Morgan Olson 2016-2018 USPS 2 Ton User manual

1801 S. Nottawa Street
Sturgis, MI 49091
Phone [phone]
Fax [phone])
www.morganolson.com
www.morganolsonparts.com
UNITED STATES POSTAL SERVICE
2- TON DELIVERY TRUCK
SERVICE MAINTENANCE MANUAL
P/N 43004536

2Genuine OEM Parts 1.800.233.4823 www.morganolsonparts.com 3
USPS 2 Ton Delivery Vehicle 2016 - 2018 Models
CONFIDENTIAL NOT FOR DISTRIBUTION CONFIDENTIAL NOT FOR DISTRIBUTION
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NOTE: USE ONLY GENUINE MORGAN OLSON PARTS
USE OF NON OEM PARTS MAY VOID YOUR WARRANTY
AND/OR VIOLATE FMVSS STANDARDS
INTRODUCTION
This catalog has been prepared to assist the U.S.P.S. In the maintenance of the
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.
Morgan Olson
1801 S. Noawa
Sturgis, MI 49091
1-800-477-8287
(Customer Service/Fleet Warranty)
For Parts Ordering:
1-800-233-4823
1-616-659-0499 (Fax)
(Service Parts)
Contents
CONTENTS & INTRODUCTION 2-3
1. BODY TIE/DOWNS 4
2. DOORS
Side Doors 5-9
Bulkhead Door 10
Rear Door 11-17
3. GAS SPRING 18
4. HEATER
Motor, Fan & Plenum 19
Troubleshoong 20-31
5. HOOD 32
6. LAMPS 33
7. BODY PANEL REPLACEMENT AND RIVETS 34
8. WINDSHIELD
Windshield Removal and Installaon 35
9. WINDSHIELD WIPERS & MOTOR 36
10. LIFT-GATE 37-61
11. BACK-UP CAMERA & MONITOR 62-70
12. REAR VIEW MIRROR SYSTEMS 71-78
13. KEY-LESS ENTRY SYSTEM 79-84
14. VEHICLE JACKING POINTS 85
15. MAINTENANCE SCHEDULE (CHASSIS) 86-95
16. ELECTRICAL WIRING DIAGRAMS 96-115
Latest version of all documents available at;
www.morganolsonparts.com/t-usps_manuals.aspx
Access code: usps2016

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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.
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.)

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USPS 2 Ton Delivery Vehicle 2016 - 2018 Models
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Side Door Removal:
1. Remove screws fastening down the lower door track but leave the track in posion.
2. Remove the Phillips screws and door pocket cover plate located in the upper rear corner
of the door pocket.
3. Remove the 4 fasteners and the door handles (inner and outer).
4. Using a socket wrench, remove the bolts fastening the door and hanger assembly.
5. To simplify door removal, remove the grab handle located forward of the door.
*Fold side view mirror back.
6. 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.
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.
Door Track (Upper) Removal:
1. The upper track is mounted to the header channel. Remove the nuts, and the track. Rein-
stall by reversing the removal sequence.
Wear Strip (Lower) Removal:
1. Remove side door.
2. Remove exisng rivets.
3. Replace wear strip and rivet in place.
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 8.
5. Mount cover plate on upper rear door pocket.
6. Mount grab handle forward of door. *Re-adjust mirror.
7. For proper door adjustment see page 10.

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USPS 2 Ton Delivery Vehicle 2016 - 2018 Models
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Side Door Adjustment:
1. Loosen all nuts on the top of the sloed 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
poron of the track can be adjusted. The forward hole of the lower track is not oversized
because the door must retain its forward posion to ensure proper alignment when the
door is closed.
4. 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.
5. With the door open and engaged in the rear strike, the rear poron of the upper and low-
er tracks can be adjusted laterally to ensure proper alignment with the rear striker.
6. When the door is posioned, ghten a few of the fasteners in the upper and lower tracks.
Operate the sliding door to ensure that it slides and latches properly.
7. When the door is operang properly, ghten all the remaining fasteners in the upper and
lower door tracks.
8. Replace any broken studs with .25 - 20x1.00 truss head screw.
9See gure 1 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.

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USPS 2 Ton Delivery Vehicle 2016 - 2018 Models
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Rear Roll-Up Door:
1. Apply oil to the roller shas and locking mechanism every 6 months.
2. Perform a visual inspecon daily checking the liing mechanism cables and the door strap
for fraying.
3. Perform a visual inspecon monthly checking for damaged parts replace immediately to
prevent wear and fague on other components.
4. Refer to Trans global Door Company instrucons for proper rear door spring adjustment
and/or replacement.
Rear Door
Bulkhead Door:
*NOTE: Where grease is required use a lithium based.
1. The latch 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.
Bulkhead Door

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ROLL-UP DOOR SERIAL NUMBER LOCATION
WHEN ORDERING PARTS FOR ROLL-UP DOORS,
PLEASE PROVIDE THE FOLLOWING INFORMATION.
THE SERIAL NUMBER LOCATED ON THE INTERIOR TOP PANEL ROADSIDE EDGE.
THE LENGTH AND HEIGHT OF THE DOOR PANEL(S) TO BE ORDERED.
IN THE EVENT OF A DAMAGED, UN-READABLE OR MISSING SERIAL NUMBER,
PLEASE TRY TO PROVIDE THE COMPOSITION DETAILS OF THE DOOR PANEL.
(PLASTIC COATED, ALUMINUM CLAD, PLYWOOD, ETC.)
Rear Door
ITEM# PART# DESCRIPTION
1 47106737 BEARING ASSEMBLY
2 47106738 SIDE SEAL SNAP-IN STYLE 75.5”
3 47106739 1” HEAD PROTECTOR YELLOW
4 47106740 LOCK CATCH
5 47106741 LATCH GUARD ANGLE - LH (CS)
6 47106742 LATCH GUARD ANGLE - RH (RS)
7 47106743 5/16” X 1” HEX HEAD BOLT GRADE 5
8 47106744 5/16 KEP NUT
9 47106745 1/4 -20 X 1 3/4” HEX HEAD BOLT (25C175HCS5Z)
10 47106746 1/4” KEP NUT
11 47106747 VERTICAL TRACK ASSEMBLY - #47106270- CURBSIDE
12 47106748 VERTICAL TRACK ASSEMBLY - #47106270- ROADSIDE
13 47106749 HORIZONTAL TRACK ASSEMBLY- #47106270- CURBSIDE
14 47106750 HORIZONTAL TRACK ASSEMBLY- #47106271- ROADSIDE
Counterbalance Assembly
15 47106751 COUNTERBALANCE ASSEMBLY - #47106270
16 47106752 5/16” X 1” HEX HEAD BOLT GRADE 5
17 47106753 CABLE DRUM LH
18 47106754 CABLE DRUM RH
19 47106755 COUNTERBALANCE SHAFT - 68.75”
21 47106737 BEARING ASSEMBLY
17
5
10
4
6
2
11
8
7
1
13
9
3
10
14
12
2
4
10
16
18
21
19
15
3
ROLL UP DOOR

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ROLL UP DOOR ROLL UP DOOR
11
18
ITEM# PART# DESCRIPTION
1 47106701 LIFT HANDLE - WHITE
2 47106703 CABLE ANCHOR BRACKET - WHITE
3 47106706 1/4” X 1” CABLE ANCHOR PIN
4 47106719 3/32” X 1” COTTER PIN
5 47106709 BEST CYLINDER LOCK AND MODIFIED RING 6.25MM
6 47106722 1/4”-20 X 1” CARRIAGE BOLT - STAINLESS STEEL
7 47106723 1/4” NYLOK NUT
8 47106724 1/4” X 5/8” SS SEMI TUBULAR RIVET
9 47106725 1/4” X 3/4” SS SEMI TUBULAR RIVET
10 47106726 1/4” X 7/8” SS SEMI TUBULAR RIVET
11 47106727 CABLE 95” 7 X 19 SS 1/4 METAL EYE (EACH)
12 47106728 12” PULL STRAP - LOOPED W/ BLACK RETAINER
13 47106729 D-RING HANDLE - 2 PT LOCK
14 47106732 .25” COMPOSITE TOP PANEL- COMPLETE- 13.5” X 68.75” W/ SEAL
15 47106733 .25” COMPOSITE INTERMEDIATE PANEL - 15” X 68.75”
16 47106735 .25” COMPOSITE 2PT LOCK PANEL- COMPLETE 15” X 68.75”
17 47106734 .25” COMPOSITE BOTTOM PANEL -COMPLETE 15” X 68.75”
18 47106736 TOP PANEL SEAL ASSEMBLY - 68.75”
6
13
5
8
12
10
1
8
3
4
17
16
15
15
14
11
9
8
2
8
2
7

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ROLL UP DOOR
6
9
10
17
1
19
3
4
20
2
14
13
5
18
8
7
13
16
15
11
ITEM# PART# DESCRIPTION
1 47106700 ROLLER HINGE COVER
2 47106702 CABLE ASSY. 29.75” WITH (2) STOPS & WASHER (EACH) 2
3 47106704 ROLLER CLAMP, 3 HOLE ROLLER CLAMP FOR 1” ROLLERS
4 47106705 3 STUD BOTTOM FIXTURE ASSEMBLY -COMPLETE
5 47106707 1” STEEL ROLLER
6 47106708 TOP CAM CATCH
7 47106710 TOP CLOSURE ASSEMBLY COMPLETE
8 47106711 TOP CLOSURE SLIDE ONLY
9 47106712 CENTER CONTROL COMPLETE
10 47106714 LATCH BASE CENTER - .80” OFF, D-RING,BEST CYLINDER,
11 47106715 ALUMINUM CABLE COVER - 68.375” LENGTH - 7.5MM COMP,
12 47106716 TWO POINT END LATCH ASSEMBLY- CURBSIDE
13 47106717 TWO POINT END LATCH ASSEMBLY- ROADSIDE
14 47106718 SPACER WASHER
15 47106720 BUCK RIVET - 11/16”
16 47106721 BUCK RIVET - 13/16”
17 47106730 1207 HEAVY DUTY
18 47106731 CENTER HINGE-HEAVY DUTY
19 47106723 1/4” NYLOK NUT
20 N/A IDENTIFICATION PLATE S/N
NS 47106756 PLASTIC LATCH GUARD
ROLL UP DOOR

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USPS 2 Ton Delivery Vehicle 2016 - 2018 Models
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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 replace-
ment parts.
Gas Spring Heater
Motor and Fan Replacement:
1. The heater is mounted to the right hand dash panel.
2. With the power to the motor o, disconnect the motor leads.
3. Remove motor mounng screws. Remove the motor and the impeller wheel.
4. Take out the set screw to remove the impeller wheel (squirrel cage).
5. For installaon, reverse the sequence.
Plenum Replacement:
1. Detach air inlet hose from plenum.
2. Disconnect wiring harness at heater box and instrument panel harness.
3. Remove fasteners from plenum diuser (located on top of the windshield rail).
4. Remove the fasteners located on top of the windshield rail.
5. Installaon sequence is opposite of removal.
Plenum