CARE & PREVENTIVE MAINTENANCE GUIDE FOR GUARDIAN LT TRUCK BODIES Model Year 2013
TABLE OF CONTENTS INTRODUCTION. 2 Using Your Operator s Manual. 2 SYSTEM SAFETY WARNINGS.. 3 Safety Warnings and Precautions.. 3 Safety Labels and Locations 5 DOOR LOCK SYSTEM GUIDE. 6 Body Lock- Out System.. 6 Keyless Entry Locking System.. 7 Door Lock Adjustment.. 9 Door Lock Latch Replacement. 11 Door Lock Strike Hoop/Post Adjustment. 12 FIBERGLASS MAINTENANCE AND REPAIR. 14 Other Body Care and Maintenance... 17 WARRANTY... 18 SERVICE AND SUPPORT... 19 Service Contacts... 19 Service Record Log... 20 Preventative Maintenance Check List... 21 1
INTRODUCTION USING YOUR OPERATOR S MANUAL This operator s manual contains important information about your Johnson Refrigerated Truck Body and should remain with the truck body at all times. The manual has been prepared to assist you in retaining the dependability, performance, and safety features that are built into a Johnson Refrigerated Truck Body. It is essential that this body receive periodic inspections, maintenance, and service parts replacement. It is important that every Refrigerated Truck Body owner and/or operator have an organized preventative maintenance program. The United States Department of Transportation requires that the maintenance records be kept on every commercial highway vehicle. It is to your advantage to be able to show that regularly scheduled inspection checks have been made on every piece of equipment operated. A regular preventative maintenance program will assure that you get the most from your Johnson Refrigerated Truck Body, (see pages 21-24). 2
SYSTEM SAFETY WARNINGS SAFETY WARNINGS AND PRECAUTIONS SAVE THESE INSTRUCTIONS These safety warnings and precautions draw attention to potential safety concerns, system damage, operation and service information. Please read all the information carefully to avoid injury and equipment damage. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. The safety alert symbol is used with a signal word (DANGER, CAUTION, WARNING), a pictorial and/or a safety message to alert you to hazards. DANGER indicates a hazard that, if not avoided, will result in death or serious injury. WARNING indicates a hazard that, if not avoided, could result in death or serious injury. CAUTION indicates a hazard that, if not avoided, might result in minor or moderate injury. NOTICE indicates a situation that could result in equipment damage. Follow safety messages to avoid or reduce the risk of injury or death. Safety precautions Johnson Refrigerated Truck Bodies recommends that a qualified service technician perform all services. However, there are several general safety practices that you should be aware of. WARNING: Always wear safety glasses or goggles when working with or around the refrigeration system. Refrigerant can cause permanent damage if it comes in contact with your eyes and/or skin. WARNING: Keep hands and loose clothing clear of fans, belts and gears at all times when the unit is operating. WARNING: Use extreme caution when servicing compressor unit, and when climbing onto, or off of chassis and equipment. CAUTION: Exposed coil fins can cause painful lacerations. Use caution when performing service work on the evaporator or condenser coils, although service work is best left to a qualified service technician. CAUTION: Disconnect electrical source and use extreme caution if drilling holes in the unit. Drilling into electrical wiring or refrigerant lines could cause a fire. Never drill into structural components. WARNING: Unit may start at any time when the unit is connected to dock power and the compressor on/off switch is turned ON. WARNING: Be sure to disconnect power supply when inspecting any part of the unit. 3
Electrical hazard WARNING: Be sure to disconnect unit from dock power before working on the unit. This is an all-electric unit and could present a potential electrical hazard. Refrigerant Although fluorocarbon refrigerants are classified as safe, observe caution when working with refrigerants or around areas where they are being used in the servicing of your unit. DANGER: Fluorocarbon refrigerants may produce toxic gases. In the presence of an open flame or electrical short, these gases are severe respiratory irritants capable of causing death. DANGER: Fluorocarbon refrigerants tend to displace air and can cause oxygen depletion which could result in death by suffocation. Provide adequate ventilation in enclosed or confined areas. WARNING: Fluorocarbon refrigerants evaporate rapidly, freezing anything they contact if accidentally released into the atmosphere from the liquid state. Refrigerant oil Observe the following precautions when working with or around refrigerant oil: WARNING: Always wear safety glasses or goggles to protect eyes from contact with refrigerant oil. WARNING: Protect skin and clothing from prolonged or repeated contact with refrigerant oil. Rubber gloves are recommended. WARNING: Wash thoroughly immediately after handling refrigerant oil to prevent irritation. First Aid Refrigerant Eyes: For contact with liquid, immediately flush eyes with large amounts of water. Get prompt medical attention. Skin: Flush areas with large amounts of warm water. Do not apply heat. Wrap burns with dry, sterile bulky dressing to protect from infection or injury. Get prompt medical attention. Inhalation: Move victim to fresh air and restore breathing if necessary. Stay with victim until arrival of emergency personnel. Refrigerant Oil Eyes: Immediately flush eyes with large amounts of water for at least 15 minutes while holding the eyelids open. Get prompt medical attention. 4
Skin: Remove contaminated clothing. Wash thoroughly with soap and water. Get medical attention if irritation persists. Inhalation: Move victim to fresh air and restore breathing if necessary. Stay with victim until arrival of emergency personnel. Ingestion: Do not induce vomiting. Immediately contact poison control center or physician. SAFETY LABELS AND LOCATIONS Understanding the system safety and operational labels These safety warnings and labels shown below are placed on this system to draw attention to potential safety concerns, system damage, operation and service information. Please read all the information carefully to avoid injury and system damage. Refrigeration system safety labels CAUTION: DO NOT CONNECT OR DISCONNECT COMPRESSORS WITH POWER ON. THIS BODY IS EQUIPPED WITH A HIGH VOLTAGE ELECTRICAL SYSTEM MANUFACTURED IN ACCORDANCE WITH OSHA REGULATIONS 29 (CFR) 1910.301 THRU 1910.308 AND 1987 NATIONAL ELECTRIC CODE ARTICLE 440. Figure 1: CAUTION connecting/disconnecting to dock power Applied to all electrical system outlets. Depending on which type, also includes voltage and phase. Figure 2: Electrical hazard Locations vary depending on model. Can be found near all power receptacles, high voltage tray covers and interface boards. Indicates a dangerous hazard which, if not avoided, will result in death or serious injury by electrical shock. Truck body safety labels WARNING DOOR MUST BE FULLY ENGAGED INTO HOLDBACK DEVICE TO RETAIN DOOR IN THE FULL OPEN POSITION. FAILURE TO SECURE DOOR INTO HOLDBACK DEVICE MAY RESULT IN THE DOOR SWINGING SHUT ON THE OPERATOR. DOOR HOLDBACK DEVICE NEEDS TO BE REPLACED IMMEDIATELY IF DAMAGED. FOR REPLACEMENT PARTS CONTACT JOHNSON REFRIGERATED TRUCK BODIES AT 800-922-8360 Figure 7: WARNING door holdback device Located at eye-level on the inside of every door of the body. Failure to secure door into holdback device may result in door swinging shut on the operator and could result in causing death or serious injury. ATTENTION: VACUUM RELIEF PORT Figure 10: ATTENTION vacuum relief port Located inside body on the rear street side wall next to vacuum relief port. Keep port free from obstruction to prevent blockage. 5
DOOR LOCK SYSTEM GUIDE BODY LOCK- OUT SYSTEM Truck bodies equipped with the body lock-out option can completely cut the 12-volt power supply to the truck body door locks, courtesy lights and interior dome lights. This option is provided to operators for the purpose of locking the truck body doors to eliminate entrance into the truck body when product is on board. Activating body lock-out 1. Switch the master ON/OFF power switches for lights and door locks to the ON position. They are located on the chassis dash. 2. Using the chassis key fob, toggle the lock button. This will lock the chassis cab doors as well as the truck body doors. 3. Insert the body lock-out key into the noted key cylinder on the truck body centralized control box/panel and rotate key clockwise to the ON position and remove the key. The 12-volt power supply is now cut to the truck body. 4. Using the chassis key fob, toggle the unlock button to unlock the chassis cab doors. NOTE: The truck body doors should remain locked and the interior/courtesy lights OFF during this step. If the truck body doors unlock, repeat steps noted above. If the system does not lock down, please contact Johnson Truck Bodies for troubleshooting assistance. 5. Switch the master ON/OFF power switches located on the chassis dash to the OFF position to insure truck body door locks and lights have no power supply. Deactivating body lock-out 1. Switch the master ON/OFF power switches located on the chassis dash to the ON position to insure truck body door locks and lights have a 12-volt power supply. 2. Insert the body lock-out key into the noted key cylinder on the truck body centralized control box/panel and rotate key counter clockwise to the OFF position and remove the key. 12- volt power supply is now provided to the truck body. 3. Using the chassis key fob, toggle the unlock button to unlock the chassis cab doors as well as the truck body doors. 6
KEYLESS ENTRY LOCKING SYSTEM OPERATING INSTRUCTIONS NOTE: Please see your chassis Operator s Manual for keyless entry key fob programming instructions. (Ford E450 & GMC G-Van Cut-A-Way Chassis Only) Keyless entry operating instructions for truck body doors 1. Locate the master power switches on the chassis dash for the truck body lights and the interior locking system. 2. Toggle the dome light switch to the ON position and the door lock switch to the LOCKS ON position. 3. Press the unlock button on the chassis key fob once to unlock the truck body interior door locking system. The rain gutter lights will illuminate when the system is in the unlock position and remain lit until the key fob lock button is pressed. If system is inactive, the lights will turn off automatically after approximately ten minutes to reduce battery drainage. 4. Re-entering the chassis cab, there are two options available to turn the body rain gutter lights off: a. Manually toggle the ON/OFF dome light switch on the dash to the OFF position. b. Press key fob lock button once to activate the door lock system and turn off body rain gutter lights. TROUBLESHOOTING If the chassis key fob keyless entry system will not unlock the truck body doors, please refer to the operating instructions first. Rain gutter lights do not illuminate a. Chassis dash master light switch is OFF Turn switch to ON b. Check the 10 and 15 amp inline fuses located under the chassis cab hood offset to the street side. Truck body doors do not lock or unlock a. Chassis dash locks on switch in the OFF position Turn switch to ON b. Chassis dash switches are in the ON position and gutter lights are not illuminated Inline 10 or 15 amp fuse may be blown (see photos and illustrations below and replace as needed). 7
Rain gutter lights illuminate, chassis dash switch for body door locks is on, but doors do not unlock a. Check battery in key fob and be sure that LED light on fob illuminates. Ford E450 10 and 15 amp in-line fuses 8
DOOR LOCK ADJUSTMENT INSTRUCTIONS Inspect the handle. Is it seated properly against the door sheet? A loose or improperly seated handle will allow warm air into the latch pocket and will travel through the latch opening causing ice build-up on the latch. If the handle is loose or not seated properly: a. Remove access panel from interior door pan. b. Remove foam block from latch pocket. c. Loosen both 10mm nuts securing handle. d. Re-seat handle in opening. e. Tighten nuts, making sure not to over-tighten. f. Check handle and latch for proper operation. The following will determine if the door seal is over or under compressed: a. Open the door. Does the handle operate smoothly? b. Inspect the seal for damage or defects. Is the seal flattened from over compression? c. Is the latch engaging both the secondary and primary catches? Close door gently until the secondary catch engages. Door should be ajar but not able to open. Close the door firmly until the primary catch engages. The door should be sealed tightly with no movement when the handle is jiggled. d. If seal is flattened or primary catch will not engage, the strike needs to be moved out. If door operates smoothly and primary catch is engaged but door is not sealing, the strike needs to be moved in. To adjust the strike: a. With a pencil, draw an outline around the strike plate for location reference. b. Drill out the rivet using a 3/16 drill bit c. Loosen strews holding down the strike, but do NOT remove. The screws should be loosened just enough to adjust the strike. d. Adjust strike to the proper location and tighten screws. It will only need minor adjusting. In this case, moving the strike in 1/16 will most likely be enough. e. Tighten strike plate screws and check door for proper seal. f. Once a good seal is achieved, drill a 3/16 hole into the door frame mullion and trough the door strike plate opposite the original rivet location. g. Install a new 3/16 rivet. 9
h. If the latch mechanism does not operate smoothly (i.e. open and/or close freely without sticking slow operation) apply a small amount of silicone lubricant spray to the claw and spring. A 14.5 oz. can of Easy Rider lubricant spray has been provided in the chassis. Do not use a mineral based spray (i.e. WD40 or the like) due to possible odor contamination. Additional cans of Easy Rider lubricant spray (JRTB Part #047-1001) can be ordered through Johnson Parts Department (800) 922-8360, ext. 3. 10
r DOOR LOCK LATCH REPLACEMENT 1. Remove the (10) Phillips screws for the access panel on the interior door pan. 2. There is a bead of silicone between the access panel and the door pan. Using a small putty knife, separate the access panel from the door pan. 3. Remove foam insert. 4. Unsnap the rod clip and rotate up to allow removal of the latch rod from the handle. 5. Remove (2) torx screws securing latch to door pan and remove door latch / rod assembly. 6. Install new latch with rod and rod clip installed as shown in photo. Secure with (2) torx drive screws. Use caution to not over-tighten these fasteners. Do not use an impact wrench. 11
7. Insert rod into rod clip on handle. Rotate rod clip and snap back into place. 8. Check for proper operation by manually rotating latch rotor to the closed position. Pull handle to release latch. Do this several times while watching and feeling for smooth operation. 9. If the latch operates smoothly, proceed to step #10. If not, check rod for obstructions and make sure that it is properly seated in the latch/handle, and that the rod clips are snapped in place. Inspect gasket between latch and door pan to ensure that it is not binding to the latch. STRIKE POST ADJUSTMENT 1. The latch is a 2-detent latch similar to the latch on the chassis cab. The secondary position is a safety feature that keeps the door from opening in the event that it is not fully closed. However, this position will not provide a positive door seal. The primary position is fully closed and will ensure a good door seal. There is no adjustment on the latches. Adjustments are made on the strike post. Strike post inspection a. With the latch rotor in the open position, close door gently on the strike post just until it clicks into the secondary detent. The door should be slightly ajar, but not able to open without pulling the handle. b. Push the door fully closed until it clicks into the primary detent. The door should not be ajar and should be fully sealed. c. Check for proper seal by placing a piece of paper in the door opening and close the door on the paper. There should be some drag on the paper when pulled out. d. If there is no drag on the paper, loosen the (2) torx drive screws on the strike post and move the strike post in to pull the door tighter. Retighten screws and re-check the door seal. 12
Move the door strike in small amounts (i.e. 1/16 increments) until proper door seal is acquired. i. If the drag on the paper is too much and the door handle is difficult to open, the strike post is set too far inside. Loosen the (2) torx drive screws on the strike post and move strike post out. Retighten screws and re-check door seal and handle function. 2. Once the latch is installed and functioning properly, reinstall foam plug. 3. Apply a small bead of silicone sealant around perimeter of access panel or around the opening in the door pan. 4. Re-install access panel using a Phillips screw driver. If using a drill or driver, set clutch to very low (3-4), and be sure not to over tighten. 13
FIBERGLASS MAINTENANCE AND REPAIR To keep the exterior of your new fiberglass truck body in good condition, periodic preventative care and maintenance should be followed. FINISH PROTECTION The Johnson fiberglass body has a beautiful, natural glass finish that will stay this way if washed periodically with common strength soap and water (NOTE: heavy doses of acetone or lacquer should not be used.) High caustic soaps and solutions will cause premature color fade and panel surface deterioration. It is acceptable to use a hot water pressure washer system for cleaning; however to prevent premature deterioration of exterior finish, the water pressure against the surface of the panel should not be extreme. Mild to moderate amounts of pressure are efficient to apply soap and remove surface dirt. For good finish protection, we recommend applying a coat of wax one or two times a year. Waxing helps protect against every day elements and ultra violet rays which cause surface deterioration and fading. Many automotive or fiberglass boat waxes can be used. Check the product label for recommended surfaces and application. A mild, abrasive rubbing compound is recommended to be used with wax. Johnson Refrigerated Truck Bodies uses a product manufactured by Maguire. Any fiberglass boat or automobile parts supplier should be able to provide this or an equivalent product for you. If you prefer a one step process, you may also use a variable compound such as 3M Imperial which polishes and refines smaller scratches at the same time. FIBERGLASS REPAIR Exterior walls, interior walls and floor Johnson Refrigerated Truck Bodies are extremely durable, but occasional accidents do occur. If so, repairs are simple, amazingly inexpensive and easily done in your own shop. Fiberglass repair kits from local boat or hardware stores are readily available. Observe all manufacturers instructions, which include safety precautions. Exterior fiberglass sheet (Rub Rails, Fenders, Doors and Corners) If a fracture ever appears, it should be repaired as soon as possible. 1. Sand entire area to remove all foreign matter, and rough up to assure a good bond 2. Fill voided foam area with a urethane based foam product 3. Allow foam to dry, and trim excess foam to within 1/4 of exterior of finished sheet 4. Sand area again to assure a good bond 5. Feather thickness of sheet 6. Fill area with Mar glass to within 1/8 of exterior of finished sheet 7. Allow to harden and sand 8. Cut oversized strips of fiberglass mat to cover area (approximately 2 larger than damaged area and about 3-4 strips) 9. Lay mat on clean cardboard 14
10. Saturate mat with resin and catalyst mixture 11. Place coated mat into hole 12. Remove all air bubbles from the layers of wet mat with brush or roller 13. Allow to dry After area has hardened: 1. Sand, flush and feather edges to original liner 2. Prime and paint as needed Exterior fiberglass surface repair If Fiberglass Reinforced Plastic (FRP) surface has superficial cracks or a porous surface: 1. Remove any decals from area of repair 2. Sand the area with 180-grit sandpaper 3. Wipe area clean and tack with a tack cloth 4. For light to moderate repairs, apply DuPont 4724 Lightweight Polyester Filler to area 5. For moderate or heavy repairs, apply DuPont Z-Chrome Rust Defender to area 6. Allow to dry and sand area with 220-grit sandpaper 7. Wipe area clean and tack with a tack cloth. May need to repeat steps 4 or 5, 6 and 7 8. Prime the area, using a DuPont Tufcoat Primer 9. Using a topcoat sealer, seal area according to customer s specifications (i.e. gel coat with Cooks Armorcoat Gel Coats or paint with DuPont s Imron or PPG s Ditzler Paints) Exterior fender replacement 1. You may need to remove the tires 2. Use a saw to cut off old fender where it joins the exterior sheet 3. Pull exterior sheet away from body just enough to allow lip of new fender to be forced up behind sheet, grind behind sheet to even surface 4. Mask all areas of fender to avoid resin from sticking to exposed visible surfaces 5. Dry fit fenders to opening, measure and cut 5-6 wood sticks to hold fender in place 6. Using either two-part epoxy based glue or resin method, install fender so lip is under exterior sheet: a) If resin method: cut fiberglass mat strips the length of the lip of the new fender for both sides b) Lay mat on clean cardboard c) Saturate mat with resin and catalyst mixture d) Place coated mat onto each side of lip of the new fender 7. Position flat pieces of wood around fender against body exterior sheet 8. Shore against building wall or clamp to keep pressure on fender lip and exterior sheet while curing 9. Trim all excess materials, resin and masking tape when material has gelled 10. Allow to dry, then sand and paint as needed. Interior fiberglass liner 15
If a fracture ever appears, it should be repaired as soon as possible. 1. Sand entire area to remove all foreign matter and rough up to assure a good bond 2. Fill voided foam area with a urethane based foam product 3. Allow foam to dry and trim excess foam to within 1/8 of sheet 4. Sand area again to assure a good bond 5. Putty over foam to allow mat to adhere 6. Cut strips of fiberglass mat to cover area 7. Coat with resin (mixed according to manufacturer s instructions) 8. Lay pre-cut pieces of fiberglass mat over fresh resin 9. Work resin into mat with clean brush or roller 10. Saturate mat with resin and catalyst mixture 11. Apply enough mixture to make a convex over the damaged area 12. Use small roller or brush to work into place removing any air bubbles 13. Trim any edges or excess mat before completely hardened After area has hardened: 1. Sand flush to original liner 2. Recoat with resin to give a smooth, glossy finish Fiberglass floor If a definite fracture or crack appears, it can be repaired in the same manner as you would the liner. If an entire area of the floor wears thin, repair as follows: 1. Sand entire area to remove all foreign matter and rough up to assure a good bond 2. Cut strips of fiberglass mat to cover area 3. Coat area with resin (mixed according to manufacturer s instructions) 4. Lay pre-cut pieces of fiberglass mat over fresh resin 5. Apply additional resin to completely saturate top of mat 6. Use paint roller to smooth the surface and remove the air bubbles If grit for a non-slip surface is desired: 1. Sprinkle grit on repaired area while resin is still wet 2. Allow to harden 3. Recoat area with mixed resin and catalyst to lock in grit 16
OTHER BODY CARE AND MAINTENANCE Cleaning body interior Clean and sanitize body interior after cold plate defrost.! After defrosting unit, spray down walls using an all-purpose cleaner.! Rinse down walls using a water hose or pressure washer (2,600 lbs or less).! Wipe down or let air dry. Interior drain holes! After defrost, make sure drains are clear of debris and check for proper drainage.! If drains are backed up or draining slowly, clean out with pressure washer or water hose. Body doors Gaskets It is recommended that gaskets be checked monthly.! Wipe away any build-up and make sure surfaces are kept clean.! Check for any visible tears.! Check that adhesive is holding. If coming loose, use 3M 4799 rubber cement glue to reattach.! If flattened out, gasket needs to be replaced. Make sure doors are sealing properly and correct leaks: 1. Place a dollar bill between the door gasket and jam while you open and close the door. 2. Try to pull the dollar bill back out. There should be some resistance as you pull. 3. Do this around the perimeter of the door checking resistance on the bill as you go. If there is no resistance either tighten the lock handle, shim the hinge at that location, or replace the door gasket if it appears to have lost its resilience or is missing. Door hardware Check and treat door hinges and hardware monthly to prevent rust and corrosion.! It is recommended to apply Fluid Film, a lanolin based rust and corrosion preventative over tightly adhering rust, dry or damp metal surfaces and painted surfaces.! Shake can before using.! Hold can 6-8 inches from work surface. Do not spray with can in inverted position. Strip curtain repair 1. Remove damaged curtain section by removing screws in aluminum strap. 2. Measure curtain length, and contact JRTB Parts Department to order replacement curtain material.
WARRANTY OWNER S WARRANTY RESPONSIBILITES As the refrigerated truck body owner, you are responsible for the performance of the preventative maintenance outlined in this Operator s Manual. As the refrigerated truck body owner, you should be aware that Johnson Refrigerated Truck Bodies may deny you warranty coverage if your refrigerated truck body, or a part or component, has failed due to abuse, neglect, improper maintenance, or unapproved modifications. You are responsible for contacting Johnson Refrigerated Truck Bodies prior to any warranty work being done on your refrigerated truck body. Johnson Refrigerated Truck Bodies has to provide prior approval for warranty work before a qualified service technician performs any repairs. Terms of the Johnson Refrigerated Truck Bodies warranty are available on request. If you have any questions regarding your warranty, please contact Johnson Refrigerated Truck Bodies and ask to speak with the Customer Service Department at (800) 922-8360. WARNING PRIOR TO CONDUCTING WARRANTY REPAIR WORK ON THIS BODY OR REFRIGERATION SYSTEM, PRE-APPROVED AUTHORIZATION MUST BE GRANTED BY MANUFACTURER OR THE MANUFACTURER S WARRENTY WILL BE VOID. TO OBTAIN PRE-APPROVED AUTHORIZATION CONTACT JOHNSON TRUCK BODIES AT 800-922-8360 45
SERVICE AND SUPPORT From pre-sale to post-sale, we are here to help you with your support needs from the initial sales inquiry to service support for life of your Johnson equipment. At Johnson Truck Bodies, we are positioned to provide you with the most efficient and convenient local and field support available through our in-house experts and authorized Great Dane service repair locations nationwide. SERVICE CONTACTS Headquarters and Manufacturing Plant 215 E Allen Street Rice Lake, WI 54868 Toll Free: 800.922.8360 Local: 715.234.7071 Fax: 715.234.4628 Sales Department Email: jtbsales@johnsontruckbodies.com Web: www.johnsontruckbodies.com FleetWise Service Repair Toll Free: 800.FLT.WISE (358.9473) FleetWise@johnsontruckbodies.com Parts Orders Genuine Johnson Truck Bodies Parts Orders Toll Free: 800.922.8360 Ext. 3 Warranty Claims Toll-Free: 800.922.8360 Ext. 420 Fax: 717.236.3742 Email: pmonroe@johnsontruckbodies.com 46
SERVICE RECORD LOG DATE MILEAGE DESCRIPTION 47
PREVENTIVE MAINTENANCE CHECKLIST Date: Unit#: JRTB Serial#: Service Provider: EXTERIOR BODY Date Item Description Roof-Fiberglass cracks or damage Compressor cowling Intact and all fasteners present Air foil intact and all fasteners present Roof band Intact, all fasteners present Sidewall S/S Fiberglass cracks or damage Sidewall C/S Fiberglass cracks or damage Front wall Fiberglass cracks or damage Rear wall Fiberglass cracks or damage Corner shells- Fiberglass cracks or damage LV vent pop-off sealed and in tact Subfloor mounted dry storage box intact Rain gutters intact Fenders over wheels check for damage Mud flaps and splash guards check for damage Rear bumper and FRP back drop check for damage Fold down product shelf option check for missing springs/damage Decals and reflective markers Doors Check exterior sheet, interior pan, door lips for damage Check rubber door gasket. Replace if missing or torn Check door hardware, bar lock or automotive for damage and operation Automotive door latch free of dirt and grime Check for silicone spray in cab for door latches and gasket Strike hoop on door frame Check door hinges operational Adjust door hardware for proper seal (dollar bill test) 48
Doors (Continued) Date Item Description Check door holdback stops and corner shell bracket Check interior wiring harness to door pan Check interior door pull straps Door canvas curtains intact SUBFRAME Date Item Description Underbody fiberglass subpan Fenders intact and attached Subfloor ovals over wheels Long stringers Angle tie-down, bolts tight, welds intact Subframe boxes attached utility, card, cord boxes Flex vent tube(s) intact Mud flaps and splash guards, present and secure Drain holes/kazoo if present Rear bumper and FRP back drop INTERIOR BODY Date Item Description Ceiling cracks or damage Sidwall S/S cracks or damage Sidewall C/S cracks or damage Front wall cracks or damage Rear wall cracks or damage Seams, cracks or damage Floor damage Wire conduit covers present, no exposed wires Vacuum relief tube open Canvas curtains above side door I.C. module present with all trays Drawer modules present with drawer Upper chutes present with poly trays Dividers fastened LIGHTS/ELECTRICAL Date Item Description Exterior box lights present and operational Tail, stop and turn light operational Back-up flood lights operational License plate light operational Interior box lights operational Exterior courtesy lights operational Inspect compressor plug-in outlet condition Compressor on/off switch and indicator light 49
LIGHTS/ELECTRICAL (Continued) Date Item Description Defrost heater switch and indicator lights operational Defrost heaters operational Circulation fan operational Master electrical box condition 12Volt master disconnect switch on electrical box operational Back-up camera and in-cab monitor operational Dash switches operable, body dome, courtesy lights and door locks Automotive door locking system (option) operational Automotive keyless locking system (option) operational REFRIGERATION CHECK (unplugged) Date Item Description Line cord Check line cord for abrasions Check line cord ends and plug-ins for damage Check cord connections to truck body plug-in Exterior condenser fins Remove any debris and hose off Straighten fins that are bent Exterior compressor/condenser box Refrigeration operating instructions posted Check for loose wiring Check copper tubing and/or hosing for chafing, rubbing, loose clamps Check for any oil stains in box Check for oil leaks Check condenser motor and fan blade for cracks, nicks and contact to fan shroud Check that discharge line thermostat is secured to high side copper pipe on compressor Inspect compressor/condenser frame for excessive corrosion, rust cracks, loose or missing bolts/fasteners Holdover plate system Check for frost build-up, never to exceed ½ Check plates for any external leaks Check all plate fittings and piping Check all mounting brackets and support channels 50
REFRIGERATION CHECK (plugged-in) Date Item Comments 1. While compressor is operating, check oil site glass; level should be 1/3 to ½ full 2. While compressor is operating, check liquid line sight glass; fluid should be clear and moisture indicator green Digital thermometer operational Interior circulation fan operating Johnson Refrigerated Truck Bodies 215 E Allen Street Rice Lake, WI 54868 800.922.8360 www.johnsontruckbodies.com 51