Utilimaster REACH Service Manual
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Utilimaster REACH Service Manual

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For Assistance Call: 800-237-7806
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www.utilimaster.com
Utilimaster Corporation attempts to provide
information that is accurate, complete, and
useful. All information contained in this
manual is based on the latest product infor-
mation available at the time of publication.
However, because of the Utilimaster policy
of continual product improvement, Utilimas-
ter reserves the right to amend the informa-
Body Service Manual
tion in this document at any time without
prior notice.
This material is confidential and the prop-
erty of Utilimaster. It is shared with your
company for the sole purpose of helping you
with the operation of the described equip-
ment.
Utilimaster makes no warranty of any kind
with regard to this material, including, but
not limited to, the implied warranties of
merchantability and fitness for a particular
purpose. Utilimaster shall not be liable for
errors contained herein or for incidental or
consequential damages in connection with
the furnishing, performance, or use of this
material.
Utilimaster expressly disclaims all respon-
sibility and liability for the installation, use,
performance, maintenance, and support of
third-party products. Customers are advised
to make their independent evaluation of such
products.
No part of this document may be photo-
copied, reproduced, or translated to another
language without the prior written consent
of Utilimaster.
Utilimaster Corporation attempts to provide
information that is accurate, complete, and
E-mail:
custsvc@utilimaster.com
Reach—Body Service Manual
1

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Summary of Contents for Utilimaster REACH

  • Page 1 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 2 Corporation. See the Reach–Body Operator’s Guide for expanded descriptions on the features and erty of Utilimaster. It is shared with your options unique to the Reach. For information on chassis and drive train operations, see the Isuzu’s NPR company for the sole purpose of helping you Stripped Chassis Owner’s and Driver’s Manual.

  • Page 3: Table Of Contents

    Access ..........................13 This material is confidential and the prop- Disconnect ........................13 erty of Utilimaster. It is shared with your Body Panel Repair .......................14 company for the sole purpose of helping you Overview .........................14 with the operation of the described equip- Gelcoat Repair ........................14...
  • Page 4 Installation........................47 This material is confidential and the prop- Catch, Front Standard ....................49 erty of Utilimaster. It is shared with your Catch, Front Keyless ......................51 company for the sole purpose of helping you Catch, Rear........................55 with the operation of the described equip- Guide ..........................56...
  • Page 5 Sidewall Cladding ......................88 This material is confidential and the prop- Fire Extinguisher ........................89 erty of Utilimaster. It is shared with your Removal..........................89 company for the sole purpose of helping you Installation........................89 with the operation of the described equip- Fuel Sending Unit Access Panel ..................90...
  • Page 6 Installation........................145 This material is confidential and the prop- Disassembly .........................145 erty of Utilimaster. It is shared with your Assembly ........................146 company for the sole purpose of helping you Hood Latch ........................147 with the operation of the described equip- Hood Cable ........................149...
  • Page 7 Blind Rivet........................172 This material is confidential and the prop- Channel Nut ........................172 erty of Utilimaster. It is shared with your Nut, Locknut........................173 company for the sole purpose of helping you Nut, Nutsert........................173 with the operation of the described equip- Nut, Torque Seal ......................173...
  • Page 8 Maintenance Checklist ......................182 This material is confidential and the prop- Body Mounting Fasteners ....................182 erty of Utilimaster. It is shared with your Bumpers ..........................182 company for the sole purpose of helping you Doors, General ........................183 with the operation of the described equip- Doors, Roll-up ........................184...

  • Page 9: Notes, Cautions, And Warnings

    If at any time you lack confidence in performing a specific repair procedure or in operating the copied, reproduced, or translated to another tools safely to perform the repair, STOP! Call your local dealer or a Utilimaster representative. language without the prior written consent •...

  • Page 10: Manual Is Based On The Latest Product Infor

    Make sure all safety equipment is present, up-to-date, and not damaged. This material is confidential and the prop- Check the windshield for cracks and chips. erty of Utilimaster. It is shared with your Check windshield wiper operation and washer spray pattern. company for the sole purpose of helping you Check all lights including headlight high beams, flashers, and turn signals.

  • Page 11: However, Because Of The Utilimaster Policy

    Lamps This material is confidential and the prop- Release Handle Bumper Parking Light erty of Utilimaster. It is shared with your Fascia company for the sole purpose of helping you Side Backup Dock with the operation of the described equip-...

  • Page 12: Vin, Body Serial, And Work Order Numbers

    Utilimaster. It is shared with your company for the sole purpose of helping you The 15-digit Utilimaster Body (or Unit) Serial Number is recorded on the Federal Certification with the operation of the described equip- Label. This label is a plastic decal (about 11" long and 2" high) that contains a variety of manufacturing information (including the VIN and Work Order Number).

  • Page 13: Service Procedures

    Carefully follow the chassis manufacturer’s recommendations for those procedures. erty of Utilimaster. It is shared with your company for the sole purpose of helping you WARNING: Battery posts and related accessories may contain lead and lead compounds. Wash with the operation of the described equip- hands after handling.

  • Page 14: Body Panel Repair

    This section summarizes the various repair options for the composite body panels (hood, sidewalls, and roof) on the Reach vehicle. They are listed in order of severity of damage and difficulty of repair. This material is confidential and the prop- Gelcoat Repair: The exterior body of the Reach has a gelcoat finish.
  • Page 15 This material is confidential and the prop- 10. Allow gelcoat to dry. erty of Utilimaster. It is shared with your Spraying on gelcoat 11. Thoroughly clean area with acetone. company for the sole purpose of helping you 12.

  • Page 16: Minor Composite Repair

    CAUTION: Utilimaster recommends that body panel repairs be done by an experienced body shop However, because of the Utilimaster policy or at Utilimaster's Customer Service Department in Wakarusa Indiana. Contact Utilimaster Customer Service Department for further assistance.

  • Page 17: Major Composite Repair

    CAUTION: Utilimaster recommends that body panel repairs be done by an experienced body shop or at Utilimaster's Customer Service Department in Wakarusa, Indiana. Contact Utilimaster Customer However, because of the Utilimaster policy Service Department for further assistance.
  • Page 18 17. Bond the perimeter of the plug to the body This material is confidential and the prop- with resin and fiberglass matting. erty of Utilimaster. It is shared with your 18. Allow resin to dry. company for the sole purpose of helping you 19.

  • Page 19: Bumpers

    2. Remove grille. This material is confidential and the prop- See Remove Grille. erty of Utilimaster. It is shared with your 3. Remove two M6 screws in headlight bezel. company for the sole purpose of helping you 4. Remove two M4 screws in headlight bezel and set bezel aside.
  • Page 20 Steel bumper brackets This material is confidential and the prop- erty of Utilimaster. It is shared with your 10. Repeat on opposite side. company for the sole purpose of helping you 11. Set bumper fascia aside.
  • Page 21 6. Secure top of fascia with two M6 screws. This material is confidential and the prop- 7. Torque to 7–8 ft•lbs. erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 22: Rear Bumper

    This material is confidential and the prop- 2. Set step bumper aside. erty of Utilimaster. It is shared with your 3. Remove hex-head bolts and nuts in frame extension(s) and remove shock absorber(s). company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 23 3. Secure rear step bumper to each shock absorber(s) with four M12 hex-head bolts and nuts. This material is confidential and the prop- erty of Utilimaster. It is shared with your 4. Torque nuts to 60–71 ft•lbs. company for the sole purpose of helping you See Bumper Maintenance.

  • Page 24: D-Bumper

    This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 25: Side Dock Bumpers

    3. Remove #8 x 5/8" screws from brackets. This material is confidential and the prop- 4. Set dock bumper aside. erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- Installation ment.

  • Page 26: Cladding

    This material is confidential and the prop- fender. These nuts are located above the wheel liner. erty of Utilimaster. It is shared with your company for the sole purpose of helping you 4. Remove two M6 screws from cladding at front door post.

  • Page 27: Rear

    This material is confidential and the prop- NOTE: If not removing header, remove bottom two M6 screws in upper erty of Utilimaster. It is shared with your post cladding. company for the sole purpose of helping you 1.
  • Page 28 3. Remove header and lay on top of roof. prior notice. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 29 See Remove Blind Rivet. This material is confidential and the prop- 4. Remove seven rivets from the bottom lip of the kickplate erty of Utilimaster. It is shared with your cladding. company for the sole purpose of helping you with the operation of the described equip- See Remove Blind Rivet.

  • Page 30: Sidewall

    This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 31 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- Cladding channel ment.

  • Page 32: Dash Panels

    HOOD CLUSTER This material is confidential and the prop- DASH VALANCE PANEL erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment. Utilimaster makes no warranty of any kind...

  • Page 33: A-Pillar

    1. Remove seven M6 scrivets from A-pillar. See Remove Scrivet. This material is confidential and the prop- 2. Set A-pillar aside. erty of Utilimaster. It is shared with your company for the sole purpose of helping you Installation with the operation of the described equip- 1.

  • Page 34: Cluster Panel

    Installation This material is confidential and the prop- erty of Utilimaster. It is shared with your 1. Secure cluster panel to dash with four M6 screws. company for the sole purpose of helping you...
  • Page 35 8. Remove tray panel. This material is confidential and the prop- See Remove Tray Panel. erty of Utilimaster. It is shared with your 9. Remove dash vent by lifting with a flat blade screwdriver and company for the sole purpose of helping you pulling spring clip out to one side.
  • Page 36 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 37: No Part Of This Document May Be Photo-Fuse Access

    The fuse panels are mounted below the convenience panel behind the dash fascia. The fuse panel on the left is for the third-party products. Customers are advised Utilimaster body features, and the panel on the right is for to make their independent evaluation of such the chassis functions.

  • Page 38: Hood Cluster Panel

    Hood Cluster Panel This material is confidential and the prop- erty of Utilimaster. It is shared with your Removal company for the sole purpose of helping you with the operation of the described equip- CAUTION: Discard ALL used fasteners and replace with new.

  • Page 39: Overhead Panel

    This material is confidential and the prop- 4. Disconnect wiring harnesses from speakers and set aside. erty of Utilimaster. It is shared with your 5. Remove scrivets from trim panel above both doors and overhead panel. company for the sole purpose of helping you See Remove Scrivet.

  • Page 40: Tray Panel

    1. Secure tray panel to dash with four M6 screws. This material is confidential and the prop- erty of Utilimaster. It is shared with your Tray panel 2. Torque to 7–8 ft•lbs. company for the sole purpose of helping you...

  • Page 41: Utilimaster Corporation Attempts To Provide Door Ajar Switch

    3. Remove switch from mounting bracket and set aside. This material is confidential and the prop- Installation erty of Utilimaster. It is shared with your 1. Use a Phillips head screwdriver to secure switch onto company for the sole purpose of helping you mounting bracket with two screws and two lock nuts.

  • Page 42: Information That Is Accurate, Complete, And Adjustment

    2. Cycle door to test resistance. prior notice. 3. Torque to 7–8 ft•lbs. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 43: Useful. All Information Contained In This

    This material is confidential and the prop- 1. Slide door into floor track toward driver's side first. erty of Utilimaster. It is shared with your 2. Secure door into roller assembly with three M6 bolts. company for the sole purpose of helping you 3.

  • Page 44: Catch Adjustment

    4. Cycle door to ensure that it seals properly and latch engages catch. prior notice. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you Catch Plate with the operation of the described equip- ment.

  • Page 45: Doors, Cab Slider

    This material is confidential and the prop- slide the door until the latch catches. erty of Utilimaster. It is shared with your To lock the doors from the inside, push the lever below the interior handle up. company for the sole purpose of helping you To unlock the door, pull down on the lever.

  • Page 46: Adjustment

    4. Adjust again if necessary. This material is confidential and the prop- 5. Torque bolts to 34–40 ft•lbs. erty of Utilimaster. It is shared with your company for the sole purpose of helping you Screw locations in guide with the operation of the described equip- Removal ment.

  • Page 47: Installation

    This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 48 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- Roller assembly screw locations ment.

  • Page 49: This Material Is Confidential And The Prop

    See Remove Washer Bottle Panel. 1. Remove two M6 bolts on catch. This material is confidential and the prop- erty of Utilimaster. It is shared with your 2. Close door. company for the sole purpose of helping you 3. Align catch with latch on door.
  • Page 50 1. Remove two M6 bolts on catch. 2. Set catch aside. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 51: Erty Of Utilimaster. It Is Shared With Your

    See Remove Washer Bottle Panel. 1. Remove two M6 bolts on catch. This material is confidential and the prop- erty of Utilimaster. It is shared with your 2. Close door. company for the sole purpose of helping you 3. Align catch with latch on door.
  • Page 52 See Remove Washer Bottle Panel. prior notice. 1. Disconnect wire harness. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 53 This material is confidential and the prop- erty of Utilimaster. It is shared with your Screws on catch company for the sole purpose of helping you with the operation of the described equip- Installation ment.
  • Page 54 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- Screw on catch extension ment.

  • Page 55: Company For The Sole Purpose Of Helping You

    4. Cycle door to ensure that it seals properly and latch engages catch. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you Catch Plate with the operation of the described equip- ment.

  • Page 56: Ment

    2. Remove five M6 screws from threshold and one M6 screw from underneath vehicle. Leave prior notice. threshold in place. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 57 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 58: Handles

    This material is confidential and the prop- To close the door, slide the door closed until the latch catches. erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 59: Lock Cylinder Removal

    This material is confidential and the prop- Removal erty of Utilimaster. It is shared with your Lock cylinder company for the sole purpose of helping you CAUTION: Discard ALL used fasteners and replace with new. If using a fastener that does NOT have with the operation of the described equip- preapplied thread lock, apply a medium-grade liquid thread lock.

  • Page 60: With Regard To This Material, Including, But Seals

    5. Align interior handle with screws and This material is confidential and the prop- EXT HANDLE push together. erty of Utilimaster. It is shared with your STOP BRACKET company for the sole purpose of helping you 6. Secure handle with locknuts.
  • Page 61 This material is confidential and the prop- 4. Remove two M8 bolts from rear catch assembly. Scrivet location erty of Utilimaster. It is shared with your 5. Set rear catch assembly aside. company for the sole purpose of helping you 6.

  • Page 62: Threshold

    2. Remove five M6 screws from threshold and one M6 screw from underneath vehicle. prior notice. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 63: Merchantability And Fitness For A Particular

    See Remove Blind Rivets. This material is confidential and the prop- 3. Lift out window. erty of Utilimaster. It is shared with your 4. Remove foam tape and discard. company for the sole purpose of helping you 5. Set window aside.
  • Page 64 This material is confidential and the prop- 2. Secure pressure-sensitive tape to back of handle. erty of Utilimaster. It is shared with your 3. Secure handle with T20 Torx head screws, finishing washers, and company for the sole purpose of helping you retainer buttons.

  • Page 65: Doors, T-Series Rear Roll-Up

    NOTE: The information in this document is generic. Images and Utilimaster makes no warranty of any kind procedures may differ from those for vehicles you are servicing. Because Utilimaster with regard to this material, including, but manufactures customized vehicle bodies, this document cannot list and illustrate every not limited to, the implied warranties of possible option for every vehicle.

  • Page 66: Adjustment

    See Roll-up Door Maintenance. prior notice. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 67: Removal

    This material is confidential and the prop- 3. Remove the hex head bolt and nut from stops erty of Utilimaster. It is shared with your located at the end of the track and remove stops. company for the sole purpose of helping you 4.
  • Page 68 CAUTION: Ensure the drums are against the This material is confidential and the prop- counterbalance shaft bearings, the setscrews are properly erty of Utilimaster. It is shared with your tightened, and the cables have equal tension. company for the sole purpose of helping you Rotating the counterbalance assembly too far may cause the cables to jump off the cable drum.

  • Page 69: Utilimaster Expressly Disclaims All Respon

    2. Remove rivets in hinges. Insert a punch in one of the rivet holes to stabilize the panel while removing the remaining rivets. erty of Utilimaster. It is shared with your company for the sole purpose of helping you See Remove Blind Rivets.

  • Page 70: Rollers

    3. Install end hinge with 1/4 x 1-1/8" elevator bolt and nut. erty of Utilimaster. It is shared with your Door roller 4. Lubricate with a light oil (Utilimaster P/N 04202540). company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 71: Spring

    9. Cycle door to check operation. the furnishing, performance, or use of this 10. Adjust again if necessary. material. 11. Lubricate with a light oil (Utilimaster P/N 04202540). Utilimaster expressly disclaims all respon- sibility and liability for the installation, use, performance, maintenance, and support of third-party products.
  • Page 72 Chalk mark Cable Drum This material is confidential and the prop- erty of Utilimaster. It is shared with your Support Bracket company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 73 7. Remove spring and set aside. This material is confidential and the prop- Installation erty of Utilimaster. It is shared with your 1. Place spring into anchor brackets and secure with bolts, lock washers, and nuts. company for the sole purpose of helping you 2.

  • Page 74: Doors, W-Series Rear Roll-Up

    NOTE: The information in this document is generic. Images and procedures may differ Utilimaster makes no warranty of any kind from those for vehicles you are servicing. Because Utilimaster manufactures customized with regard to this material, including, but vehicle bodies, this document cannot list and illustrate every possible option for every not limited to, the implied warranties of vehicle.

  • Page 75: Adjustment

    4. Tighten nuts. This material is confidential and the prop- See Roll-up Door Maintenance. erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 76: No Part Of This Document May Be Photo-Removal

    2. Remove cables. This material is confidential and the prop- See Remove Cables. erty of Utilimaster. It is shared with your 3. Remove the nuts, washers, and bolts from stops located at the end company for the sole purpose of helping you of the track and set aside.
  • Page 77 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 78 This material is confidential and the prop- 2. Remove rivets in hinges. Insert a punch in one of erty of Utilimaster. It is shared with your the rivet holes to stabilize the panel while removing company for the sole purpose of helping you the remaining rivets.

  • Page 79: Panels

    This material is confidential and the prop- 3. Install rollers. erty of Utilimaster. It is shared with your See Install Rollers. company for the sole purpose of helping you 4. Secure hinges with rivets.

  • Page 80: Rollers

    3. Replace the retainer and tighten the nuts. This material is confidential and the prop- 4. Lubricate with a light oil (Utilimaster P/N 04202540). erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 81 2. Remove the Phillips head screws from the threshold seal. This material is confidential and the prop- 3. Remove seal and discard. erty of Utilimaster. It is shared with your company for the sole purpose of helping you Threshold Seal Installation with the operation of the described equip- 1.

  • Page 82: Springs

    9. Cycle door to check operation. the furnishing, performance, or use of this 10. Adjust again if necessary. material. 11. Lubricate with a light oil (Utilimaster P/N 04202540). Utilimaster expressly disclaims all respon- sibility and liability for the installation, use, performance, maintenance, and support of third-party products.
  • Page 83 Chalk mark Cable Drum This material is confidential and the prop- erty of Utilimaster. It is shared with your Support Bracket company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 84 7. Remove spring and set aside. This material is confidential and the prop- Installation erty of Utilimaster. It is shared with your 1. Place spring into anchor brackets and secure with bolts, lock washers, and nuts. company for the sole purpose of helping you 2.

  • Page 85: Utilimaster Corporation Attempts To Provide Engine Cover

    This material is confidential and the prop- Engine cover Gasket erty of Utilimaster. It is shared with your company for the sole purpose of helping you Removal with the operation of the described equip- 1. Remove engine cover.

  • Page 86: Fenders

    NOTE: On driver's side, remove mirror head before removing front quarter fender. See Remove Mirrors. This material is confidential and the prop- erty of Utilimaster. It is shared with your 1. Remove front fender cladding. company for the sole purpose of helping you See Remove Front Fender Cladding.
  • Page 87 NOT have preapplied thread lock, apply a medium-grade liquid thread lock. This material is confidential and the prop- erty of Utilimaster. It is shared with your 1. Secure two M6 screws on outside of headlight company for the sole purpose of helping you bezel.

  • Page 88: Front Wheel Liner

    Screw locations in wheel liner See Cladding, Sidewall. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 89: Fire Extinguisher

    3. Remove bracket and set aside. This material is confidential and the prop- Installation Fire extinguisher erty of Utilimaster. It is shared with your 1. Secure the bracket with two M6 screws. company for the sole purpose of helping you 2. Torque to 7–8 ft•lbs.

  • Page 90: Fuel Sending Unit Access Panel

    This material is confidential and the prop- CAUTION: Place a wood block underneath the pry bar to prevent damage to the floor. erty of Utilimaster. It is shared with your company for the sole purpose of helping you 1. Remove floor mat from around access panel in the center of floor at the rear of the wheel well.
  • Page 91 This material is confidential and the prop- pressing firmly. erty of Utilimaster. It is shared with your company for the sole purpose of helping you 4. Place the plunger into the back of the cartridge.

  • Page 92: Glass

    CAUTION: A properly bonded windshield is critical to the structural integrity of the vehicle. ter reserves the right to amend the informa- Utilimaster recommends that professional automotive glass specialists replace the windshield and tion in this document at any time without windows.

  • Page 93: Not Limited To, The Implied Warranties Of

    Utilimas- Driver’s Side Quarter Window Glass Tool Kit (P/N 23003395SK) ter reserves the right to amend the informa- The Utilimaster driver's side quarter glass replacement tool kit consists of: tion in this document at any time without •...

  • Page 94: Windshield Removal

    3. Remove wiper arms. This material is confidential and the prop- See Remove Wiper Arms. erty of Utilimaster. It is shared with your 4. Remove six M4 screws from the top of leaf screen. company for the sole purpose of helping you 5.

  • Page 95: Merchantability And Fitness For A Particular

    This material is confidential and the prop- cutter may be required to remove the urethane sealant that is closer to the body of the vehicle. erty of Utilimaster. It is shared with your 6. Remove quarter glass and discard. company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 96: Errors Contained Herein Or For Incidental Or

    This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 97 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- Spacer placement for quarter glass ment.

  • Page 98: Consequential Damages In Connection With

    This material is confidential and the prop- NOTE: Recommended minimum thickness of adhesive layer after installation is 1/4". erty of Utilimaster. It is shared with your 1. Install glass onto vehicle and align to correct company for the sole purpose of helping you position using the support blocks.

  • Page 99: The Furnishing, Performance, Or Use Of This

    This material is confidential and the prop- NOTE: Recommended minimum thickness of adhesive layer after installation is 1/4". erty of Utilimaster. It is shared with your company for the sole purpose of helping you 1. Install glass onto frame. with the operation of the described equip- 2.

  • Page 100: Grille

    See Remove Pine-Tree Fasteners. This material is confidential and the prop- 3. Set grille aside. erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 101: Utilimaster Expressly Disclaims All Respon

    See Remove Grille. This material is confidential and the prop- 3. Remove pine-tree fasteners. erty of Utilimaster. It is shared with your See Remove Pine-Tree Fasteners. company for the sole purpose of helping you Installation with the operation of the described equip- 1.

  • Page 102: Handrail And Grab Handles

    2. Secure grab handle to A-pillar with four M6 screws. This material is confidential and the prop- 3. Torque to 7–8 ft•lbs. erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 103: Handrail

    See Remove Fire Extinguisher. This material is confidential and the prop- 3. Remove washer bottle panel. erty of Utilimaster. It is shared with your See Remove Washer Bottle Panel. company for the sole purpose of helping you 4. Remove front wheel liner.

  • Page 104: Heater

    This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 105: Blower Motor

    1/4" drive shallow socket will make the process easier. mation available at the time of publication. However, because of the Utilimaster policy WARNING: Utilimaster recommends the only a licensed/certified automotive technician services the of continual product improvement, Utilimas- vehicle's air-conditioning system.
  • Page 106 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 107 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- P-clamps ment.
  • Page 108 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- Pull wires and convoluted tubing out separately.
  • Page 109 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 110 This material is confidential and the prop- Nuts that secure motor to housing erty of Utilimaster. It is shared with your 14. Use a screwdriver to disconnect blower harness. company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 111 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 112 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 113 This material is confidential and the prop- Blower motor grommet erty of Utilimaster. It is shared with your company for the sole purpose of helping you 8. Secure top cover of blower housing with six #10 x 1/2" screws.
  • Page 114 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you Screw on left-hand side of blower motor support bracket with the operation of the described equip- 11.
  • Page 115 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 116: Condenser

    The condenser is located on the passenger side of the vehicle behind the bumper fascia. useful. All information contained in this WARNING: Utilimaster recommends that only a licensed/certified automotive technician services the manual is based on the latest product infor- vehicle's air-conditioning system.

  • Page 117: Control Module

    2. Remove two 8/32" nuts. prior notice. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 118: Dryer

    Dryer Utilimaster expressly disclaims all respon- WARNING: Utilimaster recommends that only a licensed/certified automotive technician services the vehicle's air-conditioning system. sibility and liability for the installation, use, performance, maintenance, and support of Dryer Removal third-party products.
  • Page 119 2. Remove two bolts from expansion valve and discard valve. This material is confidential and the prop- Expansion Valve Installation erty of Utilimaster. It is shared with your 1. Lubricate new O-rings with mineral oil and install on company for the sole purpose of helping you expansion valve.
  • Page 120 2. Secure switch by turning clockwise. 3. Connect wire harness. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 121: Evaporator

    NOTE: 1/4" drive ratchet with magnetic sockets will make the process easier. manual is based on the latest product infor- mation available at the time of publication. WARNING: Utilimaster recommends that only a licensed/certified automotive technician services the However, because of the Utilimaster policy vehicle's air-conditioning system.
  • Page 122 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you Screws on evaporator assembly with the operation of the described equip- NOTE: Before removing the capillary tube, identify location for proper reinstallation.
  • Page 123 This material is confidential and the prop- erty of Utilimaster. It is shared with your Top seal plate removed company for the sole purpose of helping you 7. Remove air-conditioning hoses.
  • Page 124 This material is confidential and the prop- 10. Remove foam seal from inside evaporator assembly at seal plate. erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 125 This material is confidential and the prop- Evaporator coil erty of Utilimaster. It is shared with your company for the sole purpose of helping you Installation with the operation of the described equip- 1.
  • Page 126 4. Move foam seal to back side of the evaporator case bracket. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 127 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- Foam seal ment.
  • Page 128 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you Capillary tube with the operation of the described equip- ment.
  • Page 129 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 130: Heater Core

    NOTE: 5/16" drive ratchet with magnetic sockets will make the process easier. tion in this document at any time without prior notice. WARNING: Utilimaster recommends that only a licensed/certified automotive technician services the This material is confidential and the prop- vehicle's air-conditioning system.
  • Page 131 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 132 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 133 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 134: Heater Valve

    This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you Heater hoses with the operation of the described equip- 5.
  • Page 135 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- Air intake ment.
  • Page 136 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 137: Information That Is Accurate, Complete, And Hoses

    Dryer prior notice. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 138: Useful. All Information Contained In This

    1. Remove the wire harness by pressing the tab on the top of the servo motor. This material is confidential and the prop- 2. Remove three 8/32" locknuts. erty of Utilimaster. It is shared with your 3. Pull motor off mounting studs and set aside. company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 139 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 140: Resistor

    This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 141 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 142: Thermostat

    This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 143: However, Because Of The Utilimaster Policy

    3. Raise hood and support with prop rod. prior notice. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 144: Removal

    This material is confidential and the prop- Removal erty of Utilimaster. It is shared with your company for the sole purpose of helping you CAUTION: Discard ALL used fasteners and replace with new. If using a fastener that does NOT have with the operation of the described equip- preapplied thread lock, apply a medium-grade liquid thread lock.

  • Page 145: Installation

    See Adjust Hood. This material is confidential and the prop- 5. Torque to 17–21 ft•lbs. erty of Utilimaster. It is shared with your HOOD HINGE company for the sole purpose of helping you with the operation of the described equip-...

  • Page 146: Assembly

    This material is confidential and the prop- Hood hinge bracket erty of Utilimaster. It is shared with your company for the sole purpose of helping you 6. Remove two M6 bolts in hood catch. with the operation of the described equip- 7.

  • Page 147: Company For The Sole Purpose Of Helping You

    This material is confidential and the prop- 3. Remove two M6 bolts through access holes. erty of Utilimaster. It is shared with your NOTE: For installation of latch, note location and quantity of washers to ensure proper company for the sole purpose of helping you alignment for installation.
  • Page 148 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you Latch release Cable guide with the operation of the described equip- 2.

  • Page 149: Hood Cable

    See Remove Grille. This material is confidential and the prop- 3. Remove hood latch. erty of Utilimaster. It is shared with your See Remove Hood Latch. company for the sole purpose of helping you 4. Remove cable from securement clamps.
  • Page 150 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 151: With The Operation Of The Described Equip

    This material is confidential and the prop- separate the light from the grommet. To remove all other erty of Utilimaster. It is shared with your lights, push light out through front of grommet. company for the sole purpose of helping you...
  • Page 152 This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you Headlight adjustment wheels with the operation of the described equip- 9.
  • Page 153 4. Remove two M4 screws in headlight bezel and set bezel aside. This material is confidential and the prop- 5. Disconnect wire harness. erty of Utilimaster. It is shared with your 6. Remove four M8 bolts and set headlight aside. company for the sole purpose of helping you...
  • Page 154 2. Disconnect wire harness. This material is confidential and the prop- 3. Remove rubber cover by pulling on the tabs. erty of Utilimaster. It is shared with your 4. Release spring securing headlight bulb. company for the sole purpose of helping you 5.

  • Page 155: Not Limited To, The Implied Warranties Of

    Parking light socket 3. Secure the socket by turning clockwise. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- Switches, Convenience Panel ment.

  • Page 156: Merchantability And Fitness For A Particular

    1. Turn off ignition and all lights. This material is confidential and the prop- 2. Secure with three Phillips head screws erty of Utilimaster. It is shared with your 3. Plug in wire harness. company for the sole purpose of helping you with the operation of the described equip- 4.

  • Page 157: Mirrors

    Some exterior mirrors are convex. A erty of Utilimaster. It is shared with your convex mirror’s surface is curved to increase the visible area, but use these mirrors with care, especially company for the sole purpose of helping you when changing lanes and backing up.

  • Page 158: Installation

    This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 159: Rear Vision System

    This material is confidential and the prop- 1. Clean camera lens if necessary. erty of Utilimaster. It is shared with your 2. Place the camera in the back side of the header with the flat side company for the sole purpose of helping you of the camera at 12 o'clock position.

  • Page 160: Performance, Maintenance, And Support Of Seat

    2. Remove cable from gas strut release arm. This material is confidential and the prop- 3. Remove two screws from lever mounting bracket. erty of Utilimaster. It is shared with your Remove lever and cable and discard. company for the sole purpose of helping you...

  • Page 161: To Make Their Independent Evaluation Of Such

    2. Secure spring to seat with bolt, washer and nut. prior notice. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 162: Seat Belt

    Web cut, frayed, or • Significant dirt. worn at latch area erty of Utilimaster. It is shared with your • Damage to the buckle, latch plate, retractor, or hardware. company for the sole purpose of helping you with the operation of the described equip- ment.
  • Page 163 This material is confidential and the prop- 1. Remove 7/16-20 nut and bolt from buckle and discard buckle. erty of Utilimaster. It is shared with your 2. Remove cover from retractor and remove 7/16-20 nut and bolt. company for the sole purpose of helping you 3.

  • Page 164: Stereo

    3. Remove four #8 Phillips head screws from convenience panel. This material is confidential and the prop- erty of Utilimaster. It is shared with your 4. Tilt convenience panel forward, remove radio from retaining clips, and set radio aside. Convenience panel...

  • Page 165: Swell Latches

    NOTE: Swell latches can be adjusted by This material is confidential and the prop- tightening or loosening the acorn nut. erty of Utilimaster. It is shared with your 1. Push door in tight and secure swell latch. company for the sole purpose of helping you...

  • Page 166: Utilimaster Corporation Attempts To Provide Wiper System

    3. Set wiper arm aside. This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 167: Useful. All Information Contained In This

    This material is confidential and the prop- 4. Remove washer fluid hose from pump. erty of Utilimaster. It is shared with your NOTE: The pump can be pulled out from the back of the company for the sole purpose of helping you bottle.

  • Page 168: Linkage Assembly

    3. Remove M20 nuts and washers from pivot arms. Keep for reinstallation. This material is confidential and the prop- erty of Utilimaster. It is shared with your 4. Remove four M6 bolts from wiper mount brackets. company for the sole purpose of helping you 5.
  • Page 169 4. Torque to 7–8 ft•lbs. 5. Secure pivot arm with washers and M20 nuts. This material is confidential and the prop- erty of Utilimaster. It is shared with your 6. Torque 13–16 ft•lbs. company for the sole purpose of helping you 7.

  • Page 170: Motor

    This material is confidential and the prop- erty of Utilimaster. It is shared with your company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 171: Tools, Fasteners, And Adhesive Tapes

    3/16” bit, and the F-bit in place of the This material is confidential and the prop- 1/4” bit, for more clearance when inserting the fasteners. erty of Utilimaster. It is shared with your • Torque wrenches (any quality sets with in•lb, ft•lb, or [ N•m]...

  • Page 172: Fastener Replacement

    This material is confidential and the prop- erty of Utilimaster. It is shared with your Blind Rivet company for the sole purpose of helping you...

  • Page 173: Erty Of Utilimaster. It Is Shared With Your

    This depends upon application and should be material. approved by Utilimaster Customer Service. If it is to be replaced with a nut and bolt, it is important to use flat washers on both sides of the material.

  • Page 174: Pine-Tree Fastener

    Use a rubber mallet to install the pine-tree fastener. prior notice. This material is confidential and the prop- erty of Utilimaster. It is shared with your Pin-and-Collar Fastener (Magna-Grip ® company for the sole purpose of helping you...

  • Page 175: Not Limited To, The Implied Warranties Of

    Removal This material is confidential and the prop- Peel or scrape off. erty of Utilimaster. It is shared with your Installation company for the sole purpose of helping you Use a fresh roll to adjoining surfaces. with the operation of the described equip- NOTE: Vinyl tape rolls can be ordered with the following part numbers: ment.

  • Page 176: Sealant

    Overview ter reserves the right to amend the informa- The one-compound polyurethane sealants Utilimaster uses remain permanently elastic (less cracking tion in this document at any time without due to shrinkage), can be painted, and require no mixing. They bond as well as seal, thus reducing the number of mechanical fasteners needed and reduce noise and corrosion.

  • Page 177: Towing The Vehicle

    Using a Lowboy Trailer to make their independent evaluation of such Because the height of the Reach is not typically suitable for a standard flatbed trailer or rollback truck, a products. lowboy trailer is the preferred method for moving the vehicle.

  • Page 178: Third-Party Products. Customers Are Advised

    Flat towing the Reach is NOT recommended; however, if the circumstance requires it, use a chain and purpose. Utilimaster shall not be liable for space bar specifically designed for this purpose. Do NOT tow for more than one mile at a maximum speed of 30 MPH.

  • Page 179: Maintenance Information

    Avoid breathing AC refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose, merchantability and fitness for a particular and throat. Utilimaster recommends that a licensed automotive air-conditioning specialist work purpose. Utilimaster shall not be liable for on the vehicle’s air-conditioning system.

  • Page 180: Cleaning

    Wipe interior surfaces with a clean, damp cloth using only a mild soap and water. This material is confidential and the prop- Clean debris from screen covering the heater air intake. erty of Utilimaster. It is shared with your Body Exterior company for the sole purpose of helping you...

  • Page 181: Engine And Heater Coolant

    This material is confidential and the prop- erty of Utilimaster. It is shared with your Use a mild soap or detergent and a clean sponge or soft cloth to wash the LEXAN window. Rinse well with clean water.

  • Page 182: Lubrication

    Maintenance Checklist tion in this document at any time without By design, the Utilimaster body is low maintenance. However, Utilimaster recommends the items on prior notice. the following pages should be checked every three to four months, unless otherwise stated.

  • Page 183: Doors, General

    This material is confidential and the prop- Check latch and catch alignment edges. erty of Utilimaster. It is shared with your ❑ Check operation of the windows. company for the sole purpose of helping you with the operation of the described equip- ment.

  • Page 184: With The Operation Of The Described Equip

    Lubrication points on rear roll-up door third-party products. Customers are advised to make their independent evaluation of such Lubricate the following rear roll-up door parts with a light oil (Utilimaster P/N 04202540, or products. equivalent). • ❑ Roller drums and shafts—wipe off excess oil (#1, #3).

  • Page 185: Driver Conveniences

    • ❑ Check tightness of the mirror mounting bolts. This material is confidential and the prop- • ❑ Check that mirror arms securely lock into detents. erty of Utilimaster. It is shared with your Reflective Tape company for the sole purpose of helping you • ❑ Check that all reflective tape is securely attached.

  • Page 186: Ordering Parts

    Ordering Parts information that is accurate, complete, and Utilimaster has an electronic parts catalog and ordering system that will save your team time and money useful. All information contained in this by providing 24-hour access to vehicle parts and the OEM bill of material.

  • Page 187: Customizable Parts Order Form

    Customizable Parts Order Form information that is accurate, complete, and You can also download a customizable form template file from the Utilimaster web site useful. All information contained in this http://parts.utilimaster.com. The template has a header that you can customize with your name and manual is based on the latest product infor- address.
  • Page 188 Preferred Shipper 574-862-7637 (Carrier and Service Priority) Purchase Order # Credit Card # Authorized Signature Exp. Date: Vehicle Year Utilimaster Body S/N or Chassis VIN Vehicle Model Order Quantity Part Description Comments (Optional) Part Number Item No Utilimaster Customer Service 800-237-7806 (or 574-862-3219)

  • Page 189: Reporting Safety Defects

    However, NHTSA cannot ter reserves the right to amend the informa- become involved in individual problems between you and your dealer, or Utilimaster. tion in this document at any time without prior notice.

  • Page 190: More Information And Publications

    Click on the Technical Manuals button to access the download page. To view the files, you must have the Adobe Acrobat Reader version 4.0 or higher mation available at the time of publication.

  • Page 191: Contacting Utilimaster

    Utilimaster Corporation attempts to provide Contacting Utilimaster information that is accurate, complete, and Browse our web site for more information about Utilimaster and its products, or contact Utilimaster useful. All information contained in this Customer Service by using one of the following methods: manual is based on the latest product infor- •...
  • Page 192 Dryer 118 Sidewall 29 This material is confidential and the prop- Evaporator 121 Cleaning erty of Utilimaster. It is shared with your Safety 179 General tips 179 company for the sole purpose of helping you Servo motor 138 Interior 180...
  • Page 193 Fenders 86 Installation 47 This material is confidential and the prop- Fiberglass repair 14 Seals 60 erty of Utilimaster. It is shared with your Fire extinguisher 89 Threshold 62 company for the sole purpose of helping you Forklift 9 Window, slider 63...
  • Page 194 Hood 185 Cable 149 This material is confidential and the prop- Lubrication 182 Disassembly 145 erty of Utilimaster. It is shared with your Mirrors 185 Installation 145 company for the sole purpose of helping you Reflective tape 185 Latch 147...
  • Page 195 Rear roll-up door 71, 82 This material is confidential and the prop- Pine-tree fastener 174 Stereo 164 erty of Utilimaster. It is shared with your Power steering fluid 10 Swell latches 165 company for the sole purpose of helping you...
  • Page 196 Windows Cab 10 This material is confidential and the prop- LEXAN cleaning 181 erty of Utilimaster. It is shared with your Quarter glass 95 company for the sole purpose of helping you Safety glass 180 Slider 63 with the operation of the described equip- Tempered 180 ment.

  • Page 197: Revision Control

    This material is confidential and the property of Utilimaster. It is shared with your company for the sole ment.
  • Page 198 Utilimaster. Utilimaster Corporation attempts to provide information that is accurate, complete, and Part Number: 03103361-VY12EN Utilimaster Corporation, 65528 State Road 19, P.O. Box 585, Wakarusa, Indiana 46573-0585 USA © E-mail: custsvc@utilimaster.com Reach—Body Service Manual...

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