Utilimaster REACH User manual

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
For Assistance Call: 800-237-7806 Visit us at: www.utilimaster.com
1Reach—Body Service Manual
E-mail: [e-mail]
Body Service Manual

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
For Assistance Call: 800-237-7806 Visit us at: www.utilimaster.com
2Reach—Body Service Manual
E-mail: [e-mail]
Introduction
Congratulations on operating a Reach vehicle with a quality Utilimaster®body. Utilimaster is dedicated
to serving our customers' needs through the excellence of our products, services, and information.
Please read and follow the instructions in this document for safe and optimal operation and maintenance
of this vehicle.
This manual contains drawings and photos to aid in servicing the vehicle, and it may include
maintenance information on some items installed but not manufactured by Utilimaster Corporation.
Items such as chassis and drive train components or certain interior furnishings may be covered by
separate manufacturer-supplied information. Information provided here is intended to assist Utilimaster
customers and is in no way meant to replace or supersede instructions provided by other suppliers for
their products.
This Service Manual provides basic servicing information for Reach vehicle bodies built by Utilimaster
Corporation. See the Reach–Body Operator’s Guide for expanded descriptions on the features and
options unique to the Reach. For information on chassis and drive train operations, see the Isuzu’s NPR
Stripped Chassis Owner’s and Driver’s Manual. For additional technical documentation on parts and
wiring, see the references in the More Information and Publications section.
Utilimaster Corporation attempts to provide accurate, complete, and useful information. All information
contained in this manual is based on the latest product information available at the time of publication.
However, because of the Utilimaster policy of continual product improvement, Utilimaster reserves the
right to amend the information in this document at any time without prior notice.
Reach Customer Service
HOTLINE [phone]
Monday–Friday 8 a.m. to 5 p.m. Eastern Standard Time Zone
Email: [e-mail]
NOTE: The information in this document is generic. Images and procedures may differ from
those for vehicles you are servicing. Because Utilimaster manufactures customized vehicle
bodies, this document cannot list and illustrate every possible option for every vehicle. The
most common body options are described here. Use this information as a guideline.

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
3
For Assistance Call: 800-237-7806Parts On-line: https://parts.utilimaster.com
Reach—Body Service Manual Fax: [phone]
Contents
Introduction..................................................................................................................................2
Notes, Cautions, and Warnings...................................................................................................9
“Before You Go” Inspection Checklist........................................................................................10
Vehicle Orientation ....................................................................................................................10
Vehicle Overview.......................................................................................................................11
VIN, Body Serial, and Work Order Numbers.............................................................................12
Service Procedures ...................................................................................................................13
Batteries...............................................................................................................................13
Access ............................................................................................................................13
Disconnect......................................................................................................................13
Body Panel Repair ...............................................................................................................14
Overview.........................................................................................................................14
Gelcoat Repair................................................................................................................14
Minor Composite Repair.................................................................................................16
Major Composite Repair.................................................................................................17
Bumpers ..............................................................................................................................19
Front Fascia ...................................................................................................................19
Rear Bumper ..................................................................................................................22
D-Bumper .......................................................................................................................24
Side Dock Bumpers........................................................................................................25
Cladding...............................................................................................................................26
Front Fender...................................................................................................................26
Rear................................................................................................................................27
Sidewall .........................................................................................................................30
Dash Panels.........................................................................................................................32
A-Pillar ...........................................................................................................................33
Brake Panel ...................................................................................................................33
Cluster Panel .................................................................................................................34
Dash Valance Panel ......................................................................................................34
Fuse Access ..................................................................................................................37
Hood Cluster Panel ........................................................................................................38
Overhead Panel .............................................................................................................39
Tray Panel ......................................................................................................................40
Washer Bottle Panel ......................................................................................................40
Door Ajar Switch ..................................................................................................................41

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
For Assistance Call: 800-237-7806 Visit us at: www.utilimaster.com
4Reach—Body Service Manual
E-mail: [e-mail]
Doors, Bulkhead...................................................................................................................42
Adjustment......................................................................................................................42
Removal..........................................................................................................................43
Installation.......................................................................................................................43
Catch Adjustment ...........................................................................................................44
Seals...............................................................................................................................44
Doors, Cab Slider.................................................................................................................45
Adjustment......................................................................................................................46
Removal..........................................................................................................................46
Installation.......................................................................................................................47
Catch, Front Standard ....................................................................................................49
Catch, Front Keyless ......................................................................................................51
Catch, Rear.....................................................................................................................55
Guide ..............................................................................................................................56
Handles...........................................................................................................................58
Lock Cylinder Removal...................................................................................................59
Seals...............................................................................................................................60
Threshold .......................................................................................................................62
Window, Slider ................................................................................................................63
Doors, T-Series Rear Roll-up ..............................................................................................65
Adjustment......................................................................................................................66
Removal .........................................................................................................................67
Installation.......................................................................................................................67
Cables.............................................................................................................................67
Panels.............................................................................................................................69
Rollers.............................................................................................................................70
Seals...............................................................................................................................70
Spring .............................................................................................................................71
Doors, W-Series Rear Roll-up..............................................................................................74
Adjustment......................................................................................................................75
Removal..........................................................................................................................76
Installation.......................................................................................................................76
Cables.............................................................................................................................76
Panels.............................................................................................................................78
Rollers.............................................................................................................................80
Seals...............................................................................................................................80
Springs............................................................................................................................82

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
5
For Assistance Call: 800-237-7806Parts On-line: https://parts.utilimaster.com
Reach—Body Service Manual Fax: [phone]
Engine Cover .......................................................................................................................85
Removal..........................................................................................................................85
Installation.......................................................................................................................85
Gasket ............................................................................................................................85
Strap ...............................................................................................................................85
Fenders................................................................................................................................86
Front Cladding ................................................................................................................86
Front Quarter Fender......................................................................................................86
Front Wheel Liner ...........................................................................................................88
Sidewall Cladding ...........................................................................................................88
Fire Extinguisher ..................................................................................................................89
Removal..........................................................................................................................89
Installation.......................................................................................................................89
Fuel Sending Unit Access Panel..........................................................................................90
Composite Floor .............................................................................................................90
Glass....................................................................................................................................92
Tools and Materials.........................................................................................................92
Windshield Removal .......................................................................................................94
Quarter Glass Removal ..................................................................................................95
Substructure Prep...........................................................................................................95
Glass Prep and Bonding.................................................................................................96
Windshield Installation ....................................................................................................98
Quarter Glass Installation ...............................................................................................99
Grille...................................................................................................................................100
Removal........................................................................................................................100
Installation.....................................................................................................................100
Grille Screen.................................................................................................................101
Handrail and Grab Handles................................................................................................102
Grab Handle, A-Pillar....................................................................................................102
Grab Handle, Cargo......................................................................................................102
Handrail ........................................................................................................................103
Heater ................................................................................................................................104
Blower Motor.................................................................................................................105
Condenser ....................................................................................................................116
Control Module ............................................................................................................. 117
Dryer.............................................................................................................................118
Evaporator ....................................................................................................................121
Heater Core ..................................................................................................................130

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
For Assistance Call: 800-237-7806 Visit us at: www.utilimaster.com
6Reach—Body Service Manual
E-mail: [e-mail]
Heater Valve .................................................................................................................134
Hoses............................................................................................................................137
Mode (Servo) Motor......................................................................................................138
Resistor.........................................................................................................................140
Thermostat....................................................................................................................142
Hood...................................................................................................................................143
Open.............................................................................................................................143
Adjustment....................................................................................................................143
Removal........................................................................................................................144
Installation.....................................................................................................................145
Disassembly .................................................................................................................145
Assembly ......................................................................................................................146
Hood Latch ...................................................................................................................147
Hood Cable...................................................................................................................149
Lights..................................................................................................................................151
Grommet-mounted........................................................................................................151
Headlights.....................................................................................................................151
Switches, Convenience Panel ......................................................................................155
Turn, Front Fascia.........................................................................................................156
Mirrors................................................................................................................................157
Adjustment....................................................................................................................157
Removal........................................................................................................................157
Installation.....................................................................................................................158
Rear Vision System............................................................................................................159
Camera.........................................................................................................................159
Monitor..........................................................................................................................159
Seat....................................................................................................................................160
Driver's..........................................................................................................................160
Jump Seat.....................................................................................................................161
Seat Belt .......................................................................................................................162
Stereo.................................................................................................................................164
Removal........................................................................................................................164
Installation.....................................................................................................................164
Swell Latches.....................................................................................................................165
Release.........................................................................................................................165
Securing........................................................................................................................165
Removal........................................................................................................................165
Installation.....................................................................................................................165

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
7
For Assistance Call: 800-237-7806Parts On-line: https://parts.utilimaster.com
Reach—Body Service Manual Fax: [phone]
Wiper System.....................................................................................................................166
Arms .............................................................................................................................166
Bottle and Pump ...........................................................................................................167
Linkage Assembly.........................................................................................................168
Motor.............................................................................................................................170
Tools, Fasteners, and Adhesive Tapes....................................................................................171
Recommend Tools .............................................................................................................171
Fastener Replacement.......................................................................................................172
BOM®Fastener.............................................................................................................172
Blind Rivet.....................................................................................................................172
Channel Nut..................................................................................................................172
Nut, Locknut..................................................................................................................173
Nut, Nutsert...................................................................................................................173
Nut, Torque Seal...........................................................................................................173
Pine-Tree Fastener .......................................................................................................174
Pin-and-Collar Fastener (Magna-Grip®) .......................................................................174
Scrivet...........................................................................................................................174
Tape, Double-Faced Adhesive......................................................................................175
Tape, Vinyl Barrier ........................................................................................................175
Thread Lock..................................................................................................................175
Sealant...............................................................................................................................176
Overview.......................................................................................................................176
Removing Parts With Adhesive or Sealant...................................................................176
Applying Sealant...........................................................................................................176
Towing the Vehicle...................................................................................................................177
Using a Lowboy Trailer.......................................................................................................177
Towing From the Front .......................................................................................................177
Towing From the Rear........................................................................................................178
Flat Towing.........................................................................................................................178
Emergency Repairs.................................................................................................................178
Maintenance Information.........................................................................................................179
Maintenance Safety Considerations ..................................................................................179
Cleaning.............................................................................................................................180

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
For Assistance Call: 800-237-7806 Visit us at: www.utilimaster.com
8Reach—Body Service Manual
E-mail: [e-mail]
General Tips.......................................................................................................................180
Body Exterior ................................................................................................................180
Cargo Area ...................................................................................................................180
Instrument Panel and Interior Plastic Components ......................................................180
Seats.............................................................................................................................180
Windows .......................................................................................................................180
Engine and Heater Coolant .....................................................................................................181
Lubrication...............................................................................................................................182
Manufacturers’ Recommendations..........................................................................................182
Maintenance Checklist ............................................................................................................182
Body Mounting Fasteners ..................................................................................................182
Bumpers.............................................................................................................................182
Doors, General...................................................................................................................183
Doors, Roll-up ....................................................................................................................184
Driver Conveniences..........................................................................................................185
Grab Handles and Handrails..............................................................................................185
Hood...................................................................................................................................185
Mirrors................................................................................................................................185
Reective Tape ..................................................................................................................185
Seats and Belts..................................................................................................................185
Tires ...................................................................................................................................185
Wipers ................................................................................................................................185
Ordering Parts .........................................................................................................................186
Customizable Parts Order Form ........................................................................................187
Returns...............................................................................................................................187
Reporting Safety Defects.........................................................................................................189
United States Only .............................................................................................................189
Canada Only ......................................................................................................................189
More Information and Publications..........................................................................................190
Web Site and Downloading Files .......................................................................................190
Service Manuals.................................................................................................................190
Contacting Utilimaster ............................................................................................................191
Revision Control ......................................................................................................................197
Important Notices ....................................................................................................................197

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
9
For Assistance Call: 800-237-7806Parts On-line: https://parts.utilimaster.com
Reach—Body Service Manual Fax: [phone]
When you see this symbol, read this statement rst! This alert highlights information that may
reduce the risk of personal injury or vehicle damage.
Notes, Cautions, and Warnings
Reading through the procedures, you will see NOTES, CAUTIONS, and
WARNINGS. Each is there for a specic purpose.
NOTES give additional information that will help you complete the procedure.
CAUTIONS warn against making an error that could damage the vehicle.
WARNINGS remind you to be careful when there is risk of personal injury.
Below are some basic WARNINGS that you should heed when you work on the vehicle’s body. They
are not all-inclusive and common sense must be used when servicing vehicles.
• Always read and understand all instructions before starting a repair.
• Always wear safety glasses and other appropriate protective equipment (gloves, steel-toed shoes,
face shields, knee pads, hearing protection).
• Put the transmission in Park and set the parking brake before working on the vehicle.
• Be sure that the ignition switch is Off unless otherwise required by the procedure.
• Always use safety stands, ramps, lifts, and/or wheel blocks whenever you are underneath the
vehicle.
• Always remove the keys from the ignition when you are working under a vehicle (unless the
repair requires otherwise). Put a lockout tag on the steering wheel.
• Only operate engines in a well-ventilated area.
• Keep your hair, clothing, and body away from the radiator fan, belts, and pulleys when engine is
running.
• Avoid contact with hot metal parts or uids when checking or servicing. Always allow the
vehicle cooling system to cool before opening a radiator cap.
• Always remove rings, watches, hanging jewelry, and loose clothing before working in tight
areas.
• Read and understand all warning labels.
• Always use proper ladders or scaffolding to perform required jobs.
• Always make sure tools are in proper working condition and have guards and safety devices in
place.
• Use only the recommended tools for a specic job.
• Utilimaster recommends that only a licensed/certied automotive technician services the
vehicle's air-conditioning system.
• If at any time you lack condence in performing a specic repair procedure or in operating the
tools safely to perform the repair, STOP! Call your local dealer or a Utilimaster representative.
• Do NOT drive a forklift inside the cargo area of this vehicle.

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
For Assistance Call: 800-237-7806 Visit us at: www.utilimaster.com
10 Reach—Body Service Manual
E-mail: [e-mail]
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Vehicle orientation
“Before You Go” Inspection Checklist
Before driving, inspect the following:
❑ Visually inspect the tires for possible underination or damage. Test tire ination pressure with a
quality pressure gauge at least weekly.
❑ Check wheels for cracks, damage, or any missing or loose lug nuts.
❑ Check for signs of uid leaks under the vehicle.
❑ Check the oil, antifreeze, brake, washer, and power steering uid levels.
❑ Check belts and hoses for cracking or fraying.
❑ Check exterior of vehicle for damage or loose parts.
❑ Check all doors, latches, and locks for proper operation.
❑ Make sure all safety equipment is present, up-to-date, and not damaged.
❑ Check the windshield for cracks and chips.
❑ Check windshield wiper operation and washer spray pattern.
❑ Check all lights including headlight high beams, ashers, and turn signals. Exterior lights must
illuminate properly to meet Federal Motor Vehicle Safety Standards for nighttime operation.
❑ Adjust the driver’s seat position.
❑ Adjust all mirrors.
❑ Inspect, fasten, and adjust the seat belt.
❑ When starting the engine, check for warning lights on the instrument panel.
❑ Check the operation of the heater and defroster.
❑ Check all switches on the dash and the steering column for proper operation.
❑ Check other options and features, such as a rear-vision camera system.
Vehicle Orientation
NOTE: When referring to part locations on corresponding sides of the
vehicle, refer to them as “Driver’s side,” “Passenger’s side,” “Front,”
“Rear,” “Cab,” or “Cargo Area.”

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
DEF Fill Door Diesel Fuel Fill
Reector
Reector
Side
Marker
Light
Cab Sliding Door
Sidewall Rub Rail
Driver's side prole
Side Marker
Lights
One-Piece
Roof
Vehicle overview
Front prole
Mirror
Turn and
Parking
Lights
Identication
Lights
One-Piece
Roof
Hood
Windshield
Headlight
and
Parking Light
Bumper
Fascia
Wipers
Clearance
Lights
Rear prole
Backup
Lights
Reector
Stop and
Tail
Lamps
Rear
Twin
Doors
Turn
Lamps
Side
Dock
Bumper
Release
Handle
Rear Shock
Step Bumper
License
Plate
Light
Identication
Lights Clearance
Lights
11
For Assistance Call: 800-237-7806Parts On-line: https://parts.utilimaster.com
Reach—Body Service Manual Fax: [phone]
Vehicle Overview

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
Figure LA–15
Federal Certication Label
For Assistance Call: 800-237-7806 Visit us at: www.utilimaster.com
12 Reach—Body Service Manual
E-mail: [e-mail]
VIN, Body Serial, and Work Order Numbers
The 15-digit Utilimaster Body (or Unit) Serial Number is recorded on the Federal Certication
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). This label can be found attached to the
door post behind the driver’s seat.
The 17-digit chassis Vehicle Identication Number (VIN) is the legal identier for this vehicle and is
the number recorded in the license plate registration. The VIN is recorded on the Federal Certication
Label.
The Body Serial Number or 7-digit Work Order Number can be used to identify the body for service
inquiries or if the body is no longer mounted on the original chassis.

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
13
For Assistance Call: 800-237-7806Parts On-line: https://parts.utilimaster.com
Reach—Body Service Manual Fax: [phone]
Service Procedures
Batteries
Access
NOTE: The access panel for the batteries is located in the driver’s side step well.
Disconnect
1. Make sure ignition switch is Off.
2. Disconnect the Negative (BLACK) battery cable(s) rst.
3. Tuck the battery cable away from the terminal to prevent accidental contact.
WARNING: Always remove the (BLACK) Negative cable rst and connect it last.
CAUTION: Note the location of the battery and the cable routing and reinstall in exactly the same
way. When reattaching the Positive (RED) cables, the doubling of the two cables must be in the
same positions as before.
WARNING: Batteries that are improperly connected, jumped, or charged can potentially explode
and discharge acid, causing vehicle damage and personal injury. Carefully follow the chassis
manufacturer’s recommendations for those procedures.
WARNING: Always wear proper protective equipment when working around batteries.
WARNING: Battery posts and related accessories may contain lead and lead compounds. Wash
hands after handling.
Battery access panel in driver’s step well

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
For Assistance Call: 800-237-7806 Visit us at: www.utilimaster.com
14 Reach—Body Service Manual
E-mail: [e-mail]
Body Panel Repair
Overview
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 difculty of repair.
Gelcoat Repair: The exterior body of the Reach has a gelcoat nish. Unlike painted surfaces,
supercial damage to the gelcoat can often be buffed out to its original nish. Dents and deep
scratches can be covered by applying a layer of gelcoat that is sanded and buffed back to its
nished look. Adding the color of the original body to the gelcoat before application eliminates
need for paint.
Minor Repair: Damage that penetrates the composite (glass-reinforced) substructure but does
NOT go through to the other side OR a hole no larger than a golf ball can be repaired with a
commonly obtained resin and berglass matting kit.
Major Repair: A hole or damaged area larger than a golf ball should be cut out and a
replacement plug of new material should be bonded in its place.
Extreme Repair: Damage that impacts multiple areas (roof, side wall, rear structure) that
requires replacing structural aluminum extrusions should be evaluated by an experienced
technician familiar with the Reach design before attempting the repair.
Gelcoat Repair
Use the gelcoat repair process for dents and scratches that do NOT penetrate the composite substructure.
1. Use a marker to highlight all cracks.
2. Remove any decals or body graphics in the repair area.
3. Use a die grinder with a rotary le bit to open and roughen the edges and remove any loose
debris.
4. Sand 1–2" beyond the perimeter of the repair area.
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
Service Department for further assistance.
CAUTION: Read and understand ALL product instructions and safety procedures. The effectiveness
of the repair can be compromised by environmental conditions and poor application. Product
application and safety instructions provided by the manufacturers always supersede information
provided by Utilimaster.
WARNING: Use the proper protective equipment (rubber gloves, mask, etc.) appropriate to the
process.
Mark cracks Using a die grinder to clean out gelcoat

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
15
For Assistance Call: 800-237-7806Parts On-line: https://parts.utilimaster.com
Reach—Body Service Manual Fax: [phone]
5. Inspect the damage for cracks in substructure. If there is
damage to the substructure, proceed to the Minor Repair
section.
6. Mask off or cover areas to avoid overspray.
7. Thoroughly clean the area with alcohol or acetone.
8. Mix gelcoat and hardener in container and thin with
acetone to make a mixture that can be applied with a
sprayer. Tint to OEM color.
9. Spray a thick layer of gelcoat over the repair area,
feathering out toward edges.
10. Allow gelcoat to dry.
11. Thoroughly clean area with acetone.
12. Sand with 120 grit sandpaper until ush with surface.
13. Check for low spots and holes. Apply more gelcoat
feathering out toward the edges and sand with 120 grit
sandpaper. Repeat as necessary.
14. Allow to dry.
15. Sand with 120–240 grit wet sandpaper.
16. Use a buffer and rubbing compound to smooth the
surface.
17. Use a buffer with wax or polishing or glazing compound
to blend the area.
Spraying on gelcoat
Bufng the gelcoat

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
For Assistance Call: 800-237-7806 Visit us at: www.utilimaster.com
16 Reach—Body Service Manual
E-mail: [e-mail]
Minor Composite Repair
Minor repair is necessary with damage that penetrates the composite (glass-reinforced) substructure that
does NOT go through to the other side OR holes no larger than a golf ball.
1. Remove any decals or body graphics in the repair area.
2. Use a grinder to remove the damaged material.
NOTE: For cracks, drill a hole slightly larger than the crack
width to prevent the crack from growing.
3. Sand with 80–120 grit sandpaper.
4. Thoroughly clean area with alcohol or acetone.
5. Mask off or cover areas to avoid dripping resin.
6. Repair area with resin and berglass matting.
7. Allow the resin to dry.
8. Add more resin and matting as necessary and repeat sanding.
9. Sand with 120–240 wet sandpaper.
10. Repair gelcoat.
See Repair Gelcoat.
Grind damaged section.
Resin and berglass matting
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
Service Department for further assistance.
CAUTION: Read and understand ALL product instructions and safety procedures. The effectiveness
of the repair can be compromised by environmental conditions and poor application. Product
application and safety instructions provided by the manufacturers always supersedes information
provided by Utilimaster.
WARNING: Use the proper protective equipment (rubber gloves, mask, etc.) appropriate to the
process.

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
17
For Assistance Call: 800-237-7806Parts On-line: https://parts.utilimaster.com
Reach—Body Service Manual Fax: [phone]
Major Composite Repair
Major repair is necessary when damage to the
composite (glass-reinforced) substructure is larger than
a golf ball.
1. Remove any decals or body graphics in the
repair area.
2. Remove anything mounted inside the vehicle
that would be affected by the repair process.
3. Measure the damaged area and use a straight
edge and square to cut out a replacement plug
from a new panel. The plug should be at least
1" larger than the damaged area on all sides.
4. Place the plug over the area to be removed and
trace the perimeter.
5. Use a saw or die grinder to cut out the damaged
area.
6. Use a rotary le or grinder to smooth the edges of the hole.
7. Sand with 80–120 grit sandpaper.
8. Bevel all the edges of the hole and the plug.
9. Use 120 grit sandpaper to sand 1–2" past the edges of the opening and plug.
10. Test t plug and modify as necessary.
11. Carefully center plug in the opening and secure with clamps or fasteners.
NOTE: The plug can be held in place with wood blocks and screws that can be removed after
the rst resin application.
12. Remove plug and set aside.
13. Mask off or cover areas to avoid dripping resin.
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
Service Department for further assistance.
CAUTION: Read and understand ALL product instructions and safety procedures. The effectiveness
of the repair can be compromised by environmental conditions and poor application. Product
application and safety instructions provided by the manufacturers always supersedes information
provided by Utilimaster.
WARNING: Use the proper protective equipment (rubber gloves, mask, etc.) appropriate to the
process.
CAUTION: Do NOT get resin on the clamps or mounting xtures.
Cut out damaged area

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
For Assistance Call: 800-237-7806 Visit us at: www.utilimaster.com
18 Reach—Body Service Manual
E-mail: [e-mail]
14. Thoroughly clean the repair area with alcohol
or acetone.
15. Coat all four sides of the plug and the hole
with resin, place in the opening, and secure
with clamps.
16. Carefully center the plug in the opening and
secure with clamps or fasteners.
17. Bond the perimeter of the plug to the body
with resin and berglass matting.
18. Allow resin to dry.
19. Remove temporary support and apply resin to
any low spots and holes.
20. Sand with 80–120 grit sandpaper.
21. Add more resin and matting and repeat
sanding until surfaces are smooth.
22. Sand with 120–240 wet sandpaper.
23. Repair gelcoat.
See Repair Gelcoat.
CAUTION: The replacement plug needs to be mounted at and ush with the body surface.
Bond plug in place with resin and matting.

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
19
For Assistance Call: 800-237-7806Parts On-line: https://parts.utilimaster.com
Reach—Body Service Manual Fax: [phone]
Bumpers
Front Fascia
Removal
1. Open hood.
See Open Hood.
2. Remove grille.
See Remove Grille.
3. Remove two M6 screws in headlight bezel.
4. Remove two M4 screws in headlight bezel and set bezel aside.
5. Remove two M6 screws in top center of fascia.
6. Remove four M6 screws from underside of fascia.
7. Unplug turn lights.
8. Remove two M6 nuts and bolts
from the bracket under headlight.
Turn light Bracket under headlight
Screw locations on top of fascia
Screw locations on underside of fascia
CAUTION: Discard ALL used fasteners and replace with new. If using a fastener that does NOT have
preapplied thread lock, apply a medium-grade liquid thread lock.

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-
tion in this document at any time without
prior notice.
This material is condential 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 tness 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
For Assistance Call: 800-237-7806 Visit us at: www.utilimaster.com
20 Reach—Body Service Manual
E-mail: [e-mail]
9. Remove two M6 nuts from steel bumper bracket.
10. Repeat on opposite side.
11. Set bumper fascia aside.
Installation
1. Secure steel bumper brackets to M6 bolts that are attached to the fascia.
2. Plug in turn lights.
3. Secure fascia bracket under headlight with two M6 bolts and nuts.
Steel bumper brackets
Turn light Bracket under headlight
CAUTION: Discard ALL used fasteners and replace with new. If using a fastener that does NOT have
preapplied thread lock, apply a medium-grade liquid thread lock.