Morgan Olson Amazon P80 2019 User manual

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

2Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com
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

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2019 Amazon P80 Package Delivery Vehicle
Contents
CONTENTS 3
BODY TIE/DOWNS 4
DOORS
Side Doors Adjustments & Lubricaon 5-9
Bulkhead Door Adjustments & Lubricaon 10
Rear Door Adjustments & Lubricaon 11-21
GAS SPRING 22
HEATER
Motor, Fan & Plenum 23
Troubleshoong 24-29
HOOD 30
LAMPS 31
BODY PANEL REPLACEMENT AND RIVETS 32
WINDSHIELD
Windshield Removal and Installaon 33
WINDSHIELD WIPERS & MOTOR 34-35
360 CAMERA SYSTEMS 36-48
KEY-LESS ENTRY SYSTEM 49-50
ELECTRICAL WIRING DIAGRAMS 52-81
Caution:
Before beginning maintenance, park vehicle on level ground, apply parking brake, turn
all power off and secure keys/fobs. Read all instructions before starting maintenance.
Always maintain rm footing and control of tools. Follow your Company Safety policies
including LOTO (Lock out Tag out), PPE (Personal Protective Equipment) and any
other safety policies that apply.

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Body Tie/Downs
Tie/Down Check:
The oor of the truck is fastened to bolsters that extend the length of the oor.
The lower anges of the bolsters are mounted to the chassis frame rails.
Both sets of fasteners are torqued to specicaons.
All cab and body e/downs should be checked aer 3 months and annually.

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2019 Amazon P80 Package Delivery Vehicle
Side Door
Side Door
For smooth operaon 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 striker.
(At opened and closed posions.)
Lubricate latch internal mechanism.
Grease on the latch contact points.

6Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com
Side Door Removal:
1. Remove the an rale 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.
5. Holding the top of the door in posion, pull out on the boom front corner of the door
unl it clears the body of the truck. Then lt the top of the door down and out and re-
move the door.
6. The upper track is mounted to the header channel. Remove the nuts, and the track.
Reinstall by reversing the removal sequence.
Weather Seal Removal:
1. The forward and rear weather seals are installed 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 mounng screws. Pay special aenon
to spacer locaons. You can then remove the inside and outside handles. Remember
when installing the handles, posion of the spacers idencal to the way they were at
removal.
Wear Strip (Lower) Removal:
1. Remove side door.
2. Remove exisng rivets.
3. Replace wear strip and rivet in place.

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2019 Amazon P80 Package Delivery Vehicle
Side Door Installaon:
1. Tilt the top of the door in place rst. Now posion the boom of the door into the lower
door track, which is in posion but not fastened down.
2. Put 1/8” shims between the lower door track and the wear strip.
3. Mount door to the hanger assembly.
4. Install door handles. See page 6.
5. Mount grab handle forward of door. *Return mirror to previous posion.
6. For proper door adjustment see page 8.
Door Track and Hanger Plate removal without door removal.
1. Remove access cover located on upper rear corner of the door pocket.
2. Remove the the door hanger nuts and bolts, slide the door hanger plate to the rear of the
door pocket and remove.
3. Remove the door track nuts, lower the track away from the header channel and slide
towards the rear and out throught the access area.
4. Re-install in reverse order and follow the door installaon, steps 2 and 3, and adjustment
steps.

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Side Door Adjustment:
1. Loosen all nuts on the top of the sloed upper door track.
2. With the door closed and engaged in the forward 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.
3. With the door open and engaged in the rear strike, the rear poron of the upper track can
be adjusted laterally to ensure proper alignment with the rear striker.
4. When the door is posioned, ghten a few of the fasteners in the upper track. Operate
the sliding door to ensure that it slides and latches properly.
5. When the door is operang properly, ghten all the remaining fasteners in the upper
door tracks.
6. Replace any broken studs with .25 - 20x1.00 truss head screw.
7. Adjust An-Rale Clips as needed to reduce door vibraon.
8. See illustraon on the following page.
Door Latch Adjustment:
1. The door latches (strikers) and the mounng brackets provide for adjustment in a variety
of direcons.
2. Once the door has been adjusted to slide smoothly, then adjust the strikers for proper
latch operaon.
3. Adjust the strikers side to side to center the catch; Adjust up and down unl the catch is
almost boomed out; Adjust forward and a to control the amount of compression on
the rubber door seal.

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2019 Amazon P80 Package Delivery Vehicle

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Blank

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2019 Amazon P80 Package Delivery Vehicle
Bulkhead Door:
*NOTE: Where grease is required use a lithium based.
1. The latch should be greased to prevent scking. Grease should be applied at contact
points of the latch and striker for smooth operaon. This should be done every 3 months.
2. Lubricate hanger bearings and body of nger catch latch with penetrang oil; apply a light
lm of lithium grease to the striker.
3. Adjust boom guide to within 1/16” from boom of the channel.
Bulkhead Door

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Copyright © 2017 by Transglobal Inc.
1
225 NORTH PATTERSON ST.
CAREY, OH 43316
CUSTOMER SERVICE PHONE [phone]
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” in diameter and 15” long on Single Spring Assembly and one winding
bar that is 3/8” in diameter and 15” long on Dual Spring Assembly with TG-Winder. DO NOT USE bent
winding bars, screwdrivers or punches for spring winding.
Read all instructions before starting Preventive Maintenance Checklist. Always maintain firm
footing and control of tools.
Adjustments and repairs must be made by trained service personnel using proper tools and
instructions.
DO NOT use the rear door pull strap to support yourself when entering or exiting the rear.
The strap can break or pull the door down on you. Use the grab handles for aid getting in
and out of the rear.
Stand clear of the opening while the door is moving.
To prevent damage to the cargo or vehicle, be sure that the rear door is closed and latched
before driving the vehicle.
For more detailed instructional information on repairs and adjustments, see
Transglobal’s installation and repair manual.

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2019 Amazon P80 Package Delivery Vehicle
Copyright © 2017 by Transglobal Inc.
2
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. Doors on equipment operated in areas
where road salts are used will require lock lubrication at closer intervals. Do NOT use any petroleum-
based lubricant on rubber door seals.
TGS1000
ADVANTAGES
Long lasting, non-toxic, non-static, non-staining, non-conductive,
contains no petroleum distillates, no silicones, no acids,
no carcinogens, no halogens and no allergens. Will not dry out, or
wash off with water. Will not damage plastics, paints, metals,
fiberglass, enamels, or neoprene seals. No petroleum smell.
H- Registered for Food Processing Areas.
USES
Lubricate and protect locks, hinges, rollers, air tools, roll-up doors,
lift gates, springs, chains, and bearings. Cutting oil for drilling and
tapping. Penetrates and neutralizes rust on nuts, bolts, screws,
equipment and motors. Cleans corrosion and oxidation off battery terminals and metals.
(See for Lubrication points below.)

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Copyright © 2017 by Transglobal Inc.
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LUBRICATION OF END HINGES, 2-POINT CENTER CONTROL & END LATCHES
END HINGE
2-POINT END LATCH ASSEMBLY
2-POINT CENTER CONTROL ASSEMBLY

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2019 Amazon P80 Package Delivery Vehicle
Copyright © 2017 by Transglobal Inc.
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LUBRICATION OF TOP FIXTURE, CENTER HINGE & BOTTOM FIXTURE
TOP FIXTURE
CENTER HINGE
BOTTOM FIXTURE

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Copyright © 2017 by Transglobal Inc.
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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

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2019 Amazon P80 Package Delivery Vehicle
Copyright © 2017 by Transglobal Inc.
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DOOR OPERATION –PLEASE INSPECT THE FOLLWING:
1. Check to see if the door lock operates easily and latches tight, compressing the bottom seal.
2. Check to see if the door operates freely (up and down) with side play between the tracks and
door approximately ¼” to 3/8”.
3. Check for loose fasteners or other components.
4. Are the spacer washers installed at the 1st Intermediate hinge and the last intermediate hinge on
both sides? (4 required per roller by door design, but NO less than 3 per roller to keep the door
from contacting the track). (See Figure 1).
5. Are the side seals installed in a manner that the seal uniformly contacts the door but doesn’t bind
or impede the door operation?
6. Inspect Roll-up Door Side Seals for wear/damage and replace if needed.
7. Does the top seal contact the header at the ends well as the middle while keeping the top panel
in a vertical position? (See Figure 2).
8. Inspect Roll-up Door Top Seals for wear/damage and replace if needed.
9. Inspect Roll-up Door Pull Strap for fraying or wear damage and replace if needed. (See Figure 3).
10. On Roll-up Doors with 2-point latch system, Inspect Door Latch Cables for fraying or wear
damage and replace if needed.
FIGURE 1
ROLLERS
SPACER WASHERS

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Copyright © 2017 by Transglobal Inc.
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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.
FIGURE 2
TOP FIXTURE ASSEMBILY
REAR STRUCTURE TOP HEADER
VIEW OF INCORRECT
TOP PANEL SEAL
CONTACT TO HEADER
VIEW OF CORRECT
TOP PANEL SEAL
CONTACT TO HEADER
TOP PANEL SEAL

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2019 Amazon P80 Package Delivery Vehicle
Copyright © 2017 by Transglobal Inc.
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PULL STRAP
Failure to replace worn or frayed door pull strap may result in injury.
FIGURE 3
PULL STRAP (INSIDE MOUNT SHOWN)
PULL STRAP RETAINER

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Copyright © 2017 by Transglobal Inc.
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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 have uniform pull so the door doesn’t pull to one side or the other.
1. Does the door “balance” (neither rise nor fall) without assistance?
2. Are the cables (door in open position) nearly vertical from the cable anchor bracket
to the cable drum? The cables should NOT skip grooves or travel over another cable
on the drum.
3. Inspect Roll-up Door Cables for fraying or wear damage and replace if needed. (See Figure 4).
4. Inspect Cotter Pins and Cable Anchor Bracket Pins for wear damage and replace if needed.
(See Figure 4).
SINGLE SPRING –PLEASE INSPECT THE FOLLWING:
1. Are the cable drums tight against the counterbalance shaft bearings, the set screws
properly tightened, and both cables are tight and have equal tension?
(See Figure 5).
DUAL SPRING –PLEASE INSPECT THE FOLLWING:
1. Are both springs wound to the same number of turns?
FIGURE 4
CABLE ANCHOR BRACKET
CABLE
¼” x 1” CABLE
ANCHOR PIN
3/32” x 1”
COTTER PIN
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 y open buy itself. All spring systems are designed for both cables to
have uniform pull so the door doesn’t pull to one side or the other. Any required service to the
counterbalance, springs or cables, should only be performed by a qualied technition.
1. Does the door “balance” (neither rise nor fall) without assistance?
2. Are the cables (door in open position) nearly vertical from the cable anchor bracket to the
cable drum? The cables should NOT skip grooves or travel over another cable on the drum.
3. Inspect Roll-up Door Cables for fraying or wear damage. (See Figure 4).
4. Inspect Cotter Pins and Cable Anchor Bracket Pins for wear damage.
(See Figure 4).
SINGLE SPRING – PLEASE INSPECT THE FOLLWING:
1. Are the cable drums tight against the counterbalance shaft bearings, the set screws properly
tightened, and both cables are tight and have equal tension? (See Figure 5).
DUAL SPRING – PLEASE INSPECT THE FOLLWING:
1. Are both springs wound to the same number of turns?
Any required service to the counterbalance, springs or cables,
should only be performed by a qualied technition.