103103436-A10023 Rev. A 574-848-2200

Service Guide

NOTICETo prevent damage to the cargo or vehicle, be sure that the rear door is closed and latched before driving the vehicle.

The information in this document applies to our most common roll-up door option. If your vehicle is equipped with a different roll-up door, refer to the door manufacturer's service guide for operation, adjustment, and maintenance instructions.

Rear Roll-up Door T-Series

! WARNINGThe counterbalance spring is wound under high tension. This high-tension spring can cause severe injury or death. Only qualified technicians should adjust this spring.

Use two winding bars that are 1/2” in diameter and 18” long. DO NOT USE bent winding bars, screwdrivers, or punches for spring winding.

! CAUTIONRead all instructions before starting repair. Always maintain firm footing and control of tools.

Installation, repairs, and adjustments must be made by trained service personnel using proper tools and instructions.

Read the safety and warning decals provided by the manufacturer. Never paint over the decals, and replace them if they are faded.

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 back.

Stand clear of the opening while the door is moving.

203103436-A10023 Rev. A 574-848-2200

BALANCER BRACKET

SPACER

SPRING

BALANCER SHAFT

CABLE DRUM

HEADERSEAL

SPRING WIND PLUG

ROLLER

CABLE ASSY

GUARD END

TOP HINGE

TOP PANEL

SUPPORT BRACKET

HORIZONTAL DOOR TRACK

VERT TRACK

STRIKER PLATE

ROLLER

LOCK CATCH

SIDE SEAL

HANDLE

STRAP MOUNT

PULL STRAP

BOTTOM SEAL

L-HANDLELATCH CABLE

CABLE COVER

CABLE PIN BRACKET

BOTTOM PANEL

SPACER

HINGE CENTER

LATCH ASSY

BOTTOM FIXTURE

MIDDLE PANEL

Overview of T-series roll-up door

303103436-A10023 Rev. A 574-848-2200

InspectionCheck the condition of the door and strap:

❑ Checkthatthedooropenseasilyandclosestightly.

❑ Checktheoperationandconditionoflatch.

❑ Checkforloosefastenersorothercomponents.

❑ Checktheconditionofthepull-downstrapforfrayingorwear.

❑ Checkthatthereardooriscenteredintheopening.

Lubrication points on roll-up door

1 2 3

54

6

7

Lubrication

NOTICEDo NOT use grease on doors. Do NOT get oil on rubber seals. Wipe up any drips immediately

Lubricatethefollowingrearroll-updoorpartswitha(P/N04202540orequivalent)lightoil:

❑ Rollerdrumsandshafts—wipeoffexcessoil(#1,#3).

❑ Springs—lubricatespring(s)alongtheirentirelengthtopreventrusting(#2).

❑ Cleanandlubricatetrack(#4).

❑ Hinges(centerandend)—wipeoffexcessoil(#5).

❑ Rollers(#6,#7).

❑ Latches(NS).

403103436-A10023 Rev. A 574-848-2200

NOTICEWhen ordering parts for a rear door, specify the serial number of the door. The serial number can be found on the metal tag attached to the inside upper driver's side corner of the door.

After replacement of any part, check relevant adjustments and proper operation of the door.

Two-Point Slam Lock To unlock the door from the outside,insertthekeyinthelockandturnclockwise1/4turnuntilthumblockpopsout.Rotatekeycounter-clockwise1/4turn,andremovethekeyfromthelock.To open the door from the outside,pushdownonthelowerdoorlifthandletorelievetensiononthelatchesandrotatethereleasehandleclockwiseuntilthelatchesrelease.To open the door from the inside,pushdownonthedoortorelievetensiononlatches,andpushthelevertowardthepassenger’ssideofvehicleuntilthesidelatchesrelease.To lock the door from the outside,insertthekeyandturnclockwiseandpushinonthumblock.

Master Security (Banana) Lock Tounlatchthedoor,rotatethecatchandthenrotatethe“banana”locklevercounterclockwiseuntilitcatchesintheopenposition.Tolatchthedoor,rotatethecatchandthenrotatethe“banana”lockleverclockwiseuntilitcatchesintheclosedposition.Ifequippedwithinteriorreleaselever,rotatethecatchreleaseknob90°androtatethelockleverabout180°clockwisetounlatchthedoor.

Roll-up door inside latch and serial number

Roll-up door latch and grab handle

Opening a banana lock

Optional interior banana lock release

503103436-A10023 Rev. A 574-848-2200

Cable Replacement Procedure Removal

NOTICEEven if only one cable is frayed or damaged, Utilimaster recommends replacement of the other cable at the same time.

1. Closethedoorfromtheinside.Releasethespringtensionfromthecablesbyfullyinsertingawindingbarthatis1/2”indiameterand18”longintooneofthespring-winding-plugholes.

2. Raisethebarenoughtoallowinsertionofasecondwindingbarintothelowerhole,andreleasethetensionenoughtoletthesecondbarrestagainstthetoppanel.

3. Loosenthetwosetscrewsonthecabledrum,releasingthecabledrumfromtheshaft,andremovethecablefromthecabledrum.

4. Removethecablefromthedoorbottompanelbyremovingtheanchorandcotterpins.

HeadPlateLoc_Utilimaster

PASSENGER SIDE DRIVER’S SIDE

CHALK MARK

SPRING ANCHOR BRACKET

SPRING WINDING PLUG

CABLE DRUM MUST BE TIGHTAGAINST BEARING

CABLE DRUM MUST BE TIGHT AGAINST BEARING

SETSCREWS

COTTERPIN

ANCHOR BRACKETPIN

CABLE

RIVET

RIVET

BOTTOM FIXTURE

CABLE

DOOR TOP PANEL

603103436-A10023 Rev. A 574-848-2200

Installation1. Mountthenewcableatthebaseof

thebottompanelbyslippingthecableanchorpinthroughthecableanchorbracketandtheeyeattheendofthecable.

2. Insertthecotterpininthecableanchorpintosecurethecable.

3. Bringtheothercableendtothetopofthe door and thread it over the top of the doortotheinside.

4. Temporarilytapethecabletotheoutsidetoppanelofthedoor.

5. Frominsidethecargoarea,insertthecableendintothecabledrumslot.Threadthecableintothegroovenearesttheslot,andturnthecabledrumtowardyouuntilallslackistakenout,makingsurethecableisfollowinginitspropergroove.

NOTICEThe cable must be wound from the outermost groove toward the inside of the drum.

6. Maintainingtensiononthecable,slidethecabledrumonthecounterbalanceshaftagainstthebearing,andtightenthetwosetscrewsonthedrum.

NOTICEMake sure the drums are against the counterbalance shaft bearings, the set screws are properly tightened, and the cables have equal tension.

7. Clampthecounterbalanceshaftwithalockingpliers,handleagainsttheceilingtokeepthecablestight.

8. Releasethespringtensionbyrotatingthespringwindingplugjustfarenoughtoallowremovalofthewindingbaragainstthetopofthedoor.

NOTICERotating the counterbalance assembly too far may cause cables to jump off the cable drum.

9. Removetheclamp,tape,andchecktheoperationofthedoor.

NOTICEA properly adjusted door should open easily and when stopped, it should remain at any given location.

Cable drum

SETSCREW CABLE

Cotter and anchor pins

703103436-A10023 Rev. A 574-848-2200

Winding counterbalance spring

DRIVER'S SIDE

PASSENGER'S SIDE

Chalk Mark

Support Bracket

Chalk Mark(Compressed Spring)

Winding Bars (See Dimensions)

Locking PliersAgainst Ceiling

Rotate Toward theCeiling to Compress Spring

Spring Winding Plug

Cable

Door Top Panel

Cable Drum

ProtectiveFlat Stock

Setscrew

NOTICEThis vehicle was designed using English (S.A.E.) measurements. Utilimaster provides metric conversion equivalents as a courtesy, but Utilimaster does not warrant metric values given in this manual.

Winding Bar DimensionsDoor Type

Diameter (Inches)

Diameter (Millimeters)

Approximate Length

T-Series 1/2" 127 mm 18" or 46 cm

Counterbalance Shaft

Spring Winding Adjustment

803103436-A10023 Rev. A 574-848-2200

NOTICETo determine the amount of turns on a newly installed spring, measure from the bottom of the door to the header. Divide that measurement by ten and then add three. This number is the approximate number of turns needed to wind the spring. Turns are counted by using the chalk marks, which show up as stripes as the spring is wound.

A properly counterbalanced door should, when stopped, remain at any given location. If the door leaves the floor by itself, the spring is wound too tightly, and a few quarter turns should be released. If the door has a tendency to drop when stopped, a few more quarter turns should be added.

1. Closedoorandclampcounterbalanceshaftfromtheinsidewithhandleoflockingpliersagainsttheceilingtokeepcablestight.Protecttherooffromtheplierswithapieceofplywoodorsheetmetal.

2. Insertawindingbarthatis1/2"indiameterand18"longintooneofthespring-windingplugholes.

3. Loosensetscrewsonspring-windingplug.4. Insertasecondwindingbarintooneofthespring-windingplugholes.5. Raisethebartoallowinsertionofsecondwindingbarintonextspring-windingplug.6. Continuetoraisebartowindspring.7. Tightensetscrews.8. Removelockingpliersandwindingbars.9. Cycledoortocheckoperation.10.Adjustagainifnecessary.11.Lubricatewithalightoil(UtilimasterP/N04022540).

Spring winding plug

SET SCREW

WINDING PLUG HOLES

903103436-A10023 Rev. A 574-848-2200

Top roller brackets and adjustments

Move roller UPto move panel IN

Move roller DOWNto move panel OUT

a. For a solid-coredoor,drillthroughtheentirepanelwithanF(or1/4")bit.Tipthepaneltowardyoutoinsertcarriageboltsthroughtheoutsideofthepanel.Installthehingesovertheboltsandtightenthenuts.

b. For a hollow-coredoor,drill through the interior panel onlywithanF(or1/4")bitandinstallMagna-Lokfastenersthroughthehinges.

3. Checkthedooroperationbyopeningandclosingthedoor.

4. Checkthesealgapontheoutsidetopoftheroll-updoorandadjustasnecessary.

5. Tightenthenutswithawrench.6. Checktheoperationofthedoorandadjust

asnecessary.

Top Panel ReplacementRemoval

1. Withthedoorclosed,clampthetrackbelowthetoppaneltopreventthedoorfromraising.

2. Drillouttherivetheadsinthecenterhingesonthetoppanelandtherivetheadsonthejointrollerbracketinthelowerhalfofthetoppanel.

3. Punchouttherivetsand,inatleastoneofthehinges,insertapunchinoneoftherivetholestostabilizethedoorpanelwhiledetachingtheremainingrivetsandbolts.

4. Usingawrenchandsocket,removetherollerbracketsandrollersatthetopofthepanel.

5. Removethepunchandliftouttheoldpanel.

Installation

NOTICEIf you are unable to secure the hinges with the original type of rivets that extend completely through the door, use carriage bolts or rib-neck carriage bolts to attach them. The bolt head must be on the exterior side of the door, and the nut must be on the interior.

1. Usingawrenchandsocket,attachtherollerbracketsandrollerstothetopofthenewpanelwhileputtingtherollersinthetracks.

2. Lineupthenewtoppanelwiththepanelbelowit(makingsuretheyalignforaclosefitatthejoint)and(usingthehingeholesasaguide)drillallofthehingeholesonthebottom of the newpanel:

1003103436-A10023 Rev. A 574-848-2200

Adjustment1. Checkthatthedoorhasnomorethan1/4"

maximumplay,doesNOTbindinthetrack,andiscenteredinopening.

2. Addorsubtractwashersonrollershaftstoachieveproperdooroperation.Amaximumoffourspacerwashersshouldbeatthesecondfromtopjointrollerandthesecondfrombottomjointrolleroneachside.

3. Loosenbothboltsonslideslocatedattopofdoortoadjusttoppanelinandout.

4. Loosenbothlocknutsoncatcheslocatedatbottomofdoorsothatitsitsflushonthreshold.

Upper slide bolt adjustment

Catch locknutsDoor roller

1103103436-A10023 Rev. A 574-848-2200

Intermediate PanelRemoval

1. Withthedoorclosed,clampthetrackbelowthepaneltobereplacedtopreventthedoorfromraising.

2. UsingaF-bit,drillofftherivetsinthecenterhingesonthepaneltoberemoved.

NOTICETake care not to drill through the outside panel. Punch out the rivet and in at least one of the hinges, insert a punch into one of the rivet holes to stabilize the door panel while detaching the remaining rivets and bolts.

3. Useawrench,removebothrollerbracketsandrollersatbothjointsortopofthepanel.

4. DrillofftheendhingerivetsattachedtothebottomofthepanelwithaF-bit.

5. Liftthedoorpanelsabovethepaneltobereplacedintothehorizontaltrack,andsecurethemwithalockingpliersclampedonthehorizontaltrack.

6. Removethepunchandliftouttheoldpanel.

Installation1. Transferdrillallofthehingeholesonthe

bottomofthenewpanel.2. Withtheupperdoorsectionclampedso

thatitwillnotfall,tipthepaneltowardyoutoinsertthebolts.

3. Installthehingesoverthebolts,andtightenthenuts.

4. Swingthenewpaneluprightandclampintoposition.

5. Lowerthedoorfromthehorizontaltracks,anddrillalltheholesinthetopofthenewpanel.

6. Inserttheboltsandinstallthehingesoverthebolts.Tightenthenuts.

7. Removetheclampsandcheckthedooroperationbyopeningandclosingthedoor.

8. Alsocheckthesealontheoutsidetopoftheroll-updoor.

NOTICEThe top panel can be adjusted by loosening the top roller bracket bolt and moving the top roller up or down to adjust the top panel in or out.

Center hinge

Middle roller

1203103436-A10023 Rev. A 574-848-2200

Bottom PanelRemoval

NOTICETake care not to drill through the outside panel. Punch out the rivet and in at least one of the hinges, insert a punch in one of the rivet holes to stabilize the door panel while detaching the remaining rivets and bolts.

1. Openthedoorandpushbackuntilthebottomofthedoorisabout16”orsofromtheheaderatthetopofthedooropening.

2. Placeaclampinthehorizontaltracks,oneachside,belowthebottomrollers.

3. Placeaclampononeofthecables,neartheeyeofthecable.

4. Holdclampandreleasethecablefromthebottomofdoor.

5. Allowthespringtowindthecableontothedrumuntiltheclampstopsitbycontactingthedrum.

6. Repeatwiththeoppositecable.7. Removerivetsfromcableanchorsandpull

strap.8. Drilloutthecenterandendhingerivets

attachedtothebottompanel.9. Removethepanelfromthetracksandpush

theremainderofthedoorslightlytowardsthefrontofthetruck.

10.Placeaclampinthetracktopreventthedoorfromrollingbackdown.

Installation1. Removebottomrollerbracketandcable

anchorsfromtheoldpanel.2. Inserttherollerinthebottombracketofthe

newpanel.3. Positionthenewpanelandrollerinthe

track.4. Installtheotherbottomrollerinthetrack,

andalignwiththebottomrollerbracket.

5. Usethehingesasatemplatetotransferdrillrivetholesinthenewpanel.

NOTICEMake sure the panels align for a close fit at the joint.

6. Rivetthehingesintoplace.7. Replacetherollersatthejoints,aswellas

anyspacerwashersontherollershafts.

NOTICEThe roller brackets on the top of the bottom panel and on the bottom of the top panel play an important part in maintaining proper door alignment within the track. The rollers on these brackets must have 3 to 4 spacer washers (depending on the alignment) to maintain the correct distance in the track.

8. Reattachthepullstrap.9. Rivetcableanchors.10.Reconnecteachcablebydrawingittothe

outsideofthebottomdoorpanel.11.Insertpinthroughthecableeyeandanchor

bracket.Securewiththecotterpin.12.Checktheoperationofthedoorandadjust

asnecessary.

Bottom roller bracket and fasteners

RIVETS

CABLE ANCHOR RIVETS

1303103436-A10023 Rev. A 574-848-2200

Pull Strap Replacement1. Raisetheroll-updoorpartwayandplacea

clampinthetrackbelowthebottompanel.2. Removerivets.3. Slipthenewstrapthroughthepullstrap

loop.4. Attachtoroll-updoorusingrivets.5. Removetheclampandtestthestrapwhile

openingandclosingthedoor.

Pull strap and fasteners

1403103436-A10023 Rev. A 574-848-2200

Door Seal ReplacementSide Seal

1. Raisetheroll-updoortothefullopenpositionandclampthetrackbelowthebottompanel.

2. Drillouttherivetsfromdoorframe3. Uncrimpbothendsofthesealextrusion.4. Removethesealfromtheextrusion.5. Cutthenewsealtolengthwithboltcutters.6. Insertthenewsealintotheextrusionand

crimptheends.7. Reattachtheextrusionusingaluminum

rivetsorstainless-steelsheet-metalscrews.8. Closethedoorandchecktheseals.

Top Seal1. Raisetheroll-updoortothefullopen

positionandclampthetrackbelowthebottompanel.

2. Uncrimpbothendsofthebracketandextracttheoldseal.

3. Slidethenewsealintothebracket,andcrimp the ends of the bracket to secure the seal.

4. Removetheclamp,closethedoor,andchecktheseal.

Bottom Seal1. Raisetheroll-updoorpartwayandplacea

clampinthetrackbelowthebottompanel.2. Removefastenersholdingthesealtothe

bottomdoorpanelandremoveseal.3. Installthenewseal,angleedgefirst,and

rotateitintoposition.4. Securewithnewfasteners.5. Removetheclamp,closethedoorand

checktheseal.

Top seal on roll-up door

BRACKET

Brush seal on roll-up door

Remove the rivets holding the seal strip

to the door frame

Bottom vinyl seal fasteners

1503103436-A10023 Rev. A 574-848-2200

BOLT IN STUD BASE

LATCH PLATE

LEVEL

DOOR TRACK

Square latch plate with latch(Side view)

Slam Lock Latch AdjustmentNOTICE

On rear roll-up doors with slam locks, adjust the latch if problems occur with the door latching or sealing. Also, roller/door side play is critical for slam locks.

1. Frominsidethetruck,closethedoortightly,soitissealedonthebottom.

2. Afan-typelatchshouldconsistentlylatchintheprimaryposition,withthelatchplaterodrestingonthetopofthefanofthelatchassembly.Ifthelatchisnotproperlyadjusted,itmightlatchinthesecondaryposition.

3. Ifnecessary,loosenthetwonutsonthestudbasebolts.

4. Repositionthelatchplatesothatthelatchplatefitssnuglyagainstthelatchprimarypositionforafantype.

5. Ensurethatthelatchplateislevelandsquarewiththelatchandtightenthenuts.

6. Afterlatchesonbothsidesofthedoorareproperlyadjusted,cyclethedoorseveraltimestocheckproperengagement(primaryposition).Checkthatthelatchingandunlatchingissmoothandthatthedoorsealsatthebottom.

Slam lock latch

LATCH PLATESTUD BASE

BOLTS

1603103436-A10023 Rev. A 574-848-2200

MSL (Banana Lock)

NOTICEThere is no adjustment on a Master Security Lock. If the handle becomes worn to the point that the door no longer closes tightly as it should, replace the handle.

If original rivets are unavailable, use carriage bolts or rib-neck carriage bolts to attach the handle. The bolt head must be on the exterior side of the door.

Master security (banana) lock

CATCH PLATE

COVERPAN

LOCK ASSY

LOCKPROTECTOR

HANDLEKEEPER

RIVET

Utilimaster Customer Service

574-848-2200Email: Parts@Utilimaster.com

T-Series Rear Roll-Up Door Service Guide 03103436-A10023 January 2017

©Utilimaster Corp., 603 Earthway Boulevard, Bristol, Indiana 46507 USA