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Body Service Manual For Assistance Call: 800-237-7806 Visit us at: www.utilimaster.com Body Service Manual — Revision B — 1 E-mail: [email protected] Reach—Body Service Manual Parts Online: https://parts.utilimaster.com For Assistance Call: 800-237-7806 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 574-862-3362 Monday–Friday 6:30 a.m. to 6 p.m. Eastern Standard Time Zone Email: [email protected] 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. Reach—Body Service Manual Fax: 574-862-7637 2 Parts Online: https://parts.utilimaster.com For Assistance Call: 800-237-7806 Contents Introduction ..................................................................................................................................2 Notes, Cautions, and Warnings .................................................................................................10 “Before You Go” Inspection Checklist ........................................................................................11 Vehicle Orientation ....................................................................................................................11 Vehicle Overview .......................................................................................................................12 VIN, Body Serial, and Work Order Numbers .............................................................................13 Service Procedures ...................................................................................................................14 Batteries ...............................................................................................................................14 Access ............................................................................................................................14 Disconnect ......................................................................................................................14 Body Panel Repair ...............................................................................................................15 Overview .........................................................................................................................15 Gelcoat Repair ................................................................................................................16 Minor Composite Repair .................................................................................................17 Major Composite Repair .................................................................................................18 Bumpers ..............................................................................................................................20 Front Fascia ...................................................................................................................20 Rear Bumper ..................................................................................................................23 D-Bumper .......................................................................................................................25 Side Dock Bumpers ........................................................................................................26 Cladding ...............................................................................................................................27 Front Fender ...................................................................................................................27 Rear ................................................................................................................................28 Sidewall .........................................................................................................................31 Dash Panels .........................................................................................................................33 A-Pillar ...........................................................................................................................34 Brake Panel ...................................................................................................................34 Cluster Panel .................................................................................................................35 Dash Valance Panel ......................................................................................................35 Fuse Access ..................................................................................................................38 Hood Cluster Panel ........................................................................................................39 Overhead Panel .............................................................................................................40 Tray Panel ......................................................................................................................41 Washer Bottle Panel ......................................................................................................41 Door Ajar Switch ..................................................................................................................42 Reach—Body Service Manual Fax: 574-862-7637 3 Parts Online: https://parts.utilimaster.com For Assistance Call: 800-237-7806 Doors, Bulkhead...................................................................................................................43 Removal..........................................................................................................................43 Installation.......................................................................................................................43 Catch Adjustment ...........................................................................................................43 Antenna, Bulkhead TT Keyless ......................................................................................44 Guide, Door ....................................................................................................................45 Seals ...............................................................................................................................45 Doors, Cab Slider .................................................................................................................46 Adjustment ......................................................................................................................47 Removal..........................................................................................................................47 Installation.......................................................................................................................48 Antenna, Cab Door TT Keyless ......................................................................................50 Catch, Front Standard ....................................................................................................51 Catch, Front Keyless ......................................................................................................53 Catch, Rear.....................................................................................................................58 Door Ajar Micro Switch, Keyless .....................................................................................59 Guide ..............................................................................................................................60 Latch ...............................................................................................................................62
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