freightliner MT45 2019 Service Manual
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freightliner MT45 2019 Service Manual

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Service Manual
2019 Morgan Olson Body
2019 Freightliner MT45 Chassis
DRAFT
1.800.233.4823
WWW.MORGANOLSON.COM

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  • Page 1 Service Manual 2019 Morgan Olson Body 2019 Freightliner MT45 Chassis DRAFT 1.800.233.4823 WWW.MORGANOLSON.COM...
  • Page 2 NOTE: USE ONLY GENUINE MORGAN OLSON PARTS USE OF NON OEM PARTS MAY VOID YOUR WARRANTY AND/OR VIOLATE FMVSS SAFETY STANDARDS Latest version of all documents available at; www.morganolsonparts.com Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
  • Page 3 Contents CONTENTS BODY TIE/DOWNS DOORS Side Doors Adjustments & Lubrication Bulkhead Door Adjustments & Lubrication Rear Door Adjustments & Lubrication 11-21 GAS SPRING HEATER Motor, Fan & Plenum Troubleshooting 24-37 HOOD LAMPS BODY PANEL REPLACEMENT AND RIVETS WINDSHIELD Windshield Removal and Installation WINDSHIELD WIPERS &...
  • Page 4 Body Tie/Downs Tie/Down Check: The floor of the 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 annual- Genuine OEM Parts 1.800.233.4823...
  • Page 5 Side Door Side Door For smooth operation the locking mechanism should be oiled every 3 months or as needed. Grease should also be added at the contact points of locking mechanism arm and strik- (At opened and closed positions.) Lubricate latch internal mechanism. Grease on the latch contact points.
  • Page 6 Side Door Removal: 1. Remove the anti rattle clips. 2. Remove the 4 fasteners and the door handles (inner and outer). 3. Using a socket wrench, remove the bolts fastening the door and hanger assembly. 4. To simplify door removal, remove the grab handle located forward of the door. *Fold side view mirror back.
  • Page 7 Side Door Installation: 1. Tilt the top of the door in place first. Now position the bottom of the door into the lower door track, which is in position but not fastened down. 2. Put 1/8” shims between the lower door track and the wear strip. 3.
  • Page 8 Side Door Adjustment: 1. Loosen all nuts on the top of the slotted upper door track. 2. With the door closed and engaged in the forward strike, adjust the upper track for uniform lateral placement of the door in the forward post seal. Snug the forward bolt of the upper door track.
  • Page 9 2019 Amazon P80 Package Delivery Vehicle...
  • Page 10 Blank Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
  • Page 11 Bulkhead Door Bulkhead Door: *NOTE: Where grease is required use a lithium based. 1. The latch should be greased to prevent sticking. Grease should be applied at con- tact points of the latch and striker for smooth operation. This should be done every 3 months.
  • Page 12 225 NORTH PATTERSON ST. CAREY, OH 43316 CUSTOMER SERVICE PHONE 877-876-7452 ROLL-UP DOOR PREVENTIVE MAINTENANCE CHECKLIST The Counterbalance Spring is wound under High Tension. This High Tension Counterbalance Spring can cause Severe Injury or Death. Only Qualified technicians should adjust this spring. Use two winding bars that are ½”...
  • Page 13 LUBRICATION Lubricate the Counterbalance Spring, Counterbalance Shaft Bearings, Rollers, Hinges, Top Fixtures, Bottom Roller Holders and Locks liberally with Transglobal Lube. Do NOT use grease. Wipe dirt from track. Frequency of door maintenance will vary with climate conditions and door cleaning procedures. Doors which are steam cleaned will need lubricated more often.
  • Page 14 LUBRICATION OF END HINGES, 2-POINT CENTER CONTROL & END LATCHES END HINGE 2-POINT CENTER CONTROL ASSEMBLY 2-POINT END LATCH ASSEMBLY Copyright © 2017 by Transglobal Inc. Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
  • Page 15 LUBRICATION OF TOP FIXTURE, CENTER HINGE & BOTTOM FIXTURE TOP FIXTURE CENTER HINGE BOTTOM FIXTURE 2019 Amazon P80 Package Delivery Vehicle...
  • Page 16 LUBRICATION OF SINGLE AND DUAL SPRING ASSEMBLIES On single and dual spring assemblies – lubricate spring(s) along their entire length to prevent rusting. SINGLE SPRING ASSEMBLY DUAL SPRING ASSEMBLY Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
  • Page 17 DOOR OPERATION – PLEASE INSPECT THE FOLLWING: Check to see if the door lock operates easily and latches tight, compressing the bottom seal. Check to see if the door operates freely (up and down) with side play between the tracks and door approximately ¼”...
  • Page 18 Loosen the two 5/16” nuts on both top fixture assemblies, adjust the top fixture slides until the top door panel is in the same plane as the rest of the door panels and retighten 5/16” nuts. REAR STRUCTURE TOP HEADER TOP FIXTURE ASSEMBILY TOP PANEL SEAL FIGURE 2...
  • Page 19 PULL STRAP PULL STRAP RETAINER PULL STRAP (INSIDE MOUNT SHOWN) FIGURE 3 Failure to replace worn or frayed door pull strap may result in injury. 2019 Amazon P80 Package Delivery Vehicle...
  • Page 20 SPRING BALANCER – PLEASE INSPECT THE FOLLOWING: Note: All spring systems are designed to assist in the operation of opening and closing the door. The door should never free fall or fly open buy itself. All spring systems are designed for both cables to SPRING BALANCER –...
  • Page 21 LOCATIONS OF TRANSGLOBAL’S SERIAL NUMBER PLATES Transglobal has (2) location. Outside mount / bottom panel / RS (Standard) and inside mount / top panel / RS. When ordering parts for roll-up door, specify the serial number of the door. 2019 Amazon P80 Package Delivery Vehicle Copyright ©...
  • Page 22 Gas Spring Gas Spring Replacement: 1. With the hood safely propped, remove the upper and lower retainer clips. Once the clips have been removed a slight tap will remove the gas spring from the ball studs. 2. For safety reasons, when replacing the gas springs use only Morgan Olson OEM replacement parts.
  • Page 23 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.
  • Page 24 SERVICING AND TROUBLESHOOTING A/C-HEATER-DEFROSTER CONTROL PANEL OPERATION BLOWER CONTROL The blower control provides three choices of air velocity in every oper- ating mode. When the blower switch knob is rotated fully counterclockwise (with the knob indica- tor pointing straight up) the blower is turned OFF. Rotating the knob clockwise will progressively increase the air velocity.
  • Page 25 WIRING DIAGRAM 2019 Amazon P80 Package Delivery Vehicle...
  • Page 26 WIRING DIAGRAM (Enlargement 1 of 3) Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
  • Page 27 WIRING DIAGRAM (Enlargement 2 of 3) 2019 Amazon P80 Package Delivery Vehicle...
  • Page 28 WIRING DIAGRAM (Enlargement 3 of 3) Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
  • Page 29 TROUBLESHOOTING SECTION A: AIRFLOW PROBLEMS PROBLEM A-1 No air flow, blower does not operate POSSIBLE CAUSE #1 Faulty Blower Motor CORRECTIVE ACTION With ignition turned ON, unplug the 2-pin connector at the blower mo- tor. Check the orange wire for +12 volts and the white wire for a fully grounded circuit. If power is present and the circuit grounded, remove the motor and wheel from the blower housing.
  • Page 30 Figure 3 Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
  • Page 31 POSSIBLE CAUSE #2 - Servo motor failure CORRECTIVE ACTION - If servo motor failure is suspected, the first step is to confirm that the electrical connections at the servo motors are fully connected to the servo motors (there is a pos- sibility that they are not fully 'snapped' into motor's connector).
  • Page 32 POSSIBLE CAUSE #3 - Control Panel Selector Switch is defective CORRECTIVE ACTION - With the ignition turned to Accessory, unplug each of the connectors from the Plenum servo motors and test according to the information in the Electrical Connection To Plenum Servo Motors Diagram ( Figure 5). If the test fails to find agreement with the Diagram, there is a good possibility that the Mode Selec- tion Switch at the control panel is defective.
  • Page 33 PROBLEM B-2, 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 A/C sys- tem is either low, or completely empty, a search will be required for leakage. Replace and repair as required.
  • Page 34 SECTION C: DIAGNOSIS OF REFRIGERANT RELATED PROBLEMS Consult the following Refrigerant System Evaluation chart (Figure 7) for a list of refrigerant relat- ed symptoms and their recommended resolution: Refrigerant System Evaluation Figure 7 Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
  • Page 35 SERVICE PARTS Control Panel ITEM # PART # DESCRIPTION QTY UNIT 555001416 CONTROL PANEL ASSEMBLY 47008706 KNOB 47008777 KNOB - MODE SELECTOR SWITCH 46023202 SWITCH - BLOWER SPEED 47008710 SWITCH - TEMPERATURE CONTROL 47008774 SWITCH - MODE SELECTOR 47008711 HARNESS ILLUMINATION 47008778 HARNESS 47008775...
  • Page 36 SERVICE PARTS A/C-Heater ITEM # PART # DESCRIPTION UNIT 555001110 HEATER ASSEMBLY 47008760 HEATER COIL WITH GASKETS / CLAMP Call DOOR Call A/C PARTITION 47008754 BLOWER HOUSING Call BLOWER ADAPTER 47008732 RESISTOR CAGE 47008357 RESISTOR 47008731 VENT TUBE ADAPTOR 46032339 BLOWER MOTOR 47008769 BLOWER WHEEL...
  • Page 37 SERVICE PARTS (Under-hood items for models with FCCC chassis) 555001110* Heater Assembly W/ Expansion Block 47008138 Expansion Valve 47008790 #6 Hose Receiver to Drier 34” 990002214 Binary Pressure Switch 47008789 #6 Hose Condensor to Receiver 34” 47008792 #10 Hose Evaporator to Compressor 36.5”...
  • Page 38 HOOD Hood Removal: 1. For removal of the gas springs. See page 28. 2. Disconnect wire harness plug connections. 3. Remove the 4 bolts tying the left and right hinge assemblies to the body of the truck. 4. Disconnect hood prop. 5.
  • Page 39 LAMPS Headlight Replacement: 1. Remove screws and trim ring from around headlight. 2. Remove headlight. 3. Remove wiring plug from back of headlight. 4. Replace headlight. 5. For installation reverse removal sequence. Tail, Turn Backup and Marker Lamp Replacement: 1. Push tail, turn back-up lamp into rubber grommet and use a small flat head screw driver and pry lamp from rubber grommet.
  • Page 40 BODY PANEL REPLACEMENTS & RIVETS Body Panel Replacement: 1. When replacing exterior body panels, remove rivets following procedures outlined below. 2. Apply sealant to new panel as required. 3. Install new panel in reverse order. Removing A Rivet: 1. When removing an existing rivet, place the drill bit on the small dot in the center of the rivet head.
  • Page 41 WINDSHIELD REPLACEMENT Windshield Removal: 1. Special tools are required for windshield removal. Glass and Bead Tools. 2. A soap and water solution should be applied around the rubber seal. This will al- low the tools to move smoothly when in contact with the rubber seal. 3.
  • Page 42 WINDSHIELD WIPERS & MOTOR Windshield Wipers and Wiper Drive Assembly: 1. Replace the wiper arm by removing the acorn nut and washer hose. To insure proper placement of the new wiper, mark the position of the old wiper arm before removing.
  • Page 43 WINDSHIELD WIPER ASSEMBLY Windshield Wipers and Wiper Drive Assembly: Fron inside of cab, remove upper wiper cover and disconnect power to the wiper motor. Disconnect the washer hose from the pivot cover. From the outside, remove the acorn retaining nuts, disconnect the washer hoses, re- move the wiper arms.
  • Page 44 360 CAMERA SYSTEM Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
  • Page 45 360 CAMERA SYSTEM 2019 Amazon P80 Package Delivery Vehicle...
  • Page 46 360 CAMERA SYSTEM Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
  • Page 47 360 CAMERA SYSTEM 2019 Amazon P80 Package Delivery Vehicle...
  • Page 48 360 CAMERA SYSTEM Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
  • Page 49 Wiring Diagram 2019 Amazon P80 Package Delivery Vehicle...
  • Page 50 360 CAMERA SYSTEM Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
  • Page 51 360 CAMERA SYSTEM 2019 Amazon P80 Package Delivery Vehicle...
  • Page 52 360 CAMERA SYSTEM Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
  • Page 53 360 CAMERA SYSTEM 2019 Amazon P80 Package Delivery Vehicle...
  • Page 54 360 CAMERA SYSTEM Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
  • Page 55 360 CAMERA SYSTEM 2019 Amazon P80 Package Delivery Vehicle...
  • Page 56 Troubleshooting Symptom Possible Condition Solution Check Connections at power No Power Poor Connection \ Fuse wires and ground wires. Check Vehicle fuse Check in-line fuse in the wire harness to monitor Check inline fuse in the wire harness to the signal processor In line fuses are located in the wiper compartment above the driver seat.
  • Page 57 KEYLESS ENTRY Bulkhead Door 1. Press and hold fob button for 1-second 2. Bulkhead door automatically opens and remains open until driver manually closes door 3. Door automatically latches and locks when door closes Bulkhead Door Quick Open 1. After stopping the truck using the Engine Stop button 2.
  • Page 58 CODE ENROLLMENT Quick Code Enrollment 1. Car MUST be stopped AND engine OFF 2. Press the fob button once Engine Start / Stop switch back light begins flashing, indicating a Valid ID has been detected 3. Press and HOLD the Engine Stop switch for 5-seconds Engine Start / Stop switch back light will turn ON solid 4.
  • Page 59 Blank 2019 Amazon P80 Package Delivery Vehicle...
  • Page 60 WIRING DIAGRAMS Morgan Olson Service Parts 1.800.233.4823...
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