Related Manuals for Morgan Olson 2016-2018 USPS 2 Ton
Summary of Contents for Morgan Olson 2016-2018 USPS 2 Ton
- Page 1 UNITED STATES POSTAL SERVICE 2- TON DELIVERY TRUCK SERVICE MAINTENANCE MANUAL 1801 S. Nottawa Street Sturgis, MI 49091 Phone 800-233-4823 Fax (616-659-0499) www.morganolson.com www.morganolsonparts.com P/N 43004536...
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Page 2: Table Of Contents
This catalog has been prepared to assist the U.S.P.S. In the maintenance of the Bulkhead Door Morgan Olson 2-Ton delivery truck. Inquiries on items found or not found in this manual may be made through the address and or phone numbers listed below. -
Page 3: Body Tie/Downs
Side Door Body Tie/Downs Tie/Down Check: Side Door 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. For smooth operation the locking mechanism should be oiled every 3 months or as needed. Both sets of fasteners are torqued to specifications. -
Page 4: Side Doors
Side Door Removal: Side Door Installation: 1. Remove screws fastening down the lower door track but leave the track in position. 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. - Page 5 Side Door Adjustment: 1. Loosen all nuts on the top of the slotted upper door track. 2. Loosen the 3 screws fastening down the lower door track. 3. The rear holes of the lower door track are oversized to allow for adjustment. Only the rear portion of the track can be adjusted.
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Page 6: Rear Door
Rear Door Bulkhead Door Rear Roll-Up Door: Bulkhead Door: 1. Apply oil to the roller shafts and locking mechanism every 6 months. *NOTE: Where grease is required use a lithium based. 2. Perform a visual inspection daily checking the lifting mechanism cables and the door strap 1. - Page 7 ROLL UP DOOR Rear Door RoLL-uP dooR seRiAL NumbeR LocAtioN WheN oRdeRiNg PARts foR RoLL-uP dooRs, PLeAse PRovide the foLLoWiNg iNfoRmAtioN. ITEM# PART# DESCRIPTION the seRiAL NumbeR LocAted oN the iNteRioR toP PANeL RoAdside edge. 47106737 beARiNg AssembLy the LeNgth ANd height of the dooR PANeL(s) to be oRdeRed. 47106738 side seAL sNAP-iN styLe 75.5”...
- Page 8 ROLL UP DOOR ROLL UP DOOR ITEM# PART# DESCRIPTION 47106701 Lift hANdLe - White 47106703 cAbLe ANchoR bRAcket - White 47106706 1/4” x 1” cAbLe ANchoR PiN 47106719 3/32” x 1” cotteR PiN 47106709 best cyLiNdeR Lock ANd modified RiNg 6.25mm 47106722 1/4”-20 x 1”...
- Page 9 ROLL UP DOOR ROLL UP DOOR ITEM# PART# DESCRIPTION 47106700 RoLLeR hiNge coveR 47106702 cAbLe Assy. 29.75” With (2) stoPs & WAsheR (eAch) 2 47106704 RoLLeR cLAmP, 3 hoLe RoLLeR cLAmP foR 1” RoLLeRs 47106705 3 stud bottom fixtuRe AssembLy -comPLete 47106707 1”...
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Page 10: Gas Spring
2. With the power to the motor off, disconnect the motor leads. 2. For safety reasons, when replacing the gas springs use only Morgan Olson OEM replace- 3. Remove motor mounting screws. Remove the motor and the impeller wheel. - Page 11 BLOWER CONTROL The BLOWER CONTROL provides three choices of air velocity in every operat- ing mode. When the blower switch knob is rotated fully counterclockwise (with the knob indicator pointing straight up) the blower is turned OFF.
- Page 12 , Blower operates, but not in all blower switch settings POSSIBLE CAUSE #1 ~ Blower resistor failure. CORRECTIVE ACTION ~ If the blower operates only on the highest blower speed (blower switch rotated fully clock- wise), the blower resistor has, most likely, failed. [Hint: The resistor is bypassed when the highest blower speed is select- ed.] Refer to the Blower Motor Resistor -wire connector from the resistor.
- Page 13 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 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.
- Page 14 POSSIBLE CAUSE #3 ~ Control Panel Selector Switch is defective , A/C system not providing cool air CORRECTIVE ACTION ~ With the ignition turned to Accessory, unplug each of the connectors from the Plenum servo POSSIBLE CAUSE #1 ~ Loss of refrigerant motors and test according to the information in the Electrical Connection To Plenum Servo Motors Diagram.
- Page 15 Consult the following Refrigerant System Evaluation chart (below) for a list of refrigerant related symptoms and their recommended resolution: USPS 2 Ton Delivery Vehicle 2016 - 2018 Models Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
- Page 16 ITEM # PART # DESCRIPTION UNIT 555001107 heAteR coRe AssembLy 47008760 heAteR coiL W/gAsket & cLAmP 47008753 dooR W/seAL 47008754 bLoWeR housiNg 47008755 bLoWeR AdAPteR 47008732 ResisteR cAge 47008357 ResisteR 47008756 bLoWeR motoR 47008757 bLoWeR WheeL 47008730 veNt tube 47008731 veNt tube AdAPteR 47008716 ReLAy...
- Page 17 HOOD LAMPS Headlight Replacement: Hood Removal: 1. Remove screws and trim from around headlight. 1. For removal of the gas springs. See page 14. 2. Remove headlight. 2. Disconnect wire harness plug connections. 3. Remove the 4 bolts tying the left and right hinge assemblies to the body of the truck. 3.
- Page 18 BODY PANEL REPLACEMENTS & RIVETS WINDSHIELD REPLACEMENT Body Panel Replacement: Windshield Removal: 1. Special tools are required for windshield removal. Glass and Bead Tools. 1. When replacing exterior body panels, remove rivets following procedures outlined below. 2. A soap and water solution should be applied around the rubber seal. This will allow the 2.
- Page 19 LIFT-GATE WINDSHIELD WIPERS & MOTOR If anyone observes improper installation, improper operation, or damage, they should immediately Windshield Wipers and Wiper Drive Assembly: contact a qualified person for assistance and correction. We strongly urge anyone that has any questions or 1.
- Page 20 SAFETY INFORMATION SAFETY INFORMATION WARNING WARNING Read, understand, and follow all of the warning listed below. Lift-gates with Tilt Function Failure to follow these warning could result in severe personal injury or death. • Proper use of the Control Switches is of extreme importance. •...
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Page 21: Troubleshooting
WALTCO Warranty Policy Chapter 2 Liftgate Terminology TERMINOLOGY WALTCO warrants its products free of defects in materials and workmanship. WALTCO will replace components found defective during the warranty period. Labor will be 1. Travel Plate (Drop - In Design) 9. Latch reimbursed according to our flat rate labor schedule at the prevailing shop rate. - Page 22 Chapter 2 Liftgate Terminology Chapter 3 Operation Instructions Explanation of Specification Tag TO OPEN PLATFORM Drop-In Design Manual Close Model Name Description Capacity MDL-10 Medium Duty Lift 1000 lbs. Use switch to raise platform up out of travel plates. Pull platform open to horizontal position. Never force platform open.
- Page 23 PREVENTIVE MAINTENANCE OPERATION INSTRUCTIONS Chapter 3 Operation Instructions Chapter 4 Preventive Maintenance Waltco recommends that the MDL Series liftgate be inspected at 6 month or 3000 cycle intervals LOADING OF PLATFORM to help assure proper function and operation of the liftgate. Load and unload from rear of platform and not side of Note: Photocopy the following PM Checklist to help keep track of periodic maintenance on the liftgate.
- Page 24 PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE PLATFORM ADJUSTMENT MONTHLY INSPECTION Unfold and raise platform to bed level and check for: Operate the lift-gate throughout its entire opera- If platform travels more than ¼” above the tional cycle. Check for: top of the crossbeam box, and lift-gate is not •...
- Page 25 PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE Chapter 4 Preventive Maintenance Chapter 4 Preventive Maintenance There is no speed adjustment on this liftgate. HYDRAULICS Lowering speed is controlled by the pressure Inspect for oil leaks in: compensative valve plumbed at the cylinder. Hydraulic cylinder(s) Regardless of weight on platform, liftgate should lower at approximately six (6) inches Hydraulic hoses - Replace hoses if they...
- Page 26 PLACEMENT OF DECALS PLACEMENT OF DECALS All decals must be in place and legible or all warranties are void. ITEM DECAL QTY PART NO LOCATION Safety Instructions 80100850 Operation Decals (See Owners Manual for Details) Snap Lock / Manual 80101575 Drop-In Manual 80101577 Drop-In / Power Close...
- Page 27 LUBRICATION INSTRUCTIONS SCHEMATIC Lubricate lifting chains including sections in Suggested Minimum Lubrication Schedule (days) crossbeam box, rails, & runner assemblies Monthly Light Medium Heavy with machine oil or motor oil. Cycles Duty Duty Duty <250 Lubricate latch, inside rails, crossbeam box, 250-350 and platform hinges with machine oil or mo- 350-400...
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Page 28: Lamps
HYDRAULIC PUMP UNIT MAIN FRAME ASSEMBLY ITEM PART NUMBER DESCRIPTION 70430695 hydraulic Pump unit, 14” reservoir Non-thermal switch 70092312 motor, 12v ITEM PART NUMBER DESCRIPTION 43016835 Reservoir, 14” 43020013 Sprocket, 13T, #50 Chain, MDL-12, 16, 20 70092355 Relief valve 80001065 motor solenoid 43120213 Kit, 13T Sprocket, #50 Chain, MDL-12, 16, 20... - Page 29 PLATFORM ASSEMBLY RUNNER ASSEMBLY ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 91371350 Runner Assembly, MDL-10, C/S 91371110 ENTIRE PLATFORM ASSEMBLY 91371355 Runner Assembly, MDL-10, D/S 27813982 HINGE ROD 43016696 Alum Ext Runner, Forked, 4x30.5 C/S 27813983 PIN, CRUSHED ENDS 43116695 Alum Ext Runner, Forked, 4x30.5 D/S 27813985...
- Page 30 CYLINDER ASSEMBLY DECK ASSEMBLY ITEM PART NUMBER DESCRIPTION ITEM PART NUMBER DESCRIPTION 90995801 Cylinder Assembly Complete, MDL-10 91371110 DECK Assembly, 36 X 82, MOOD FLAP 90995850 Cylinder Assembly, MDL-10 43120213 SUPPORT CHAIN, 30” DP 28 LINKS 43020013 Sprocket, 13T, #50 Chain 43012382 COVER, SUPPORT CHAIN, 30”...
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Page 31: Lift-Gate
Repairs should be made only by authorized mechanics using WALTCO Replace- Every vehicle that has a WALTCO Lift gate must have legible WARNING AND OPERA- ment parts. TION DECALS clearly posted on the vehicle and an OWNER’S MANUAL in the vehicle at all times as a guide for proper operation and maintenance. -
Page 32: Back-Up Camera & Monitor
5" Color Backup Camera System........2 MORGAN OLSON Components List and Description . - Page 33 COMPONENT LIST AND DESCRIPTION 5” Color Monitor Backup Camera System User Manual MONITOR BUTTONS PART NO. DESCRIPTION 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.
- Page 34 BACK-UP CAMERA & MONITOR MENU SETTINGS SUMMARY NOTE: The monitor buttons do not function while the vehicle is in reverse. The settings can only be adjusted when the vehicle is running in park/neutral/drive. It is recommended that the buttons are ONLY used in park/neutral. MENU SETTINGS SCREEN 1: "MONITOR DIM MODE SETTINGS / MONITOR BRIGHT MODE SETTINGS"...
- Page 35 5” Color Monitor Backup Camera System User Manual 5” Color Monitor Backup Camera System User Manual MONITOR KIT INSTALLATION CAMERA KIT INSTALLATION MONITOR KIT INSTALL ATION CAMERA KIT INSTALL ATION fig 2 CAMERA LOCATION fig 2 CAMERA LOCATION • Select a high and centered location at the •...
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Page 36: Rear View Mirror Systems
BACK-UP CAMERA & MONITOR REAR VIEW MIRROR SYSTEM 5” Color Monitor Backup Camera System User Manual SYSTEM TECHNICAL SPECIFICATIONS: MORGAN OLSON STSM214 Monitor: (Includes STSM214/PHAR, STSA1004, STSU1004) Screen size (diagonal): 5" R E A R V I E W M I R R O R S Y S T E M Maximum No. - Page 37 Wear Component Replacement ..........5 MORGAN OLSON Rearview Mirror System - DRIVER MANUAL 6647RSSPH / 6647LSSPH Heated Mirror Replacement .
- Page 38 MORGAN OLSON Rearview Mirror System - DRIVER MANUAL 6647RSSPH / 6647LSSPH MORGAN OLSON Rearview Mirror System - DRIVER MANUAL 6647RSSPH / 6647LSSPH OPERATING HEATED MIRRORS WEAR COMPONENT REPL ACEMENT OPERATING HEATED MIRRORS WEAR COMPONENT REPLACEMENT During the life of the mirror assembly, the upper and lower locking...
- Page 39 MORGAN OLSON Rearview Mirror System - SERVICE MANUAL HEATED MIRROR REPLACEMENT Step lbs. Replace mirror heads when glass is broken, or when the heating diag element fails to heat the glass. The following steps apply to either a flat or convex mirror head.
- Page 40 6647RSSPH / 6647LSSPH Step 5: Tighten mirror head hardware on the clamp to 200 in. Morgan Olson Operator & Service Manual lbs. be sure that clamp location on the tube is correct per below for Keyless Entry Controller Diagnostics diagram:...
- Page 41 Operation Guide Trouble Shooting Guide Morgan Olson - 46029040 Morgan Olson - 46029040 Transmitters / Keyfobs Status & Diagnostic LEDs Cab Keyless Unlock Curbside Door Unlock Press and release the fob button. Green The curbside and roadside doors unlock. Power Reset Auto relocks in 6-seconds.
- Page 42 Trouble Shooting Guide Morgan Olson - 46029040 Trouble Shooting Guide Morgan Olson - 46029040 Sympton 3 Sympton 1 Poor range 0’ to 25’ (pulsating 0’ to 25’) No output from one or more outputs on receiver when transmitter buttons are pressed...
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Page 43: Vehicle Jacking Points
VEHICLE JACKING POINTS Limited Three (3) Year Warranty Section One Seller will warrant any product originally manufactured or assembled and sold by seller for a period of up to THREE YEARS. Section Two The following are in lieu of all warranties; expressed; implied; or statutory, including but not limited to, any implied warranty of merchantability of fitness for a particular purpose and of any other warranty obligation on the part of seller. - Page 44 SCHEDULED MAINTENANCE Scheduled Maintenance 2016 calendar year 6.8L-2V/3V engines will change to SAE 5W-20 engine oil from SAE GENERAL MAINTENANCE Genuine Ford and Motorcraft 5W-30 engine due to dynamometer certification requirements for 6.8L-3V engines. Replacement Parts INFORMATION Dealerships stock Ford, Motorcraft and FORD recommendation to the USPS is to follow OEM maintenance schedules outlined Why Maintain Your Vehicle? Ford-authorized branded re-manufactured...
- Page 45 Scheduled Maintenance Scheduled Maintenance Oils, Fluids and Flushing Ford Motor Company has recommended Check every six months maintenance intervals for various parts In many cases, fluid discoloration is a Hinges, latches and outside locks for proper operation. Lubricate if necessary. and component systems based upon normal operating characteristic and, by engineering testing.
- Page 46 Scheduled Maintenance Scheduled Maintenance Be sure to ask your dealership service your vehicle. Your checklist gives you Other maintenance items advisor or technician about the multi-point immediate feedback on the overall vehicle inspection. It is a comprehensive condition of your vehicle. Replace rear axle fluid.
- Page 47 Scheduled Maintenance Scheduled Maintenance SPECIAL OPERATING perform extra maintenance as indicated. Extensive idling or low-speed driving for long distances, as in heavy commercial use If you operate your vehicle occasionally CONDITIONS SCHEDULED (such as delivery, taxi, patrol car or livery) under any of these conditions, it is not MAINTENANCE necessary to perform the extra...
- Page 48 Scheduled Maintenance Hot climate oil change intervals: above 70°F (21°C) and at wide-open throttle for long periods above 45 mph (72 Vehicles operating in the Middle East, km/h), change non-synthetic rear axle fluid North Africa, Sub-Saharan Africa or every 3000 miles (4800 kilometers) or locations with similar climates using an three months, whichever comes first.
- Page 49 USPS 2 Ton Delivery Vehicle 2016 - 2018 Models Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
- Page 50 USPS 2 Ton Delivery Vehicle 2016 - 2018 Models Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
- Page 51 USPS 2 Ton Delivery Vehicle 2016 - 2018 Models Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
- Page 52 USPS 2 Ton Delivery Vehicle 2016 - 2018 Models Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
- Page 53 USPS 2 Ton Delivery Vehicle 2016 - 2018 Models Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
- Page 54 USPS 2 Ton Delivery Vehicle 2016 - 2018 Models Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
- Page 55 USPS 2 Ton Delivery Vehicle 2016 - 2018 Models Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
- Page 56 USPS 2 Ton Delivery Vehicle 2016 - 2018 Models Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
- Page 57 USPS 2 Ton Delivery Vehicle 2016 - 2018 Models Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com...
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