assist with ...

Page 39: ... either a flat or convex mirror head Step 1 Pull out black grommet and cable from oval hole and expose butt spliced connections Cut wires as shown Step 2 Remove 5 16 18 hex head screw and lock washer to disassemble defective mirror head Remove defective mirror head Ensure that remaining mirror head harness stays in place Step 3 Loosely attach new mirror head to the clamp Run heater harness through...

Page 40: ...NTIAL NOT FOR DISTRIBUTION CONFIDENTIAL NOT FOR DISTRIBUTION Morgan Olson Operator Service Manual for Keyless Entry Controller Diagnostics PN 46029040 NST12302 3_A ai 2015 10 07 1801 South Nottawa Road Sturgis MI 49091 800 233 4823 6647RSSPH 6647LSSPH Step 5 Tighten mirror head hardware on the clamp to 200 in lbs be sure that clamp location on the tube is correct per below diagram 7 ...

Page 41: ...ide doors unlock Auto relocks in 6 seconds Cab Manual Unlock Press and release dash switch The curbside and roadside doors unlock Auto relocks in 6 seconds LED Green LED Red LED Operation Flashes once every 5 seconds ON solid 6 seconds ON solid Status System ON Curbside and roadside doors unlocked Cab Area Unlock request from unlock switch or fob Status LED on receiver located over driver door Key...

Page 42: ...Chassis ground connection has failed 2 3 1 Check heart beat LED If it is not flashing the microprocessor has failed Call factory for assistance in either case 2 3 2 Check yellow output LEDs If they DO NOT flash each time correspond ing channel is activated the receiver has failed 2 3 Receiver and or microprocessor has failed 3 1 1 Check antenna placement It should not be touching any metal or tint...

Page 43: ...uctions dont il fait l objet peut causer des interférences gênantes avec les communications radio Cependant nous ne pouvons vous garantir qu une interférence ne se produira pas dans une installation particulière Si cet équipement produit des interférences graves lors de réceptions radio ou télévisées qui peuvent être détectées en allumant et en éteignant l équipement vous êtes invités à les suppri...

Page 44: ...tions page 191 Failure to perform scheduled maintenance invalidates warranty coverage on parts affected by the lack of maintenance Why Maintain Your Vehicle at Your Dealership Factory trained Technicians Service technicians participate in extensive factory sponsored certification training to help them become experts on the operation of your vehicle Ask your dealership about the training and certif...

Page 45: ... Make sure you perform the following basic maintenance checks and inspections every month or at six month intervals Check every month Engine oil level Function of all interior and exterior lights Tires including spare for wear and proper pressure Windshield washer fluid level Check every six months Battery connections Clean if necessary Body and door drain holes for obstructions Clean if necessary...

Page 46: ...ength and hoses Inspect exhaust system and heat shields Inspect steering linkage ball joints suspension tie rod ends driveshaft and U joints Other maintenance items Replace engine air filter Every 30000 miles 48000 km Change automatic transmission fluid and filter 5 Speed Transmission only Consult dealer for requirements Every 60000 miles 96000 km Replace front wheel bearing grease and grease seal...

Page 47: ...0 miles 8000 km or six months 273 E Series TE4 Canada United States of America enUSA Edition date 03 2015 Second Printing Scheduled Maintenance Extensive idling or low speed driving for long distances as in heavy commercial use such as delivery taxi patrol car or livery Change engine oil and filter Every 5000 miles 8000 km or six months or 200 engine hours Replace front wheel bearing grease and gr...

Page 48: ...n the oil change interval is 3000 miles 4800 kilometers Engineairfilterreplacement The life of the engine air filter is dependent on exposure to dusty and dirty conditions Vehicles operated in these conditions require frequent inspection and replacement SCHEDULED MAINTENANCE RECORD E146852 Repair Order Distance Engine hours optional Multi point inspection recommended Signature Dealer stamp 275 E S...

Page 49: ...800 233 4823 www morganolsonparts com 97 USPS 2 Ton Delivery Vehicle 2016 2018 Models CONFIDENTIAL NOT FOR DISTRIBUTION CONFIDENTIAL NOT FOR DISTRIBUTION CONFIDENTIAL NOT FOR DISTRIBUTION CONFIDENTIAL NOT FOR DISTRIBUTION 31 ...

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