Body

Operator’s
Guide

FedEx Ground
2 FedEx Ground
 Part Number: 03102285
Revision Control
Revision Publication Date
Rev. B November 2000

Important Notices
©2000, Utilimaster.® Printed in U.S.A.

Title: FedEx Ground Body Operator’s Guide

Utilimaster attempts to provide accurate, complete, and useful information. Should you
find inadequacies in the text, please send your comments to the following address:

Utilimaster
Attn: Designer of Technical Publications
65906 State Road 19, P.O. Box 585
Wakarusa, Indiana, 46573–0585, U.S.A.
219–862–4561, FAX 219–862–3961

This material is confidential and the property of Utilimaster. It is shared with your company
for the sole purpose of helping you with the operation of the described equipment. However,
because of Utilimaster’s policy of continual product improvement, Utilimaster reserves the
right to amend the information in this document at any time without prior notice.

Utilimaster makes no warranty of any kind with regard to this material, including, but not
limited to, the implied warranties of merchantability and fitness 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 responsibility 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 photocopied, reproduced, or translated to another

language without the prior written consent of Utilimaster.

Utilimaster® is a registered trademark of Utilimaster Corporation. All other products or

name brands mentioned in this document are trademarks of their respective owners.

Browse www.utilimaster.com for more information about Utilimaster and its products.
For manual updates and other important information, visit www.utilimaster.com/fedexupd,
the FedEx page on our award-winning web site.

Body Operator’s Guide 3

Contents
Introduction ................................................................................................. 6
Welcome .............................................................................................. 6
Safety Considerations ........................................................................... 8
Exterior Overview .................................................................................. 9
Pre-trip Inspection .............................................................................. 10
Seats and Safety Belts .............................................................................. 11
Driver’s Seat Adjustment ..................................................................... 11
Safety Belts ......................................................................................... 11
Safety Belt Operating Instructions ...................................................... 12
Dash and Heater Controls ......................................................................... 14
Overview ............................................................................................. 14
Heater Controls ................................................................................... 16
Fresh Air Ventilation ........................................................................... 16
Features and Options ................................................................................ 18
Overview ............................................................................................. 18
Mirrors ................................................................................................ 18
Lighting ............................................................................................... 18
Safety Equipment ............................................................................... 19
Window Care and Cleaning Information ............................................... 19
Cab Sliding Doors ............................................................................... 20
Battery Access Cover ......................................................................... 20
Utility Compartment and Trash Bucket ................................................ 20
Bulkhead Sliding Door ........................................................................ 21
Step-down Floor .................................................................................. 22
Rear Roll-Up Door ............................................................................... 23

4 FedEx Ground
 Keys ................................................................................................... 25
Vehicle Access Control System (VACS) ............................................. 25
Hood Operation ................................................................................... 29
Maintenance .............................................................................................. 30
Routine Maintenance .......................................................................... 30
Wipers ................................................................................................ 31
Rear Roll-Up Door ............................................................................... 32
Emergency Repairs ............................................................................ 33
Towing ................................................................................................ 33
Warranty, Parts, and Customer Service ..................................................... 34
Customer Assistance ......................................................................... 34
Warranty ............................................................................................. 34
Filing Warranty Claims ........................................................................ 34
Reporting Safety Defects (U.S. Only) .................................................. 36
VIN and Utilimaster Body Serial Number ............................................ 37
Ordering Parts .................................................................................... 38
Glossary of Terms ..................................................................................... 39
Index ......................................................................................................... 42
Notes ........................................................................................................ 44

Body Operator’s Guide 5

Introduction
Welcome
Welcome. This Operator’s Guide provides you with the neces-
sary information to aid you with the operation, maintenance, and
safety of the vehicle. Please read it and follow the instructions
carefully so that you can experience safe motoring.
This guide describes usage of the Utilimaster body. This guide
covers those assemblies manufactured or installed by Utilimaster ® Corporation.
Items such as chassis and drive train components are covered in the Chassis
Manufacturer’s Owner’s Guide.
For detailed service and maintenance procedures, see the FedEx Ground Body
Service Manual. For replacement parts, see the FedEx Ground Body Parts
Manual. For manual updates and other important information, visit
www.utilimaster.com/fedexupd, the FedEx page on our award-winning web site.
Table of Contents provides an easy reference to the appropriate topic.
Introduction gives an overview of the manual.
Safety Considerations gives a general overview of cautions, warnings and other
considerations to avoid personal injury.
Exterior Overview provides an quick and easy reference to sections referring to
parts of the van.
Pre-trip Inspection provides a check list for safely operating the vehicle.
Seats and Safety Belts reviews the operation and adjustment of safety belts.
Dash and Heater Controls reviews the operation of the driver’s cab systems.
Features and Options reviews the vents, mirrors, lights, windows, doors, hood,
VACS or vehicle access control system (keyless entry), and other equipment.
Maintenance explains basic operator maintenance.
Warranty, Parts, and Customer Service describes the Utilimaster warranty policy
and the procedure for ordering parts.
Glossary of Terms describes industry terms commonly used.
Index contains an alphabetical listing of manual topics and their corresponding
page numbers.

6 FedEx Ground
All information, specifications, and illustrations contained in this guide are based
on the latest product information available at the time of publication. However,
because of Utilimaster’s policy of continual product improvement, Utilimaster
reserves the right to amend the information in this document at any time without
prior notice.

Throughout the guide safety alerts provide information that

may reduce the risk of personal injury or vehicle damage
and are marked with this triangular icon.

Body Operator’s Guide 7

Safety Considerations
As you read through the procedures, you will come across
NOTES, CAUTIONS, and WARNINGS. Each one is there for a
specific purpose. NOTES give you added information that will
help you to complete a particular procedure. CAUTIONS are
given to prevent you from making an error that could damage
the vehicle. WARNINGS remind you to be especially careful in
those areas where carelessness can cause personal injury.

The following list contains some general WARNINGS that you should follow when
you work on a vehicle.

• Always wear safety glasses for eye protection.

• Use safety stands whenever a procedure requires you to be under the
vehicle.
• Be sure that the ignition switch is always in the OFF position, unless
otherwise required by the procedure.
• Set the parking brake when working on the vehicle and if the vehicle has
an automatic transmission, put the transmission in PARK.
• Operate the engine only in a well-ventilated area to avoid the danger of
carbon monoxide.
• Keep yourself and your clothing away from moving parts when the engine
is running, especially the fan and belts.
• To prevent serious burns, avoid contact with hot metal parts such as the
radiator, exhaust manifold, tail pipe, catalytic converter, and muffler.
• Do not smoke while working on the vehicle.
• To avoid injury, always remove rings, watches, loose hanging jewelry, and
loose clothing before beginning to work on a vehicle. Tie long hair
securely behind your head.
• Keep hands and other objects clear of the radiator fan blades. Electric
cooling fans can start to operate at any time by an increase in under hood
temperatures—even though the ignition is in the OFF position. Therefore,
disconnect the electric cooling fan when working under the hood.

8 FedEx Ground
Exterior Overview

Identification Clearance Identification Rear Cargo Door

Lights Lights Lights

265752

265752
Side
Mirrors Brake/Tail
Light

Hazard/Turn/
Tail Lights

Headlights Hood Backup Lights

Turn Signal
VACS
Rear
Sensor
Bumper

Side Marker Light

Cab Vent
265752
(Driver's Side Only)

VACS
Sensor

Side Marker
Light
US DOT 265752

Reflector Fuel Fill Port Reflector

Body Operator’s Guide 9

Pre-trip Inspection
Before operating this vehicle, you should perform the FedEx Ground pre-trip
inspection and any of the following checks which may or may not be included in
the FedEx Ground plan. This inspection serves as a safety check on the operation
of critical equipment.
• Adjust all mirrors. See Page 18.
• Adjust the driver’s seat position. See Page 11.
• Fasten and adjust the seat belt. See Page 12.
• Check the function of the service reminder indicators when turning the key to
“ON” .
• Check the fuel gauge to see that you have sufficient fuel.
• Check dash switches and accessories for proper operation.
• Check heater and defroster controls. See Page 16.
• Check the operation of all exterior lights including brake lights and turn
signals.
• Check the operation of all internal lights.
• Check the operation of all doors.

10 FedEx Ground
Seats and Safety Belts
Driver’s Seat Adjustment
The driver’s seat has been designed to give you maximum comfort and visibility
while operating the vehicle.
The driver’s seat may have optional adjustment features.
1. Enter the vehicle and sit in the seat.
2. To move the seat to the desired height, the aid of a second person is recom-
mended. Seat height is adjusted as follows:
a. Turn the pedestal knob counterclockwise to loosen the post.
b. Remove the locking pin (underneath the seat on the left side).
c. Lift the seat to align with the post hole nearest the desired height.
d. Replace the locking pin in the hole.
e. Turn the pedestal knob clockwise to lock and stabilize the post.
3. Adjust the distance between the driver and the steering wheel forward or
backward using the lever on the left side of the driver’s seat. Pull lever out to
unlock and move to the correct position, then release the lever to lock the seat
in position.
4. Try to move the seat with your body to make sure the seat is locked and
secure.

WARNING: Do not adjust the seat when the vehicle is

moving. The sudden movement could cause you to lose
control of the vehicle.

Safety Belts
The driver and any passenger must wear their safety belt at all times when the
vehicle is moving. Failure to do so could increase the chance of injury and/or the
severity of injury in accidents. Safety belts provide added protection in the event
of sudden braking or a collision.

Body Operator’s Guide 11

Most seat belt restraint systems incorporate webbed belts with inertia-sensitive
retractors. The system is designed to lock (i.e., prevent belt travel) during very
sudden stops or impacts. However, the shoulder belt moves freely with the wearer
under normal conditions. If the belt is jerked or pulled rapidly by hand, the belt
may lock. If this occurs, let go of the belt, then pull out on it slowly and smoothly.

Safety Belt Operating Instructions

Buckling the Belt
The belt restraint is equipped with a retracting shoulder harness for added comfort.
1. Enter the vehicle and close the door.
2. Adjust the seat. See page 11. Sit up straight and well back in the seat.
3. Grasping the latch plate, slide it up the webbing, while pulling forward with a
slow steady motion. You should pull out enough webbing to extend approxi-
mately one arm’s length or enough to go across your lap. If the retractor
should engage while you are doing this, let go of the belt, then pull out on it
slowly and smoothly. Do not let the belt become twisted.
4. Pull the belt across your lap and push the latch plate into the buckle until it
clicks. Pull on the belt to make sure it is secure.
5. Adjust the height of the shoulder harness to fit your body. Start by pulling
down on the pillar height adjuster lever, if so equipped. Slide the height
adjuster up or down until you reach the desired position. Release the knob.
The recommended fit is to have the belt come over your left shoulder and
down across your chest—not across your neck.

12 FedEx Ground
The shoulder belt allows unrestricted movement of the upper body under normal
conditions, and it locks in the event of an accident.

Releasing the Belt

1. Press the (lap belt) buckle release button and allow the belt to retract.
2. If the belt does not retract smoothly, pull it out and check for kinks or twists.
Inspect the belt system periodically. Check for cuts, frays, and loose parts.
Damaged parts must be replaced immediately. Do not disassemble or modify the
system.

Safety belt assemblies must be replaced:

1. If they have been subjected to extreme stress by a wearer in an accident (even
if no damage is obvious).
2. If they have been damaged by an accident (e.g., bent retractor, torn webbing).
3. If there are any worn parts, including any loose components or fraying belts.
Always replace the entire assembly.

WARNING: After inserting the latch plate, make sure it is

locked and the belt is not twisted. A twisted belt can lead to
serious injury because it reduces the amount of protection.
Do not wear the shoulder belt under your arm or in any
position other than the one described here. Such use could
increase the chance of severe injury in an accident. The lap
belt should be worn snug and low across the hips.

WARNING: If there is any question regarding belt or retractor

condition, replace the entire assembly.

Body Operator’s Guide 13

Dash and Heater Controls
Overview
The components described in the follow-
ing sections are general to FedEx Ground
265752

trucks. Dash configuration and some

options may vary. For further informa-
tion, see the Chassis Manufacturer’s
US DOT 265752

Owner’s Guide.

Air Louvers
These circular vents, located on either side of the instrument panel, rotate to allow
you to adjust the direction of the air flow when the fan is on. When the heater
control is set to defrost, little air comes out of these louvers since most of the air
flow is directed (higher) through the defrost ducts near the windshield. As the
mode control switch is turned to other settings (see page 16), a varying amount of
air is directed (lower) through the louvers and the floor ducts.
To direct even more air to the defrost or floor ducts, the louvers can be closed by
rotating them around their pivots approximately 90 degrees.

Wiper/Washer Instrument Panel Heater Controls Open Door VACS (Vehicle Access
Bypass Switch Control System) Ignition
Cup Control Reader
Holder

Headlight/
Parking
Light Cruise
Switch Control
Switches

Parking Brake Ignition (on VACS-equipped vehicles Chassis Diagnostic Side Door Unlock
the ignition switch is in same position Switches Switches (LH/RH)
Cargo Light but located underneath dash) underneath dash
Dome Light

Hazard Lights next to turn signal lever.

Dimmer Switch at end of turn signal lever.

14 FedEx Ground
Vehicle Access Control System (Optional)
See pages 25–28 for details on the keyless entry and ignition system.

Headlight/Parking Lights
Flip the three-way toggle switch all the way up to turn on the headlights. Move the
switch to the midway position for parking lights. To turn both headlights and
parking lights off, press the switch all the way down. The dimmer switch for
headlights is at the end of the turn signal lever on the left side steering column.

Instrument Panel
For information about the Instrument Panel gauges, indicator lights, and steering
column controls, see the Chassis Manufacturer’s Owner’s Guide.

Windshield Wiper/Washer Switch

For a single wipe, turn the knob counterclockwise and hold it in this position until
the wipers start, then release the knob. For low speed wiping, turn the knob
clockwise to first stop. For high speed wiping, turn the knob clockwise all the way.
To wash, push the knob in and hold until enough washer fluid is sprayed on the
windshield. Wipers will continue to operate on low speed until they are turned off.

Cruise Control
To turn cruise control on, flip the two-way on/off toggle switch up. Lift the two-
way set/resume toggle switch up to set cruise speed. Applying the brake will
disengage cruise control. Resume earlier cruise control setting by pressing the set/
resume toggle switch down.

Cargo and Cab Light Switch

The interior cargo area and cab lights are controlled by switches on
the dash panel. Press the top half of the rocker switch to turn a light
on. Press the lower half of the switch to turn a light off.
Note: The cargo light is a three-way switch with the other switch in the rear,
curb-side cargo area near the floor. The cargo light automatically turns on
for one minute when the roll-up door, or the bulkhead door, is opened.

Body Operator’s Guide 15

Hazard Light Switch
The hazard switch on the left side steering column controls the intermittent flashing
of lights on the body. The hazard lights work with the engine on or off and with or
without the ignition key. See the Chassis Owner Guide for more details.

Fuse Panel
The fuse panel is mounted underneath the dash. See the Chassis Manufacturer’s
Owner’s Guide for detailed information.

Heater Controls
The heating system is controlled by three knobs
located on the dash panel.
The top knob on the heater control face controls the
fan speed. Turn the knob clockwise to increase the
speed. Turn it counterclockwise to decrease the
speed.
For a warmer airflow, turn the middle temperature
control clockwise (toward red). For a cooler airflow,
turn the temperature control counterclockwise
(toward blue).
The bottom knob (mode control) directs the airflow
to the defroster outlets, the floor ducts, or some
combination of the two.

Fresh Air Ventilation

Fresh air enters the cab through the heater system and the hingeless vents.
For fresh air, rotate the temperature control knob on the heater control panel to the
maximum blue position. Adjust the fan speed to increase the flow of air. Adjust the
air louvers and the cab ventilation fan to direct the air where required.

16 FedEx Ground
Cab Ventilation Fan
Adjust the tilt and direction of the gimbal-mounted fan as desired while the truck is
parked. The ignition switch must be on for the fan to run.

Hingeless Vents
The vehicle is equipped with two-way hingeless vents
in the cab and cargo areas. To open, move the handle
bar toward the rear of the vehicle. When the vehicle is
moving, the vent will bring fresh air from the airstream
into the cab. The handle mechanism has detents that
allow the vent to catch at different angles. To close,
move the handle to the center position.
Hingeless Vent

Body Operator’s Guide 17

Features and Options
Overview
265752

The components described in the

following sections are general to FedEx
Ground trucks. For further informa-
tion on chassis-related items, see the
US DOT 265752

Chassis Manufacturer’s Owner’s

Guide.

Mirrors
To receive maximum benefit from the outside mirrors, have someone assist you by
loosening the mirror mounts and adjusting the passenger-side, and driver’s side
mirrors while you sit back in the driver’s chair. Adjust the driver’s side mirror so
you can see the side of the vehicle.
To adjust a mirror, loosen the nut until the mirror is just loose enough to turn, then
grab the outside edge of the mirror and gently pull in the desired direction. Re-
tighten the nut when mirror is in desired position.
Some exterior mirrors are convex. A convex mirror’s surface is curved so you can
see more from the driver’s seat—but it makes things appear farther away than they
really are.

WARNING: A convex mirror can make things appear farther

away than they are. Use care when utilizing these mirrors,
especially when changing lanes and backing up.

Lighting
Note: See the illustration on page 9 for locations of the exterior lights.
Headlights, Parking Lights
Activated by a switch on the instrument panel. See page 15.
Cab Light
Activated by the switch on the instrument panel.

18 FedEx Ground
Cargo Lights
The cargo light is turned on by three-way Cargo Light
Switch
switches—one on the instrument panel and a
second switch near the floor in the rear, curb-
side corner of the cargo area. In a VACS-
equipped vehicle, the cargo light automatically
turns on for one minute when the roll-up door,
or the bulkhead door, is opened. See page 15.
Turn Signals
Activated by the turn signal lever. For more
information about the steering column controls,
see the Chassis Manufacturer's Owner’s Guide. Light Switch next to Rear Door
Hazard Lights
Activated by the hazard flasher switch on the steering column. Refer to the Chassis
Manufacturer’s Owner’s Guide.

Brake Lights
Activated when the brake pedal is pressed.
Backup Lights
Activated when the gear shift on the transmission is in the reverse (R) mode. For
more information about the steering column controls, see the Chassis
Manufacturer's Owner’s Guide.
License Plate Light
Activated with the running lights.

Safety Equipment
A fire extinguisher is located on the cowl near the passenger door, and a reflector
kit is located behind the driver’s seat.

Window Care and Cleaning Information

Wash windows with a mild soap or detergent, using a clean sponge or soft cloth.
Rinse well with clean water. To prevent water spots, dry with a chamois or moist
cellulose sponge. Do not use razor blades or other sharp objects that could score
the glass! Do not clean in the hot sun or at elevated temperatures!

Body Operator’s Guide 19

Fresh paint splashes, grease, and smeared glazing compounds can be removed
easily before drying by rubbing lightly with a grade of VM&P naphtha or isopro-
pyl. Naptha also works with labels and stickers. Butyl cellosolve works well for
removal of paints and marking pen inks. Afterwards, a warm final wash should be
made, using a mild soap or detergent solution and ending with a thorough rinsing
with clean water.

Battery Access Cover

Batteries are located under the right-hand
stepwell. The access cover is held in place
by rubber quick release straps. To open the
cover, pull up and out on each strap, and
then pull up on the cover.

Utility Compartment and Trash Stepwell Battery Access

Bucket
A utility compartment for personal items
and a trash bucket are provided in the left-
hand or driver’s side stepwell.
The compartment access cover is held in
place by rubber quick release straps. To
open the cover, pull up and out on each
strap, and then pull up on the cover.
The trash bucket is held in place by hook
and loop tape.
Driver’s Stepwell

Cab Sliding Doors

To enter the cab on vehicles equipped with the VACS system, swipe the VACS reader
with a wrist transponder before opening the sliding door. (See page 25.)
To open the door (from the inside or outside) unlock it and push the top of the
handle toward the rear of the vehicle. The handle unlatches the catch, allowing
you to push the door backward. Once the door is completely open, the latch holds
the door in position.
To close the door, push the top of the handle toward the front of the vehicle and
slide the door forward until the latch mechanism catches.

20 FedEx Ground
To lock the doors from the inside on vehicles
without the VACS system, locate the lever below the
interior handle, and push up.
To lock the doors from the outside, insert the key,
and rotate the top of the key toward the rear of the
vehicle. To unlock, rotate toward the front.
Both doors on VACS-equipped vehicles can be
unlocked by the door unlock switches beneath the
VACS control module. A door will automatically lock
when it is closed. (See pages 25–28 for details on
VACS).

Note: All doors must be completely closed and latched in

VACS-equipped vehicles before the engine will start.
However, the VACS system can be overriden to start the
engine with the passenger-side sliding door open. (See
page 27.)

Bulkhead Sliding Door

This door allows access from the cab to the cargo area Bulkhead Door (Cab
without having to exit the vehicle. Side, VACS-equipped)
To enter the cargo area from the cab on vehicles
equipped with the VACS system, swipe the VACS sensor
above the jump seat before opening the bulkhead door.
Note: A door must be opened within 5 seconds before the
VACS locks the door again.
To open the door from the cab side on VACS-equipped
vehicles, push the top of the handle toward the driver’s
side to unlatch the catch and slide the door to the right.
To open the door from the cab side on vehicles without
VACS, insert the key in the access port to the right of the
jump seat, turn the key clockwise, and pull the door open
using the grab handle.

Bulkhead Door (Cab

Side, non-VACS)

Body Operator’s Guide 21

To open the door from the cargo side
in vehicles equipped with the VACS
system, press the “door unlock”
switch above the catch mechanism.
Push the top of the handle toward
the driver’s side to unlatch the catch
and slide the door to the right.
Note: The VACS system can also be
overridden by pushing the manual
override lever to the right.
To open the door from the cargo side
on vehicles without VACS, lift up on
Bulkhead Door (Cargo Side)
the catch lever and slide the door to
the left.
To close the door from the cab side, grab the latch cable to release the locking latch
at the top and pull the door to the left until the handle latch catches.
Note: All doors, including the bulkhead door, must be completely closed and latched on
VACS-equipped vehicles before the engine will start. However, the VACS system can be
overriden to start the engine with the passenger-side sliding door open. (See page 27.)

Step-down Floor
A 9-inch drop in the floor at the rear of the
cargo area makes loading and unloading the
cargo area easier.

Caution: 9-inch step!

WARNING: Watch your step!
The cargo area has a 9-inch
step down toward the rear.

Cargo Step

22 FedEx Ground
Rear Roll-Up Door
To enter the cargo area from the outside
on vehicles equipped with the VACS VACS Access Reader

system, swipe the VACS reader to the Key Access

right of the roll-up door with a wrist Catch

transponder before opening the door. Master Security Lock

("Banana" Lock)

Note: Door must be opened within 5

Catch

seconds before the VACS locks the door

again.
Press down on the handle to relieve Access from the Outside
tension on the door before opening. (VACS-equipped)
Unlatch the door by moving the catch to
the right and rotating the “banana” lock
lever to the left.
If the door catches again (about a foot
from the floor), swipe the VACS access
reader again to release the door.
To close the door from the outside, pull
down on the door strap, release the
“banana” lock lever and rotate the lever
to the right to latch. Access from the Outside
(non-VACS-equipped)

Moving door can cause

injury or death.

Stand clear of opening

while door is moving.

Body Operator’s Guide 23


Rear Door Unlock Switch
(VACS-equipped)
Rear Door (Interior)
Release Levers
To exit the cargo area from the
inside on vehicles equipped with
the VACS system, press the “door
unlock” switch on the curb-side wall
next to the roll-up door.
Note: Door must be opened within 5
seconds before the VACS locks the door
again.
Unlatch the catch mechanism by
rotating the catch release lever
counter-clockwise (about 30
degrees) until it stops, and then
rotate the “banana” lock release
lever 180 degrees clockwise.
Press down on the “banana” lock
release before pulling the door open
to relieve tension on the door before
opening.
If the door catches again, press the
“door unlock” switch again to
release the door.
Be sure the rear cargo door is
closed and locked before driving the
vehicle.

WARNING: Failure to secure cargo will increase the risk of

injury in a collision or sudden stop.

WARNING: 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 upon you. Use the grab
handles to aid getting in and out of the back.

24 FedEx Ground
Keys
Make a spare set of all keys and keep in a
secure place.
Turn key clockwise to open door or start
engine; counterclockwise to lock or turn off
engine.
An emergency key is provided for access
through the rear door for vehicles equipped
with a “keyless entry” Vehicle Access
Control System or VACS. (See page 26.)
An emergency keyed ignition switch is
located underneath the dash panel in the
event the VACS module fails.
Take key from ignition when leaving the
vehicle.

Alternate Ignition Switch

Vehicle Access Control System (VACS)

Many vehicles are equipped with a keyless entry and ignition system called VACS
or Vehicle Access Control System.

Waking Up System
NOTE: Vehicle will not respond unless it reads a pro- Hold for 5 seconds
grammed transponder.
NOTE: For optimum performance, hold transponder 3–6
inches from the reader.

If the vehicle is unused for more than an hour, wake

up the VACS by using one of the following methods:
Wake up
• Hold the transponder in position by any
access reader for up to 5 seconds.
• Pressing an interior door release switch.
• Starting the engine.

Body Operator’s Guide 25

Unlock From Outside
• To unlock a cab exterior door from the
outside, the rear door from the outside, or
the bulkhead door from the cab side, slowly
pass the transponder in front of the access
reader. This will unlock the door for 5
seconds.
Open door (outside)
Unlock From Inside
NOTE: A transponder is not required to exit from the vehicle.
• To open a cab door from inside the cab,
press the door unlock switch (mounted on
the dash). This will unlock the door for 5
seconds.
• To open the bulkhead door from inside the
cargo area, press the button mounted beside
the bulkhead door on the curbside bulkhead
panel. (See page 22.) This will unlock the
door for 5 seconds. Open door (inside)
• To open the rear door from inside the cargo
area, press the button mounted beside the
rear door on the curbside wall. (See page 24.)
This will unlock the door for 5 seconds.

Emergency Entrance and Exit

• In the event of a dead battery, the vehicle
may be entered with a key via the rear rollup
door.
• Each door dead bolt can be manually
operated from the interior.

26 FedEx Ground
Starting and Stopping Vehicle Less than
1/2 second
Activating Accessories ST
AR
T

• Place the hand with the transponder

strapped to the wrist above the ignition
control reader and press the green start
switch for less than 1/2 second. This will
activate the accessory mode. Accessory Mode

Starting Engine
NOTE: Doors must be closed (including bulkhead) to
start vehicle in normal operation. If a door is ajar, a red
LED on the ignition reader will flash when attempting to
start the unit.
• Place hand with the transponder above
ignition control reader, and press the green
start switch for less than 1/2 second or Close all doors
until the Instrument Panel lights turn on.
This will activate the accessory mode.
NOTE: You have 10 seconds after the start switch is
released to try and restart the vehicle. If this time has
expired, the red stop switch has to be pressed, and then the
green start switch has to be pressed again to start the
engine.

• Once the “Wait to Start” light on the

Instrument Panel goes out, press the green
“start” button until the engine starts.

Starting Engine with Passenger-Side Sliding Door

Open
The black open door bypass switch to the left of the More than
ignition control reader allows the driver to start the 1/2 second
ST

vehicle with the passenger-side door open.

AR
T

• To override, press and hold down the black

bypass button while pressing the green
button for less than 1/2 second or until the
Instrument Panel lights turn on. Start engine

Body Operator’s Guide 27

 • Keep the black bypass button depressed and pause for the “Wait to Start”
light to go out on the Instrument Panel.
• Once the “Wait to start” light goes out, press the green start button until
engine starts.
NOTE: Both the black and green buttons must be depressed for the engine to start.
NOTE: Release the green button first. The engine will stall if the black button is released
first.
If the engine doesn’t start, recheck the doors (especially the bulkhead door) to
make sure all doors except the passenger-side door are closed.

Stopping Engine
NOTE: No transponder is needed to shut off the
engine.
ST
OP

• Press the red stop switch for more than 1/4

second. The engine will stop, and the
interior lights will activate for 10 seconds.

Vehicle Security Stop engine

Operating Modes
NOTE: If the alarm is disarmed/deactivated and the vehicle is not started or in
accessory mode, the system will arm itself after 10 seconds.
VACS has two operating modes. To toggle between modes (only available while
engine is running), press the black mode button.
• Door Opened (Red LED): The security Door open
system will be armed 10 seconds after any
exterior door is opened.
• Door Closed (Yellow LED): The security
system will be armed 10 seconds after all
exterior doors are closed.
Door
closed
Operating modes

28 FedEx Ground
Disarming/Deactivating the Alarm
The alarm can be deactivated by any one of the ST
AR
T

following methods:
• A valid transponder is read by any access
reader.
• Starting the vehicle with a valid transpon-
der.
Disarm alarm

Hood Operation
The hood will not remain open without the hood
support rod. Special precautions should be taken to
prevent personal injury or damage to the hood by
using the safety support rod.
To open the hood.
1. Release the hood latches on both sides.
2. Pull the hood completely open.
3. Secure the hood safety support rod in the
catch next to the grill.
To close the hood.
1. Return the safety support rod to its
original position.
2. Lower the hood.
3. Engage the hood latches.

WARNING: Engage the hood support rod when the hood is

open.

Body Operator’s Guide 29

Maintenance
Routine Maintenance
Most of the body construction is sturdy, lightweight, rust-free aluminum. By
design, the Utilimaster body is low maintenance. However, the following sugges-
tions for the operator would add to the overall upkeep of the vehicle:
• Clean the windows and windshield wiper blades as necessary. Use water, a
mild detergent, or windshield washer fluid.
• Clean rubber “Kazoo” or “duck bill” drain valves in the rear cargo floor corners
periodically to ensure that the drain is not blocked by debris or dirt and is able
to drain properly. From the interior of the vehicle, use a small pointed tool,
such as a pen or small screwdriver, to gently poke down through the drain. Or,
from underneath the vehicle, you can squeeze the wide section of the bottom
to open the “lips” and release any accumulation that did not drain normally.
• Wash and wax the body periodically to help preserve the exterior finish, but
avoid harsh cleaning solutions or high-pressure washes. (Do not power wash
for the first 90 days.)
• Inspect all door handles and locking hardware for secure mounting, operation,
latch alignment, and condition. Have qualified personnel correct any problems
immediately.
• In the winter, use a lock antifreeze to keep your locks from freezing.
• Lubricate the door tracks, handles, latches, and locks periodically with a
lightweight oil to allow for ease of operation. (See also the rear door section
on page 32.)
• Inspect seats pedestal, sliding mechanism, and safety belts for secure mount-
ing, operation, and condition. Have qualified personnel correct any problems
immediately.
• Check all lights for burned out bulbs. Replace if necessary.
• Check cab fan for operation and tightness of mounting.
• Check the wiper linkage for operation and tightness of mounting.
• Check windshield washer operation and spray pattern.
• Check that the blades wipe clean and are streak free.

30 FedEx Ground
 • Check all windows for cracks or defects and window latch operation.
• Check all doors for ease of opening.
• Check hood latches, struts, and guides for operation and wear.
• Lightly lubricate socket and door catches with petroleum jelly.
• Check rear bumper, mounting brackets, and dock bumpers for tightness and
wear.
• Check all vents for operation and clean any debris.
For more detailed maintenance and repair information see the Utilimaster Body
Service Manual.
Maintenance

Wipers
Replace the windshield wiper blades when they lose their effectiveness in clearing
water from the windshield.
To replace the blades on most vehicles:
1. Pull the wiper arm away from the windshield, and lock the arm into the service
position.
2. Push the blade toward the windshield about an inch.
3. Unhook the blade assembly from the arm.
4. Hook in a new blade, and push the blade away from the vehicle until the blade
locks in place.
5. Lower the arm.

Wiper blade assembly

Retaining clip

End of wiper arm

Body Operator’s Guide 31

Rear Roll-Up Door
Every three to four months, use a lightweight
oil, (such as Door Lube Utilimaster P/N
04202540), to lubricate the counterbalance
bearings, rollers, center and end hinges, lock,
and latches.
Wipe dirt from the tracks and lubricate the
tracks.
Blow dirt out of panel joints.
At all lubrication points, take care to wipe off
excess oil, and do not get oil on the rubber
door seals. Do not use grease or a penetrat-
ing oil (e.g., not WD–40®). Moving door can cause
injury or death.
At every maintenance, check the lift cable
and pull-down strap for wear or fraying.
Stand clear of opening
Frequency of maintenance depends on while door is moving.
climatic conditions. When road salts are
used, the door may need to be lubricated
more frequently.
If the door becomes difficult to operate or some other defect is found, have it
repaired by a qualified mechanic. For details, see the Utilimaster Body Service
Manual.

WARNING: A counterbalance spring on the rear roll-up

door is wound under high tension. Only qualified
technicians should adjust this spring.

WARNING: 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 upon you. Use the grab
handles to aid getting in and out of the back.

32 FedEx Ground
Emergency Repairs
See the “Roadside Emergencies” section in the Chassis Manufacturer’s Owner’s Guide
for engine and chassis emergency information such as fuses, jump-starting, and
changing tires.
A fire extinguisher and a reflector kit are located behind the driver’s seat.

Towing
See the Chassis Manufacturer's Owner’s Guide for complete details.
If the vehicle needs towing, a wheel lift or flatbed equipment is recommended.
If a sling or J-hook method of towing is used, check the front and rear tow hooks
for damage or loose mounting.
Unloading the vehicle to reduce stress on the chassis during towing is recom-
mended.
Be sure to fully release the parking brake before towing.

WARNING: When manually releasing the spring brakes, be

sure to block the wheels so the vehicle cannot move when
the brakes are released.

WARNING: Make sure the vehicle is securely connected to

the tow vehicle and that the tow vehicle parking brakes are
applied before releasing the disabled vehicle’s spring
brakes.

Body Operator’s Guide 33

Warranty, Parts, and Customer Service

Customer Assistance
The Customer Service Department of Utilimaster welcomes you. We want you to
know that we are interested in your satisfaction with this product and our service.
When this vehicle is delivered, please take the time to thoroughly inspect the unit.
If there is any damage or shortage of parts, you must note them on the Accessory
Check List and Delivery Acceptance Form. In the event there is damage or a parts
shortage, please contact the warranty department to have the situation resolved.

Warranty
The warranty is issued to the original purchaser and is neither transferable to nor
enforceable by any other person. Utilimaster Corporation warrants that the body
shall be free from defects in factory materials and workmanship made or supplied
by Utilimaster under normal use and service, in accordance with and for the
specified period.
The warranty begins on the in-service date. The chassis, engine, and tires are
warranted separately by the manufacturers of those components.

Filing Warranty Claims

If a problem is caused by a defect in materials or
workmanship, it will be covered by our Limited War-
ranty. Claims must meet the requirements listed on this
page. Failure to meet these requirements may result in a
denied or delayed claim.
Complete a repair order with the following information:
· Owner’s and/or service facility’s name.
· Service center representative’s signature.
· Chassis VIN or Utilimaster Body/Unit Serial Number (see page 37).
· Date vehicle was repaired.
· Mileage at time of failure.

34 FedEx Ground
· Itemized description of the problem.
Complaint
Cause of failure (if known)
Correction (describe in detail)
· Service center labor rate and total time of repair.
· Total claim amount, including cost of parts, labor, miscellaneous charges, and
sales tax (if applicable).
· Your claim number or repair order number
Note: The claim number or repair order number is the number
used to match Utilimaster payment with the work done. It will be
noted on our payment.
· Utilimaster authorization number (for repairs costing over $500).

The claim can be mailed, faxed, emailed, or performed on-line on our web site
(assuming all required information is included).
· Warranty claims should be mailed to:
Utilimaster
Attn: Warranty Department
65528 State Road 19
P.O. Box 585
Wakarusa, IN 46573–0585
· Alternately, you can fax your claim (if no photographs are involved) with the
above information to 219–862–7637. (The resolution of the received copies
must be acceptable, or you will be asked to mail in hard copies.)
· Or you can email your claim with the above information to
CustSvc@Utilimaster.com.
· You can also fill out the online warranty claim form on the Utilimaster web site
www.utilimaster.com.

Other claim requirements:

· Any repairs over $500 or for structural warranty claims require prior
authorization from Utilimaster, and that number must appear on the repair
order.
· Any claim that is not legible and complete will be returned for completion.
· All paint claims require pictures, two estimates, and prior authorization.
· Shipping damage claims may also require pictures, estimates, and prior
authorization. The damage must also be noted on the Delivery Acceptance
form. This form requires the signature of the carrier driver.

Body Operator’s Guide 35

· Sublet work must have the sublet repair order attached to the service facility’s
repair order that is being submitted.
· Claims must be submitted within 30 days after the repair is completed.

If the return of a failed part is requested, contact a Utilimaster warranty representa-

tive for a return goods authorization (RGA). Please reference that number with the
returned part and enclose a copy of the repair order. Shipping charges should be
entered on the same repair order that is submitted for warranty payment. COD
charges for returned parts will not be accepted, and the part will be returned.
Chassis, engine, tires, and battery failures are covered by the individual manufac-
turers.
Claims are paid semimonthly. Utilimaster generally does not pay sales tax on claims
(dependent on state law). If you do not have our tax exemption number on file,
please call 800–582–3454 or 219–862–4561 and ask for the accounting department
to obtain the number.

Reporting Safety Defects (U.S. Only)

If you believe that your vehicle has a defect that could cause a crash, or could
cause injury or death, you should immediately inform the National Highway Traffic
Safety Administration (NHTSA) in addition to notifying Utilimaster.
If NHTSA receives similar complaints, it may open an investigation, and if it finds
that a safety defect exists in a group of vehicles, it may order a recall and remedy
campaign. However, NHTSA cannot become involved in individual problems
between you, your dealer, or Utilimaster.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-
424-9393; in the Washington, D.C., area call 202-366-0123 or write to:
NHTSA
U.S. Department of Transportation
400 Seventh Street
Washington, DC 20590
You can also obtain other information about motor vehicle safety from the Hotline.

36 FedEx Ground
VIN and Utilimaster Body Serial Number
The chassis Vehicle Identification Number (VIN) is the legal identifier for this
vehicle and is the number recorded in the license plate registration. The VIN
appears on a metal plate mounted inside the engine compartment wall on the
driver’s side. The number is also recorded on the Federal Certification Decal (see
below).
The Utilimaster Body (or Unit) Serial Number is recorded on the Federal Certifica-
tion Label. This label is a plastic decal (about 11" long and 2" high) that contains a
variety of manufacturing information (including the VIN). This label is near the top
of the driver’s door frame between the door and the quarter-panel window.

Federal Certification Label

Body Operator’s Guide 37

Ordering Parts
To order parts for this vehicle, gather the following informa-
tion:
· Model and Year of Vehicle (200_ FedEx Ground).
· Chassis VIN or Utilimaster Body Number or Asset
Number (see section on page 37).
· Complete shipping address.
· Preferred method of shipping.
· Method of payment.*
· Complete description of all the parts necessary (see the
Utilimaster Body Parts Manual).
Then contact Utilimaster Customer Service by one of the following methods:
· Call 800–237–7806 (or 219–862–3219) and ask for the parts department.
· Fax your order with the above information to 219–862–7637.
· Email your order with the above information to FGparts@Utilimaster.com.
· You may also mail the order to the following address:
Utilimaster
Attn: Parts Department
65528 State Road 19
P.O. Box 585
Wakarusa, IN 46573–0585
U.S.A.
*Customer Service prefers payment by Visa, MasterCard, Discover, or American
Express credit cards. Purchase Orders from customers with established open
accounts are also accepted.
To return parts for credit, call the Customer Service department for prior authoriza-
tion. All returns must be shipped prepaid freight. A restocking fee will be charged
to all returns. Special-order parts are not returnable.

38 FedEx Ground
Glossary of Terms
Body—The aluminum cab and cargo structure built by Utilimaster upon the chassis
frame. The body does not include the engine, drive train, or the chassis compo-
nents.
Bulkhead—Wall dividing the cab area from the cargo area.
Bumper, Step—A light-truck bumper with a flat-top surface to provide a step for
entry into the vehicle.
Cab—The driver/passenger-carrying compartment of the truck.
Caution—A notice to prevent damage to the vehicle.
Certification Label—A label, required by Public Law 89-563, which states (certifies)
that a motor vehicle or item of motor vehicle equipment complies to all applicable
Federal Motor Vehicle Safety Standards (FMVSS) in effect on the date of manufac-
ture.
Clearance Lights—Lighting required by Federal Motor Vehicle Safety Standards
to indicate the overall width (for vehicles in excess of 80-inches wide) and height of
a vehicle. Lights are red in rear and amber in front.
Cowl—The front part of a cab or body directly below the base of the windshield
between the cab and engine compartment.
Curb Side—See Right Hand.
Curb Weight—The weight of a motor vehicle with all permanently mounted
equipment and maximum capacity of engine fuel, oil, and coolant. Same as Tare
Weight.
Door, Roll-up—Any multi-paneled door that opens vertically on a track system.
Door, Slide Sliding—Any single-paneled door that opens horizontally on a track
system.
DOT (Department Of Transportation)—Several Federal agencies dealing with
regulations concerning both the manufacture and operation of motor vehicles.
Duck Bill Drain—A self-closing drain that prevents siphoning.

Body Operator’s Guide 39

FMVSS (Federal Motor Vehicle Safety Standard)—Mandated regulations promul-
gated by the National Highway Traffic Safety Administration (NHTSA) under
Public Law 89-563.
GVWR (Gross Vehicle Weight Rating)—The maximum total vehicle weight that
the vehicle is rated to safely carry.
Identification Lights—Lighting required by Federal Motor Vehicle Safety Stan-
dards to indicate the type of motor vehicle. Lights are red in rear and amber in
front.
Kazoo Drain—See Duck Bill Drain.
LH (Left Hand)—Position on the vehicle to the driver’s left as the driver faces
forward.
Marker Lights—Amber and red lights attached to the vehicle body which indicate
the overall length.
NHTSA (National Highway Traffic Safety Administration)—The Federal agency
responsible for compliance of regulations dealing with the manufacture and
certification of motor vehicles.
Overall Vehicle Height—Distance from the ground to the highest point of the
vehicle.
Overall Vehicle Width—Refers to the nominal design dimension of the widest part
of the vehicle, excluding signal lamps, rear view mirrors, flexible fender extensions
and mud flaps, determined with doors and windows closed and wheels in the
straight-ahead positions.
Parallel Batteries—When all batteries have their positive terminals connected on
a common cable and all negative terminals on another common cable.
Riser—Steel section between chassis frame and van body underframe to give
proper tire clearance and/or ground-to-floor height.
Right Hand (RH)—Position on the vehicle to the driver’s right as the driver faces
forward.

Roof Bow—Transverse support member in the roof of a body.

Roof Rail—Member running longitudinally which connects the roof to the side of
the body.

40 FedEx Ground
Rub Rail—Member running longitudinally providing a rub surface on the exterior
side of a body to minimize damage to the surface of the sidewall.
Serial Number—A number stamped on a metal plate by the manufacturer and
placed on a component or the vehicle for identification purposes. See also VIN.
Shipping Weight—The dry weight of a completed vehicle with all standard
equipment including grease and oil but without any fuel or coolant.
Tare Weight—The total weight of an empty vehicle in a condition ready to receive
payload. Same as Curb Weight.
VIN (Vehicle Identification Number)—The 17-character number is the legal
identifier of the vehicle assigned by the chassis manufacturer as required by
FMVSS.
Walk-in—A complete vehicle built on a strip-chassis platform.
Warning—A notice to prevent personal injury.
WB (Wheel Base)—Horizontal dimension from the center line of the front axle to
the center of the rear axle on a single-rear-axle truck chassis.

Body Operator’s Guide 41

 Index
A G
Address Glass. See Windows
National Highway Traffic Safety Administra-
tion 36 H
Parts Department 38
Technical Publications 3 Hazard lights 16
U.S. Department of Transportation 36 Headlights 15
Warranty Department 35 Heater 16, 31
Air louvers 14
I
B Inspection 10, 30, 34
Battery 20 Instrument panel 15
Bumpers 31
K
C Keyless entry
Cab light 15 Vehicle Access Control System 25
Cargo Keys 21, 25
Drains. See Drain valves
Light 15 L
Cleaning 30 Lights 15, 18, 30
Cruise control 15 Locks. See Doors
Lubrication 30, 32
D
Dash 14 M
Doors Maintenance 10, 30, 31
Bulkhead 21 Mirrors 10
Cab sliding 20
Maintenance 30, 31
Side sliding 20 O
Drain valves 30 Online information 3

E P
Email Parking lights 15
Customer Service 38 Phone numbers 3, 35, 36, 38
Index

Parts Department 38
Warranty Department 35 R
Emergencies 33
Reflector kit 19, 33
Repairs. See Maintenance
F Replacement parts 38
Fan 17, 30
FAX S
Parts Department 38
Technical Publications 3 Safety considerations 8
Warranty Department 35 Fire extinguisher 19
Fire extinguisher 19 Reflector kit 19, 33
Fresh Air Ventilation 16 Seat belts 11, 30
Fuse panel 16 Seats 11, 30

42 FedEx Ground
Service. See Maintenance
Step-down Floor 22

T
Towing 33
Trash Bucket 20

U
Utilimaster body serial number. See VIN
Utility Compartment 20

V
Vents 17, 31
VIN 34, 37

W
Warranty 34
Window Care 19
Wipers 15, 30, 31

Body Operator’s Guide 43

Notes

44 FedEx Ground
Body Operator’s Guide 45
46 FedEx Ground